Hole saw with a large carbide overhang

Abstract

A hole saw is provided that has a variety of different tooth inlays and / or sizes that protrude from the sidewall. In some embodiments, large teeth protrude from the inner diameter of the sidewall to create a cut that is greater than the thickness of the sidewall. Similarly, the tooth inlay or variation in the circumferential direction of the teeth increases the cut in the workpiece either inwardly or outwardly. In a number of different embodiments, one or both of the increased tooth protrusion and / or the tooth inlay increases the cut of the hole saw relative to the sidewall thickness. This results in improved wear resistance, reduced heat on the teeth during cutting, and facilitates waste removal.

Description

[0001] Cross - reference to related patent applications

[0002] This application claims the benefit and priority of U.S. Provisional Patent Application No. 62 / 935,315, filed on November 14, 2019, the entire content of which is incorporated herein by reference. Background Art

[0003] The present invention generally relates to the field of tools. In particular, the present invention relates to a hole saw having a plurality of cutting teeth. Generally, a hole saw includes a cylindrical structure having cutting teeth at one end of the cylinder. In use, the hole saw rotates at a high speed to cut a hole in a workpiece that generally matches the size and shape of the cylindrical structure. Summary of the Invention

[0004] One embodiment of the present invention relates to a hole saw that includes a body, such as a cylindrical saw body, having cutting teeth at one end of the sidewall and an end cap at the opposite end. The cutting teeth form a cutting edge at the cutting end of the sidewall. At the opposite end of the saw body, the end cap secures the saw blade and couples the sidewall of the saw blade to a power tool or a rotating device. At least some of the cutting teeth are made of carbide material. At least some of the carbide cutting teeth protrude from the inner diameter of the sidewall of the cylindrical saw body such that the protruding teeth extend radially inward from the sidewall. In some such embodiments, the protruding teeth are wider in the radial direction than the width of the saw body, and this additional width provides an internally extending protrusion.

[0005] Inlay refers to positioning the carbide teeth at an inward or outward angle of the saw teeth relative to the sidewall. These teeth extend inward or outward relative to the cylindrical sidewall. In some embodiments, the protruding teeth are also inlaid inwardly between 0.005” and 0.027” (e.g., 0.005 inches to 0.027 inches) to increase the cutting edge notch and reduce wear on the teeth and / or the blade. Thus, in such embodiments, the cutting edge of the hole saw is increased in size by including wide protruding teeth that are further inlaid inwardly to further increase the degree of inward protrusion of at least some of the cutting teeth.

[0006] Another embodiment relates to the insert of the cutting teeth, the insert including some carbide teeth with the cutting edge insert being 0.027” on the inner side and some carbide teeth being 0.015” or less on the outer side. For example, the cutting edge insert is 0.22” on the inner side and 0.015” on the outer side. This configuration creates inwardly oriented offset teeth to reduce wear on the cutting edges of the remaining cutting teeth. This also creates a larger or wider cut, resulting in smaller waste material that is easier to remove from the inner diameter of the hole saw. For example, the combination of the internal overhang teeth and the outward insert teeth creates a cut that radially extends from the defined inner diameter of the cut of the overhang / insert teeth to the defined outer diameter of the cut of the overhang / insert teeth. In this embodiment, the outer diameter of the cut is greater than the outer diameter of the sidewall, and the inner diameter of the cut is less than the inner diameter of the sidewall. In other words, the cut is wider / larger than the thickness of the sidewall.

[0007] Another embodiment of the present invention relates to a hole saw having an end cap coupled to the base of a sidewall. The sidewall axially extends from the base to a cutting end of the sidewall opposite the base. The sidewall has a thickness between an inner diameter of the sidewall and an outer diameter of the sidewall. The sidewall includes cutting teeth disposed on the sidewall at the cutting end and overhang teeth wider than the cutting teeth. The overhang teeth radially extend inwardly from the sidewall to form an inner diameter of the cut that is less than the inner diameter of the sidewall.

[0008] Another embodiment of the present invention relates to a hole saw having an end cap coupled to the base of the sidewall to form a cylindrical body. The sidewall axially extends from the base to a cutting end opposite the base and defines a thickness between an inner diameter of the sidewall and an outer diameter of the sidewall. The sidewall has cutting teeth disposed on the sidewall and carbide teeth at the cutting end. The carbide teeth define a cut having an inner diameter of the cut. The carbide teeth have an internal overhang and an internal insert. The internal overhang of the carbide teeth radially extends inwardly on the inner diameter of the sidewall. The internal insert of the carbide teeth defines an inward angle relative to the inner diameter of the sidewall. The internal overhang and the internal insert form an inner diameter of the cut that is less than the inner diameter of the sidewall.

[0009] Another embodiment of the present invention relates to a hole saw having an end cap coupled to the base of the sidewall to form a cylindrical body. The sidewall axially extends from the base to a cutting end opposite the base and defines a thickness between an inner diameter of the sidewall and an outer diameter of the sidewall. The sidewall has cutting teeth without inserts disposed on the cutting end of the sidewall. Internal insert teeth are located on the sidewall and define an internal insert having an inward angle relative to the inner diameter of the sidewall. The internal insert teeth radially extend inwardly from the inner diameter of the sidewall at the inward angle such that the inner diameter of the cut is less than the inner diameter of the sidewall. Outward insert teeth disposed on the cutting end of the sidewall define an outward insert having an outward angle relative to the outer diameter of the sidewall. The outward insert teeth radially extend outwardly from the outer diameter of the sidewall at the outward angle such that the outer diameter of the cut is greater than the outer diameter of the sidewall.

[0010] Alternative exemplary embodiments relate to other features and combinations of features that can typically be recited in the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The present application will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which like reference numerals indicate like elements, and in which:

[0012] Figure 1 is a perspective view of a hole saw and a shank according to one embodiment.

[0013] Figure 2 is a cut workpiece with a cutout and waste according to an exemplary embodiment.

[0014] Figure 3 is a side plan view of a side wall of a hole saw according to an exemplary embodiment.

[0015] Figure 4 is according to an exemplary embodiment Figure 3 a plan view of the teeth on the cutting end of the side wall of.

[0016] Figure 5 is according to an exemplary embodiment Figure 4 a detailed view of the carbide tooth offset of.

[0017] Figure 6 is a detailed view of a hole saw having carbide teeth with both an inset angle and an offset according to an exemplary embodiment.

[0018] Figure 7 is a side plan view of a side wall of another hole saw according to an exemplary embodiment.

[0019] Figure 8 is according to an exemplary embodiment Figure 7 a plan view of the teeth on the cutting end of the side wall of.

[0020] Figure 9 is according to an exemplary embodiment Figure 8 a detailed view of the carbide tooth offset of.

[0021] Figure 10 is according to an exemplary embodiment similar to Figure 8 and Figure 9 a detailed view of the carbide tooth inset and offset of a plan view similar to.

[0022] Figure 11 is according to an exemplary embodiment similar to Figure 8 and Figure 9 a detailed view of the carbide tooth inset and offset of a plan view similar to. DETAILED DESCRIPTION

[0023] Generally referring to the drawings, multiple different embodiments of a hole saw are shown. As discussed in more detail herein, Applicant has developed a variety of hole saw designs that utilize wide / protruding teeth and / or angled inserts to improve cutting performance. Generally, a hole saw includes an end cap that is coupled to a sidewall that has cutting teeth at an end opposite the end cap. The sidewall is generally cylindrical. To form the cylindrical sidewall, a flat sidewall having a cutting end and a base opposite the cutting end is wound around the end cap to form the cylindrical sidewall that is coupled / fixed to the end cap. The end cap supports the cylindrical sidewall and includes a mounting structure that releasably couples the hole saw to a power driving device (e.g., a power tool). For example, the power tool rotates a shank that is connected to the end cap to drive the hole saw to rotate and cut a hole in a workpiece through the cutting teeth. The end cap provides support and rigidity to the sidewall, and the sidewall supports the cutting teeth.

[0024] As discussed herein, the orientation of the cutting teeth determines the size of the groove or cut made by the rotating teeth in the workpiece. In some embodiments, the cut is larger than the thickness of the sidewall of the hole saw. For example, the teeth are oriented such that the inner diameter of the cut made by the inner teeth of the sidewall is less than the inner diameter of the sidewall or the end cap that supports the sidewall. The maximum diameter of the waste material formed between the inner inserts of the teeth is less than the minimum diameter of the sidewall near the end cap (e.g., not at the cutting teeth). This sizing allows the operator to more easily remove the waste material after cutting because the outer diameter of the waste material is less than the inner diameter of the sidewall.

[0025] The cut size is affected by two design parameters. First, the inward orientation of large or oversized blades on the teeth. For example, large carbide blades create an internal protrusion that extends inward from the sidewall. Second, the tooth offset, position, angle, or insert affects the cut. The insert on the tooth refers to the position or angle of the carbide material on the tooth. For example, the insert refers to angled teeth that are oriented inward and / or outward from the sidewall diameter. This insert creates a tooth offset around the circumference of the sidewall, which increases the cut around the sidewall. In other words, both the protrusion of the large blade on the tooth and the insert (e.g., angled offset) of the tooth create an enlarged cut. The resulting enlarged cut is larger than the thickness of the sidewall. The hole saws discussed herein that include wide protruding teeth and / or insert designs / patterns provide a selected cut size. Additionally, the hole saws discussed herein that utilize wide protruding teeth, angled insert patterns, and / or carbide materials provide improved cutting and sawing performance, e.g., by helping to prevent heat buildup on the cutting teeth and thus extending the life of the cutting teeth by reducing wear during the cutting operation.

[0026] Figure 1The hole saw 10 and the shank 12 are shown. The hole saw 10 has an end cap 14 and a sidewall 16 which has a base 18 at one end and cutting teeth 20 at the opposite cutting end 22. As described below, the cutting teeth 20 include teeth with and / or without overhangs, offsets, and / or inserts. When rolled into a cylindrical shape, the sidewall 16 extends axially from the base 18 to the cutting end with the cutting teeth 20. The thickness of the sidewall 16 is equal to the distance between the inner surface 24 and the outer surface 26. The thickness of the sidewall 16 is defined as half of the difference between the outer diameter 28 of the sidewall and the inner diameter 30 of the sidewall. The end cap 14 is coupled to the base 18 of the sidewall 16 to form the cylindrical hole saw 10 (e.g., the sidewall 16 wraps or winds around the circumference of the end cap 14). The shank 12 is releasably coupled to the end cap 14 to rotate the cutting teeth 20 on the sidewall 16 about the longitudinal axis 32 and cut out a circular hole through the workpiece 34( Figure 2 ). A central elongated cavity 36 is formed inside the cylindrical sidewall 16, within the inner surface 24 (e.g., the inner diameter 30 of the sidewall).

[0027] In some embodiments, openings 40 are located in the sidewall 16 to reduce weight and / or provide access to the waste 38( Figure 2 ) or other debris formed during operation of the hole saw 10. For example, an operator places a screwdriver or another available tool / device through the opening 40 in the sidewall 16 to pry the waste 38 out of the cavity 36. The cutting teeth 20 have inserts (e.g., are offset or have insert teeth 42) and / or include blades 44 with overhang teeth 46 which cut the workpiece 34 to form a cut 48. The cut 48 is the thickness of the cut produced by the cutting teeth 20 of the hole saw 10 and is defined as half of the difference between the outer diameter 50 of the tooth or cut and the inner diameter 52( Figure 2 ) of the tooth or cut. The cutting edge produces a cut 48 that extends radially from the inner diameter 52 of the cut to the outer diameter 50 of the cut such that the cut 48 exceeds or is greater than the radial width or thickness of the sidewall 16. In some embodiments, the cut 48 is greater than the thickness of the sidewall 16 to form a larger hole in the workpiece 34 and / or reduce the size of the waste 38, e.g., to facilitate removal of the waste 38 from the cavity 36. In other words, the outer diameter of the waste 38 is less than the inner diameter 30 of the sidewall.

[0028] Figure 2 The workpiece 34 is shown, with a cut 48 and waste 38 formed partially or completely. As will be understood from the following description, the cut 48 is produced by the rotation of the cutting teeth 20 of the hole saw 10 that support the blade 44 and is formed by insert teeth 42 and / or overhang teeth 46 of the blade 44( Figure 6 、 Figure 10 and Figure 11Half of the difference between the outer diameter of the cutout (50). The insert teeth 42 and / or the blade 44 overhanging teeth 46 reduce friction, heat, and / or wear on the cutting teeth 20 (e.g., carbide and / or cutting teeth) and increase the life of the hole saw 10.

[0029] The overhanging teeth (“overhanging teeth 46”) are wider in the radial direction of the sidewall 16 than the width of the sidewall 16 or the cutting teeth 20. The wider overhanging teeth 46 (e.g., on multiple cutting teeth 20) define the inner diameter of the cutout 52. Similarly, the insert teeth 42 define the inward (or outward) angle of the cutting teeth 20 and / or the overhanging teeth 46 relative to the inner diameter of the sidewall 30. For example, the cutting teeth 20 form an inward angle (e.g., inner insert teeth 42) and the overhanging teeth 46 extend radially inward from the inner surface 24 of the sidewall 16 to form an inner diameter of the cutout 52 that is less than the inner diameter of the sidewall 30.

[0030] In one embodiment, the sidewall 16 has a first overhanging tooth 46 that extends (e.g., inwardly) on the inner diameter of the sidewall 30 and a second overhanging tooth 46 that extends (e.g., outwardly) on the outer diameter of the sidewall 28. The overhanging teeth 46 are wider than the width or thickness of the sidewall 16.

[0031] In this way, the thickness of the cutout 48 is greater than the thickness of the sidewall 16. The insert teeth 42 and / or the blade 44 overhanging teeth 46 reduce friction, heat, and / or wear on the cutting teeth 20 and facilitate the removal of the waste 38, which has an outer diameter less than the inner diameter of the sidewall 30 (e.g., approximately equal to the inner diameter of the cutout 52).

[0032] Figure 3 The “flat” or unfolded sidewall 16 of the hole saw 10 is shown. The sidewall 16 includes openings 40 and oriented cutting teeth 20 and / or insert teeth 42 in a repeating pattern. In some embodiments, the cutting teeth 20 include blades 44 and / or carbide material. The blade 44 is the hardened end of the tooth 20 configured to engage and cut the workpiece 34, e.g., a blade 44 with a carbide tip. The blade 44 includes overhanging teeth 46 that extend inwardly / outwardly from the outer / inner diameter of the sidewall 28 and / or 30. The hardened carbide steel or diamond material forms the blade 44, the overhanging teeth 46, and / or the cutting teeth 20. Figure 4 Shown is Figure 3 the cutting teeth 20 on the cutting end 22 of the sidewall 16 in Figure 3 and Figure 4 shows the repeating pattern of the cutting teeth 20 and the carbide tips or blades 44. Figure 3 The repeating pattern in Figure 4 is the same as or similar to that in

[0033] Figure 5 is Figure 3 and / or Figure 4 a detailed view showing one embodiment of cutting teeth 20 having blade 44 overhanging teeth 46. In some embodiments, the overhanging teeth 46 comprise carbide material. Figure 5 The configuration of only includes overhanging teeth 46 (e.g., in the cutting teeth 20, there are no insert teeth 42 on the inner diameter 30 of the sidewall). Using this configuration, each blade 44 of each cutting tooth 20 is an overhanging tooth 46 on the inner surface 24 and flush with the outer surface 26 of the sidewall 16. This configuration produces a cut 48 that is thicker than the thickness of the sidewall 16 (e.g., the distance between the inner surface 24 and the outer surface 26). The teeth 20 of the overhanging teeth 46 have a radially outer surface that is flush with the outer surface 26 (e.g., + / - 0.001” flush). The overhanging teeth 46 extend radially inward from the inner surface 24. Unless otherwise specifically indicated, all dimensions herein have a tolerance of ±0.001”. In multiple different embodiments, the overhanging teeth 46 extend between 0.010” and 0.040”, particularly between 0.015” and 0.030”, and more particularly between 0.020” and 0.025” (±0.001”). In one embodiment, the overhanging teeth 46 are 0.020” (±0.001”) on the inner surface 24 and 0.001” (±0.001”) on the outer surface 26. In other words, the wide overhanging teeth 46 extend inward (e.g., radially inward) and define a cut inner diameter 52 that is less than the sidewall inner diameter 30.

[0034] In some embodiments, the overhanging teeth 46 have a pattern. For example, every other tooth 20 has an overhanging tooth 46. In multiple different embodiments, every third or fourth tooth 20 has an overhanging tooth 46. In some embodiments, the first overhanging tooth 46 extends radially inward (inward), and the second overhanging tooth 46 extends radially outward (outward). Similarly, every other tooth 20 is an insert tooth 42 (e.g., every third or fourth tooth 20 is an insert tooth 42). In some embodiments, the first insert tooth 42 extends radially inward, and the second insert tooth 42 extends radially inward. In other embodiments, less than or equal to 50% of the cutting teeth 20 include overhanging teeth 46. In multiple different embodiments, less than or equal to 35%, 25%, 20%, 17%, 15% or 12.5% of the cutting teeth 20 on the hole saw 10 include insert teeth 42 and / or overhanging teeth 46.

[0035] For example, radially inwardly extending teeth 20 (e.g., overhang teeth 46 and / or insert teeth 42) and radially outwardly extending teeth 20 (e.g., overhang teeth 46 and / or insert teeth 42) are separated by one, two, three, four, five, six, seven, eight, nine, ten or more cutting teeth 20 (not offset relative to the overhang teeth 46 and / or insert teeth 42). For example, two or more cutting teeth separate the insert teeth 42 and / or the overhang teeth 46. In one embodiment, each insert tooth 42 and / or overhang tooth 46 is separated by three or more carbide cutting teeth (e.g., without insert teeth 42 or overhang teeth 46).

[0036] In other words, the cutting teeth 20 on the sidewall 16 repeat in a pattern of internal insert teeth 42, some cutting teeth 20 without inserts, offsets or overhangs, and outward insert teeth 42. In particular, the two sides of the teeth 20 having internal inserts (e.g., internal insert teeth 42) are adjacent to cutting teeth 20 without insert teeth 42 or overhang teeth 46 (e.g., on either side). Similarly, the two sides of the teeth 20 having outward inserts (e.g., outward insert teeth 42) are adjacent to cutting teeth 20 without inserts, offsets or overhangs (e.g., on either side).

[0037] Similarly, Figure 6 A series of cutting teeth 20 are shown, which include both insert teeth 42 and overhang teeth 46 to further increase the kerf 48. In other words, the teeth of the overhang teeth 46 are offset in the radial direction and are wider than the cutting teeth 20 in the radial direction. This configuration is similar to Figure 4 and Figure 5 but includes both insert teeth 42 (e.g., the blade 44 is offset) and overhang teeth 46 to increase the thickness of the resulting kerf 48. In one configuration, the insert teeth 42 are 0.022” (±0.001”) towards the inner surface 24 and 0.015” (±0.001”) towards the outer surface 26, with overhang teeth 46 of 0.005” (±0.001”) on the inner surface 24. In a number of different embodiments, the insert teeth 42 are between 0.001” and 0.010” (±0.001”) on the inner surface 24 and 0.001” (±0.001”) on the outer surface 26, the outward overhang teeth 46 are between 0.001” and 0.010”, and in particular, the insert teeth 42 are between 0.002” and 0.007” (±0.001”) on the inner surface 24 and 0.001” (±0.001”) on the outer surface 26, and the blade 44 overhang teeth 46 are between 0.002” and 0.007”.

[0038] Figure 7 Shown is the sidewall 16 cutting teeth 20 of one embodiment of a hole saw 10, for example, without an opening 40. In a number of different embodiments, Figure 7including openings 40 of different sizes, e.g., the same or similar to the opening 40 of Figure 3 and having a variety of different shapes (e.g., square, hexagonal, circular, oval, elliptical, etc.). Figure 8 and Figure 9 show cutting teeth 20 on the cutting end 22 of the side wall 16 of Figure 7 . In particular, Figure 9 is a detailed view of the inserted teeth 42 of the cutting teeth 20 and the overhanging teeth 46 of the blade 44. Referring to Figures 7 to 9 , the cutting teeth 20 do not have inserted teeth 42 (e.g., 0.000” ± 0.001”), and the blade 44 has an internal overhanging tooth 46 with a tolerance of +0.002” and -0.001” and an external overhanging tooth 46 of 0.001” (±0.001”) towards the inner surface 24 and an external overhanging tooth 46 of 0.001” (±0.001”) towards the outer surface 26.

[0039] Figure 10 shows carbide inserted teeth 42 and overhanging teeth 46 of the blade 44 similar to the embodiments shown in Figure 8 and Figure 9 . Figure 10 The embodiment of

[0040] includes both inserted teeth 42 and overhanging teeth 46 of the blade 44, which causes the hole saw 10 to produce an increased cut 48 thickness. In one configuration, the inserted teeth 42 are 0.022” (±0.001”) towards the inner surface 24 and 0.015” (±0.001”) towards the outer surface 26, with an overhanging tooth 46 of 0.005” ± 0.001” on the inner surface 24. In a plurality of different embodiments, the inserted teeth 42 are between 0.001” and 0.010” (±0.001”) on the inner surface 24 and 0.001” (±0.001”) on the outer surface 26, the overhanging teeth 46 of the blade 44 are between 0.001” and 0.010”, in particular, the inserted teeth 42 are between 0.002” and 0.007” (±0.001”) on the inner surface 24 and 0.001” (±0.001”) on the outer surface 26, the overhanging teeth 46 are between 0.002” and 0.007”, or the overhanging teeth 46 are between 0.015” and 0.025” (±0.001”).

[0040] Referring to the specific internal inserted teeth 42, Figure 2 and Figures 9 to 10The internal insert teeth 42 are shown, which define an inward angle on the teeth 20 relative to the inner surface 24 or the inner diameter 30 of the sidewall (e.g., the internal insert 42). In other words, the internal insert teeth 42 extend radially inward (e.g., inward) from the inner diameter 30 of the sidewall and the inner surface 24 of the sidewall 16. This orientation results in a cut inner diameter 52 that is less than (e.g., lower than) the inner surface 24. Because of this, the cut inner diameter 52 is less than the inner diameter 30 of the sidewall. For example, the internal insert teeth 42 extend from the sidewall 16 at an inward radial angle (e.g., radially inward). Accordingly, the internal insert teeth 42 produce a cut inner diameter 52 that is less than or lower than the inner diameter 30 of the sidewall.

[0041] Similarly, the outward insert teeth 42 define an outward angle relative to the outer surface 26 of the sidewall 16 (e.g., the outward insert 42). Due to the outward insert teeth 42 (e.g., the outer angle), the teeth 20 extend radially outward (e.g., outward) from the outer surface 26. In this way, the outward insert teeth 42 produce a cut outer diameter 50 that is greater than the outer diameter 28 of the sidewall. Accordingly, the internal or outward insert teeth 42 produce a cut 48 that is greater than the sidewall thickness (e.g., half of the difference between the outer diameter 28 of the sidewall minus the inner diameter 30 of the sidewall).

[0042] Figure 11 is shown similar to Figures 7 to 10 the inlay / offset on the carbide teeth 20 with the blade 44 and the overhanging teeth 46 as shown in the embodiment. In some embodiments, the insert teeth 42 are 0.027” (±0.001”) towards the inner surface 24 and 0.015” (±0.001”) towards the outer surface 26, with the overhanging teeth 46 having 0.005” ±0.001” on the inner surface 24. In a number of different embodiments, the insert teeth 42 are between 0.025” and 0.030” (±0.001”) on the inner surface 24 and between 0.012” and 0.018” (±0.001”) on the outer surface 26, the overhanging teeth 46 are between 0.001” and 0.020”, in particular, the insert teeth 42 are between 0.025” and 0.030” (±0.001”) on the inner surface 24 and between 0.012” and 0.018” (±0.001”) on the outer surface 26, the blade 44 overhanging teeth 46 are between 0.003” and 0.007”, or the overhanging teeth 46 are between 0.018” and 0.022” (±0.001”).

[0043] It should be understood that the drawings show the exemplary embodiments in detail, and it should be understood that the present application is not limited to the details or methods set forth in the specification or shown in the drawings. It should also be understood that the terms are for descriptive purposes only and should not be considered restrictive.

[0044] In view of this specification, other modifications and alternative embodiments of the various different aspects of the present invention will be apparent to those skilled in the art. Accordingly, this specification should be construed as merely illustrative. The constructions and arrangements shown in the various different exemplary embodiments are merely illustrative. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible without materially departing from the novel teachings and advantages of the subject matter described herein (e.g., changes in the size, dimensions, structure, shape and proportions of the various different elements, parameter values, mounting arrangements, use of materials, colors, orientations, etc.). Some elements shown as integrally formed may be composed of multiple parts or elements. The positions of the elements may be reversed or otherwise changed, and the nature or number or position of the separate elements may be altered or varied. According to alternative embodiments, the order or sequence of any process, logical algorithm or method step may be changed or re-ordered. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangements of the various different exemplary embodiments without departing from the scope of the present invention.

[0045] For the purposes of this disclosure, the term "coupled" means that two components are directly or indirectly connected to each other. Such a connection can be fixed in nature or movable in nature. Such a connection can be achieved by integrally forming two members and any additional intermediate members into a single unitary body with each other, or by attaching two members or two members and any additional members to each other. Such a connection can be permanent in nature or alternatively removable or releasable in nature.

[0046] In the various different exemplary embodiments, as shown in the drawings, the relative dimensions, including angles, lengths and radii, are proportional. The actual measurements of the drawings will disclose the relative dimensions, angles and proportions of the various different exemplary embodiments. The various different exemplary embodiments extend to various ranges around the absolute and relative dimensions, angles and proportions that can be determined from the drawings. The various different exemplary embodiments include any combination of one or more relative dimensions or angles that can be determined from the drawings. Further, the actual dimensions not explicitly listed in this specification can be determined by using the dimension ratios measured in the drawings in combination with the explicit dimensions listed in this specification.

Claims

1. A hole saw, comprising: A sidewall axially extending from a base to a cutting end of the sidewall opposite the base, the sidewall having: a thickness between an inner surface and an outer surface of the sidewall; Cutting teeth disposed on the sidewall at the cutting end, the width of the cutting teeth being the same as the thickness of the sidewall; and Protruding teeth wider than the cutting teeth, wherein the protruding teeth extend radially inward from the sidewall to form an inner diameter of a cut smaller than the inner diameter of the sidewall, and wherein an outer radial surface of the protruding teeth is flush with the outer surface of the sidewall; and An end cap coupled to the base of the sidewall, wherein the hole saw further comprises outwardly inlaid teeth, wherein the protruding teeth and the outwardly inlaid teeth create a cut extending radially from the inner diameter of the cut to an outer diameter of the cut, wherein the outer diameter of the cut is greater than the outer diameter of the sidewall, and wherein the cut is wider than the thickness of the sidewall.

2. The hole saw according to claim 1, wherein, The protruding teeth comprise a cemented carbide material.

3. The hole saw according to claim 1, further comprising an external overhanging tooth that is wider than the thickness of the side wall, and wherein, The outer protruding teeth extend outwardly and define the outer diameter of the cut.

4. The hole saw according to claim 1, wherein The protruding teeth are angled inwardly relative to the sidewall to define an inlay, wherein the inlay is between 0.005 inches and 0.020 inches.

5. The hole saw according to claim 1, wherein, The outwardly inlaid teeth extend from the outer surface of the sidewall by 0.015 inches or less.

6. The hole saw according to claim 1, wherein, Each protruding tooth is adjacent to a cutting tooth.

7. The hole saw according to claim 1, wherein The protruding teeth are blades having cemented carbide tips, the blades extending radially inward from the inner surface of the sidewall by 0.027 inches or less.

8. The hole saw according to claim 1, further comprising an opening in the sidewall.

9. The hole saw according to claim 1, wherein, The protruding teeth have no inlay relative to the inner surface of the sidewall and have an internal protrusion between 0.005 inches and 0.027 inches.

10. The hole saw according to claim 1, wherein, The entire outer radial surface of each of the protruding teeth is flush with the outer surface of the sidewall.

11. A hole saw, comprising: A cylindrical body, the cylindrical body comprising: A sidewall axially extending from a base to a cutting end of the sidewall opposite the base, the sidewall having a thickness defined between an inner surface and an outer surface of the sidewall; Cutting teeth disposed on the sidewall at the cutting end, the width of the cutting teeth being the same as the thickness of the sidewall; and First cemented carbide teeth at the cutting end, the first cemented carbide teeth being wider than the cutting teeth and defining a cut having an inner diameter of the cut, wherein the first cemented carbide teeth comprise: Internal protruding teeth, wherein the internal protruding teeth of the first cemented carbide teeth extend radially inward on the inner surface of the sidewall, an outer radial surface of the internal protruding teeth being flush with the outer surface of the sidewall; and Internal inlaid teeth, the internal inlaid teeth of the first cemented carbide teeth defining an inward angle relative to the inner surface of the sidewall, wherein the internal protruding teeth and the internal inlaid teeth form the inner diameter of the cut smaller than the inner diameter of the sidewall; and An end cap coupled to the base of the sidewall.

12. The hole saw according to claim 11, wherein, Up to 35% of the teeth on the sidewall are the first cemented carbide teeth having the internal protruding teeth or the internal inlaid teeth.

13. The hole saw according to claim 11, wherein, The notch is equal to the width of these first carbide teeth having the internal overhanging teeth, and wherein the notch is greater than the thickness of the sidewall.

14. The hole saw according to claim 11, further comprising a blade having an outward overhang, wherein, The outward overhang is between 0.001 inches and 0.011 inches.

15. The hole saw according to claim 11, further comprising second carbide teeth having outward inlays, wherein, The outward inlay has an external overhang greater than the thickness of the sidewall, and wherein the internal inlay of these first carbide teeth is between 0.005 inches and 0.020 inches.

16. The hole saw according to claim 11, wherein, The cutting teeth and the first carbide teeth further include a pattern that includes the first carbide teeth, carbide cutting teeth, and second carbide teeth, wherein the first carbide teeth have an internal overhang and an internal inlay, and wherein the second carbide teeth have an external overhang and an outward inlay, and wherein three or more carbide cutting teeth are between the first carbide teeth and the second carbide teeth in the pattern.

17. A hole saw, comprising: A cylindrical body, the cylindrical body comprising: A sidewall that axially extends from a base to a cutting end opposite the base, the sidewall having a thickness defined between an inner surface and an outer surface of the sidewall; Cutting teeth without inlay disposed on the cutting end of the sidewall, the width of the cutting teeth being the same as the thickness of the sidewall; Internal inlay teeth that define an internal inlay having an inward angle relative to the inner surface of the sidewall, wherein the internal inlay teeth radially extend inwardly from the inner surface of the sidewall at the inward angle such that the inner diameter of the notch is less than the inner diameter of the sidewall; and Outward inlay teeth that define an outward inlay having an outward angle relative to the outer surface of the sidewall, wherein the outward inlay teeth radially extend outwardly from the outer surface of the sidewall at the outward angle such that the outer diameter of the notch is greater than the outer diameter of the sidewall; Overhanging teeth that are wider than the thickness of the sidewall, the overhanging teeth having a radially outer surface flush with the outer surface of the sidewall; and An end cap coupled to the base of the sidewall.

18. The hole saw according to claim 17, further comprising an opening in the side wall, and wherein, Two or more cutting teeth separate the internal inlay teeth and the outward inlay teeth.

19. The hole saw according to claim 17, wherein, The overhanging teeth are 0.001 inches to 0.005 inches wider than the thickness of the sidewall.

20. The hole saw according to claim 17, wherein, Both sides of the internal inlay teeth and the outward inlay teeth are adjacent to cutting teeth without the inlay or overhang.

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