# US 12,214,432 B2 · Circular saw

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- Number: US 12,214,432 B2
- Document ID: US12214432B2
- Status: Granted
- Kind: B2
- Application number: 17/051,817
- Filed: 2020-07-23
- Published: 2023-04-13
- Granted: 2025-02-04
- Earliest claimed: 2019-07-26
- Assignees: Milwaukee Electric Tool Corporation
- Applicants: Milwaukee Electric Tool Corporation
- Inventors: Jacob R. McDonald; Timothy J. Bartlett; Karly M. Schober; Paul W. Eiche
- Web page: https://patentgrep.com/patent/US12214432B2

## CPC

- B23D 59/006: {for removing or collecting chips}
- B27B 9/00: Portable power-driven circular saws for manual operation (details or components, e.g. handles, casings, of portable power-driven tools not particularly related to the operation performed B25F5/00)
- B23D 45/16: Hand-held sawing devices with circular saw blades
- B23D 47/12: of drives for circular saw blades
- B25F 5/00: Details or components of portable power-driven tools not particularly related to the operations performed and not otherwise provided for
- B25F 5/008: {Cooling means}
- B27G 19/04: for manually-operated power-driven circular saws
- B23D: PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR (making toothed gears or the like B23F; cutting metal by applying heat locally B23K; arrangements for copying or controlling B23Q)
- B27B: SAWS FOR WOOD OR SIMILAR MATERIAL; COMPONENTS OR ACCESSORIES THEREFOR (saws specially adapted for pruning or debranching A01G3/08; sawing apparatus specially adapted for felling trees A01G23/091; features not restricted to a particular type of wood saw B23D, e.g. attaching saw blades B23D51/00; machine tool frames, beds, pillars or like members, in general B23Q1/01)
- B25F: COMBINATION OR MULTI-PURPOSE TOOLS NOT OTHERWISE PROVIDED FOR; DETAILS OR COMPONENTS OF PORTABLE POWER-DRIVEN TOOLS NOT PARTICULARLY RELATED TO THE OPERATIONS PERFORMED AND NOT OTHERWISE PROVIDED FOR {(machines or arrangements of machines for performing specified combinations of different metal-working operations not covered by a single other subclass B23P23/00 and subgroups)}
- B27G: ACCESSORY MACHINES OR APPARATUS FOR WORKING WOOD OR SIMILAR MATERIALS; TOOLS FOR WORKING WOOD OR SIMILAR MATERIALS (tools for grinding B24D; sawing tools B27B33/00; tools for slotting or mortising machines B27F5/02; tools for the manufacture of wood shavings, chips, powder or the like B27L11/00); SAFETY DEVICES FOR WOOD WORKING MACHINES OR TOOLS

## Abstract

A circular saw includes a blade guard and a saw blade at least partially enclosed within the blade guard. The saw blade has an outer diameter that is greater than 6 inches. The circular saw further includes a motor housing coupled to the blade guard, a brushless electric motor supported within the motor housing, and a battery pack for providing power to the brushless electric motor.

## Claims

### Claim 1

A circular saw comprising:
a blade guard;
a saw blade at least partially enclosed within the blade guard, the saw blade has an outer diameter that is greater than 6 inches;
a motor housing coupled to the blade guard;
a brushless electric motor supported within the motor housing;
a battery pack for providing power to the brushless electric motor;
a cover removably coupled to the blade guard, the cover including an inner wall and an outer wall defining a storage receptacle therebetween in which debris is collected during a cutting operation; and
a rib positioned within a gap between the blade guard and the inner wall of the cover to prevent debris from falling out while travelling to the storage receptacle.

### Claim 2 (depends on 1)

The circular saw of claim 1, wherein the battery pack has a nominal voltage less than 20 volts.

### Claim 3 (depends on 2)

The circular saw of claim 2, wherein the battery pack is configured to output at least 100 amperes of current to the brushless electric motor.

### Claim 4 (depends on 3)

The circular saw of claim 3, wherein the battery pack is configured to provide a power output of at least 1,800 watts.

### Claim 5 (depends on 1)

The circular saw of claim 1, wherein the brushless electric motor has an output shaft with a pinion, the output shaft defining a motor rotation axis;
wherein the circular saw further includes a drive gear with a drive axis that is parallel with the motor rotation axis, the drive gear is coupled to an arbor to which the saw blade is clamped to for rotation; and
wherein the brushless electric motor is configured to rotate the output shaft as the pinion interfaces with the drive gear.

### Claim 6 (depends on 5)

The circular saw of claim 5, wherein the drive axis also defines a rotational axis of the saw blade.

### Claim 7 (depends on 6)

The circular saw of claim 6, wherein the saw blade is driven by the brushless electric motor to rotate within a range of 3,500 revolutions per minute and 4,000 revolutions per minute.

### Claim 8 (depends on 1)

The circular saw of claim 1, wherein the brushless electric motor is operable at a maximum speed that is greater than 15,000 revolutions per minute.

### Claim 9 (depends on 1)

The circular saw of claim 1, wherein the outer diameter of the saw blade is greater than 8 inches.

### Claim 10 (depends on 1)

The circular saw of claim 1, wherein the saw blade is configured to cut metal.

### Claim 11 (depends on 1)

The circular saw of claim 1, wherein the blade guard defines an exhaust chamber and the brushless electric motor includes a fan having a base plate and a plurality of blades extending from the base plate, and wherein the circular saw further includes a first baffle positioned adjacent the fan and a second baffle positioned radially outward of the fan, the first baffle is in facing relationship with the base plate.

### Claim 12 (depends on 11)

The circular saw of claim 11, wherein a cooling airflow is axially induced by the fan through the brushless electric motor in response to activation of the brushless electric motor, the fan is configured to redirect the cooling airflow in a radial direction against the second baffle, and wherein the second baffle is configured to redirect the cooling airflow in an axial direction toward the exhaust chamber in the blade guard.

### Claim 13 (depends on 12)

The circular saw of claim 12, wherein the plurality of blades are located between the base plate and the first baffle.

### Claim 14 (depends on 12)

The circular saw of claim 12, wherein the brushless electric motor includes a case, and wherein the second baffle extends between the case and the blade guard.

### Claim 15 (depends on 12)

The circular saw of claim 12, wherein the blade guard includes an exhaust opening, and wherein the cooling airflow is exhausted to atmosphere through the exhaust opening.

### Claim 16 (depends on 15)

The circular saw of claim 15, wherein the motor housing includes an inlet opening, and wherein the cooling airflow is drawn into the motor housing through the inlet opening.

### Claim 17 (depends on 12)

The circular saw of claim 12, wherein the circular saw further includes a circuit board positioned within the cooling airflow.

### Claim 18 (depends on 1)

The circular saw of claim 1, wherein the rib is one of a plurality of ribs, and wherein the plurality of ribs includes radial ribs and a horizontal rib.

### Claim 19 (depends on 1)

The circular saw of claim 1, wherein the rib is disposed on the blade guard.

### Claim 20

A circular saw comprising:
a blade guard;
a saw blade at least partially enclosed within the blade guard;
a motor housing coupled to the blade guard;
an electric motor supported within the motor housing, the electric motor includes an output shaft that is operable at a maximum speed greater than 15,000 revolutions per minute;
a battery pack for providing power to the electric motor, the battery pack has a nominal voltage up to 20 volts and is configured to output at least 100 amperes of current to the electric motor to provide a power output of at least 1,800 watts;
a cover removably coupled to the blade guard, the cover including an inner wall and an outer wall defining a storage receptacle therebetween in which debris is collected during a cutting operation; and
a rib positioned within a gap between the blade guard and the inner wall of the cover to prevent debris from falling out while travelling to the storage receptacle.

### Claim 21 (depends on 20)

The circular saw of claim 20, wherein the saw blade has an outer diameter that is greater than 6 inches.

### Claim 22 (depends on 20)

The circular saw of claim 20, wherein the blade guard defines an exhaust chamber and the electric motor includes a fan, and wherein the circular saw further includes a first baffle and a second baffle that direct airflow from the fan to the exhaust chamber.

### Claim 23 (depends on 20)

The circular saw of claim 20, wherein the rib is one of a plurality of ribs, and wherein the plurality of ribs includes radial ribs and a horizontal rib.

### Claim 24 (depends on 20)

The circular saw of claim 20, wherein the rib is disposed on the blade guard.