Cutting tool and method for manufacture

A cutting tool for use in a manually manipulated air hammer while the cutting tool is reciprocated by the air hammer and used to separate laminated materials, said cutting tool comprising:

• a blade of thin resiliently flexible metal, said blade having opposite major surfaces, a first sharpened edge, and a driven edge opposite said sharpened edge, opposite side edges extending between said sharpened and driven edges, and an imaginary centerline midway between said side edges extending between said sharpened and driven edges;
• and
• an adapter comprising
• a blade holder portion around a portion of said blade adjacent said driven edge including a rear part abutting said driven edge and front parts extending from said rear part along portions of said major surfaces of said blade toward said sharpened edge;
• means for retaining said portion of said blade adjacent said driven edge in said blade holder portion;
• and
• an elongate shank portion having an axis, said shank portion having a rear end, a portion adjacent said rear end shaped for engagement by said air hammer, and a front end axially spaced from and opposite said rear end, said front end being attached to said blade holder portion with said axis of said shank portion generally in the same plane as the imaginary centerline of said blade, and said shank portion extending generally away from said sharpened edge from said front end toward said rear end;
• said cutting tool having a mass of no greater than about 4.86 ounces per inch of length of the driven edge of the blade.

A method for making a cutting tool to be used in a manually manipulated air hammer while the cutting tool is reciprocated by the air hammer and used to separate laminated materials, said method comprising:

• providing a blade of thin resiliently flexible metal, said blade having opposite major surfaces, a first sharpened edge, and a driven edge opposite said sharpened edge, opposite side edges extending between said sharpened and driven edges, and an imaginary centerline midway between said side edges extending between said sharpened and driven edges;
• and
• molding polymeric material to form an adapter comprising
• a blade holder portion around a portion of said blade adjacent said driven edge including a rear part abutting said driven edge and front parts extending from said rear part along portions of said major surfaces of said blade toward said sharpened edge;
• and
• an elongate shank portion having an axis, said shank portion having a rear end, a portion adjacent said rear end shaped for engagement by said air hammer, and a front end axially spaced from and opposite said rear end, said front end being attached to said blade holder portion with said axis generally in the same plane as the imaginary centerline of said blade, and said shank portion extending generally away from said sharpened edge from said front end toward said rear end;
• said molding step being performed so that at least the majority of said adapter is formed of polymeric material to provide an average specific gravity for said adapter that is less than about 1.84.