Portable circular saw with improved cutting capabilities

Abstract

Disclosed herein is a portable circular saw with improved cutting capabilities. The portable circular saw includes a motor and an arbor configured to operably mount a circular saw blade to the portable circular saw. In some examples, the portable circular saw includes a circular saw blade, the portable circular saw has a blade diameter, the portable circular saw has a maximum cutting depth, and the ratio of the maximum cutting depth to the blade diameter is at least 0.35 and at most 0.45. In some examples, the portable circular saw includes a base plate defining an arbor-facing side. In some such examples, at least 95% of the portable circular saw is completely contained within the footprint of the portable circular saw. In some such examples, the entire portable circular saw may be contained within the base plate width of the base plate.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63 / 044,034, filed June 25, 2020, the entire disclosure of which is incorporated herein by reference.

[0002] FIELD OF THE DISCLOSURE The present disclosure relates generally to a portable circular saw with improved cutting capabilities. [Background technology]

[0003] Circular saws utilize a rotating circular saw blade to cut a workpiece. Portable circular saws are a class of circular saws configured to be held and manipulated by a user while operatively using the portable circular saw to cut a workpiece. Conventional portable circular saws are generally relatively lightweight and may be utilized to produce cuts that may be inaccessible to larger and / or heavier fixed and / or semi-fixed circular saws, such as table saws, radial arm saws, miter saws, chop saws, up-cut saws, and panel saws. As an example, conventional portable circular saws may be moved and / or utilized in locations where it may be impractical or impossible to utilize fixed and semi-fixed circular saws. As another example, conventional portable circular saws may be smaller than fixed and semi-fixed circular saws, thereby allowing conventional portable circular saws to access areas of a workpiece that may be inaccessible to fixed and semi-fixed circular saws. Although effective in certain environments, conventional portable circular saws may still suffer from obvious limitations. Therefore, there is a need for a portable circular saw with improved cutting capabilities. Summary of the Invention [Means for solving the problem]

[0004] A portable circular saw with improved cutting capabilities is disclosed herein. The portable circular saw includes a motor including a motor shaft configured to rotate about a shaft rotation axis, and an arbor configured to operably mount a circular saw blade to the portable circular saw and to receive torque from the motor when the motor shaft rotates about the shaft rotation axis. In some examples, the portable circular saw includes a circular saw blade. In some such examples, the circular saw blade has a blade diameter, the portable circular saw has a maximum cutting depth, and a ratio of the maximum cutting depth to the blade diameter is at least 0.35 and at most 0.45. In some examples, the portable circular saw includes a base plate defining an arbor-facing side. In some such examples, when viewed from the arbor-facing side, a protrusion of the base plate defines a footprint for the portable circular saw, and at least 95% of the portable circular saw is completely contained within the footprint. In some such examples, the base plate may define a base plate width, and the entire portable circular saw may be contained within the base plate width. [Brief description of the drawings]

[0005] [Figure 1] 1 is a schematic diagram of an example of a portable circular saw according to the present disclosure. [Diagram 2] FIG. 2 is a less schematic top profile view of an example portable circular saw according to the present disclosure. [Diagram 3] FIG. 2 is a less schematic right side view of an example portable circular saw according to the present disclosure. [Figure 4] FIG. 2 is a less schematic left side view of an example portable circular saw according to the present disclosure. [Diagram 5] FIG. 2 is another less schematic left side view of an example portable circular saw according to the present disclosure. [Figure 6] FIG. 2 is another less schematic left side view of an example portable circular saw according to the present disclosure. [Figure 7] FIG. 2 is a less schematic front view of an example of a portable circular saw according to the present disclosure. [Figure 8] FIG. 2 is a less schematic rear view of an example portable circular saw according to the present disclosure. [Figure 9]FIG. 2 is a less schematic top view of an example of a portable circular saw according to the present disclosure. [Figure 10] FIG. 2 is a less schematic bottom view of an example portable circular saw according to the present disclosure. [Figure 11] 11 is a less schematic cross-sectional view of the circular saw of FIGS. 2 to 10 taken along line 11-11 of FIG. 4. [Figure 12] 2A-2C are less schematic illustrations of example components of a portable circular saw according to the present disclosure. [Figure 13] 2A-2C are less schematic illustrations of example components of a portable circular saw according to the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0006] Figures 1-13 provide examples of portable circular saws 10, and / or components thereof, according to the present disclosure. Elements that serve similar or at least substantially similar purposes are labeled with the same numbers in each of Figures 1-13, and these elements may not be discussed in detail herein with reference to each of Figures 1-13. Similarly, not all elements are labeled in each of Figures 1-13, but the reference numbers associated therewith may be utilized herein for consistency. Elements, components, and / or features discussed herein with reference to one or more of Figures 1-13 may be included in and / or utilized with any of Figures 1-13 without departing from the scope of the present disclosure.

[0007] In general, elements that tend to be included in a particular embodiment are illustrated with solid lines, while elements that are optional are illustrated with dashed lines, however, elements shown with solid lines may not be essential to all embodiments and may be omitted in some embodiments without departing from the scope of the disclosure.

[0008] FIG. 1 is a schematic diagram of an example of a portable circular saw 10 according to the present disclosure, while FIGS. 2-10 are less schematic illustrative diagrams of an example of a portable circular saw 10 according to the present disclosure that may also include and / or be a plunge saw 30, a track saw 40, and / or a bevel saw 50. More specifically, FIG. 2 illustrates a top profile view of the portable circular saw 10, and FIG. 3 illustrates a right side view of the portable circular saw 10. FIG. 4 illustrates a left side view of the portable circular saw 10 illustrating the portable circular saw in a fully lowered orientation 52, FIG. 5 illustrates a left side view of the portable circular saw 10 illustrating the portable circular saw in a fully retracted orientation 54, and FIG. 6 illustrates the left side view of FIG. 5 with several covers removed. 7 is a front view of the portable circular saw 10, FIG. 8 is a rear view of the portable circular saw 10, FIG. 9 is a top view of the portable circular saw 10, and FIG.

[0009] As collectively illustrated by FIGS. 1-10 , the portable circular saw 10 includes a motor 90 including a motor shaft 92 configured to rotate about a shaft rotation axis 94. The portable circular saw 10 also includes an arbor 100 configured to operatively mount a circular saw blade 200 to the portable circular saw and to receive torque from the motor 90 when the motor shaft 92 rotates about the shaft rotation axis. Receipt of this torque may cause the arbor to rotate about the arbor rotation axis 106, which may in turn cause the circular saw blade to rotate about the arbor rotation axis. In other words, the circular saw blade 200 may be configured for rotational movement with the arbor 100. Rotation of the circular saw blade 200 may facilitate cutting of a workpiece 98 with the circular saw blade, as illustrated diagrammatically in FIG. 1 .

[0010] The portable circular saw 10 may be any suitable type or style of portable circular saw adapted, configured, designed, and / or constructed to utilize the circular saw blade 200 to cut a workpiece. In some examples, the portable circular saw 10 may include additional features and / or functionality. Examples of such portable circular saws 10 include the plunge saw 30, the track saw 40, and / or the bevel saw 50. In some examples, the portable circular saw 10 may include structures and / or features from and / or incorporate the functionality of more than one of the above saws. By way of example, and as discussed in more detail herein, a given portable circular saw 10 may be the plunge saw 30, the track saw 40, and / or the bevel saw 50, and / or may incorporate or include the functionality of the portable circular saw 12, the plunge saw 30, the track saw 40, and / or the bevel saw 50. Thus, while a portable circular saw 10 according to the present disclosure may include one or more of the features disclosed herein, it is not necessary that the portable circular saw 10 include all of the features disclosed herein.

[0011] The motor 90 may include any suitable structure capable of providing motive power for rotation of the motor shaft 92 and / or for operation of the circular saw blade 200. Examples of the motor 90 include an electric motor, an AC electric motor, a DC electric motor, a brushless DC motor, a variable speed motor, and / or a single speed motor.

[0012] As illustrated in dashed lines in Figure 1 and solid lines in Figures 2, 4-6, 8-9 and 11, the portable circular saw 10 may include a gripping area 60 configured to be grasped and / or held by a user while operating the portable circular saw. The gripping area 60, when present, may be referred to herein as and / or may be a handle or handgrip.

[0013] As also illustrated by dashed lines in Figure 1 and solid lines in Figures 2, 4-6, and 11, the portable circular saw 10 may include at least one switch 65. The switch 65, when present, may be configured to be selectively activated by a user of the portable circular saw, such as to enable and / or allow current to be provided to at least one other component of the portable circular saw and / or to allow power to be driven to that at least one other component of the portable circular saw.

[0014] As an example, selective actuation of the switch 65 may be utilized to enable operation of the motor controller 554 of the portable circular saw, selectively apply current to the motor 90, enable the motor controller to selectively apply current to the motor, and / or allow or direct the motor to provide motive force for rotation of the motor shaft, as shown in FIGS. 1 and 12-13. In some examples, the current may be utilized to power or directly power at least one other component of the portable circular saw, such as the motor 90. In some such examples, the current may be referred to herein as a power signal. In some examples, the current may be an electrical data signal that is sent to at least one other component of the portable circular saw, such as the motor controller of the portable circular saw. In some such examples, the current may be referred to herein as a data signal and / or an electrical data signal. Examples of the switch 65 include an electrical switch, a normally open electrical switch, a momentary electrical switch, and / or a latching momentary electrical switch.

[0015] As also illustrated in dashed lines in Figure 1 and solid lines in Figures 2-10, the portable circular saw 10 may include a workpiece support 300. The workpiece support 300, when present, may be configured to support the workpiece 98 and / or to position the portable circular saw relative to the workpiece when the workpiece is being cut or otherwise acted upon by the implement. For example, many portable circular saws 10 include a workpiece support 300 in the form of a base plate 304, foot plate, shoe, rack, and / or pad.

[0016] The portable circular saw 10 may include any suitable power source and corresponding power structure to power the motor 90. Examples of power structures include a power supply structure 70, such as a power cord 72 and / or a battery 74, as illustrated in FIG.

[0017] As also illustrated in dashed lines in FIG. 1 and solid lines in FIGS. 2-11, the portable circular saw 10 may include a blade guard 80. The blade guard 80, when present, may be configured to cover, store, and / or contain at least a region of the circular saw blade 200, such as to prevent or reduce the possibility of contact between a user and the circular saw blade. Some examples of the portable circular saw 10 may be configured such that the circular saw blade 200 moves and / or pivots in and out of the blade guard 80 as illustrated, such as by translation between the configuration illustrated in FIG. 3 and the configuration illustrated in FIG. 6. Some examples of the portable circular saw 10 may be configured such that the blade guard 80 includes a storable region 82, as illustrated in FIG. 1. The storable region may be configured to fold, rotate, and / or otherwise be stored when the portable circular saw is utilized to cut a workpiece. The storable region 82 may additionally or alternatively be referred to as a storage region 82 and / or a folding region 82.

[0018] In some examples, as discussed, the portable circular saw 10 includes and / or may be a plunge saw 30. In examples of portable circular saws 10 that are or include a plunge saw 30, the arbor 100 may be configured to move relative to the workpiece support 300 such that the areas 320 of the circular saw blade 200 that protrude from the workpiece support 300 are selectively different and / or the cutting depth of the portable circular saw is selectively different. For example, the arbor 100 may be configured to pivot relative to the workpiece support 300 as illustrated by translation between the configurations illustrated in Figures 3-4 and 7-8 and the configurations illustrated in Figures 5-6.

[0019] In a more detailed example, the workpiece support 300 may include and / or be a base plate 304, which may define an arbor-facing side 308 and an arbor-opposite side 312. The arbor 100 may be operatively attached to the arbor-facing side 308 of the base plate 304 with, through, and / or with the aid of a base plate pivot 316. In other words, the arbor-facing side 308 may face towards the arbor 100. In such an example, the arbor 100 and base plate 304 may be configured to rotate about the base plate pivot 316 relative to one another, such that the region 320 of the circular saw blade 200 extending on the arbor-opposing side 312 of the base plate is selectively different, as perhaps best illustrated by a translation from the configuration illustrated in Figures 1, 3-4, 7-8, and 11 illustrating a fully lowered orientation 52 to the configuration illustrated in Figures 5-6 illustrating a fully retracted orientation 54.

[0020] In other words, the arbor 100 may be configured to pivot relative to the workpiece support 300 through a range of relative orientations or angles, which may be bounded by a fully lowered orientation and a fully retracted orientation. For each relative orientation in this range of relative orientations, the circular saw blade 200 may extend on the arbor opposite side 312 by a corresponding amount, thereby providing a corresponding cutting depth to the portable circular saw.

[0021] In some examples, as discussed, the portable circular saw 10 includes and / or may be a track saw 40. In examples of portable circular saws 10 that are or include a track saw 40, the base plate 304 may include a rib receiving channel 324, as illustrated in FIGS. 1-2 and 7-11. The rib receiving channel 324 may be configured to receive a raised elongated rib 44 of the track 42, as perhaps best illustrated in FIG. 1. The track 42, sometimes referred to herein as an elongated track 42, may be formed from one or more elongated track segments or track portions 46, which may be operably attached relative to one another to define any suitable track length. During operation of the track saw 40, the track 42 may be operably attached or fastened to the workpiece 98 such that the edges of the track correspond to the desired cut line for the track saw. The track saw may then be positioned relative to the track such that the raised elongated ribs 44 are positioned within the rib receiving channels 324, and the track saw may then be translated along at least a portion of the length of the elongated track, thereby producing a straight cut along the desired cut line.

[0022] A portable circular saw 10 according to the present disclosure may have and / or exhibit an improved, high, and / or relatively high maximum cutting depth 224 as illustrated in Figures 1, 3-4, 7-8, and 11, as compared to conventional portable circular saws. This improved maximum cutting depth 224 may allow and / or facilitate cutting of thicker workpieces for a given blade diameter 220 of the circular saw blade 200 as compared to conventional portable circular saws, as illustrated in Figures 1 and 11. As a result, a portable circular saw 10 according to the present disclosure may provide improved and / or increased functionality and / or versatility as compared to conventional portable circular saws.

[0023] As used herein, the phrases "maximum cutting depth" and / or "maximum cutting depth 224" may indicate and / or refer to the maximum extent to which the circular saw blade 200 may extend below the arbor-opposing side 312 of the base plate 304 of the portable circular saw 10. In other words, the "maximum cutting depth" may indicate and / or refer to the maximum thickness of the workpiece 98 that the portable circular saw 10 can cut or be configured to cut in a single pass. When the portable circular saw 10 includes a plunge saw 30, the "maximum cutting depth" may correspond to the fully lowered orientation 52 of the plunge saw.

[0024] It may be desirable to optimize, maximize, and / or increase the maximum cutting depth 224 of the portable circular saw, such as to maximize and / or increase the thickness of a workpiece that may be cut in a single pass using the portable circular saw 10. In other words, it may be desirable to optimize and / or maximize the maximum cutting depth 224 that may be realized and / or achieved for a given blade diameter 220.

[0025] With this in mind, a portable circular saw 10 according to the present disclosure may have and / or define a ratio of maximum cutting depth 224 to blade diameter 220 that is greater than the corresponding ratio achievable with conventional portable circular saws. Example ratios include ratios of at least 0.3, at least 0.31, at least 0.32, at least 0.33, at least 0.34, at least 0.35, at least 0.36, at least 0.37, at least 0.38, at least 0.39, at least 0.4, at least 0.41, at least 0.42, at least 0.43, at least 0.44, at most 0.5, at most 0.49, at most 0.48, at most 0.47, at most 0.46, at most 0.45, at most 0.44, at most 0.43, at most 0.42, at most 0.41, at most 0.40, at most 0.39, at most 0.38, at most 0.37, at most 0.36, and / or at most 0.35.

[0026] As illustrated in Figures 1 and 11, a portable circular saw 10 according to the present disclosure may include an arbor 100 with an arbor rotation axis 106 that is parallel, or at least substantially parallel, to a shaft rotation axis 94 of a motor shaft 92 of a motor 90. By way of example, the angle between the arbor rotation axis and the shaft rotation axis may be at most 20 degrees, at most 15 degrees, at most 10 degrees, at most 8 degrees, at most 6 degrees, at most 4 degrees, at most 2 degrees, at most 1 degree, 0-10 degrees, 0-5 degrees, 0-2 degrees, or 0 degrees. This may be in contrast to a worm-driven portable circular saw, where the arbor rotation axis may be perpendicular, or at least substantially perpendicular, to the shaft rotation axis. With this in mind, a portable circular saw 10 according to the present disclosure may not be a worm-driven portable circular saw, may not be referred to herein as a worm-driven portable circular saw, and / or may be distinguished from a worm-driven portable circular saw.

[0027] The increase in maximum cutting depth 224 exhibited by the portable circular saw 10 according to the present disclosure may be accomplished in any suitable manner. By way of example, and with continued reference to Figures 1 and 11, the arbor axis of rotation 106 may be separate from and / or non-colinear with the shaft axis of rotation 94. In other words, the arbor 100 may be a separate structure from the motor shaft 92 and / or may be configured to operatively engage the motor shaft 92 to receive torque therefrom.

[0028] As a specific example, the motor shaft 92 may include and / or be operably attached to a shaft gear 93. Additionally or alternatively, the arbor 100 may include and / or be operably attached to an arbor gear 101. The shaft gear 93 may be configured to interface and / or mesh with the arbor gear 101, such as to transmit or efficiently transmit torque from the motor 90 to the arbor 100, thereby rotating the arbor 100 about an arbor rotation axis 106. In some examples, as illustrated, the arbor gear 101 may be positioned between the shaft gear 93 and the workpiece support 300 and / or its base plate 304. In some such examples, the arbor rotation axis 106 may extend directly between the shaft rotation axis 94 and the workpiece support 300. Additionally or alternatively, in some such examples, a line extending perpendicular to the arbor-facing side 308 and / or the arbor-opposite side 312 of the base plate 304 may pass through both the arbor rotation axis 106 and the shaft rotation axis 94. Such a configuration may allow the arbor rotation axis 106 to be positioned closer to the arbor-opposite side 312 of the base plate 304 than would otherwise be possible if the arbor rotation axis 106 was collinear with the shaft rotation axis 94, thereby increasing the maximum cutting depth 224 for conventional portable circular saws in which a conventional arbor rotation axis may be collinear with a conventional shaft rotation axis. In other words, as illustrated, the motor 90 may have and / or define a motor diameter 91 that may be relatively large and / or may significantly limit the maximum cutting depth 224 if the arbor rotation axis 106 was collinear with the shaft rotation axis 94 and / or if the arbor 100 was not positioned between the shaft gear 93 and the arbor gear 101.

[0029] With this in mind, in some examples, arbor gear diameter 102 of arbor gear 101 and / or shaft gear diameter 95 of shaft gear 93 may be selected based at least in part on motor diameter 91, such as to allow and / or provide clearance for the arbor gear and shaft gear. By way of example, the sum of arbor gear diameter 102 and shaft gear diameter 95 may be a multiple of a threshold gear diameter and / or may be within a range of a multiple of the threshold gear diameter of motor diameter 91. Examples of multiples of the threshold gear diameter and / or ranges of multiples of the threshold gear diameter include multiples of at least 0.20, at least 0.22, at least 0.24, at least 0.26, at least 0.28, at least 0.3, at least 0.32, at least 0.34, at least 0.36, at least 0.38, at least 0.40, at least 0.42, at least 0.44, at least 0.46, at most 0.5, at most 0.48, at most 0.46, at most 0.44, at most 0.42, and / or at most 0.40. Arbor gear diameters, shaft gear diameters, and motor diameters may also be referred to herein as equivalent diameters and / or may be measured in a plane perpendicular to the shaft rotation axis 94 and / or arbor rotation axis 106.

[0030] In some examples, motor diameter 91 may be a threshold blade diameter multiple of blade diameter 220 and / or may be within a range of threshold blade diameter multiples of blade diameter 220. Examples of threshold blade diameter multiples and / or ranges of threshold blade diameter multiples include multiples of at least 0.20, at least 0.22, at least 0.24, at least 0.26, at least 0.28, at least 0.3, at least 0.32, at least 0.34, at least 0.36, at least 0.38, at least 0.40, at least 0.42, at least 0.44, at least 0.46, at most 0.5, at most 0.48, at most 0.46, at most 0.44, at most 0.42, and / or at most 0.40.

[0031] Additionally or alternatively, the arbor gear diameter 102 and the shaft gear diameter 95 may be selected based at least in part on a desired number of revolutions, or range of revolutions, for the circular saw blade 200. By way of example, the ratio of the arbor gear diameter 102 to the shaft gear diameter 95 may be a percentage of a threshold gear diameter and / or may be within a range of percentages of the threshold gear diameter. Examples of percentages of the threshold gear diameter and / or ranges of percentages of the threshold gear diameter include ratios of at least 3, at least 2.75, at least 2.5, at least 2.25, at least 2, at least 1.75, at least 1.5, at least 1.25, at least 1, at least 0.75, at least 0.5, at most 5, at most 4.5, at most 4, at most 3.5, at most 3, at most 2.5, and / or at most 2.

[0032] 12-13 are less schematic illustrations of example components 550 of a portable circular saw 10 according to the present disclosure. The portable circular saw 10 of FIGS. 12-13 may include and / or be a more detailed and / or different example, view, and / or example of the portable circular saw 10 of FIGS. 1-11. As a result, any structure, function, and / or feature disclosed herein with reference to the portable circular saw 10 of FIGS. 12-13 may be included in and / or utilized with the portable circular saw 10 of FIGS. 1-11 (although not necessarily in all examples) without departing from the scope of the present disclosure. Similarly, any structure, function, and / or feature disclosed herein with reference to the portable circular saw 10 of Figures 1-11 may be included in and / or utilized with the portable circular saw 10 of Figures 12-13 (although not necessarily in all instances) without departing from the scope of the present disclosure.

[0033] Figure 12 illustrates a heat sink 552 and motor controller 554 for a portable circular saw 10. Figure 13 illustrates the heat sink and motor controller of Figure 12 in combination with a motor 90 for a portable circular saw. Within a portable circular saw 10 according to the present disclosure, the components 550 may be selected and / or oriented to reduce the width of the portable circular saw 10 as compared to conventional portable circular saws.

[0034] 1, 8-9, and 11, the component 550 may be contained within the footprint of the portable circular saw by a majority, a substantial majority, and / or at least a threshold fraction of the portable circular saw. Examples of a threshold fraction include at least 90%, at least 92.5%, at least 95%, at least 97.5%, at least 99%, or the entirety of the portable circular saw. In other words, a threshold fraction of the portable circular saw is contained within the footprint of the portable circular saw and does not protrude or extend beyond the footprint in a direction parallel to a plane within which the footprint is defined.

[0035] The footprint of the portable circular saw may be defined by the base plate 304 of the portable circular saw. More specifically, the footprint of the portable circular saw may be defined as the protrusion or contour of the base plate when viewed from the arbor-facing side 308 of the base plate 304. As used herein, the phrase "contained within the footprint of the portable circular saw" may mean that a majority, a substantial majority, at least a threshold fraction, and / or the entirety of the portable circular saw does not protrude or extend beyond the protrusion or contour of the base plate when viewed from the arbor-facing side 308 of the base plate.

[0036] 1, 8-9, and 11, the base plate 304 may define a base plate width 372. The base plate width 372 may be measured in a direction perpendicular, or at least substantially perpendicular, to the base plate within which the circular saw blade rotates, and / or parallel, or at least substantially parallel, to an arbor rotation axis of the arbor of the portable circular saw. In some examples of the portable circular saw 10, the entirety of the portable circular saw may be contained within the base plate width.

[0037] Additionally or alternatively, components 550, including motor 90, heat sink 552, motor controller 554, and / or protective cover 556 for components 550 as illustrated in FIG. 8, may not protrude beyond the edge of the base plate, may protrude at least substantially the same or the same distance as the edge of the base plate, may be contained within the base plate width, and / or may protrude less than a threshold distance past the edge of the base plate. Examples of the threshold distance include distances of at most 1 millimeter (mm), at most 2 mm, at most 3 mm, at most 4 mm, at most 5 mm, at most 6 mm, at most 7 mm, at most 8 mm, at most 9 mm, and / or at most 10 mm. In some examples, base plate 304 may have and / or define blade-opposing edge 380 and / or blade-proximal edge 382 as illustrated in FIG. In some such examples, the component 550 may not protrude beyond the blade-opposing edge and / or the blade-proximal edge, may protrude the same or at least substantially the same distance as the blade-opposing edge and / or the blade-proximal edge, and / or may protrude less than a threshold distance beyond the blade-opposing edge and / or the blade-proximal edge. This may be facilitated by positioning the heat sink 552 and / or the motor controller 554 relative to the motor 90 such that neither the heat sink nor the motor controller 554 extend beyond the motor 90 in a direction that is parallel to the base plate width, as illustrated, for example, in FIG.

[0038] Such a configuration may allow the portable circular saw 10 according to the present disclosure to access smaller areas and / or cut closer to protruding structures than would be possible with a conventional portable circular saw. Additionally or alternatively, such a configuration may allow and / or facilitate improved and / or easier blade replacement of the circular saw 10. By way of example, when a user desires to replace the blade of the circular saw 10, the anti-blade surface of the portable circular saw may be supported on a surface such that the arbor is accessible to allow for blade replacement. When so supported, the above configuration allows the anti-blade surface of the portable circular saw to be at, or at least substantially at, the height of the surface. Stated in slightly different terms, the circular saw may have no components that protrude beyond the base plate width by more than a threshold distance, and the motor shaft and / or shaft rotation axis may extend perpendicular, or at least substantially perpendicular, to the surface. Additionally or alternatively, the arbor-facing side of the base plate and / or the arbor-opposite side of the base plate may extend perpendicular, or at least substantially perpendicular, to the surface. Additionally or alternatively, the base plate may extend parallel, or at least substantially parallel, to the surface.

[0039] As used herein, the term "and / or" placed between a first entity and a second entity means one of (1) the first entity, (2) the second entity, and (3) the first entity and the second entity. Multiple entities listed with "and / or" should be construed in the same manner, i.e., "one or more" of the entities so combined. Other entities may optionally be present other than the entity specifically identified by the "and / or" phrase, whether related to the specifically identified entity or not. Thus, as a non-limiting example, when used with open-ended language such as "comprising," a reference to "A and / or B" may refer in one embodiment to only A (optionally including entities other than B), in another embodiment to only B (optionally including entities other than A), and in yet another embodiment to both A and B (optionally including other entities). These entities may refer to elements, acts, structures, steps, operations, values, and the like.

[0040] As used herein, the phrase "at least one" in reference to a list of one or more entities should be understood to mean at least one entity selected from any one or more entities in the list of entities, but does not necessarily include at least one of each and every entity specifically listed in the list of entities, and does not exclude any combination of entities in the list of entities. This definition also allows for entities other than those specifically identified in the list of entities to which the phrase "at least one" refers, may optionally be present, whether or not related to the specifically identified entities. Thus, as a non-limiting example, "at least one of A and B" (or, equivalently, "at least one of A or B," or, equivalently, "at least one of A and / or B") may refer, in some embodiments, to at least one, optionally including more than one, A, in the absence of B (and optionally including entities other than B); in other embodiments, to at least one, optionally including more than one, B, in the absence of A (and optionally including entities other than A); and in yet other embodiments, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other entities). In other words, the phrases "at least one," "one or more," and "and / or" are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions "at least one of A, B, and C," "at least one of A, B, or C," "one or more of A, B, and C," "one or more of A, B, or C," and "A, B, and / or C" may mean A only, B only, C only, A and B together, A and C together, B and C together, A, B, and C together, as well as any of the above in combination with at least one other entity.

[0041] If any patent, patent application, or other reference is incorporated herein by reference, (1) defines a term in a manner that is inconsistent with either the unincorporated portions of this disclosure or any other incorporated reference, and / or (2) otherwise inconsistent with either the unincorporated portions of this disclosure or any other incorporated reference, the unincorporated portions of this disclosure shall control and the term herein or the incorporated disclosure shall control only with respect to the reference in which the term is defined and / or in which the incorporated disclosure was originally located.

[0042] As used herein, the terms "adapted" and "configured" mean that an element, component, or other subject matter is designed and / or intended to perform a given function. Thus, use of the terms "adapted" and "configured" should not be interpreted to mean that a given element, component, or other subject matter is merely "capable" of performing a given function, but rather that the element, component, and / or other subject matter is specifically selected, generated, implemented, utilized, programmed, and / or designed for the purpose of performing the function. It is within the scope of this disclosure that elements, components, and / or other listed subject matter that are listed as adapted to perform a particular function may additionally or alternatively be described as configured to perform that function, and vice versa.

[0043] As used herein, the phrases "for example," "as an example," and / or simply the term "example," when used in reference to one or more components, features, details, structures, embodiments, and / or methods according to the present disclosure, are intended to convey that the described components, features, details, structures, embodiments, and / or methods are illustrative, non-exclusive examples of the components, features, details, structures, embodiments, and / or methods according to the present disclosure. Thus, the described components, features, details, structures, embodiments, and / or methods are not intended to be limiting, necessary, or exclusive / exhaustive, and other components, features, details, structures, embodiments, and / or methods, including structurally and / or functionally similar and / or equivalent components, features, details, structures, embodiments, and / or methods, are also within the scope of the present disclosure.

[0044] As used herein, "at least substantially" may include not only the "substantial" degree or relationship listed, but also the entire range of the degree or relationship listed when modifying the degree or relationship. A substantial amount of the listed degree or relationship may include at least 75% of the listed degree or relationship. For example, an object at least substantially formed from a material includes an object in which at least 75% of the object is formed from the material, and also includes an object formed entirely from the material. In another example, a first length that is at least substantially the same length as a second length includes a first length that is within 75% of the second length, and also includes a first length that is the same length as the second length.

[0045] Illustrative, non-exclusive examples of portable circular saws according to the present disclosure are presented in the paragraphs listed below.

[0046] A1. A motor including a motor shaft configured to rotate about a shaft rotation axis; Optionally, a circular saw blade; an arbor configured to operatively mount a circular saw blade to a portable circular saw and to receive torque from the motor when the motor shaft rotates about a shaft axis of rotation; Including, portable circular saw.

[0047] A2. The portable circular saw of paragraph A1, wherein the motor includes an electric motor.

[0048] A3. The portable circular saw of paragraphs A1 or A2, wherein the portable circular saw further includes a gripping area configured to be gripped by a user of the portable circular saw while operating the portable circular saw to cut a workpiece.

[0049] A4. The portable circular saw of any of paragraphs A1-A3, wherein the portable circular saw further includes a switch configured to selectively apply current to at least one other component of the portable circular saw.

[0050] A5. The portable circular saw of any of paragraphs A1-A4, wherein the portable circular saw further includes a blade guard configured to prevent contact between a / its user and the portable circular saw.

[0051] A6. The portable circular saw of paragraph A5, wherein the blade guard includes a retractable area configured for storage when the portable circular saw is utilized to cut one / its workpiece.

[0052] A7. The portable circular saw described in any one of paragraphs A1-A6, further including a workpiece support configured to position the workpiece and the portable circular saw relative to one another when the workpiece is cut by the portable circular saw.

[0053] A8. Portable circular saws are (i) a power cord configured to provide electrical current to a portable circular saw; and (ii) A battery configured to provide electrical current to a portable circular saw. The portable circular saw of any one of paragraphs A1 to A7, further comprising at least one of the following:

[0054] A9. Portable circular saws are (i) Plunge saw, (ii) track saw; (iii) Bevel saw The portable circular saw according to any one of paragraphs A1 to A8, which is at least one of the above.

[0055] A10. The portable circular saw of any one of paragraphs A1-A9, wherein the portable circular saw is one / that plunge saw.

[0056] A11. The portable circular saw of paragraph A10, wherein the plunge saw includes a base plate defining an arbor facing side and an arbor opposing side.

[0057] A12.(i) The arbor is operably attached to the arbor-facing side of the base plate via a base plate pivot; (ii) The arbor-facing side of the base plate faces the arbor. The portable circular saw of paragraph A11, wherein the portable circular saw is at least one of:

[0058] A13. The portable circular saw of paragraph A12, wherein the arbor and the base plate are configured to operatively rotate relative to one another about a base plate pivot to selectively vary an area of ​​the circular saw blade extending on an arbor-opposite side of the base plate.

[0059] A14. The portable circular saw of any one of paragraphs A1 to A13, wherein the portable circular saw is one / that track saw.

[0060] A15. The portable circular saw of paragraph A14, wherein the track saw includes a / the base plate defining one / the arbor-facing side and one / the arbor-opposite side.

[0061] A16. The portable circular saw of paragraph A15, wherein the base plate further includes a rib receiving channel configured to receive the raised elongated rib of the track.

[0062] A17. The portable circular saw of paragraph A16, wherein the track saw further includes a track, the track including a raised elongated rib.

[0063] A18. A circular saw blade has a blade diameter, a portable circular saw has a maximum cutting depth, and the ratio of the maximum cutting depth to the blade diameter is (i) at least 0.3, at least 0.31, at least 0.32, at least 0.33, at least 0.34, at least 0.35, at least 0.36, at least 0.37, at least 0.38, at least 0.39, at least 0.4, at least 0.41, at least 0.42, at least 0.43, or at least 0.44, and (ii) at most 0.5, at most 0.49, at most 0.48, at most 0.47, at most 0.46, at most 0.45, at most 0.44, at most 0.43, at most 0.42, at most 0.41, at most 0.40, at most 0.39, at most 0.38, at most 0.37, at most 0.36, or at most 0.35 The portable circular saw according to any one of paragraphs A1 to A17, which is at least one of the above.

[0064] A19. The portable circular saw of any one of paragraphs A1 to A18, wherein the portable circular saw is not a worm-driven portable circular saw.

[0065] A20. The portable circular saw of any of paragraphs A1-A19, wherein the arbor is configured to rotate about an arbor rotation axis and the motor shaft is configured to rotate about a shaft rotation axis.

[0066] A21. The portable circular saw of paragraph A20, wherein the arbor rotation axis is parallel, or at least substantially parallel, to the shaft rotation axis.

[0067] A22. The portable circular saw of paragraph A20 or A21, wherein the angle between the arbor rotation axis and the shaft rotation axis is at most 20 degrees, at most 15 degrees, at most 10 degrees, at most 8 degrees, at most 6 degrees, at most 4 degrees, at most 2 degrees, at most 1 degree, 0 to 10 degrees, 0 to 5 degrees, 0 to 2 degrees, or 0 degrees.

[0068] A23. The arbor rotation axis is (i) spaced apart from the shaft axis; (ii) Not collinear with the shaft axis The portable circular saw according to any one of paragraphs A20 to A22, which is at least one of the above.

[0069] A24. The portable circular saw of any of paragraphs A20-A23, wherein the arbor is distinct from the motor shaft and configured to operatively engage the motor shaft to receive torque from the motor shaft.

[0070] A25. The portable circular saw of any one of paragraphs A1-A24, wherein the arbor includes an arbor gear, the motor shaft includes a shaft gear, and the shaft gear is further configured to interface with the arbor gear to transfer torque from the motor shaft to the arbor.

[0071] A26. The portable circular saw of paragraph A25, wherein the arbor gear is positioned between the shaft gear and one of the portable circular saw's / its workpiece supports.

[0072] A27. The portable circular saw according to paragraph A26, wherein the / the arbor rotation axis of one of the arbors extends directly between the / the motor shaft rotation axis of one of the motor shafts and the workpiece support.

[0073] A28. The portable circular saw of any of paragraphs A25-A27, wherein the arbor gear defines an arbor gear diameter, the shaft gear defines a shaft gear diameter, and the motor defines a motor diameter.

[0074] A29. The sum of the arbor gear diameter and the shaft gear diameter is a multiple of the threshold gear diameter of the motor diameter, and optionally, the multiple of the threshold gear diameter is (i) at least 0.20, at least 0.22, at least 0.24, at least 0.26, at least 0.28, at least 0.3, at least 0.32, at least 0.34, at least 0.36, at least 0.38, at least 0.40, at least 0.42, at least 0.44, or at least 0.46, and (ii) at most 0.65, at most 0.6, at most 0.55, at most 0.5, at most 0.48, at most 0.46, at most 0.44, at most 0.42, or at most 0.40 The portable circular saw of paragraph A28, wherein at least one of

[0075] A30. The ratio of the arbor gear diameter to the shaft gear diameter is the ratio of the threshold gear diameter, and optionally the ratio of the threshold gear diameter is (i) at least 3, at least 2.75, at least 2.5, at least 2.25, at least 2, at least 1.75, at least 1.5, at least 1.25, at least 1, at least 0.75, or at least 0.5, and (ii) A portable circular saw according to paragraph A28 or A29, which is at least one of: at most 5, at most 4.5, at most 4, at most 3.5, at most 3, at most 2.5, or at most 2.

[0076] A31. The portable circular saw of any one of paragraphs A1-A30, wherein the portable circular saw includes a / its base plate, the base plate defining an arbor-facing side, and when viewed from the arbor-facing side, a projection of the base plate defines a footprint for the portable circular saw, and further wherein at least a threshold fraction of the portable circular saw is completely contained within the footprint, optionally the threshold fraction comprising at least 90%, at least 92.5%, at least 95%, at least 97.5%, at least 99%, or the entirety of the portable circular saw.

[0077] A32. A portable circular saw includes a / its base plate, the base plate defines a base plate width, and further, the entire portable circular saw is contained within the base plate width, and optionally the base plate width is (i) measured in a direction perpendicular, or at least substantially perpendicular, to the blade plane in which the circular saw blade is configured to rotate; (ii) the maximum dimension of the base plate in a direction perpendicular, or at least substantially perpendicular, to the blade plane; (iii) measured in a direction parallel to the axis of rotation of one of the arbors; (iv) The maximum dimension of the base plate in a direction parallel to the arbor rotation axis. The portable circular saw according to any one of paragraphs A1 to A31, which is at least one of the above.

[0078] A33. The motor defines a motor diameter and the ratio of the motor diameter to the blade diameter is: (i) at least 0.20, at least 0.22, at least 0.24, at least 0.26, at least 0.28, at least 0.3, at least 0.32, at least 0.34, at least 0.36, at least 0.38, at least 0.40, at least 0.42, at least 0.44, or at least 0.46, and (ii) The portable circular saw of any one of paragraphs A1-A32, wherein the n-th angle is at most 0.65, at most 0.6, at most 0.55, at most 0.5, at most 0.48, at most 0.46, at most 0.44, at most 0.42, or at most 0.40.

[0079] A34. When the opposite side of the blade of a portable circular saw is supported on a surface such that the arbor is accessible to allow blade replacement, (i) the motor shaft extends perpendicular, or at least substantially perpendicular, to the surface; (ii) the shaft rotation axis extends perpendicular, or at least substantially perpendicular, to the surface; (iii) one of the portable circular saws / one of its base plate / one of its arbor-facing sides extends perpendicular or at least substantially perpendicular to the surface; (iv) One of the portable circular saws / one of its base plates / one of its arbor opposite sides extends perpendicular or at least substantially perpendicular to the surface. The portable circular saw according to any one of paragraphs A1 to A33, which is at least one of the above.

[0080] A35. A portable circular saw as described in any one of paragraphs A1 to A34, wherein the portable circular saw includes a motor controller and a heat sink for the motor controller, and further wherein the motor controller and heat sink are positioned within the portable circular saw relative to the motor such that neither the motor controller nor the heat sink extend beyond the motor in a direction parallel to the width of the portable circular saw / one of its base plates / one of its base plates.

[0081] Industrial Applicability The circular saws disclosed herein can be utilized in the power tool industry.

[0082] The present disclosure above is believed to encompass multiple separate inventions with independent utility. Each of these inventions is disclosed in a preferred form, but the specific embodiments thereof as disclosed and illustrated herein are not to be taken in a limiting sense, as many variations are possible. The subject matter of the invention includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions, and / or properties disclosed herein. Similarly, when a claim recites "a" or "first" element or the equivalent thereof, such claim should be understood to include combinations of one or more of such elements, without requiring or excluding a plurality of such elements.

[0083] The following claims are believed to specifically point out certain novel and nonobvious combinations and subcombinations of one of the disclosed inventions. Inventions embodied in other combinations and subcombinations of features, functions, elements, and / or properties may be claimed through modification of the claims or presentation of new claims in this or a related application. Such modified or new claims, whether different, broader, narrower, or equal in scope to the original claims, whether they relate to different or the same invention, are also deemed to be included within the inventive subject matter of this disclosure.

Claims

1. a motor including a motor shaft configured to rotate about a shaft axis of rotation; an arbor configured to operably mount a circular saw blade having a blade diameter on a portable circular saw and to receive torque from the motor when the motor shaft rotates about the shaft axis of rotation; Equipped with the portable circular saw has a maximum cutting depth, and further wherein a ratio of the maximum cutting depth to the blade diameter is at least 0.35 and at most 0.45; the arbor includes an arbor gear and the motor shaft includes a shaft gear, the shaft gear further configured to interface with the arbor gear to transfer the torque from the motor shaft to the arbor; a ratio of the diameter of the arbor gear to the diameter of the shaft gear is a ratio of a reference gear diameter, the ratio of the reference gear diameter being at least 2 and at most 3; Portable circular saw.

2. 10. The portable circular saw of claim 1, further comprising a workpiece support configured to position the workpiece and the portable circular saw relative to one another when the workpiece is cut by the portable circular saw.

3. The portable circular saw of claim 2 , wherein the arbor is configured to rotate about an arbor axis of rotation, further wherein the arbor axis of rotation is parallel to the shaft axis of rotation.

4. The portable circular saw of claim 3 , wherein the arbor is distinct from the motor shaft and configured to operatively engage the motor shaft to receive the torque from the motor shaft.

5. the arbor gear is positioned between the shaft gear and the workpiece support; 3. The portable circular saw of claim 2.

6. 5. A portable circular saw according to claim 3 or 4, wherein the arbor axis of rotation extends linearly between the shaft axis of rotation and the workpiece support.

7. The portable circular saw of any one of claims 2 to 6, wherein the workpiece support includes a base plate defining an arbor-facing side and an arbor-opposite side.

8. 8. The portable circular saw of claim 7, wherein the portable circular saw is a plunge saw, and further wherein the arbor is operably attached to the arbor-facing side of the base plate via a base plate pivot, the arbor-facing side of the base plate facing toward the arbor.

9. 9. The portable circular saw of claim 8, wherein the arbor and the baseplate are configured to operatively rotate about the baseplate pivot relative to one another such that areas of the circular saw blade extending on opposite sides of the baseplate to the arbor are selectively different.

10. The portable circular saw of any one of claims 7 to 9, wherein the portable circular saw is a track saw, and the base plate further includes a rib receiving channel configured to receive a raised elongated rib of a track.

11. 11. The portable circular saw of claim 10, wherein said track saw further includes said track, said track including said raised elongated rib.

12. 12. The portable circular saw of any one of claims 1 to 11, wherein the arbor gear defines an arbor gear diameter, the shaft gear defines a shaft gear diameter, and the motor defines a motor diameter, a sum of the arbor gear diameter and the shaft gear diameter is a multiple of a nominal gear diameter of the motor diameter, and further wherein the multiple of the nominal gear diameter is at least 0.20 and at most 0.

65.

13. 8. The portable circular saw of claim 7, wherein the base plate contour defines a footprint for the portable circular saw when viewed from the arbor-facing side, and further wherein at least 95% of the portable circular saw is completely contained within the footprint.

14. 8. The portable circular saw of claim 7, wherein the entire portable circular saw is contained within a base plate width of the base plate.

15. 15. The portable circular saw of claim 14, wherein the portable circular saw includes a motor controller and a heat sink for the motor controller, and further wherein the motor controller and the heat sink are positioned within the portable circular saw relative to the motor such that neither the motor controller nor the heat sink extend beyond the motor shaft in a direction parallel to the baseplate width of the baseplate.

16. A portable circular saw as described in any one of claims 1 to 15, wherein when the portable circular saw is supported using a surface of the opposite side of the blade, which is the side of the portable circular saw opposite to the side on which the blade is attached, as a support surface so that the arbor can be accessed for blade replacement, the shaft rotation axis extends perpendicular to the surface of the opposite side of the blade.

17. The portable circular saw of any one of claims 1 to 16, wherein the motor defines a motor diameter, and further wherein a ratio of the motor diameter to the blade diameter is at least 0.20 and at most 0.

6.

18. The portable circular saw of any one of claims 1 to 16, further comprising a gripping area configured to be gripped by a user of the portable circular saw during operation of the portable circular saw.

19. The portable circular saw according to any one of claims 1 to 18, wherein the portable circular saw is a battery-powered portable circular saw.

20. The portable circular saw of any one of claims 1 to 19, further comprising the circular saw blade operably attached to the portable circular saw by the arbor.

21. a motor including a motor shaft configured to rotate about a shaft axis of rotation; an arbor configured to operably mount a circular saw blade to a portable circular saw and to receive torque from the motor when the motor shaft rotates about the shaft axis of rotation; a base plate defining an arbor-facing side, the base plate having an outline defined by a footprint for the portable circular saw when viewed from the arbor-facing side, and further wherein at least 95% of the portable circular saw is completely contained within the footprint; Including, The portable circular saw includes a motor controller and a heat sink for the motor controller, the motor controller and the heat sink being positioned within the portable circular saw relative to the motor such that neither the motor controller nor the heat sink extend beyond the motor shaft in a direction parallel to a base plate width of the base plate.

22. 22. The portable circular saw of claim 21, further comprising a gripping area configured for the portable circular saw to be gripped by a user of the portable circular saw during operation to cut a workpiece.

23. 23. The portable circular saw of claim 21 or 22, wherein the portable circular saw is a battery-powered portable circular saw.

24. The portable circular saw comprises: (i) Plunge saw; (ii) a track saw; (iii) bevel saw, The portable circular saw according to any one of claims 21 to 23, wherein the portable circular saw is at least one of the above.

25. A portable circular saw as described in any one of claims 21 to 24, wherein when the portable circular saw is supported using a surface of the opposite blade side, which is the side of the portable circular saw opposite to the side on which the blade is attached, as a support surface so that the arbor is accessible for blade replacement, the shaft rotation axis extends perpendicular to the surface of the opposite blade side.

26. a motor including a motor shaft configured to rotate about a shaft axis of rotation; an arbor configured to operably mount a circular saw blade to a portable circular saw and to receive torque from the motor when the motor shaft rotates about the shaft axis of rotation; a base plate, the base plate defining a base plate width, the portable circular saw being entirely contained within the base plate width; Including, the portable circular saw includes a motor controller and a heat sink for the motor controller, and further wherein the motor controller and the heat sink are positioned within the portable circular saw relative to the motor such that neither the motor controller nor the heat sink extend beyond the motor shaft in a direction parallel to the baseplate width of the baseplate. Portable circular saw.

27. 27. The portable circular saw of claim 26, further comprising a gripping area configured for the portable circular saw to be gripped by a user of the portable circular saw during operation to cut a workpiece.

28. 28. The portable circular saw of claim 26 or 27, wherein the portable circular saw is a battery-powered portable circular saw.

29. The portable circular saw comprises: (i) Plunge saw; (ii) a track saw; (iii) Bevel saw The portable circular saw according to any one of claims 26 to 28, wherein the at least one of the above is selected.

30. A portable circular saw as described in any one of claims 26 to 29, wherein when the portable circular saw is supported on a surface of the opposite blade side, which is the side of the portable circular saw opposite to the side on which the blade is attached, as a support surface so that the arbor is accessible for blade replacement, the shaft rotation axis extends perpendicular to the surface of the opposite blade side.

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