Reciprocating Saw Blade with Plunge Nose

Abstract

A reciprocating saw blade has a body with two ends and two edges. The first end is a shanking end to secure the blade with a reciprocating saw. The second end is a plunging end to enter into a workpiece. The first edge has a plurality of teeth and gullets. A second edge opposes the first edge. The plurality of teeth has a first tooth immediately adjacent the plunging end. The first tooth is a full tooth and is also a raker or unset tooth. The first gullet adjacent the first tooth has a size at least 1.5 times the gullet size of the remainder of the plurality of gullets.

1 . A reciprocating saw blade comprising:
 a body having two ends and two edges, a first shanking end for securing the blade with a reciprocating saw and a second plunging end for entering a workpiece, a first edge having a plurality of teeth and gullets, said plurality of teeth and gullets being the same size, a second back edge opposing said first edge; and   said plurality of teeth having a first tooth immediately adjacent said plunging end, said first tooth having a size substantially equal to the remainder of teeth of said plurality of teeth, said first tooth being a full tooth and also a raker or unset tooth, a first gullet adjacent said first tooth said first gullet having a size at least 1.5 times the gullet size of the remainder of gullets of said plurality of gullets.   
   
   
       2 . The reciprocating saw blade according to  claim 1 , wherein said first gullet size is from 2 to 5.5 times the size of said plurality of gullets. 
   
   
       3 . The reciprocating saw blade according to  claim 1 , wherein said first tooth having relief face on a relief angle of about 35° to 50°. 
   
   
       4 . The reciprocating saw blade according to  claim 1 , wherein said plunging end has an end surface intersecting said first tooth forming a cutting edge. 
   
   
       5 . The reciprocating saw blade of  claim 1 , wherein said plurality of teeth are set teeth. 
   
   
       6 . A reciprocating saw blade comprising:
 a body having two ends and two edges, a first shanking end for securing the blade with a reciprocating saw and a second plunging end for entering a workpiece, a first edge having a plurality of teeth and gullets, said plurality of teeth and gullets being the same size, a second back edge opposing said first edge; and   said plurality of teeth having a first tooth immediately adjacent said plunging end, said first tooth having a size substantially equal to the reminder of teeth of said plurality of teeth, said first tooth being a full tooth and also a raker or unset tooth;   said plurality of teeth having substantially the same size and one tooth immediately adjacent said first tooth of said plurality of teeth is missing from said plurality of teeth forming a gap between said first tooth and said plurality of teeth so that said first tooth engages a workpiece during plunge cutting and initiates a kurf prior to the remaining plurality of teeth contacting the workpiece.   
   
   
       7 . The reciprocating saw blade of  claim 6 , wherein two teeth of said plurality of teeth are missing to form said gap. 
   
   
       8 . The reciprocating saw blade according to  claim 6 , wherein said first tooth having a relief face on a relief angle of about 30° to 50°. 
   
   
       9 . The reciprocating saw blade according to  claim 6 , wherein said plunging end has an end surface intersecting said first tooth forming a cutting edge. 
   
   
       10 . The reciprocating saw blade of  claim 6 , wherein said plurality of teeth are set teeth. 
   
   
       11 . The reciprocating saw blade of  claim 6 , wherein a cutting edge is formed at the intersection of said relief face and an end surface of the second edge. 
   
   
       12 . A method for manufacturing a reciprocating saw blade comprising:
 forming a plurality of teeth into coil stock;   feeding said coil stock into a die set;   locating the teeth on said coil stock in said die set;   flattening a portion of said teeth on said coil stock in said die set;   forming a first tooth and a first gullet of a reciprocating saw blade out of said flattened portion of said coil stock in said die set; and   forming a reciprocating saw blade having a first tooth with a first gullet, said first gullet being enlarged with respect to remaining gullets of said plurality of gullets.   
   
   
       13 . The method of  claim 12 , further comprising said flattening, flattening at least three teeth of said plurality of teeth. 
   
   
       14 . The method of  claim 12 , further comprising punching said coil stock to form said first tooth, first gullet, third tooth and saw blade. 
   
   
       15 . The method of  claim 12 , further comprising milling and setting said plurality of teeth on said coil stock. 
   
   
       16 . The method of  claim 15 , further comprising flattening said set teeth to form said first tooth and third tooth as a raker or unset teeth. 
   
   
       17 . The method of  claim 12 , further comprising said first gullet having a size 1.5 to 5.5 times the size of the remaining gullets of said plurality of gullets.