Patent ID: 12233467

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings. Terms of degree, such as “about,” “substantially,” or “approximately” are understood by those of ordinary skill to refer to reasonable ranges outside of the given value, for example, general tolerances associated with manufacturing, assembly, and use of the described embodiments.

FIGS.1-5illustrate a hole saw100including a cylindrical body105defining a cavity110. The cylindrical body105includes a sidewall115having a first end120and a second end125with the second end125positioned opposite the first end120. The hole saw100also includes an end cap130coupled to the second end125and has an aperture135sized to receive an arbor140such that the hole saw100can be coupled to and driven by a tool145(e.g., a power drill or the like) via the arbor140. The tool145drives the hole saw100about a rotational axis150in a cutting direction155(FIG.2). In the illustrated embodiment, the arbor140is selectively coupled to the end cap130, but in other embodiments, the arbor140can be fixedly coupled to the end cap130. In some embodiments, a pilot drill bit156(e.g., a twist drill bit, a spade drill bit, etc.) can be selectively or fixedly coupled to the arbor140to extend through the cavity110and beyond the first end120of the sidewall115. The illustrated cylindrical body105is made of a metallic material (e.g., low carbon steel, etc.). In other embodiments, the cylindrical body105can be made of a different metallic material (e.g., high carbon steel, etc.).

As best shown inFIG.2, the sidewall115defines a maximum outer diameter160. The outer diameter160can be between about 1 inch and about 7 inches. In some embodiments, the outer diameter160can be about 1.37 inches, about 2.56 inches, about 4 inches, or about 6.25 inches. In further embodiments, the outer diameter160can be greater than 7 inches. The sidewall115also defines a maximum thickness165. The thickness165can be between about 0.07 inches and about 0.11 inches. In some embodiments, the thickness165can be about 0.08 inches, about 0.09 inches, about 0.1 inches, or about 0.104 inches. As best shown inFIG.3, the sidewall115further defines a sidewall height or dimension170extending between the first end120and the second end125in a direction parallel to the rotational axis150. The illustrated sidewall height170is between about 2.5 inches and about 3 inches. In other embodiments, the sidewall height170can be between about 1.5 inches and about 5 inches.

In the illustrated embodiment, the sidewall115includes three gullets175equally spaced about the rotational axis150(e.g., each gullet175is spaced about 120 degrees relative to an adjacent gullet175). In other embodiments, the hole saw100can include more than three gullets175(e.g., four, five, six, etc.) or can include less than three gullets (e.g., two or one) with the gullets175equally or non-equally spaced about the rotational axis150. For example, the hole saw100can include two gullets175(spaced 180 degrees apart) when the outer diameter160is less than about 2.25 inches.

With reference toFIG.3, each gullet175defines a central longitudinal axis180extending between the first end120and the second end125. Each gullet175includes an open end185adjacent the first end120and is defined by a bottom surface190of the sidewall115opposite the open end185, a leading surface195of the sidewall115extending between the open end185and the bottom surface190, and a trailing surface200of the sidewall115extending between the open end185and the bottom surface190. The leading surface195and the trailing surface200of each gullet175are in relation to the cutting direction155of the hole saw100(i.e., the leading surface195is forward the trailing surface200as the hole saw100moves in the cutting direction155). Each trailing surface200includes a seat or notch205formed adjacent the open end185and a trailing surface portion210positioned between the notch205and the bottom surface190in a direction parallel to the rotational axis150. In particular, a first portion215of each trailing surface200extends between the notch205and the trailing surface portion210and a second portion220of each trailing surface200extends between the trailing surface portion210and the bottom surface190. In addition, an edge225is positioned between the leading surface195and the first end120that defines a substantially 90 degree edge. In other embodiments, the edge225can be a curved edge.

In the illustrated embodiment, all three gullets175include the substantially same geometry, but in other embodiments, two or more gullets175can include different geometries. One of the gullets175will be described in detail below but can be applicable to one or more of the remaining gullets175. The illustrated first portion215of the trailing surface200is a substantially linear surface oriented substantially parallel to the rotational axis150. In addition, the central longitudinal axis180of the gullet175is parallel to the rotational axis150so that the first portion215is also parallel to the central longitudinal axis180. In other embodiments, the first portion215can be a curved surface. The illustrated trailing surface portion210defines a first radius230between about 1 inch and about 1.25 inches. In other embodiments, the first radius230can be between about 1.25 inches and about 2 inches or the first radius230can be between about 0.4 inches and about 1 inch. In addition, the trailing surface portion210is formed in a lower half of the gullet175in a direction parallel to the rotational axis150. The illustrated second portion220of the trailing surface200is a substantially linear surface, but in other embodiments, the second portion220can be a curved surface. The second portion220is also oriented at an oblique angle235relative to the rotational axis150. The illustrated oblique angle235is between about 40 degrees and about 50 degrees. In other embodiments, the oblique angle235can be between about 50 degrees and about 70 degrees or the oblique angle235can be between about 20 degrees and about 40 degrees. A first angle240is defined between the first portion215and the second portion220. The illustrated first angle240is between about 130 degrees and about 140 degrees. In other embodiments, the first angle240can be between 140 degrees and about 170 degrees, or the first angle240can be between about 80 degrees and about 130 degrees. In further embodiments, the first radius230of the trailing surface portion210can be omitted such that only the first angle240is formed between the first portion215and the second portion220. The illustrated bottom surface190defines a second radius245between about 0.25 inches and about 0.4 inches. In other embodiments, the second radius245can be between about 0.4 inches and about 1 inch, or the second radius245can be between about 0.1 inches and about 0.25 inches. In some embodiments, the second radius245can be equal to or less than the first radius230. A ratio of the first radius230to the second radius245is between about 2.5 to about 5. In other embodiments, the ratio of the first radius230to the second radius245is between about 1 and about 6. In further embodiments, the ratio of the first radius230to the second radius245is between about 3 and about 4.

The illustrated leading surface195is a substantially linear surface oriented substantially parallel to the rotational axis150. A second angle250is defined between the second portion220and the leading surface195. The illustrated second angle250is between about 40 degrees and about 50 degrees. In other embodiments, the second angle250can be between 50 degrees and about 80 degrees or the second angle250can be between about 10 degrees and about 40 degrees. In further embodiments, the second radius245can be omitted such that only the second angle250is formed between the second portion220and the leading surface195.

With continued reference toFIG.3, the gullet175defines a gullet height or dimension255extending between the first end120and the bottom surface190in a direction parallel to the rotational axis150. The illustrated gullet height255is greater than about 1.5 inches. In other embodiments, the gullet height255can be between about 1.7 inches and about 1.9 inches, or the gullet height255can be between about 1.9 inches and about 3 inches. As such, a ratio of the sidewall height170over the gullet height255is about 1.4. In other embodiments, the ratio of the sidewall height170over the gullet height255can be between about 1.1 and about 2. In further embodiments, the ratio of the sidewall height170over the gullet height255can be between about 2 and about 4. The illustrated sidewall115also defines a height260extending between the bottom surface190of each gullet175and the second end125of the sidewall115. The height260is between about 0.7 inches and about 0.9 inches. In other embodiments, the height260can be between about 0.9 inches and about 1.5 inches or the height260can be between about 0.1 inches and about 0.7 inches. The gullet175also defines a maximum gullet width265extending between the leading surface195and the trailing surface200in a direction perpendicular to the rotational axis150. In particular, the maximum gullet width265extends between the leading surface195and a point270located on the first portion215directly below the notch205. The illustrated maximum gullet width265is between about 0.75 inches and about 1.2 inches. In other embodiments, the maximum gullet width265can be between about 1.2 inches and about 1.5 inches, or the maximum gullet width265can be between about 0.4 inches and about 0.75 inches.

The hole saw100also includes cutting teeth275positioned adjacent the first end120of the sidewall115. Each cutting tooth275has a cutting tip280positioned beyond the first end120(i.e., above the first end120as illustrated inFIG.4). In particular, the cutting teeth275are carbide cutting teeth that are seated within the notches205of the sidewall115and secured to the sidewall115(e.g., by a brazing operation or the like). The carbide cutting teeth275include a material hardness that is greater than a material hardness of the sidewall115. In other embodiments, the cutting teeth275can be made of a different material (e.g., hardened steel, etc.). In further embodiments, the sidewall115can form the cutting teeth275so that the cutting teeth275are not separately secured to the sidewall115. Each cutting tooth275includes a rake surface285and a relief surface290with each rake surface285facing into one of the gullets175. Each rake surface285defines a positive rake angle295(e.g., angled toward the cutting direction155) relative to the rotational axis150between about 5 degrees and about 15 degrees. As such, a minimum gullet width296between each cutting tip280and the corresponding leading surface195perpendicular to the rotational axis150is between about 0.5 inches and about 0.7 inches. In other embodiments, the minimum gullet width296can be between about 0.7 inches and about 1.2 inches. In further embodiments, the minimum gullet width296can be greater than the maximum gullet width265. In yet further embodiments, the rake angle295can be a negative rake angle (e.g., angled away from the cutting direction155). A tooth angle300is defined between the rake surface285and the relief surface290between about 60 degrees and about 70 degrees (FIG.4). As best shown inFIG.2, each cutting tip280defines a tip width305between about 0.1 inches and about 0.2 inches. The tip width305of each cutting tooth275is greater than the thickness165of the sidewall115. As such, a total cutting diameter of the hole saw100is greater than the maximum outer diameter160of the sidewall115. In other embodiments, the tip width305can be substantially the same as the thickness165of the sidewall115with the cutting teeth275bent radially inward or outward relative to the rotational axis150.

With continued reference toFIG.4, a recess or relief310is formed within the first end120of the sidewall115directly behind each cutting tooth275with a trailing portion315of each recess310angled in a direction away from the cutting direction155. Each recess310defines a recess angle320relative to the rake surface285that is less than the tooth angle300. As such, during a grinding process to shape the cutting teeth275(e.g., to shape the tooth angle300), the recesses310provide enough clearance for a grinding wheel or the like to shape the cutting teeth275without contacting the sidewall115.

Once the cutting teeth275are coupled to the sidewall115, each gullet175defines an area325between the rake surface285, the trailing surface200, the bottom surface190, and the leading surface195. In the illustrated embodiment, the area325of each gullet175is equal to or greater than 1.2 inches squared. In other embodiments, the area325of each gullet175is between about 1.2 inches squared and about 3.5 inches squared. In further embodiments, the area325of each gullet175is between about 1.2 inches squared and about 2 inches squared. As the hole saw100includes three gullets175, the total area of the illustrated gullets175is equal to or greater than 3.6 inches squared. Each gullet175also defines a volume, which is determined by multiplying the area325of each gullet175by the maximum thickness165of the sidewall115. As such, the volume of each gullet175is equal to or greater than 0.084 inches cubed. In some embodiments, a ratio of the tip width305over the volume of one of the gullets175is about 0.2. In other embodiments, the ratio of the tip width305over the volume of one of the gullets175can be between about 0.1 and about 1.1.

With reference toFIG.5, the hole saw100is operable to cut into a workpiece330that defines a workpiece height335. In the illustrated embodiment, the workpiece height335is about 1.5 inches (e.g., height of a standard 2 by 4 piece of lumber). In other embodiments, the workpiece height335can be less than 1.5 inches. In operation, the cutting teeth275cut into the workpiece330, thereby forming workpiece chips that collect within the gullets175. As the hole saw100bores deeper into the workpiece330, more workpiece chips are collected within the gullets175. Accordingly, the illustrated gullets175include a particular volume to accommodate the workpiece chips as the hole saw100cuts into the workpiece330. If the volume of the gullets175is not sufficient to accommodate the workpiece chips, the workpiece chips will build up within the gullets175and decrease the efficiency of the hole saw100cutting into the workpiece330. Once the hole saw100bores through the workpiece330, a cylindrical workpiece plug will be removed from the cavity110of the hole saw100. In particular, a user can grip the cylindrical workpiece plug (via their fingers) through the gullets175to axially slide the cylindrical workpiece plug along the rotational axis and out of the cavity110. The minimum gullet width296of each gullet175is sized to provide enough clearance between each cutting tip280and the corresponding leading surface195so that a user's finger avoids contact with the cutting tip280as the cylindrical workpiece plug is removed from the hole saw100.

FIG.6illustrates a planar view of a portion of a hole saw400according to another embodiment. The hole saw400is similar to the hole saw100ofFIGS.1-5; therefore, similar components are designated with similar references numbers plus300. At least some differences and/or at least some similarities between the hole saws100,400will be discussed in detail below. In addition, components or features described with respect to one or some of the embodiments described herein are equally applicable to any other embodiments described herein and can include similar reference numbers.

The illustrated hole saw400is moveable about a rotational axis450in a cutting direction455and includes a sidewall415having a first end420and a second end425. The sidewall415also includes gullets475(only one gullet475is illustrated inFIG.6) each defining a central longitudinal axis480. Each gullet475includes a notch505, an open end485, a bottom surface490defining a second radius545, a leading surface495, and a trailing surface500. Each trailing surface500includes a trailing surface portion510defining a first radius530, a first portion515, and a second portion520with the trailing surface portion510positioned between the first portion515and the second portion520. In the illustrated embodiment, each first portion515is parallel to the leading surface495; however, in other embodiments, the first portion515can be obliquely angled relative to the leading surface495. In other embodiments, the second portion520can be omitted so that the trailing surface portion510directly connects with the bottom surface490. In the illustrated embodiment, the first portion515of each trailing surface500is oriented at a third angle640between about 5 degrees and about 15 degrees relative to the rotational axis450so that the first portion515is angled from the first end420to the second end425in a direction toward the cutting direction455. As a result, each central longitudinal axis480is also oriented between about 5 degrees and about 15 degrees relative to the rotational axis450so that the central longitudinal axis480is angled from the first end420to the second end425in a direction toward the cutting direction455. In other embodiments, the third angle640is greater than about 5 degrees. In further embodiments, the third angle640is less than about 15 degrees. In yet further embodiments, the third angle640is between about 1 degree and about 40 degrees.

The hole saw400also includes cutting teeth575(only one cutting tooth575is illustrated inFIG.6) each having a cutting tip580and seated within one notch505. Each cutting tooth575includes a rake surface585and a relief surface590.

FIG.7illustrates a planar view of a portion of a hole saw700according to another embodiment. The hole saw700is similar to the hole saw100ofFIGS.1-5; therefore, similar components are designated with similar references numbers plus600. At least some differences and/or at least some similarities between the hole saws100,700will be discussed in detail below. In addition, components or features described with respect to one or some of the embodiments described herein are equally applicable to any other embodiments described herein and can include similar reference numbers.

The illustrated hole saw700is moveable about a rotational axis750in a cutting direction755and includes a sidewall715having a first end720and a second end725. The sidewall715also includes gullets775(only one gullet775is illustrated inFIG.7) each defining a central longitudinal axis780. Each gullet775includes a notch805, an open end785, a bottom surface790defining a second radius845, a leading surface795, and a trailing surface800. Each trailing surface800includes a trailing surface portion810defining a first radius830, a first portion815, and a second portion820with the trailing surface portion810positioned between the first portion815and the second portion820. Each leading surface795includes a third portion945, a fourth portion950, and a support surface955positioned between the third portion945and the fourth portion950in a direction parallel to the rotational axis750. The support surface955is also positioned at a support surface distance960between about 0.7 inches and about 1 inch from the first end720of the sidewall715. In other embodiments, the support surface955can be formed within at least one of the gullets775. In the illustrated embodiment, the third portion945is oriented parallel to the fourth portion950of each leading surface795and the first portion815of each trailing surface800. Each third portion945and fourth portion950are also offset (e.g., nonlinear) relative to each other. In other embodiments, the third portion945can be obliquely angled relative to the first portion815and/or the fourth portion950. Each support surface955is oriented at a support angle965relative to the rotational axis750. The support angle965is less than 90 degrees relative to the rotational axis750so that the support surface955is angled downwardly and toward the cutting direction755(e.g., the support surface955generally faces upwardly toward the first end720). In other embodiments, the support angle965can be less than 90 degrees and greater than 75 degrees relative to the rotational axis750. Also, each support surface955is positioned above the trailing surface portion810in a direction parallel to the rotational axis750. In other embodiments, each support surface955can be positioned at the same height of the trailing surface portion810or positioned below the trailing surface portion810.

The hole saw700also includes cutting teeth875(only one cutting tooth875is illustrated inFIG.7) each having a cutting tip880and seated within one notch805. Each cutting tooth875includes a rake surface885and a relief surface890.

In operation, a cylindrical workpiece plug can be removed from the hole saw700by using a tool (e.g., a screwdriver or the like). In particular, the tool is inserted within one of the gullets775below the cylindrical workpiece plug. In some embodiments, the tool engages the bottom surface790of the gullet775to leverage and push the cylindrical workpiece plug out of the first end720. The tool can also engage the support surface955to leverage and push the cylindrical workpiece plug out of the first end720. As the support surface955is angled downwardly and toward the cutting direction755, the tool can be captured on the support surface955without sliding into the gullet775as the tool is used to leverage the cylindrical workpiece plug out of the hole saw700.

FIG.8illustrates a planar view of a portion of a hole saw1000according to another embodiment. The hole saw1000is similar to the hole saw100ofFIGS.1-5; therefore, similar components are designated with similar references numbers plus900. At least some differences and/or at least some similarities between the hole saws100,1000will be discussed in detail below. In addition, components or features described with respect to only one or some of the embodiments described herein are equally applicable to any other embodiments described herein and can include similar reference numbers.

The illustrated hole saw1000is moveable about a rotational axis1050in a cutting direction1055and includes a sidewall1015having a first end1020and a second end1025. The sidewall1015also includes gullets1075(only one gullet1075is illustrated inFIG.8) each defining a central longitudinal axis1080. Each gullet1075includes a notch1105, an open end1085, a bottom surface1090defining a second radius1145, a leading surface1095, and a trailing surface1100. Each trailing surface1100includes a trailing surface portion1110defining a first radius1130, a first portion1115, and a second portion1120with the trailing surface portion1110positioned between the first portion1115and the second portion1120. Each leading surface1095includes a third portion1245, a fourth portion1250, and a support surface1255(similar to the support surface955ofFIG.7) formed on a protrusion1270of the sidewall1015, which extends into each gullet1075. The illustrated third portion1245and fourth portion1250are substantially collinear surfaces with the support surface1255oriented at a substantially 90 degree angle relative to the rotational axis1050.

The hole saw1000also includes cutting teeth1175(only one cutting tooth1175is illustrated inFIG.8) each having a cutting tip1180and seated within one notch1105. Each cutting tooth1175includes a rake surface1185and a relief surface1190.

FIGS.9-11illustrate a hole saw1300according to another embodiment. The hole saw1300is similar to the hole saw100ofFIGS.1-5; therefore, similar components are designated with similar references numbers plus1200. At least some differences and/or at least some similarities between the hole saws100,1300will be discussed in detail below. In addition, components or features described with respect to one or some of the embodiments described herein are equally applicable to any other embodiments described herein and can include similar reference numbers.

The illustrated hole saw1300is moveable about a rotational axis1350in a cutting direction1355and includes a cylindrical body1305having a sidewall1315that defines a cavity1310and an end cap1330having an aperture1335. The sidewall1315includes a first end1320and a second end1325. The sidewall1315defines a maximum outer diameter1360(FIG.11), a maximum thickness1365(FIG.11), and a sidewall height or dimension1370(FIG.10) extending between the first end1320and the second end1325in a direction parallel to the rotational axis1350. The sidewall height1370can be between about 3.3 inches and about 3.7 inches. In other embodiments, the sidewall height1370can be between about 3.7 inches and about 4.5 inches. The sidewall1315also includes gullets1375each defining a central longitudinal axis1380oriented at an oblique angle (e.g., between about 5 degrees and about 15 degrees) relative to the rotational axis1350. Each gullet1375includes a notch1405, an open end1385, a bottom surface1390defining a second radius1445, a leading surface1395, and a trailing surface1400. Each trailing surface1400includes a trailing surface portion1410defining a first radius1430, a first portion1415, and a second portion1420with the trailing surface portion1410positioned between the first portion1415and the second portion1420. Each leading surface1395includes an edge1425and two support surfaces1555a,1555b(similar to the support surfaces955,1255illustrated inFIGS.7and8) so that each leading surface1395includes a third portion1545, a fourth portion1550, and a fifth portion1575. With the two support surfaces1555a,1555bformed in the leading surface1395, the leading surface1395defines a zig-zag shaped surface. The illustrated third portion1545, fourth portion1550, and fifth portion1575are all linear surfaces with the third portion1545obliquely oriented relative to the fourth portion1550and the fourth portion1550oriented substantially parallel to the fifth portion1575. In other embodiments, two or more of the third portion1545, the fourth portion1550, and the fifth portion1575can be substantially parallel relative to each other or obliquely oriented relative to each other. In further embodiments, at least one of the third portion1545, the fourth portion1550, and the fifth portion1575can be a curved surface. In yet further embodiments, the third portion1545, the fourth portion1550, the fifth portion1575, and the two support surface1555a,1555bcan be omitted so that the leading surface1395is one linear surface. The illustrated first support surface1555ais positioned from the first end1320at a first support distance1560aof between about 2 inches and about 2.2 inches. The second support surface1555bis positioned from the first end1320at a second support distance1560bof between about 1 inch and about 1.5 inches. In other embodiments, each leading surface1395can include one support surface. In other embodiments, each leading surface1395can include more than two support surfaces.

In addition, each gullet1375defines an oblique angle1435between the second portion1420and the rotational axis1350. The oblique angle1435is between about 55 degrees and about 65 degrees. In particular, the oblique angle1435is defined between the rotational axis1350and a tangent line extending through a midpoint of the second portion1420. A first angle1440is defined between the first portion1415and the second portion1420that is between about 120 degrees and about 135 degrees. In particular, the first angle1440is defined between the first portion1415and a tangent line extending through a midpoint of the second portion1420. In other embodiments with the first portion1415defining a curved surface, the first angle1440is defined between tangent lines extending through midpoints of the first and second portions1415,1420. A second angle1450is defined between the second portion1420and the third portion1545that is between about 35 degrees and about 45 degrees. In particular, the second angle1450is defined between the third portion1545and a tangent line extending through a midpoint of the second portion1420. In other embodiments with the third portion1545defining a curved surface, the second angle1450is defined between tangent lines extending through midpoints of the second and third portions1420,1545.

As best shown inFIG.10, each gullet1375defines a gullet height or dimension1455extending between the first end1320and the bottom surface1390in a direction parallel to the rotational axis1350. The illustrated gullet height1455is between about 3 inches and about 3.2 inches. In other embodiments, the gullet height1455can be between about 3.2 inches and about 4 inches, or the gullet height1455can be between about 2.5 inches and about 3 inches. As such, a ratio of the sidewall height1370over the gullet height1455is between about 1.05 and about 1.2. In other embodiments, the ratio can be between about 1.2 and about 2. The illustrated sidewall1315also defines a height1460extending between the bottom surface1390of each gullet1375and the second end1325of the sidewall1315. The height1460is between about 0.3 inches and about 0.4 inches. In other embodiments, the height1460can be between about 0.4 inches and about 1 inch, or the height1460can be between about 0.1 inches and about 0.3 inches. In addition, a maximum gullet width1465is defined by a point1470on the first portion1415and the fifth portion1575adjacent the second support surface1555b.

The hole saw1300also includes cutting teeth1475each having a cutting tip1480and seated within one notch1405. Each cutting tooth1475includes a rake surface1485and a relief surface1490. A minimum gullet width1496extends between each cutting tip1480and the corresponding leading surface1395. Once the cutting teeth1475are coupled to the sidewall1315, each gullet1375defines an area1525between the rake surface1485, the trailing surface1400, the bottom surface1390, and the leading surface1395. In the illustrated embodiment, the area1525of each gullet1375is equal to or greater than 3.2 inches squared. In other embodiments, the area1525of each gullet1375is between about 2 inches squared and about 4 inches squared. In further embodiments, the area1525of each gullet1375is between about 3.2 inches squared and about 4 inches squared. As the hole saw1300includes three gullets1375, the total area of the illustrated gullets1375is equal to or greater than 9.6 inches squared. Each gullet1375also defines a volume, which is determined by multiplying the area1525of each gullet1375by the maximum thickness1365of the sidewall1315. As such, the volume of each gullet1375is equal to or greater than 0.256 inches cubed. In other embodiments, the volume of each gullet1375can be between about 0.227 inches cubed and about 0.3 inches cubed.

With reference toFIG.11, the hole saw1300is operable to cut into two workpieces1530that defines a workpiece height1535. In the illustrated embodiment, the workpiece height1535is about 3 inches (e.g., two standard 2 by 4 pieces of lumber). In other embodiments, the workpiece height1535can be less than 3 inches. In further embodiments, the workpiece height1535can be between about 1.5 inches and about 3 inches. In yet further embodiments, the two workpieces1530can be formed as one workpiece with the workpiece height1535. In operation, the cutting teeth1475cut into the two workpieces1530, thereby forming workpiece chips that collect within the gullets1375. As the hole saw1300bores deeper into the two workpieces1530, more workpiece chips are collected within the gullets1375. Accordingly, the illustrated gullets1375include a particular volume to accommodate the workpiece chips as the hole saw1300cuts into the two workpieces1530. Once the hole saw1300bores through the two workpieces1530, a cylindrical workpiece plug will be removed from the cavity1310of the hole saw1300. In one embodiment, a user can grip the cylindrical workpiece plug (via their fingers) through the gullets1375to axially slide the cylindrical workpiece plug along the rotational axis1350and out of the cavity1310. In other embodiments, a tool can be inserted into one of the gullets1375to be supported on one of the support surfaces1555a,1555bfor a user to leverage the cylindrical workpiece plug out of the hole saw1300.

FIG.12illustrates a planar view of a portion of a hole saw1600according to another embodiment. The hole saw1600is similar to the hole saw100ofFIGS.1-5; therefore, similar components are designated with similar references numbers plus1500. At least some differences and/or at least some similarities between the hole saws100,1600will be discussed in detail below. In addition, components or features described with respect to only one or some of the embodiments described herein are equally applicable to any other embodiments described herein and can include similar reference numbers. For example, the hole saw1600can be sized to bore into the single workpiece330ofFIG.5similar to the hole saw100, or the hole saw1600can be sized to bore into the two workpieces1530ofFIG.11similar to the hole saw1300.

The illustrated hole saw1600is moveable about a rotational axis1650in a cutting direction1655and includes a sidewall1615having a first end1620and a second end1625. The sidewall1615also includes gullets1675(only one gullet1675is illustrated inFIG.12) each defining a central longitudinal axis1680. Each gullet1675includes a notch1705, an open end1685, a bottom surface1690defining a second radius1745, a leading surface1695, and a trailing surface1700. Each trailing surface1700includes a trailing surface portion1710defining a first radius1730, a first portion1715, and a second portion1720with the trailing surface portion1710positioned between the first portion1715and the second portion1720. The sidewall1615also includes three support apertures1880(only one is illustrated inFIG.12) each positioned at a substantially same location that is circumferentially between adjacent gullets1675. In particular, each support aperture1880is positioned above the bottom surfaces1690of the gullets1675. For example, each support aperture1880is positioned above the trailing surface portions1710of the gullets1675. Each support aperture1880is also positioned between adjacent gullets1675as to not circumferentially overlap with any portion of the gullets1675. Each support aperture1880is oblong-shaped and includes a longitudinal axis that is substantially perpendicular to the rotational axis1650. The support apertures1880function similar to the support surfaces illustrated withinFIGS.7-11for a tool to be inserted into one of the support apertures1880to leverage and remove a cylindrical workpiece plug from the hole saw1600. In other embodiments, the sidewall1615can include fewer than or more than three support apertures1880and/or the support apertures1880can be located at different positions circumferentially around the sidewall1615.

The hole saw1600also includes cutting teeth1775(only one cutting tooth1775is illustrated inFIG.12) each having a cutting tip1780and seated within one notch1705. Each cutting tooth1775includes a rake surface1785and a relief surface1790.

FIG.13illustrates a planar view of a portion of a hole saw1900according to another embodiment. The hole saw1900is similar to the hole saw100ofFIGS.1-5; therefore, similar components are designated with similar references numbers plus1800. At least some differences and/or at least some similarities between the hole saws100,1900will be discussed in detail below. In addition, components or features described with respect to one or some of the embodiments described herein are equally applicable to any other embodiments described herein and can include similar reference numbers. For example, the hole saw1900can be sized to bore into the single workpiece330ofFIG.5similar to the hole saw100, or the hole saw1900can be sized to bore into the two workpieces1530ofFIG.11similar to the hole saw1300.

The illustrated hole saw1900is moveable about a rotational axis1950in a cutting direction1955and includes a sidewall1915having a first end1920and a second end1925. The sidewall1915also includes gullets1975(only one gullet1975is illustrated inFIG.13) each defining a central longitudinal axis1980. Each gullet1975includes a notch2005, an open end1985, a bottom surface1990defining a second radius2045, a leading surface1995, and a trailing surface2000. In particular, the second radius2045of each bottom surface1990extends directly from the trailing surface2000to the leading surface1995. The sidewall1915also includes three support apertures2180(only one is illustrated inFIG.13) each positioned below the bottom surfaces1900. Each support aperture2180is also positioned as to circumferentially overlap with one of the gullets1975.

The hole saw1900also includes cutting teeth2075(only one cutting tooth2075is illustrated inFIG.13) each having a cutting tip2080and seated within one notch2005. Each cutting tooth2075includes a rake surface2085and a relief surface2090.

FIG.14illustrates a planar view of a portion of a hole saw2200according to another embodiment. The hole saw2200is similar to the hole saw100ofFIGS.1-5; therefore, similar components are designated with similar references numbers plus2100. At least some differences and/or at least some similarities between the hole saws100,2200will be discussed in detail below. In addition, components or features described with respect to one or some of the embodiments described herein are equally applicable to any other embodiments described herein and can include similar reference numbers. For example, the hole saw2200can be sized to bore into the single workpiece330ofFIG.5similar to the hole saw100, or the hole saw2200can be sized to bore into the two workpieces1530ofFIG.11similar to the hole saw1300.

The illustrated hole saw2200is moveable about a rotational axis2250in a cutting direction2255and includes a sidewall2215having a first end2220and a second end2225. The sidewall2215also includes gullets2275(only one gullet2275is illustrated inFIG.14) each defining a central longitudinal axis2280. Each gullet2275includes a notch2305, an open end2285, a bottom surface2290defining a second radius2345, a leading surface2295, and a trailing surface2300. Each trailing surface2300includes a trailing surface portion2310defining a first radius2330, a first portion2315, and a second portion2320with the trailing surface portion2310positioned between the first portion2315and the second portion2320. The first portion2315of each gullet2275defines a third angle2440that extends from the notch2305to the trailing surface portion2310in a direction away from the cutting direction2255. As a result, the trailing surface portion2310is positioned behind the first portion2315relative to the cutting direction2255. In other embodiments, the third angle2440can be oriented in a direction toward the cutting direction2255with at least a portion of the trailing surface portion2310positioned behind a portion of the first portion2315in a direction relative to the cutting direction2255. The sidewall2215also includes three support apertures2480(only one is illustrated inFIG.14) each positioned below a trailing surface portion2310.

The hole saw2200also includes cutting teeth2375(only one cutting tooth2375is illustrated inFIG.14) each having a cutting tip2380and seated within one notch2305. Each cutting tooth2375includes a rake surface2385and a relief surface2390.

FIG.15illustrates a planar view of a portion of a hole saw2500according to another embodiment. The hole saw2500is similar to the hole saw100ofFIGS.1-5; therefore, similar components are designated with similar references numbers plus2400. At least some differences and/or at least some similarities between the hole saws100,2500will be discussed in detail below. In addition, components or features described with respect to one or some of the embodiments described herein are equally applicable to any other embodiments described herein and can include similar reference numbers. For example, the hole saw2500can be sized to bore into the single workpiece330ofFIG.5similar to the hole saw100, or the hole saw2500can be sized to bore into the two workpieces1530ofFIG.11similar to the hole saw1300.

The illustrated hole saw2500is moveable about a rotational axis2550in a cutting direction2555and includes a sidewall2515having a first end2520and a second end2525. The sidewall2515also includes gullets2575(only one gullet2575is illustrated inFIG.15) each defining a central longitudinal axis2580. Each gullet2575includes a notch2605, an open end2585, a bottom surface2590defining a second radius2645, a leading surface2595, and a trailing surface2600. Each leading surface2595includes a support surface2755positioned between a third portion2745and a fourth portion2750.

The hole saw2500also includes cutting teeth2675(only one cutting tooth2675is illustrated inFIG.15) each having a cutting tip2680and seated within one notch2605. Each cutting tooth2675includes a rake surface2685and a relief surface2690.

FIG.16illustrates a planar view of a portion of a hole saw2800according to another embodiment. The hole saw2800is similar to the hole saw100ofFIGS.1-5; therefore, similar components are designated with similar references numbers plus2700. At least some differences and/or at least some similarities between the hole saws100,2800will be discussed in detail below. In addition, components or features described with respect to one or some of the embodiments described herein are equally applicable to any other embodiments described herein and can include similar reference numbers. For example, the hole saw2800can be sized to bore into the single workpiece330ofFIG.5similar to the hole saw100, or the hole saw2800can be sized to bore into the two workpieces1530ofFIG.11similar to the hole saw1300.

The illustrated hole saw2800is moveable about a rotational axis2850in a cutting direction2855and includes a sidewall2815having a first end2820and a second end2825. The sidewall2815also includes gullets2875(only one gullet2875is illustrated inFIG.16) each defining a central longitudinal axis2880. Each gullet2875includes a notch2905, an open end2885, a bottom surface2890defining a second radius2945, a leading surface2895, and a trailing surface2900. Each trailing surface2900includes a trailing surface portion2910defining a first radius2930, a first portion2915, and a second portion2920with the trailing surface portion2910positioned between the first portion2915and the second portion2920. The sidewall2815also includes three support apertures3080(only one is illustrated inFIG.16). Each support aperture3080defines a greater area than an area of one of the gullets2875. Each support aperture3080circumferentially overlaps with one of the gullets2875so that the leading surface2895of the gullet2875is positioned forward the support aperture3080but a portion of the support aperture3080is positioned behind the trailing surface2900of the gullet2875relative to the cutting direction2855.

The hole saw2800also includes cutting teeth2975(only one cutting tooth2975is illustrated inFIG.16) each having a cutting tip2980and seated within one notch2905. Each cutting tooth2975includes a rake surface2985and a relief surface2990.

FIG.17illustrates a planar view of a portion of a hole saw3100according to another embodiment. The hole saw3100is similar to the hole saw100ofFIGS.1-5; therefore, similar components are designated with similar references numbers plus3000. At least some differences and/or at least some similarities between the hole saws100,3100will be discussed in detail below. In addition, components or features described with respect to one or some of the embodiments described herein are equally applicable to any other embodiments described herein and can include similar reference numbers. For example, the hole saw3100can be sized to bore into the single workpiece330ofFIG.5similar to the hole saw100or the hole saw3100can be sized to bore into the two workpieces1530ofFIG.11similar to the hole saw1300.

The illustrated hole saw3100is moveable about a rotational axis3150in a cutting direction3155and includes a sidewall3115having a first end3120and a second end3125. The sidewall3115also includes gullets3175(only one gullet3175is illustrated inFIG.17) each defining a central longitudinal axis3180. Each gullet3175includes a notch3205, an open end3185, a bottom surface3190defining a second radius3245, a leading surface3195, and a trailing surface3200. Each trailing surface3200includes a trailing surface portion3210defining a first radius3230, a first portion3215, and a second portion3220with the trailing surface portion3210positioned between the first portion3215and the second portion3220. The sidewall3115also includes three support apertures3380(only one is illustrated inFIG.17). Each support aperture3380circumferentially overlaps with one of the gullets3175so that a portion of the support aperture3380is positioned forward the leading surface3195but a portion of the first portion3215is positioned behind the support aperture3380relative to the cutting direction3155.

The hole saw3100also includes cutting teeth3275(only one cutting tooth3275is illustrated inFIG.17) each having a cutting tip3280and seated within one notch3205. Each cutting tooth3275includes a rake surface3285and a relief surface3290.

FIG.18illustrates a planar view of a portion of a hole saw3400according to another embodiment. The hole saw3400is similar to the hole saw100ofFIGS.1-5; therefore, similar components are designated with similar references numbers plus3300. At least some differences and/or at least some similarities between the hole saws100,3400will be discussed in detail below. In addition, components or features described with respect to one or some of the embodiments described herein are equally applicable to any other embodiments described herein and can include similar reference numbers. For example, the hole saw3400can be sized to bore into the single workpiece330ofFIG.5similar to the hole saw100, or the hole saw3400can be sized to bore into the two workpieces1530ofFIG.11similar to the hole saw1300.

The illustrated hole saw3400is moveable about a rotational axis3450in a cutting direction3455and includes a sidewall3415having a first end3420and a second end3425. The sidewall3415also includes three pairs of gullets3475(only one pair of gullets3475is illustrated inFIG.18). Each pair3475includes a smaller gullet3475adefining a central longitudinal axis3480aand a larger gullet3475bdefining a central longitudinal axis3480b. In the illustrated embodiment, the central longitudinal axes3480a,3480bare substantially parallel; however, in other embodiments, the central longitudinal axes3480a,3480bcan be obliquely angled. The smaller gullet3475aincludes a notch3505a, an open end3485a, a bottom surface3490adefining a second radius3545a, a leading surface3495a, and a trailing surface3500a. Likewise, the larger gullet3475bincludes a notch3505b, an open end3485b, a bottom surface3490bdefining a second radius3545b, a leading surface3495b, and a trailing surface3500b. The bottom surface3490bof the larger gullet3475bis positioned closer to the second end3425of the sidewall3415than the bottom surface3490aof the smaller gullet3475a. In other embodiments, the sidewall3415can include fewer or more than three pairs of gullets3475. In the illustrated embodiment, the second radius3545bof the larger gullet3475bis greater than the second radius3545aof the smaller gullet3475a. In other embodiments, the second radius3545bof the larger gullet3475bcan be equal to or less than the second radius3545aof the smaller gullet3475a.

The hole saw3400also includes cutting teeth3575(only one pair of cutting teeth3575are illustrated inFIG.18) each having a cutting tip3580and seated within one notch3505a,3505b. Each cutting tooth3575includes a rake surface3585and a relief surface3590.

FIG.19illustrates a planar view of a portion of a hole saw3700according to another embodiment. The hole saw3700is similar to the hole saw100ofFIGS.1-5; therefore, similar components are designated with similar references numbers plus3600. At least some differences and/or at least some similarities between the hole saws100,3700will be discussed in detail below. In addition, components or features described with respect to one or some of the embodiments described herein are equally applicable to any other embodiments described herein and can include similar reference numbers. For example, the hole saw3700can be sized to bore into the single workpiece330ofFIG.5similar to the hole saw100, or the hole saw3700can be sized to bore into the two workpieces1530ofFIG.11similar to the hole saw1300.

The illustrated hole saw3700is moveable about a rotational axis3750in a cutting direction3755and includes a sidewall3715having a first end3720and a second end3725. The sidewall3715also includes gullets3775(only one gullet3775is illustrated inFIG.19) each defining a central longitudinal axis3780parallel to the rotational axis3750. Each gullet3775includes a notch3805, an open end3785, a bottom surface3790defining a second radius3845, a leading surface3795, and a trailing surface3800. Each trailing surface3800includes a trailing surface portion3810defining a first radius3830, a first portion3815, and a second portion3820with the trailing surface portion3810positioned between the first portion3815and the second portion3820. The sidewall3715also includes three support apertures3980(only one is illustrated inFIG.19). Each support aperture3980defines a longitudinal axis that substantially aligns with one central longitudinal axis3780of one gullet3775. In particular, each support aperture3980is directly below one gullet3775.

The hole saw3700also includes cutting teeth3875(only one cutting tooth3875is illustrated inFIG.19) each having a cutting tip3880and seated within one notch3805. Each cutting tooth3875includes a rake surface3885and a relief surface3890.

Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the invention as described. Various features and advantages of the invention are set forth in the following claims.