Saw blade having thin film ceramic coating

Patent metadata

Field	Value
Publication number	US-2025025953-A1
Application number	US-202418906636-A
Country	US
Kind code	A1
Filing date	Oct 4, 2024
Priority date	Jul 19, 2019
Publication date	Jan 23, 2025
Grant date	—

Abstract

A saw blade may include a body and a plurality of teeth disposed on the body. At least one tooth of the plurality of teeth includes a substrate forming a tip of the at least one tooth. The saw blade may further include a thin film ceramic coating overlaying at least the substrate and having a greater strength than the substrate. The substrate is edge prepped to refine a micro geometry of the plurality of teeth. The thin film ceramic coating is applied after the substrate is edge prepped and a thickness of the thin film ceramic coating varies at locations where the substrate is edge prepped.

First claim

1 . A saw blade comprising:
a body; a plurality of teeth disposed on the body and defining a cutting portion, at least one tooth of the plurality of teeth including a substrate forming a tip of the at least one tooth; and a thin film ceramic coating overlaying at least the substrate and having a greater strength than the substrate, wherein the substrate is edge prepped to refine a micro geometry of the plurality of teeth, wherein the thin film ceramic coating is applied after the substrate is edge prepped, and wherein a thickness of the thin film ceramic coating varies at locations where the substrate is edge prepped.

2 . The saw blade of claim 1 , wherein the body and the plurality of teeth form a single monolithic component.

3 . The saw blade of claim 1 , wherein the substrate is received by a pocket provided on the at least one tooth.

4 . The saw blade of claim 1 , wherein the thin film ceramic coating also overlays the plurality of teeth.

5 . The saw blade of claim 1 , wherein each of the plurality of teeth includes a substrate that forms a tip of each tooth.

6 . The saw blade of claim 5 , wherein the thin film ceramic coating overlays the substrate on each of the plurality of teeth.

7 . The saw blade of claim 1 , wherein the thin film ceramic coating is applied to the substrate via physical vapor deposition.

8 . The saw blade of claim 1 , wherein the thin film ceramic coating has a thickness between approximately 3.0 micrometers and approximately 4.0 micrometers.

9 . The saw blade of claim 8 , wherein the thin film ceramic coating has a thickness of approximately 3.5 micrometers.

10 . The saw blade of claim 1 , wherein the thin film ceramic coating is composed of one selected from a group consisting of aluminum titanium nitride, aluminum chromium nitride, aluminum titanium chromium nitride, and titanium molybdenum nitride.

11 . The saw blade of claim 1 , wherein the substrate is a separate component that is secured onto the at least one tooth via welding.

12 . The saw blade of claim 1 , wherein the substrate is composed of one selected from a group consisting of H6F grade carbide having a sub-micron grain size, H10F grade carbide having a sub-micron grain size, and H15F grade carbide having a sub-micron grain size.

13 . The saw blade of claim 1 , wherein the thin film ceramic coating is composed of an aluminum-based material.

14 . A saw blade comprising:
a body having a first end, a second end, and an edge extending between the first end and the second end; a cutting portion disposed on the edge, the cutting portion including a plurality of teeth extending along the edge; a plurality of substrates, each substrate coupled to a lip of one of the plurality of teeth to form a tip of the one of the plurality of teeth; and a thin film ceramic coating overlaying a portion of the cutting portion, such that the plurality of substrates is covered by the thin film ceramic coating, wherein each substrate is edge prepped to refine a micro geometry of the plurality of teeth, wherein the thin film ceramic coating is applied after the plurality of substrates is edge prepped, and wherein a thickness of the thin film ceramic coating varies at locations where the substrates are edge prepped.

15 . The saw blade of claim 14 , wherein the thin film ceramic coating overlays an entirety of the body.

16 . The saw blade of claim 14 , wherein each substrate is a separate component that is secured onto each tooth via welding.

17 . The saw blade of claim 14 , wherein the thin film ceramic coating is composed of one selected from a group consisting of aluminum titanium nitride, aluminum chromium nitride, aluminum titanium chromium nitride, and titanium molybdenum nitride.

18 . A method for manufacturing a saw blade, the method comprising:
forming a body and a plurality of teeth disposed along an edge of the body; securing a substrate to a lip of each one of the plurality of teeth to form a tip of each of the plurality of teeth; edge prepping the substrate to refine a micro geometry of the plurality of teeth; and applying a thin film ceramic coating after the substrate is edge prepped, wherein a thickness of the thin film ceramic coating overlaying at least the substrate varies at locations where the substrate is edge prepped.

19 . The method of claim 18 , wherein securing the substrate includes welding a carbide substrate to the lip of each one of the plurality of teeth.

20 . The method of claim 18 , wherein applying the thin film ceramic coating includes applying the thin film ceramic coating via physical vapor deposition.

Assignees

• Milwaukee Electric Tool Corp

Inventors

• Dietz Carl
• Marich Milorad
• Gilbert Chris

Classifications

• C23C14/34

  Sputtering · CPC title

• C23C14/24

  Vacuum evaporation · CPC title

• C23C14/0641

  Nitrides (C23C14/0617 takes precedence) · CPC title

• B23D61/125

  Composite body, e.g. laminated · CPC title

• B23D61/127 Primary

  of special material · CPC title