Chemically sharpening blades

Patent metadata

Field	Value
Publication number	US-10478984-B2
Application number	US-201715845351-A
Country	US
Kind code	B2
Filing date	Dec 18, 2017
Priority date	Mar 2, 2015
Publication date	Nov 19, 2019
Grant date	Nov 19, 2019

Abstract

A method for forming a cutting tool includes masking a metal base with one or more masks, the one or more masks including at least one variable permeability mask, and chemically etching the masked metal base to form a blade of the cutting tool.

First claim

What is claimed is:

1. A method for forming a metal base, the method comprising
applying a first mask and a second mask to a first side of the metal base to form a first window between the first mask and the second mask;
applying a third mask and a fourth mask to a second side of the metal base to form a second window between the third mask and the fourth mask;
applying a first variable permeability mask adjacent to the third mask of the second side of the metal base; and
chemically etching the metal base at the first window and the second window in a first stage to form a first void on the first side and a second void on the second side.

2. The method of claim 1 , wherein the first variable permeability mask is in contact with the third mask.

3. The method of claim 1 , wherein the first variable permeability mask is continuous with the third mask.

4. The method of claim 1 , further comprising applying a fifth mask to cover the second side of the metal base including the second void.

5. The method of claim 4 , wherein the first void includes a trench which will isolate a residual end of the metal base for removal in the second etching stage.

6. The method of claim 4 , further comprising applying a sixth mask on the first side of the metal base and a second variable permeability mask adjacent to the sixth mask.

7. The method of claim 6 , wherein the second variable permeability mask is located between the sixth mask and the first void.

8. The method of claim 7 , wherein a space between the second variable permeability mask and the first void is larger than the second variable permeability mask.

9. The method of claim 6 , further comprising chemically etching the first void to create a blade surface in the metal base with an inflection point defined by a juncture of a distal convex portion and a proximal concave portion.

10. The method of claim 9 , wherein chemically etching the first void of the metal base removes material from only the first side of the metal base.

11. The method of claim 9 , wherein chemically etching the first void of the metal base includes forming a blade to include two bevels, the two bevels being located on the top and bottom sides of the blade, respectively.

12. The method of claim 1 , wherein chemically etching the metal base removes material from both of the first side and the second side of the metal base.

Assignees

• Hutchinson Technology

Inventors

• Pesavento Paul V
• Ladwig Peter F
• Davis Michael W
• Theget John A
• Swanson Kurt C
• Michaletz Joel B
• Anderson Philip W
• Mcdaniel Timothy A

Classifications

• B26D2001/0053

  having a special cutting edge section or blade section · CPC title

• B26B9/00

  Blades for hand knives · CPC title

• B26D1/0006 Primary

  Cutting members therefor · CPC title

• B26B9/02

  characterised by the shape of the cutting edge, e.g. wavy · CPC title

• C23F1/04

  Chemical milling · CPC title