Abstract
Chain bar apparatus and methods are disclosed that may be formed from plastic, metal or other materials. Laser cutting of a chain bar core can provide improved structural characteristics, for example when adhesive is used to assemble the chain bar. Flow diversion elements can be used to optimize flow throughout the chain bar.
Claims
1-38. (canceled)
35. A method of supporting a conveyor comprising moving a conveyor along a support structure defining a conveyor path, wherein the support structure includes a support surface having a plurality of raised portions wherein adjacent ones of the raised portions are separated by a respective recessed portion and wherein the conveyor does not bear against a bottom portion of the recessed portion during movement of the conveyor.
36. The method of claim 35 wherein the conveyor moves along the support surface and contacts with substantially no portion of the recessed portion.
37. The method of claim 35 wherein the conveyor supports cutting elements affixed to the conveyor and wherein the conveyor moves along the support surface to move the cutting elements along the conveyor path.
38. The method of claim 35 wherein the support surface is a first support surface on a first side plate and wherein the support structure includes a second side plate having a second support surface with a plurality of the second raised portions and wherein the conveyor is supported by the raised portions on the first support surface during at least one time when the conveyor is not supported by the second raised portions.
39. The method of claim 35 further including moving the conveyor at high speed.
40. A method of supporting a chain with a chain bar wherein the chain bar includes at least one support surface on a support plate extending in a first direction defining a path for the chain and wherein the support surface includes a plurality of raised portions wherein adjacent raised portions are spaced apart and separated by a respective recessed portion and moving the chain over the raised portions.
41. The method of claim 40 wherein the chain bar raised portions include substantially flat surfaces and the chain travels across the flat surfaces.
42. The method of claim 40 wherein the support plate is a first support plate and the chain bar further includes a second support plate having second raised portions and wherein the chain is moved over the raised portions on the first support plate and on the second raised portions.
43. The method of claim 42 wherein the chain can be supported on a second raised portion at a first linear position along the path when an opposite side of the chain at the first linear position is not supported by a raised portion on the first support plate.
44. The method of claim 40 wherein the chain is run on a support plate of the chain bar that has been heat-treated to a discrete depth.
45. The method of claim 40 wherein the chain is run at high speed.
46. The method of claim 40 wherein the chain wears a bearing surface on a raised portion before wearing a wall of a recessed portion.
47. A laminated element having a peripheral edge surface for supporting a tool component, the laminated element comprising a core element and an outer surface element at least partly coextensive with the core element, wherein the core element includes a perimeter extending around the core element, wherein part of the perimeter forms a flow channel wall, and a closed-circuit wall defining at least one passageway in the core element extending along or substantially parallel to the flow channel wall.
48. The laminated element of claim 47 wherein the passageway is formed by laser cutting.
49. The laminated element of claim 47 includes a first and second side plates to form a chain bar.
50. The laminated element of claim 49 further including adhesive on the laminated element on a side of the passageway opposite the flow channel wall.
51. A laminated chain bar comprising at least first and second side plates on opposite sides of a chain bar core and wherein the first side plate includes a first inlet opening, the second side plate includes a second inlet opening, and where the chain bar core includes a divider separating the first and second inlet openings and wherein the divider extends past a first outlet on the chain bar.
52. The laminated chain bar of claim 51 wherein the divider extends past a second outlet on the chain bar.
53. The laminated chain bar of claim 51 where the divider extends at least half the length of the chain bar core.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is an upper right isometric view of a chain bar assembly in accordance with one example described herein.
[0031] FIG. 2 is a top plan view of the chain bar assembly of FIG. 1.
[0032] FIG. 3 is a bottom plan view of the chain bar assembly of FIG. 1.
[0033] FIG. 4 is an exploded view of the chain bar assembly of FIG. 1.
[0034] FIG. 5 is a front elevation view of a core element of the chain bar assembly of FIG. 1.
[0035] FIG. 6 is a top plan view of the core element of FIG. 5.
[0036] FIG. 7 is a bottom plan view of the core element of FIG. 5.
[0037] FIG. 8 is a detailed view of a portion of the side of the chain bar core of FIG. 5 showing upper and lower bosses and a fluid flow channel.
[0038] FIG. 9 is a detailed view of a portion of the side of the chain bar core of FIG. 5 showing the nose end portion of the core.
[0039] FIG. 10 is a partial cross-sectional view of the core of FIG. 5 taken along line 10-10 of FIG. 6.
[0040] FIG. 11 is an isometric view of the core of FIG. 5.
[0041] FIG. 12 is a detailed view of a portion of the core of FIG. 11.
[0042] FIG. 13 is a right side view of the chain bar core of FIG. 5.
[0043] FIG. 14 is a detail of a top plan view of the chain bar core of FIG. 6.
[0044] FIG. 15 is a side elevation view of a flow valve in the chain bar shown in FIG. 4.
[0045] FIG. 16 is a top plan view of the valve of FIG. 15.
[0046] FIG. 17 is a cross-sectional view of a right end of a chain bar assembly omitting the nose sprocket.
[0047] FIG. 18 is a top plan view of a chain bar core according to another example described herein.
[0048] FIG. 19 is a detailed view of a portion of the core of FIG. 18.
[0049] FIG. 20 is an upper isometric view of a chain bar as one example of a support structure for a moving element.
[0050] FIG. 21 is an exploded view of the chain bar of FIG. 20.
[0051] FIG. 22 is a side elevation of the chain bar of FIG. 20.
[0052] FIG. 23 is a detailed view of a portion of the chain bar of FIG. 20 taken at 23 and FIG. 20.
[0053] FIG. 24 is a side elevation and partial cutaway view of a portion of the chain bar of FIG. 20 taken long lines 24-24 in FIG. 22.
[0054] FIG. 25 is a side elevation view of a portion of a side plate of a chain bar such as that shown in FIG. 20.
[0055] FIG. 26 is a detailed plan view of a nose portion of the chain bar of FIG. 20 with a side plate removed to show a coolant supply channel for a nose sprocket assembly.
[0056] FIG. 27 is a schematic of a side plate and a laser cutting machine used to form a support structure such as one used in the chain bar of FIG. 20.
[0057] FIG. 28 is a plan view of medial or core components showing various openings through the components for adhesive flow and sealing between the components and adjacent chain bar side plates.
DETAILED DESCRIPTION
[0058] This specification taken in conjunction with the drawings sets forth examples of apparatus and methods incorporating one or more aspects of the present inventions in such a manner that any person skilled in the art can make and use the inventions. The examples provide the best modes contemplated for carrying out the inventions, although it should be understood that various modifications can be accomplished within the parameters of the present inventions.
[0059] Examples of tool components and of methods of making and using the tool components are described. Depending on what feature or features are incorporated in a given structure or a given method, benefits can be achieved in the structure or the method. For example, tool components using fluid for cooling may achieve better cooling and longer lifetime. Cutting tool components may also benefit from lighter-weight components, lower-cost and reduced wear.
[0060] Tool components that use water for cooling and/or lubrication may benefit also from one or more features described, for example reducing the possibility of corrosion. Improved corrosion prevention characteristics help component life and promote tool integrity.
[0061] Tool components that use water for cooling and/or lubrication may benefit also from one or more features described, for example reducing the possibility of fluid pressure variations adversely affecting the integrity of the tool. Improved fluid pressure characteristics lead to more predicable operation and also promotes tool integrity.
[0062] In tool components similar to chain bar configurations, one or more aspects of the examples described may allow better cooling and heat transfer, and improved tool performance. In support structures for moving tools, such as cutting or abrading tools moving along a guide or track and for example at high speed over the guide (such as between 2000 and 6000 linear feet per minute, defined for present purposes as high speed), the support structure can show reduced wear by having surface discontinuities or raised and recessed formations. Where the support structure is laser cut for example, the area supporting the moving tool experiences heat treating of the material, thereby improving the resistance to wear. By way of further example, the wear rate may be reduced.
[0063] These and other benefits will become more apparent with consideration of the description of the examples herein. However, it should be understood that not all of the benefits or features discussed with respect to a particular example must be incorporated into a tool, component or method in order to achieve one or more benefits contemplated by these examples. Additionally, it should be understood that features of the examples can be incorporated into a tool, component or method to achieve some measure of a given benefit even though the benefit may not be optimal compared to other possible configurations. For example, one or more benefits may not be optimized for a given configuration in order to achieve cost reductions, efficiencies or for other reasons known to the person settling on a particular product configuration or method.
[0064] Examples of several tool configurations and of methods of making and using the tool components are described herein, and some have particular benefits in being used together. However, even though these apparatus and methods are considered together at this point, there is no requirement that they be combined, used together, or that one component or method be used with any other component or method, or combination. Additionally, it will be understood that a given component or method could be combined with other structures or methods not expressly discussed herein while still achieving desirable results.
[0065] It should be understood that terminology used for orientation, such as front, rear, side, left and right, upper and lower, and the like, are used herein merely for ease of understanding and reference, for example with reference to views in the drawings, and are not used as exclusive terms for the structures being described and illustrated.
[0066] A tool component in the form of a chain bar 100 (FIGS. 1-4) is formed as a laminate of two or more components for supporting a cutting chain. The chain bar can be used as part of a chainsaw for cutting wood, concrete or other workpieces, as would be known to one skilled in the art. The assembly and use of a chainsaw with chain bars are well known to those skilled in the art and will not be considered in detail. However, it should be understood that the chain bars described herein can be used with a number of chainsaw configurations as would be appreciated by one skilled in the art.
[0067] The chain bar 100 includes a first or top (as viewed in FIGS. 1 and 4) side plate 102 and a second or bottom side plate 104 (as viewed in FIG. 4) forming with a core 106 a laminated chain bar. The chain bar 100 by a chainsaw motor at a mounting end 108 having a mounting and support slot 110, a drive sprocket area 112 for accommodating a drive sprocket and a pair of fluid inlet openings 114. The fluid inlet openings 114 receive fluid such as water for cooling the chain bar and cooling and lubricating the chain bar groove 116 that supports and guides the cutting chain (not shown), and for cooling and lubricating the nose sprocket 118. Additionally, any fluid exiting the chain bar in the area of the cutting chain also cools and lubricates the cutting chain. Because the chain bar 100 is reversible, two fluid inlet openings 114 are provided, only one of which is used at any given time for supplying fluid to the chain bar. The other of the fluid inlet openings receives a chain tightening mechanism to adjust the chain tension. The chain bar laminate assembly is formed so that the chain bar groove 116 has the conventional configuration.
[0068] In the example of the chain bar 100 shown in FIGS. 1-12, the chain bar includes a plurality of inter-engagement elements. The inter-engagement elements help to laminate the components of the chain bar to form the final chain bar assembly. The inter-engagement elements help to register adjacent planar components relative to each other. They also help to strengthen the structure, for example by improving the sheer strength of the laminate. In the present examples, the inter-engagement elements are formed from complementary elements in the outer plate 102 and 104 with components in the core 106. In the present example, the inter-engaging elements include a plurality of bosses 120 distributed substantially symmetrically about a central longitudinal axis bisecting the mounting and support slot 110. As shown in FIGS. 1-3, the bosses 120 extend into the side plates 102 and 104. The bosses are also shown in FIGS. 5-10. The bosses extend substantially outward from the core 106, and each of the bosses extend in one direction from the corresponding side of the core 106 opposite a similarly located and configured boss extending outward from the opposite surface, except for the pair of bosses at the nose end of the core 106. The bosses 120 at the nose end are positioned on the core 106 to extend only from the top surface, as viewed in FIG. 5.
[0069] The bosses 120 form part of inter-engagement elements to improve the assembly and the structural integrity of the chain bar. Each of the upper and lower side plates 102 and 104 include openings 122 complementary to the respective bosses on the core 106. The openings and the bosses provide registration for adjacent layers and also improved sheer strength for the chain bar. The inter-engagement elements can be shaped to be circular, polygon, asymmetric or other configurations complementary to each other. Other structures in the laminate may also be complementary to each other. While all of the bosses are shown as being located on the core 106 and all of the complementary openings on the first and second side plates 102 and 104, it should be understood that all of the bosses can be on the side plates, or some on the side plates and some on the core with respective complementary inter-engagement elements positioned as appropriate.
[0070] The nose sprocket 118 is a conventional sprocket for supporting the chain. The sprocket is supported for movement on bearings 124 (FIG. 4) about a hub 126 secured between the first and second plates 102 and 104 in the conventional manner. The bearings and the sprocket are cooled with fluid from the fluid inlet openings 114.
[0071] The first side plate 102 in the present example is substantially flat on both sides and includes the openings as indicated. The second side plate 104 is also substantially flat and substantially the same thickness as the first side plate 102, and includes the openings as indicated. In addition to the slot 110, water inlet openings 114, the complementary openings 122 and the openings for securing the nose sprocket, the second side plate 104 includes an opening 128 (FIGS. 3-4) for receiving and supporting a portion of the core 106, described more fully below. The opening 128 provides space for the portion of the core 106 to extend out of the plane of the core. The opening 128 is substantially oval in the present example. The first and second side plates in the present examples are metal, as in conventional side laminates.
[0072] The core 106 (FIGS. 4-12) has a substantially flat bottom surface 130 except for a projection in the form of an outlet manifold 132 (FIGS. 5-7 and 9-10). The outlet manifold 132 extends into the oval opening 128 in the second side plate 104, as described more fully below. The bosses 120 extend substantially normal to the respective surface of the core 106, and our substantially circular in the present examples. The core includes respective water inlet openings 134, corresponding to the water inlet openings 114. The sides of the core other than the distal portion corresponding to the outlet manifold 132 conform substantially to the site configurations of existing chain bar cores, for supporting a cutting chain. Additionally, except for the bosses 120, the outlet manifold 132 and the flow channels described more fully herein, the thickness of the chain bar core 106 is substantially similar to existing chain bar cores.
[0073] The core 106 may be formed from a number of materials, including metal, plastic, composite materials and the like. In the present example, the core is formed from a fiber reinforced plastic. In one configuration, the core has good strength characteristics in compression, and the bosses provide good sheer strength. The plastic core is easily formed through conventional molding techniques having the configurations described herein.
[0074] The core includes an inlet manifold area 136 (FIGS. 6 and 11) with an inlet channel 138 corresponding to each of the inlet openings 134. The inlet channel 138 has a relatively large cross-sectional area for flow and has a relatively gradual curvature to a flow junction 140. As in substantially all of the flow channels of the chain bar in the present example, the flow cross-sectional area is determined by the depth and width of the flow channel formed into plastic core. The remaining side of the flow channel is closed by the adjacent first plate 102 and the adhesive (not shown) between the two. The flow junction 140 extends from an apex point 142 to an exit area 144, at which point fluid flow continues down a substantially central channel 146, as described more fully below. The gradual curvature of the flow inlet to the junction 140 has a substantially constant radius of curvature to the junction, and minimizes abrupt bends or sharp corners. The cross-sectional flow area of each inlet channel 138 is substantially constant from the respective inlet opening 134 to the apex 142.
[0075] The apex point 142 includes an opening 148 for receiving and supporting a flow valve 150 (FIGS. 4 and 15-16). The flow valve 150 pivots freely in the junction area 140 is a function of the direction from which fluid flow is coming. The flow valve 150 serves as a backflow valve reducing the amount of fluid flowing from the inlet channel 138 into the opposite inlet channel 138 (not presently in use for fluid flow). The flow valve also promotes better flow in the remainder of the channel, for example by reducing flow eddies or cavitation.
[0076] The central channel 146 extends substantially along a medial or longitudinal axis of the chain bar core. The flow cross-sectional area gradually decreases in the distal direction to the distal end and the outlet manifold 132. The cross-sectional flow area decreases in width but not substantially in depth out to the distal end portion of the core.
[0077] Considering the various flow paths in further detail, each side of the core from the media line includes to flow branches 152 and 153, each of which branch again before reaching the lateral edge 154 of the core forming the outer perimeter of the core. Each of the respective branches have respective flow cross-sectional areas less than the upstream flow area from which it came, to maintain flow pressure and velocity for example. As shown in FIG. 14, a first branch 152 from the central channel 146 extends substantially straight at an angle from the central channel to a second smaller branch 156 and to a still smaller branch 158 terminating at an outlet port 160. The second smaller branch 156 terminates in a further outlet port 162 (FIGS. 5-6 and 8) further along the perimeter of the core from the outlet port 160. A similar flow channel arrangement is on the opposite side of the central channel, including with comparable cross-sectional flow areas. The flow branches 153 downstream from the first pair of flow branches 152 have a similar layout but smaller flow cross-sectional areas.
[0078] As the central channel 146 approaches the distal end of the core, the cross-sectional flow area continues to decrease to a third flow diversion 164, in the present example. Respective side flow branches 166 having a smaller cross-sectional flow area than the flow branches 152 and 153, respectively, terminate at respective flow outlets 168 (FIGS. 6 and 9). The side flow branches 166 extend away from a flow diversion element 170 (FIGS. 6, 10, 11-13 and 17). The flow diversion element 170 may be an island, flow channel projection or block or some other element for diverting fluid flow. The flow diversion element 170 helps to promote laminar flow, helps to do for fluid flow to the side perimeter 154 of the chain bar core, and in the present example through surface tension and pressure promotes fluid flow to the nose sprocket assembly. The flow diversion element 170 includes a pair of substantially concave upstream flow surfaces 172 and a pair of downstream slightly convex surfaces 174, forming a somewhat elongated diamond-shaped island. The distal flow diversion element helps to maintain flow pressure at the distal end portion of the core.
[0079] Upstream flow islands or flow diversion elements may also be included. For example, flow diversion elements 176 (FIG. 6) are positioned substantially across the openings of the flow branches 152. These flow diversion elements 176 are narrower than the flow diversion element 117 downstream. The diversion elements 176 promote laminar flow and direct flow. The flow diversion element 176 on the opposite side of the flow Inlet channel 138 from which fluid flows helps to direct flow from that side, as does the flow valve 150. For example, the flow diversion element 176 redirects fluid flow from the Inlet channel 138 along the central channel so that the newly incoming fluid flow from the opposite side inlet channel does not flow predominantly out the opposite flow branch 152. Additionally, the opposite flow diversion element 176 may help to encourage flow into the respective flow branch. Other flow diversion elements may be placed as desired to encourage or promote a desired flow pattern. Additionally, further flow outlet ports may be included in the core to improve fluid flow to the cutting chain.
[0080] The outlet manifold 132 at the distal end portion of the core 106 includes planar panel portions 180 and 182 distal of the flow channels 166. The panel portions 180 and 182 extend substantially in the plane of the core. Bosses 120 extend upward from the respective panel portions (FIG. 12). The panel portions 180 and 182 extend distally to respective end surfaces 184 adjacent the nose sprocket.
[0081] The main flow channel leaves the diamond-shaped diversion element 170 and continues toward the nose sprocket and becomes deeper below the upper surface of the planar portions 180 and 182. The distal flow channel 186 (FIG. 12) has a depth that increases to be greater than the thickness of the planar portion of the core and into the outlet manifold 132, including that portion of the outlet manifold that extends into the plane of the second side plate 104 through the oval opening 128 (FIG. 4). The distal flow channel 186 permits fluid flow from the main flow channel underneath the nose sprocket to the bearings 124 and to the side of the nose sprocket 118. The outlet manifold includes a protruding plate 188 that extends into the oval opening. The distal flow channel 186 is formed in part in the protruding plate 188 while still being formed as part of the core 106. The distal flow channel 186 continues within the protruding plate 188 with a substantially flat bottom surface 192 and upwardly-curving surface 192 at the end of the flow channel. The upwardly-curving surface 192 forces the fluid to flow against the nose sprocket and the bearings. Other configurations of the core and/or outlet manifold can direct fluid in the area of the sprocket and bearings as desired.
[0082] The water flow channel surfaces are formed substantially smooth with a smooth finish. The remaining portions of the core 106, when formed from a plastic material, include a textured finish. The finish is a random texture that increases the surface area for bonding using adhesive or a bonding agent. The texture can be formed with a plastic part is molded, for example, or after. Molding can include a texture, such as through the technique applied by Mold-Tech. Other structures and methods may also be used for increasing bonding strength, such as cuts in the plastic or other core material described more fully herein.
[0083] The chain bar can be assembled from the first and second side plate and the core 106 by applying adhesive, for example to the second side plate over those surfaces where the core will be substantially opposite and in contact with the side plate but for the existence of the adhesive. The core is then placed against the second side plate using the bosses and the respective openings 122 for registration and alignment. The flow valve and nose sprocket assembly are placed in their respective positions relative to the core. The first side plate 102, with adhesive on that part of the surface that will come into contact with the core and bosses 120, is then placed against the core with the bosses 120 and registration with the openings 122. The nose sprocket and the fastening holes in the side plates are aligned as is conventional. The adhesive can then be cured to secure the laminate. It is noted that a plastic core 106 can be used to resist corrosion of the second side plate 104, and the adhesive on the first side plate 102 can also inhibit corrosion of the first side plate. Additionally, the adhesive can be cured with the first side plate down or on the bottom of the chain bar assembly during curing so that adhesive from the first side plate does not flow upward into the flow channels.
[0084] In another example of a chain bar core that can be used with the side plates as described to form a chain bar assembly, a core 200 (FIG. 18) includes flow channels 202 that are formed completely through the entire thickness of the core. (The circles in FIG. 18 corresponding to the fluid inlet openings would not be present in the core, and the post for receiving the fluid valve 150 in the example of FIG. 4 would be supported on one of the adjacent side plate. Additionally, any islands or flow diversion elements that would be freestanding in a flow channel would be supported by one or both adjacent side plates.) The core can be formed from metal, plastic or other materials, for example by laser cutting or other forming technique.
[0085] In one example, the water channels are formed by cutting and connecting tabs such as tab 204 (FIG. 19) is maintained in the core to keep the various segments of the core coupled to each other and in the desired arrangement prior to assembly with the adjacent side plates. In the present example, the tab 204 includes a bridge portion 206 extending between adjacent spaced apart sidewalls of the corresponding flow channel and a manipulating portion 208. In the present example, the bridge portion 206 is internal to the perimeter of the core. In other examples, the bridge portion can be connected to the perimeter surface elements of the spaced apart segments forming a flow channel. The manipulating portion 208 can be used to remove the bridge portion 206 at the desired time, for example when the core 200 has been applied to an adjacent side plate, for example through adhesive. Each of the outlet ports can include respective tabs for maintaining the various otherwise separate core segments in their desired orientation with respect to each other. Additionally, tabs can be used to position islands or flow diversion elements as desired until such time as the core elements are positioned relative to a side plate. When a core assembly is ready to be applied to an adjacent side plate, for example through adhesive, the core and the side plate can be combined and the tabs removed. Thereafter, the opposite side plate can be applied to form the assembly and the adhesive cured. In this example, the depth of the flow channels extends the entire thickness of the core. In this example also, if desired, the portions of the outlet manifold 132 in the embodiment of FIGS. 4-17 outside the plane of the core can be omitted.
[0086] In any of the core examples described herein, flow channels and other core components can be formed by cutting, for example laser cutting. Additionally, the complementary openings 120 as well as other openings such as the channel 110 can be formed in the side plates by laser cutting or other cutting means. A core can also have laser cut or other formed openings through the core to assist in strengthening the resulting chain bar. For example, in the example of the core 200 shown in FIG. 18, serpentine laser cut lines 210 are formed in the core 200 forming passageways extending through the thickness of the core. The lines 210 are each a closed-circuit, and do not extend to an outer perimeter of the core. These lines are nonlinear longitudinally and transversely of the core. The lines in the present example are noncircular, and spaced apart sidewalls have substantially the same spacing. Additionally, the spacing between sidewalls is substantially the same from one end of the opening to the other. On assembly, for example with an adhesive to bond the layers together, adhesive enters the openings of the lines 200, and may even extend completely through the thickness of the core, and between the spaced apart sidewalls. Such adhesive pocketed cuts or lines improve the sheer strength of the chain bar.
[0087] In any of the core examples described herein, lighting components may also be included or otherwise adapted for illumination through the chain bar for illuminating the surrounding area. For example, LEDs can be mounted on the side plates, for example three per side, and set into respective openings in the side plates (not shown). In addition, or alternatively, light sources in the chainsaw motor housing can illuminate the chain bar, and a translucent side plate or side plates can transmit light from such light sources to the surrounding area. Translucent materials may include polycarbonate and Lexan. Current may be provided to LEDs or other light sources through conductors embedded in the core such as a plastic core, or in flow paths in the core. Current may be generated by a generator producing current arising from fluid flow past the generator. Alternatively, a battery or other energy source may be embedded in the chain bar, for example in the core or a side plate. Lighting can be turned on through a manually accessible switch, or a detent switch adjacent the chain that is activated through chain motion. Alternatively, power can be obtained from the chainsaw, such as through a spark plug or other electrical source.
[0088] The chain bar is an example of a structure that supports a moving tool such as an abrading or cutting chain, for example for cutting concrete. U.S. Pat. No. 5,078,119 is an example of an application for a chain cutting apparatus, the specification and drawings of which are incorporated herein by reference. While the present description of apparatus and methods for supporting working structures and methods of making such supporting structures describes chain bars, it should be understood that similar configurations and methods of forming the configurations can be applied to other structures and assemblies. However, the present description provides as examples chain bars for chainsaw cutting assemblies, for example for concrete and wood applications.
[0089] In another example of a support structure for supporting a moving structure such as a cutting chain, a chain bar 400 (FIGS. 20-22) can be assembled in one or more of the ways and having one or more of the structures described previously with respect to the chain bar 100 and FIGS. 1-19, but may adopt one or more of the features described with respect to FIGS. 20-26 and 28. Where features of the chain bar 100 are included in the chain bar 400, such features are designated with the same reference numeral. However, it should be understood that additional features may be included, or other features than those of FIGS. 1-19 may be used. In the present example, the chain bar includes first and second side plates 402 and 404, respectively, each of which includes a mounting and support slot 110 for engaging a complimentary support bar of a conventional chainsaw (not shown but represented schematically in the referenced patent). Each of the side plates 402 and 404 include respective tensioning openings 406 for properly tensioning the cutting chain as desired.
[0090] The first side plate includes a first fluid inlet opening 408 (FIGS. 20 and 21) for allowing cooling fluid from the coolant supply of the chainsaw to flow into passageways in the core, designated generally at 410 (FIG. 21) and described more fully below. The second side plate includes a second fluid inlet 412 (FIG. 21) for allowing coolant to flow into a respective passageway formed in the core 410. The first and second inlet openings 408 and 412 are positioned on opposite sides of the support slot 110 so that the chain bar can be reversible about a longitudinal axis (not shown) on the chainsaw and still allow coolant supply from a single coolant supply on the chainsaw.
[0091] The chain bar also includes a nose sprocket 118A having a plurality of evenly distributed openings to reduce the weight of the sprocket. The sprocket is supported for rotational movement on a plurality of bearings 124 (FIG. 21) which are distributed about an apertured hub 126A. The hub and therefore the nose sprocket is secured between the first and second side plates through appropriate fasteners (not shown) conventional to chain bars.
[0092] Each of the first and second side plates include a plurality of matching holes, openings or apertures 414 for receiving registration or stack up pins (not shown) for assembling and securing the first and second side plates with the core elements during assembly. Each opening 414 in one side plate is exactly opposite a corresponding opening in the second side plate. Additionally, a pin extending between corresponding openings 414 in the side plates also pass through an adjacent structure or core element of the core assembly 410. During assembly, pins are placed in the openings 414 of one side plate and the core components of the assembly 410 are placed on their corresponding pins with adhesive 416 between the core component and the adjacent side plate. Adhesive is placed on the opposite core element surfaces and the other side plate placed against the core assembly 410 on the appropriate pins. The adhesive can then be cured to secure the side plates and the core assembly together. The nose sprocket assembly is secured in the conventional manner.
[0093] The side plates and the core assembly 410 include a proximal mounting area 418 (FIG. 20) for mounting the chain bar to a chainsaw. The geometry of the mounting area 418 is configured to correspond to the chainsaw with which it is to be used. The side plates in the mounting area include longitudinally extending and curving peripheral edge surfaces 420 and 422 (FIGS. 20-21) extending to a respective apex 424 and 426, respectively. The peripheral edge surfaces of the side plates support the cutting chain so that the cutting chain can extend longitudinally about the chain bar and pass over the outer peripheral edges of the chain bar. The peripheral edge surfaces of the chain bar are formed by respective peripheral edge surfaces of the corresponding side plates.
[0094] Considering first the first side plate 402, the side plate includes a longitudinally extending peripheral edge surface, designated generally at 428. For purposes of the present description, both the upper and lower longitudinally extending peripheral edge surfaces of the first side plate will be designated 428 as they are mirror images of each other about a longitudinal axis, and the chain bar is reversible. It will be understood that the description of the peripheral edge surface 428 applies to both the upper and lower longitudinally extending peripheral edge surfaces. Additionally, the longitudinally extending, opposite peripheral edge surfaces of the second side plate 404 are also identical to each other.
[0095] The edge surface 428 of the first side plate 402 (FIGS. 20-24) includes a plurality of surface discontinuities designated generally at 430. The surface discontinuities can take a number of configurations, and one or more such a configurations may make the edge surface 428 non-straight or other than continuously straight. The discontinuities can be uniform or non-uniform, but the discontinuities illustrated in the drawings repeat and have uniform configurations between one another. The discontinuities can be formed by a plurality of grooves, channels, slots, depressions, dimples or other recessed areas formed into the peripheral, transversely facing edge surfaces of the side plate 402. The recessed areas can be uniform or nonuniform, but in the present examples are uniform in spacing between each other and are uniform transversely from one side of the first side plate to the opposite side of the first side plate. Between the recessed areas, raised areas extend forming raised formations, and may be ridges, plateaus, lands or other raised structures. The raised structures form raised formations that can be uniform or nonuniform between each other, but in the present examples are uniform in dimensions and are uniform transversely from one side of the first side plate to the opposite side of the first side plate. The raised formations provide support structures and they are spaced apart from each other by the recessed formations to support the cutting chain has the cutting chain moves longitudinally in a direction of chain movement, for example distally toward the nose of the chain bar and then returning from the nose to the drive sprocket (not shown). With the spaced apart raised formation areas, the cutting chain is supported by the peripheral edges of the first side plate but contact occurs only at the raised formations and little if any contact occurs between the chain and the recessed formations. This helps to reduce heat generation between the chain and the chain bar, and may also reduce wear. The raised formations can have flat top supporting surfaces, rounded supporting surfaces or other surface geometries in the direction of chain movement as well as transversely.
[0096] In the example shown in FIGS. 20-26, each raised formation forms a land 432 that is substantially identical to each other raised formation on the first side plate, and includes a relatively flat land surface 434 (FIGS. 23-24) extending transversely or widthwise of the side plate and longitudinally between adjacent grooves 436. Each land extends longitudinally a first distance 438 (FIG. 25) about 0.100 inch, and in the present examples 0.098 inch.
[0097] Each recessed formation is formed by the grooves 436, which in the present examples are substantially uniform between one another and spaced the same distance apart from each other. Each groove is substantially identical to each other and extends transversely or widthwise of the first side plate. Each groove extends longitudinally from a first, proximal radiused surface 440 (FIG. 23) to a second, distal radiused surface 442. The groove includes a first angled surface 444 extending downwardly and distally from the first surface 440 to a bottom radiused surface 446 (FIG. 24). The first angled surface in the present example extends at an approximately 60 angle to a vertical, or a line transverse to the longitudinal axis of the chain bar. A second angled surface 448 extends upwardly and distally to the second radiused surface 442. The second angled surface is also at approximately 60 to a vertical. The depth of the grooves can be selected as desired, and can range from approximately 0.010 inch or less to as much as approximately 0.100 inch or more. The groove depth in the present example is approximately 0.015 inch. The depth of the grooves can also range from approximately 5% of the length of the land surface to 100% or more. Additionally, the longitudinal length of a groove, or the spacing between adjacent land surfaces, may be between 40 and 60% of the length of the land surface, but can be more or less. In the present examples, their length is approximately half the length of the land surface. The length 450 of the angled surfaces (FIG. 25) can be approximately 0.0235, and the radius 452 of the bottom surfaces is 0.015, and the radius 454 of the proximal and distal surfaces 440 and 442 are 0.010.
[0098] In the example of the chain bar described with respect to FIGS. 20-26, both of the first and second side plates 402 and 404 include respective peripheral surface discontinuities. In the present example, both of the first and second side plates include identical sets of land formations 432 and groove formations 436 with adjacent ones in a given side plate identical to each other. The land formations and groove formations in the first side plate are identical to respective land formations and groove formations in the second side plate. However, the proximal to distal or longitudinal positioning of the land and groove formations on the second side plate 404 are shifted longitudinally relative to adjacent land and groove formations on the first side plate 402, as depicted in FIGS. 22-24. In the present example, they are shifted approximately halfway relative to each other, for example so that the bottom of a groove on one side plate extending transversely would intersect an approximate midpoint of a land formation on the second side plate. The relative positioning of the lands and grooves of one side plate to the other side plate can be different, but a 50% or 90 phase shift maximizes the support for a given point on the cutting chain as the cutting chain moves along the peripheral surfaces of the side plates. It also reduces the likelihood that any element of the chain would contact a groove surface below the radiused surfaces 440 and 442.
[0099] The groove formations and the land formations in each of the side plates can be formed by laser cutting, for example using a laser cutting apparatus such as that depicted schematically at 456 producing a laser cutting beam 458 for cutting the desired surface configurations on a chain bar plate such as the first side plate 402 (FIG. 27). For example, after the side plate 402 is cut or formed to produce a general chain bar profile and openings cut in the side plate, for example using the laser, such as for openings 110, 406, 408 and 414, the side plate can be heat-treated. Then the laser 456 is used to cut the recessed and raised formations to produce the final edge configuration 428, such as that depicted in FIGS. 20-26. In the present example, the laser 456 cuts continuously from a point distal of the Apex 424 (FIG. 21) to form the land surfaces and groove surfaces as described herein. Laser cutting continues along the longitudinal peripheral surface, and in the present example, to the beginning of the curvature forming the nose of the chain bar.
[0100] In conjunction with the laser cutting process, the resulting edge surface in a metal side plate such as those used in the chain bar is heat-treated to a known heat treat depth 460 (FIG. 25) of approximately 0.020 inch. This heat treat depth in the present example is continuous longitudinally under the peripheral edge surfaces formed by the laser cutting of the land formations and groove formations. Consequently, the maximum heat treat depth from the top of a land surface 434 to a point 462 transversely inward from the bottom of a groove is the heat treat depth available to support the movement of the chain over the side plate. Therefore, even if a land surface 434 wears down approximately 0.020 inch, each groove on each side of the land surface includes heat-treated material, such as at 464, which continues to support the chain. Additionally, the amount of support surface past or beyond the 0.020 heat treatment zone under the land surface 434 is approximately equal to the groove depth. Therefore, the groove depth effectively increases the depth of the heat-treated material as seen by the moving cutting chain. Because the heat treatment provided by laser cutting extends to a known depth, the relative dimensions of the land formations and the groove formations can be selected as desired to optimize the wear characteristics of the side plates and chain bar. Once the raised and recessed formations are formed on the respective side plates, the first and second side plates can be assembled with the core assembly through adhesive and the registration pins as described herein. The adhesive can then be cured to produce the final chain bar assembly.
[0101] In the present example, the core assembly 410 (FIGS. 21-24 and 26) includes a plurality of core elements 470 (FIG. 21) formed and configured to provide the desired flow channel configurations for the chain bar. The peripherally-outside surfaces of core elements also define a channel for receiving portions of the cutting chain between the side plates 402 and 404. In the present example, the proximal-most core element 470A includes a central body portion 474 extending approximately half the length of the chain bar to define the interior edge surfaces of longitudinally extending flow channels to feed the side flow channels defined by others of the core elements 470. Each of the core elements includes respective openings 476 for receiving the registration pins extending between the opposite side plates for fixing the side plates and the core elements. When the chain bar is ready to be assembled, adhesive 416 is applied to the surfaces facing the respective side plates and the chain bar assembled and the adhesive cured.
[0102] A distal-most core element 470B (FIGS. 21 and 26) includes a proximal-facing, U-shaped cut 478 forming an inlet channel 480 for feeding fluid to the nose sprocket assembly. The inlet channel 480 extends to an opening 482 (FIGS. 21 and 26) formed into the second side plate 404. In the example shown, the opening 482 extends completely through the second side plate, but in another example can be formed to a depth into the second side plate less than the entire thickness of the side plate. In the example shown, the opening 482 is closed on the exposed side of the side plate by a cover, plug or other fluid seal to minimize the escape of fluid to the outside of the second side plate. Fluid flows parallel to the second side plate from the inlet 480 to an area underneath the nose sprocket assembly (as shown in FIG. 26). Other configurations for supplying fluid to the area of the nose sprocket assembly can be used.
[0103] In a manner similar to that described previously with respect to FIG. 18, each of the core elements 470 can include a plurality of openings, apertures or laser cuts 482 extending through the entire thickness of each core component to allow adhesive to extend through each core component and between the opposite side plates (FIG. 28). A plurality of the cuts 482 extends along or substantially parallel to flow channel edge surfaces of the core element. The cuts 482 can be continuous or broken, many of the cuts shown in FIG. 28 being broken or discontinuous. Laser cuts 44 adjacent to channel 480 in the distal-most core element are cut at locations between the wall 478 and the interior edge of the applied adhesive layer 416, to minimize adhesive flow into the inlet 480.
[0104] When a cutting chain is mounted on the chain bar with the chain bar installed on a chainsaw, the chain bar supports the cutting chain but the cutting chain links make only intermittent contact with the peripheral edge surfaces of each side plate. During operation, wear of the peripheral edge surfaces can be reduced because of the intermittent contact between the chain and the side plate surfaces. The cutting chain moves continuously at a relatively high speed over the chain bar surfaces but the generation of heat through friction can be reduced by the intermittent contact between the chain and the side plate edge surfaces. While the chain cuts the concrete, moving around the chain bar, the exposed surfaces of the land formations gradually wear exposing outer or shallow portions of the groove surfaces, while leaving deeper portions of the grooves relatively untouched. Therefore, as wear continues, heat-treated surfaces still remain for supporting the chain further into the groove and below, to the extent of the known heat treat depth. Additionally, the staggered or shifted land formations between the first and second side plates help to fully support the chain on the chain bar. The cutting chain can be in contact with a raised land formation on the first side plate while passing over a recessed groove area on the second support plate.
[0105] Having thus described several exemplary implementations, it will be apparent that various alterations and modifications can be made without departing from the concepts discussed herein. Such alterations and modifications, though not expressly described above, are nonetheless intended and implied to be within the spirit and scope of the inventions. Accordingly, the foregoing description is intended to be illustrative only.
