Reciprocating Saw Blade Having Variable-Height Teeth and Related Method

A method comprising the following steps:

• mounting within a chuck of a reciprocating saw a reciprocating saw blade including a tang having an elongated axis and a blade portion having a cutting edge defined by a plurality of cutting teeth;
• wherein the cutting teeth define a repeating pattern of successive groups of teeth, each group of teeth includes a plurality of teeth of different species, including a plurality of set teeth, at least one relatively high tooth, and at least one relatively low tooth;
• and wherein prior to tooth set the at least one relatively high tooth is at least about 0.002 inch higher than the at least one relatively low tooth;
• driving the reciprocating saw blade with the reciprocating saw in a reciprocating cutting action between forward and backward strokes;
• and
• cutting a work piece by engaging the work piece with the reciprocatingly driven reciprocating saw blade and, in turn, during each of a plurality of forward strokes, engaging multiple teeth of the same species with the work piece, bearing a relatively higher chip load with the relatively high teeth in comparison to the relatively low teeth, protecting the relatively low teeth from chipping or damage with the preceding relatively high teeth, and cutting the work piece with the relatively low teeth at a higher speed in comparison to the relatively high teeth.

A reciprocating saw blade for use in a portable power reciprocating saw including a chuck for releasably engaging the saw blade, the reciprocating saw blade comprising:

• a reciprocating saw blade tang having an elongated axis and being engageable with the chuck of the reciprocating saw for attaching the reciprocating saw blade to the reciprocating saw;
• and
• a reciprocating saw blade portion having a cutting edge defined by a plurality of cutting teeth including at least one relatively high tooth, and at least one relatively low tooth, and wherein prior to any tooth set a difference in height between the at least one relatively high tooth and the at least one relatively low tooth is at least about 0.002 inch;
• wherein the at least one relatively high tooth defines a first clearance angle, and the at least one relatively low tooth defines a corresponding second clearance angle that is greater than the first clearance angle, wherein either (i) the first clearance angle defines a primary clearance angle of the at least one relatively high tooth and the second clearance angle defines a primary clearance angle of the at least one relatively low tooth;
• or (ii) the first clearance angle defines a secondary clearance angle of the at least one relatively high tooth and second clearance angle defines a secondary clearance angle of the at least one relatively low tooth.

A reciprocating saw blade for use in a portable power reciprocating saw, the reciprocating saw blade comprising:

• first means engageable with the reciprocating saw for attaching the reciprocating saw blade to the reciprocating saw;
• and
• a reciprocating saw blade cutting edge defined by a plurality of second means for cutting including at least one relatively high second means, and at least one relatively low second means, and wherein prior to any set a difference in height between the at least one relatively high second means and the at least one relatively low means is at least about 0.002 inch;
• wherein the at least one relatively high second means defines a first clearance angle, and the at least one relatively low second means defines a corresponding second clearance angle that is greater than the first clearance angle, wherein either (i) the first clearance angle defines a primary clearance angle of the at least one relatively high second means and the second clearance angle defines a primary clearance angle of the at least one relatively low second means;
• or (ii) the first clearance angle defines a secondary clearance angle of the at least one relatively high second means and the second clearance angle defines a secondary clearance angle of the at least one relatively low second means.

A method comprising the following steps:

• mounting within a chuck of a reciprocating saw a reciprocating saw blade including a tang having an elongated axis and a blade portion having a cutting edge defined by a plurality of cutting teeth including at least one relatively high tooth, and at least one relatively low tooth;
• and
• wherein prior to any tooth set a difference in height between the at least one relatively high tooth and the at least one relatively low tooth is at least about 0.002 inch, wherein the at least one relatively high tooth defines a first clearance angle, and the at least one relatively low tooth defines a corresponding second clearance angle that is greater than the first clearance angle, wherein either (i) the first clearance angle defines a primary clearance angle of the at least one relatively high tooth and the second clearance angle defines a primary clearance angle of the at least one relatively low tooth;
• or (ii) the first clearance angle defines a secondary clearance angle of the at least one relatively high tooth and the second clearance angle defines a secondary clearance angle of the at least one relatively low tooth;
• driving the reciprocating saw blade with the reciprocating saw in a reciprocating cutting action between forward and backward strokes;
• and
• cutting a work piece by engaging the work piece with the reciprocatingly driven reciprocating saw blade and, in turn, during each of a plurality of forward strokes, engaging multiple teeth with the work piece, bearing a relatively higher chip load with the at least one relatively high tooth in comparison to the at least one relatively low tooth, protecting the at least one relatively low tooth from chipping or damage with the preceding at least one relatively high tooth, and cutting the work piece with the at least one relatively low tooth at a higher speed in comparison to the at least one relatively high tooth.