Chainsaw chain

Abstract

A chainsaw chain includes a plurality of drive links, a plurality of cutters configured to cut a workpiece during a cutting operation, and a plurality of rivets. Each cutter includes a cutter body having a pair of rivet holes extending therethrough. The cutter body defines a longitudinal axis extending through the pair of rivet holes and a vertical axis oriented perpendicular to the longitudinal axis. Also, each cutter includes a cutting tooth coupled to the cutter body. The cutting tooth has a rake face and a relief face extending opposite the rake face. Each cutter further includes a cutting insert having a front portion and a top portion that is substantially flush with the relief face of the cutting tooth.

Description

CHAINSAW CHAINCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 696,139, filed September 18. 2024. and U.S. Provisional Patent Application No. 63 / 617,581 , filed January 4, 2024, the entire contents of both of which are incorporated herein by reference.FIELD OF THE INVENTION

[0002] The present invention relates to chainsaw chains.BACKGROUND OF THE INVENTION

[0003] A chainsaw chain typically includes cutters, drive links, tie straps, and rivets. The components of the chainsaw chain may be coupled to each other in various patterns and rotatably driven along a guide bar of a chainsaw to perform cutting operations.SUMMARY OF THE INVENTION

[0004] Aspects of the invention relate to chainsaw chains for chainsaws. A chainsaw chain may include a plurality of cutters configured to cut a workpiece during a cutting operation. In some aspects, one or more of the cutters may include a cutting tooth that takes the size and shape of a cutting tooth from a saw blade, such as a hole saw blade, a circular saw blade, a reciprocating saw blade, and the like.

[0005] The invention provides, in one aspect, a chainsaw chain for a chainsaw. The chainsaw chain includes a plurality of drive links configured to connect the chainsaw chain to the chainsaw. Each drive link includes a drive link body and a pair of rivet holes extending though the drive link body. The chainsaw chain further includes a plurality- of cutters configured to cut a workpiece during a cutting operation. Each cutter includes a cutter body having a pair of rivet holes extending therethrough. The cutter body defines a longitudinal axis extending through the pair of rivet holes and a vertical axis oriented perpendicular to the longitudinal axis. Each cutter further includes a cutting tooth coupled to the cutter body. The cutting tooth includes a rake face and a relief face extending opposite the rake face. Each cutter also includes a feed limiter coupled to the cutter body and spaced from the cutting tooth, a gullet defined between the cutting tooth and the feed limiter, and a cutting insertcoupled to the cutting tooth. The cutting insert includes a front portion and a top portion that is substantially flush with the relief face of the cutting tooth. Moreover, the chainsaw chain includes a plurality of rivets received within corresponding rivet holes of the plurality of drive links and the plurality of cutters to couple the plurality of drive links and the plurality of cutters together.

[0006] This invention provides, in another aspect, a chainsaw chain for a chainsaw. The chainsaw- chain includes a plurality of drive links configured to connect the chainsaw' chain to the chainsaw , a plurality7of cutters configured to cut a w orkpiece during a cutting operation, a first projection positioned on a first side of the plurality of drive links and extending in a first direction, and a second projection positioned on a second side of the plurality of drive links and extending in a second direction opposite the first direction such that the first projection and the second projection extend outwardly from the plurality of drive links.

[0007] This invention provides, in another aspect, a chainsaw chain for a chainsaw. The chainsaw7chain includes a plurality of drive links configured to connect the chainsaw' chain to the chainsaw'. Each drive link includes a drive link body, a rivet hole extending through the drive link body, a tang extending from the drive link body and configured to engage a drive element of the chainsaw, and a projection extending from the drive link body in a direction opposite the tang. The chainsaw' chain further includes a plurality of cutters configured to cut a w orkpiece during a cutting operation. Each cutter includes a cutter body having a rivet hole extending therethrough and a cutting tooth coupled to the cutter body. Moreover, the chainsaw chain includes a plurality7of rivets received within corresponding rivet holes of the plurality of drive links and the plurality of cutters to couple the plurality of drive links and the plurality of cutters together.

[0008] This invention provides, in another aspect, a chainsaw chain for a chainsaw. The chainsaw chain includes a plurality of drive links configured to connect the chainsaw chain to the chainsaw and a set of cutters configured to cut a workpiece during a cutting operation. The set of cutters includes a pair of cutters parallel to each other with at least one drive link of the plurality of drive links is disposed between the pair of cutters. The chainsaw7chain further includes a plurality of other cutters configured to cut the workpiece during the cutting operation. Each cutter of the plurality of other cutters is positioned on a first side of the plurality of drive links or a second side of the plurality of drive links. Moreover, the chainsaw chain includes a plurality7of tie straps. Each tie strap of the plurality of tie straps isconfigured to interconnect consecutive drive links of the plurality of drive links and positioned opposite on an opposite side of the consecutive drive links from a cutter of the plurality of other cutters.

[0009] This invention provides, in another aspect, a chainsaw chain for a chainsaw. The chainsaw chain includes a plurality of drive links configured to connect the chainsaw chain to the chainsaw. Each drive link includes a drive link body, a pair of rivet holes extending though the drive link body, a tang extending from the drive link body and configured to engage a drive element of the chainsaw, a cutting tooth coupled to the drive link body, and a drive link insert coupled to the cutting tooth. The chainsaw chain further includes a plurality of cutter links configured to interconnect consecutive drive links. Each cutter link includes a cutter link body having a pair of rivet holes extending therethrough. The cutter link body defines a longitudinal axis extending through the pair of rivet holes, a vertical axis oriented perpendicular to the longitudinal axis, and a first thickness measured transverse the longitudinal axis. Each cutter link further includes a cutting tooth coupled to the cutter link body and a cutter link insert coupled to the cutting tooth. The cutter link insert defines a second thickness greater than the first thickness.BRIEF DESCRIPTION OF DRAWINGS

[0010] FIG. 1 is a perspective view of a chainsaw.

[0011] FIG. 2 is a perspective view of a chainsaw chain according to an embodiment of the present invention.

[0012] FIG. 3A is a perspective view of a drive link according to an embodiment of the present invention.

[0013] FIG. 3B is a perspective view of a drive link according to another embodiment of the present invention.

[0014] FIG. 3C is a perspective view of a drive link according to another embodiment of the present invention.

[0015] FIG. 4A is a perspective view of a tie strap according to an embodiment of the present invention.

[0016] FIG. 4B is a perspective view of a tie strap according to another embodiment of the present invention.

[0017] FIG. 5 is a perspective view of a cutter according to an embodiment of the present invention.

[0018] FIG. 6 is a side view of the cutter of FIG. 5.

[0019] FIG. 7 is an enlarged side view of a cutting tooth of the cutter of FIG. 5, the cutting tooth having a cutting insert illustrated in an initial state and a final state.

[0020] FIG. 8 is a perspective view of a cutter according to another embodiment of the present invention, the cutter having a cutting tooth set in a right direction.

[0021] FIG. 9 is a perspective view of a cutter according to another embodiment of the present invention, the cutter having a cutting tooth set in a left direction.

[0022] FIG. 10 is a perspective view of chainsaw chain according to another embodiment of the present invention.

[0023] FIG. 11 is a perspective view of a cutter according to another embodiment of the present invention.

[0024] FIG. 12 is a side view of the cutter of FIG. 11.

[0025] FIG. 13 is a perspective view of a cutter according to another embodiment of the present invention, the cutter having a cutting tooth set in a right direction.

[0026] FIG. 14 is a perspective view of a cutter according to another embodiment of the present invention, the cutter having a cutting tooth set in a left direction.

[0027] FIG. 15 is a flowchart depicting a method of manufacturing the chainsaw chain of FIG. 2.

[0028] FIG. 16 is a perspective view of a chainsaw chain according to another embodiment of the present invention.

[0029] FIG. 17 is a perspective view of a cutter according to another embodiment of the present invention.

[0030] FIG. 18 is a side view- of the cutter of FIG. 17.

[0031] FIG. 19 is a perspective view of a cutter according to another embodiment of the present invention, the cutter having a cutting tooth set in a right direction.

[0032] FIG. 20 is a perspective view of a cutter according to another embodiment of the present invention, the cutter having a cutting tooth set in a left direction.

[0033] FIG. 21 is a perspective view of a chainsaw chain according to another embodiment of the present invention.

[0034] FIG. 22 is a perspective view of a chainsaw chain according to another embodiment of the present invention.

[0035] FIG. 23 is a perspective view of a chainsaw chain according to another embodiment of the present invention.

[0036] FIG. 24 is a perspective view of a chainsaw chain according to another embodiment of the present invention, the chainsaw chain including a set of outset tie straps.

[0037] FIG. 25 is a perspective view of a first outset tie strap of the set of outset tie straps of FIG. 24.

[0038] FIG. 26 is a perspective view of a second outset tie strap of the set of outset tie straps of FIG. 24.

[0039] FIG. 27 is a perspective view of a chainsaw chain according to another embodiment of the present invention.

[0040] FIG. 28 is a perspective view of a cutter link according to an embodiment of the present invention.

[0041] FIG. 29 is a side view' of the cutter link of FIG. 28.

[0042] FIG. 30 is a top view of the cutter link of FIG. 28.

[0043] FIG. 31 is a perspective view' of a cutter link according to an embodiment of the present invention, the cutter link set in a right direction.

[0044] FIG. 32 is a perspective view of a cuter link according to an embodiment of the present invention, the cuter link set in a left direction.

[0045] FIG. 33 is a perspective view of a drive link according to another embodiment of the present invention.

[0046] FIG. 34 is a side view of the drive link of FIG. 33.

[0047] FIG. 35 is a top view of the drive link of FIG. 33.

[0048] FIG. 36A is a side view of a drive link according to an embodiment of the present invention.

[0049] FIG. 36B is a perspective view of the drive link of FIG. 36A.

[0050] FIG. 37A is a side view of a drive link according to an embodiment of the present invention.

[0051] FIG. 37B is a perspective view of the drive link of FIG. 37A.

[0052] FIG. 38A is a perspective view of a drive link according to an embodiment of the present invention.

[0053] FIG. 38B is a side view of the drive link of FIG. 38A.

[0054] FIG. 39 is a perspective view of a drive link according to an embodiment of the present invention.

[0055] FIG. 40 is a perspective view of a cuter according to another embodiment of the present invention.

[0056] FIG. 41 is a side view of the cuter of FIG. 40.

[0057] FIG. 42 is a perspective view of a chainsaw chain according to another embodiment of the present invention.

[0058] FIG. 43A is a front perspective view of a combination cutter according to an embodiment of the present invention.

[0059] FIG. 43B is a rear perspective view of the combination cuter of FIG. 43 A.

[0060] FIG. 44 is a perspective view of a cutter according to another embodiment of the present invention.

[0061] FIG. 45 is a side view of the cutter of FIG. 44.

[0062] 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 earned 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.DETAILED DESCRIPTION

[0063] FIG. 1 illustrates a chainsaw 1 configured to perform cutting operations on a workpiece. The chainsaw 1 includes a housing 2 configured to support a motor and a drive mechanism, a battery receptacle 3 coupled to a rear portion of the housing 2, a power source 4 coupled to the battery receptacle 3, a handle 5 coupled to the housing 2 and the battery receptacle 3, a trigger coupled to the handle 5, and a guide bar 6 coupled to a front portion of the housing 2. In some embodiments, the chainsaw 1 may be provided with two handles. In the illustrated embodiment, the power source 4 is a battery' pack, such as an 18-volt Li-ion battery pack. The battery pack is configured to selectively supply power to the motor to activate the chainsaw 1. In other embodiments, the chainsaw 1 may have other types of power sources, such as a gasoline engine or an AC power cord. A chainsaw chain 7 is disposed along a periphery of the guide bar 6 and configured to be rotatably driven by the motor and the drive mechanism when the trigger is moved from an OFF position to an ON position. As the chainsaw chain 7 is driven along the guide bar 6, a user is able to perform cutting operations on material such as wood. In additional embodiments, the chainsaw 1 may include a chain tension control mechanism for adjusting a tension of the chainsaw chain 7, a chain brake operable to turn off the chainsaw 1 during an emergency (e.g., chainsaw 1 experiencing kickback), and a trigger lockout for preventing accidental accusation of the chainsaw 1. The illustrated chainsaw 1 is just one example of a chainsaw 1. In other embodiments, the chainsaw 1 may have other components and / or configurations.

[0064] FIG. 2 illustrates an embodiment of the chainsaw chain 7. The illustrated chainsaw chain 7 includes a plurality’ of cutters 10 constructed to perform cutting operations, a plurality of drive links 14 positioned at a central portion of the chainsaw chain 7, and a plurality of tie straps 18 or tie links that interconnect consecutive drive links of the plurality of drive links 14. The illustrated cutters 10 are designed to cut workpieces which may have relatively hard objects embedded therein (e.g., nail-embedded wood). As such, the cutters 10 are specifically structured to handle an impact of striking a fastener (e.g.. a nail) when cutting a workpiece. The cutters 10, the drive links 14, and the tie straps 18 are each coupled to each other by rivets 20. In some embodiments, the rivets 20 may undergo deformation to permanently couple the components of the chainsaw chain 7 together. In other embodiments, the cutters 10, the drive links 14, and the tie straps 18 may be coupled together by other suitable fasteners.

[0065] FIG. 3 A illustrates one drive link 24a of the plurality' of drive links 14. The drive link 24a includes a drive link body 28a, one or more rivet holes 32a extending through the drive link body 28a, and a bottom scooping portion or a tang 36a positioned below the pair of rivet holes 32a. The drive link 24a may also include one or more stabilizing features (e.g., a feed limiter or other configurations) to further provide stability and support to the chainsaw chain 7. A thickness of the drive link body 28a defines a gauge of the chainsayv chain 7, and thereby corresponds to a size of the guide bar 6 working yvith the chainsaw chain 1. The thickness of the drive link body 28a may be about 0.043 inches, 0.050 inches, 0.063 inches, or other values. To achieve an appropriate gauge of the chainsayv chain 7, the drive link body 28a may have a coined section in w hich one portion of the drive link 24a may be thinner than another portion of the drive link 24a. In addition, the rivet holes 32a are each configured to receive a rivet 20 (FIG. 2), so that the drive link 24a can be coupled to a respective cutter 10 and / or a respective tie strap 18.

[0066] The tang 36a extends downwardly from the drive link body 28a. In the illustrated embodiment, the tang 36a is integrally formed yvith the drive link body 28a. In other embodiments, the tang 36a may be a separate piece that is secured to the drive link body 28a. The tang 36a is defined by a curved gap formed within the drive link body 28a and is configured to support the chainsaw chain 7 along the guide bar 6 of the chainsaw 1. The tang 36a also engages a drive element moving within the guide bar 6 to drive the chainsayv chain 7 around the guide bar 6 and carry lubricating fluid (e.g., oil) through the guide bar 6 to keepthe chainsaw chain 7 lubricated. The drive link 24a further includes an opening 44a proximate the tang 36a. The opening 44a also carries and spreads lubricating fluid through the guide bar 6. Therefore, the chainsaw chain 7 can remain lubricated and attached to the guide bar 6 during operation of the chainsaw 1. In other embodiments, the opening 44a may instead be formed as an indent, a coating, or other features configured to spread a lubrication fluid or reduce friction.

[0067] The drive link body 28a of the drive link 24a has a top edge 38a formed by a first curved portion 38al concentric with one of the rivet holes 32a and a curved convex portion 38a2 concentric with the other one of the rivet holes 32a. In the illustrated embodiment, the first and second curved portions 38al. 38a2 are convex portions. The top edge 38a is also formed by a third curved portion 38a3 positioned between the first and second curved portions 38al, 38a2. In the illustrated embodiment, the third curved portion 38a3 is a concave portion. The top edge 38a has a constant wall thickness around the rivet holes 32a. As such, an outer diameter of a respective area, that is at least partially defined by the first and second convex portions 38al, 38a2, ranges between 6.5 mm and 8 mm, and is about 7. 1 mm to ensure that the drive link 24a has an appropriate size (e.g., is sufficiently small) to fit underneath any configuration of the cutters 10. In other embodiments, the outer diameter may be other values since the outer diameter may vary according to the pitch of the chainsaw chain or the overall design of the drive link 24a.

[0068] FIG. 3B illustrates another drive link 24b that may be incorporated into the chainsaw chain 7 of FIG. 2 or any other chainsaw chain discussed herein below. The drive link 24b is similar to the drive link 24a of FIG. 3 A; therefore, like structure will be identified by like reference number plus "‘b” and only the differences will be discussed hereafter. The drive link 24b includes a drive link body 28b, one or more rivet holes 32b extending through the drive link body 28b, and a bottom scooping portion or a tang 36b positioned below the pair of rivet holes 32b. The drive link 24b further includes a plurality’ of openings 44b 1-3 formed as multiple slots located at a central portion of the drive link 24b. The openings 44bl-3 cany’ and spread lubricating fluid through the guide bar 6. In the illustrated embodiment, the plurality7of openings 44b 1-3 includes a first opening 44b 1, a second opening 44b2, and a third opening 44b3 that each have different lengths. In other embodiments, each opening 44b 1-3 may have the same length. The Illustrated openings 44b 1-3 are linear slots that extend parallel to each other. In other embodiments, the openings44b 1-3 may be non-linear and / or may not extend parallel to each other. In further embodiments, the plurality of opening 44b 1-3 may instead be formed as indents, coatings, or other features configured to spread a lubrication fluid or reduce friction.

[0069] FIG. 3C illustrates another drive link 24c that may be incorporated into the chainsaw chain 7 of FIG. 2 or any other chainsaw chain discussed herein below. The drive link 24c is similar to the drive link 24a of FIG. 3 A; therefore, like structure will be identified by like reference number plus "‘c” and only the differences will be discussed hereafter. The drive link 24c includes a drive link body 28c, one or more rivet holes 32c extending through the drive link body 28c, and a bottom scooping portion or a tang 36c positioned below the pair of rivet holes 32c. The drive link 24b further includes a plurality of openings 44c 1-3 that carry and spread lubricating fluid through the guide bar 6. The plurality of openings 44cl-3 includes a first circular opening 44c 1, a second circular opening 44c2, and a third opening 44c3 formed as an arcuate slot. The third opening 44c3 is arranged below the first circular opening 44c 1 and the second circular opening 44c2. In other embodiments, the drive link 24c may have fewer or more openings 44cl-3 and / or openings 44cl-3 of different shapes or sizes. Additional or alternatively, the openings 44cl-3 may be arranged in other ways. In further embodiments, the plurality of opening 44cl-3 may instead be formed as indents, coatings, or other features configured to spread a lubrication fluid or reduce friction.

[0070] FIG. 4A illustrates one tie strap 48a of the plurality of tie straps 18. The tie strap 48a includes a tie strap body 52a, one or more rivet holes 56a extending through the tie strap body 52a, a toe 60a, and a heel 64a. In other embodiments, the tie strap body 52a may be marked or specifically colored to identify the start of the chainsaw chain 7 or the tvpe of the chainsaw chain 7. The tie strap 48a is configured to interconnect the drive link 24a to a respective cutter fO or consecutive drive links 14 to form the chainsaw chain 7. For example, one of the rivet holes 56a of the tie strap 48a may be aligned and coaxial with one of the rivet holes 32a of the drive link 24a to receive a rivet 20 for coupling. The other of the rivet holes 56a of the tie strap 48a may be aligned and coaxial with one of the rivet holes 56a of another drive link 24a to receive a different rivet 20 for coupling. In other embodiments, the other of the rivet holes 56a of the tie strap 48a may be aligned and coaxial with one of the rivet holes of a respective cutter 10. The rivet holes 56a are sized and shaped to receive a respective rivet that is to undergo a deformation process and achieve a desired pitch of the chainsaw chain 7.

[0071] The toe 60a of the tie strap 48a is configured to assist with guiding and properly positioning the chainsaw chain 7 along the guide bar 6 of the chainsaw 1. The heel 64a of the tie strap 48a provides stability and support to the chainsaw chain 7 during a cutting operation. In addition, the toe 60a and the heel 64a may also handle material that has been removed during a cutting operation. In the illustrated embodiment, the toe 60a and the heel 64a are formed with a curvilinear shape. In other embodiments, the toe 60a and the heel 64a may be formed as other shapes.

[0072] Feet 65a are formed along a bottom portion of the tie strap 48a as flat surfaces. In the illustrated embodiment, the feet 65a are evenly (i.e.. flat or planar) formed along the bottom portion of the tie strap 48a. In other embodiments, the feet 65a may be unevenly formed along the bottom portion of the tie strap 48a to assist with performing a bucking cut operation and an angular cut operation. Also, along the bottom portion of the tie strap 48a, an arched surface 66a is formed between the feet 65a of the tie strap 48a such that a size and shape of the arched surface 66a depends on the pitch of the chainsaw chain 7 and the size of the guide bar 6. The arched surface 66a of the tie strap 48a provides clearance as the chainsaw chain 7 is driven around the guide bar 6. Along a top portion of the tie strap 48a, a pair of cutouts 67a is defined such that a respective cutout 67a is located at a respective comer of the tie strap 48a. Each illustrated cutout 67a has a curvilinear shape. In other additional embodiments, each cutout 67a may have other shapes.

[0073] In some embodiments, the tie strap 48a may be reversible when another arched surface is formed on along a top portion of the tie strap 48a and opposite the arched surface 66a. In other embodiments, the tie strap 48a may be formed of a lightweight material or have further cutouts to minimize weight of the tie strap 48a, and ultimately the chainsaw chain 7. In further embodiments, the tie strap 48a may include a feed limiter.

[0074] FIG. 4B illustrates another tie strap 48b that may be incorporated into the chainsaw chain 7 of FIG. 2 or any other chainsaw chain discussed herein below. The tie strap 48b is similar to the tie strap 48a of FIG. 4A; therefore, like structure will be identified by like reference number plus “b” and only the differences will be discussed hereafter. The tie strap 48b includes a tie strap body 52b, one or more rivet holes 56b extending through the tie strap body 52b, a toe 60b, and a heel 64b. The toe 60b and the heel 64b are formed as chamfer-like edges. Feet 65b are formed along a bottom portion of the tie strap 48b as flatsurfaces. Also, a trapezoidal surface 66b is also formed along the bottom portion of the tie strap 48b between the feet 65b.

[0075] FIGS. 5-7 illustrate one cutter 68 of the plurality of cutters 10. In the illustrated embodiment, the cutters 10 of the chainsaw chain 7 are substantially the same, except for maybe a set direction of each cutter (as explained below with respect to FIGS. 8 and 9). As such, the description of the cutter 68 is applicable to any of the cutters 10. In other embodiments, some of the cutters 10 of the chainsaw chain 7 may have different configurations, and the description of the cutter 68 may only apply to some of the cutters 10.

[0076] The illustrated cutter 68 includes a cutter body 72. a cutting tooth 76. a feed limiter 80, a gullet 84, a toe 88, and a heel 92. The cutter body 72 includes one or more rivet holes 94 extending therethrough. Each rivet hole 94 is configured to receive a rivet 20 (FIG. 2). The cutter body 72 defines a longitudinal axis 96 of the cutter 68 and a vertical axis 98 of the cutter 68. The longitudinal axis 96 of the cutter 68 extends through the rivet holes 94, while the vertical axis 98 is oriented perpendicular to the longitudinal axis 96. The cutting tooth 76 is coupled to and extends from an upper portion of the cutter body 72. In the illustrated embodiment, the cutting tooth 76 is integrally formed with the cutter body 72. In other embodiments, the cutting tooth 76 may be a separate piece that is secured to the cutter body 72. The cutting tooth 76 takes the size and shape of a cutting tooth from a saw blade (e.g., hole saw blade, circular saw blade, and reciprocating saw blade). The feed limiter 80, or depth gauge, is also coupled to and extends from the upper portion of the cutter body 72. The feed limiter 80 is spaced apart from the cutting tooth 76 in front of the cutting tooth 76 in a cutting direction. In the illustrated embodiment, the feed limiter 80 is integrally formed with the cutter body 72. In other embodiments, the feed limiter 80 may be a separate piece that is secured to the cutter body 72. The feed limiter 80 is configured to limit how far the cutting tooth 76 can cut into a workpiece and limit the amount of material the cutter 68 can remove from the workpiece. The gullet 84 is defined between the cutting tooth 76 and the feed limiter 80. The feed limiter 80 is specifically positioned on the cutter 68 to provide a large gullet 84. As such, the positioning of the feed limiter 80 helps the chainsaw 1 to operate efficiently at high cutting speeds. The toe 88 and the heel 92 are formed along a bottom portion of the cutter body 72. The toe 88 is positioned closer to the feed limiter 80, while the heel 92 is positioned closer to the cutting tooth 76. In the illustrated embodiment, each of the toe 88 and the heel 92 is formed as a chamfer-like edge.

[0077] The cutting tooth 76 of the cutter 68 is the portion of the chainsaw chain 7 that performs the cutting operation. The illustrated cutting tooth 76 includes a cutting tip 100, a rake face 102 extending from the cutting tip 100, and a relief face 104 extending from the cutting tip 100 opposite the rake face 102. The cutting tooth 76 extends parallel to the feed limiter 80 and the vertical axis 98 of the cutter 68. As such, the cutting tooth 76 is unset relative to the feed limiter 80. A cutting insert 108 of the cutting tooth 76 forms at least a part of the cutting tip 100. The cutting insert 108 can be coupled to the cutting tooth 76 by various joining methods (e.g., resistance welding, laser welding, cladding, etc.) and formed of various materials. In some embodiments, the cutting insert 108 can be formed of carbide, while the cutting tooth 76 and the cutter body 72 can be formed of steel (e.g.. high speed steel). In other embodiments, the cutting insert 108, the cutting tooth 76. and / or the cutter body 72 can be formed of other suitable materials. In an initial state, the cutting insert 108 is formed as a cylindrical carbide piece 112 (FIG. 7). In other embodiments, the cutting insert 108 may take the form of other shapes. After the cutting insert 108 is secured to the cutting tooth 76, the cutting insert 108 may then be ground to a desired shape to be in a final state (e.g.. the cutting insert 108 of FIGS. 5-7).

[0078] With reference to FIGS. 6 and 7, the cutting tooth 76 of the cutter 68 further includes a pocket 116 defined along the cutting tip 100. The pocket 116 includes a first surface 120 and a second surface 124. The first surface 120 of the pocket 116 extends perpendicular from the rake face 102 of the cutting tooth 76. The second surface 124 of the pocket 116 extends betw een the first surface 120 and the relief face 104 of the cutting tooth 76 as the second surface 124 is oriented perpendicular to the first surface 120.

[0079] The cutting insert 108 is coupled to the pocket 116 in an axial orientation such that the cylindrical carbide piece 112 is welded to the pocket 116 in parallel to a final grind orientation of the cutting insert 108. The carbide piece 112 is oriented such that a longitudinal axis 128 (FIG. 7) of the cutting insert 108 is parallel to the second surface 124 of the pocket 116. In addition, the longitudinal axis 128 of the cutting insert 108 is oriented at an inclination angle Al relative to a cutting tooth axis 130 that is parallel to the vertical axis 98 of the cutter 68. The inclination angle Al preferably ranges between 4 and 6 degrees, and is preferably 5 degrees. In other embodiments, the inclination angle Al may have other values.

[0080] After joining the carbide piece 112 to the cutting tooth 76. the carbide piece 112 is then ground into the final state (i.e. , the cutting insert 108). In the final state, the cutting insert 108 includes atop portion 132 and a front portion 136. The top portion 132 may also be referred to as a top edge, and the front portion 136 may also be referred to as a front edge. The top portion 132 of the cutting insert 108 serves as a relief face for the cutting insert 108, while the front portion 136 serves as a rake face for the cutting insert 108. Also, the cutting insert 108 includes side surfaces 137a. 137b (FIG. 5) extending between the top portion 132 and the front portion 136. The cutting insert 108 is ground until the front portion 136 is oriented at a rake angle A2 relative to a rake axis 138 that is parallel to the vertical axis 98 and the top portion 132 is oriented at a relief angle A3 relative to a relief axis 139 that is parallel to the longitudinal axis 96. In the illustrated embodiment, the rake angle A2 is a positive rake angle. In some embodiments, the rake angle A2 may be a negative rake angle. In other embodiments, the rake angle A2 may be a neutral rake angle. As such, various ranges and values of the rake angle A2 and the relief angle A3 may produce chainsaw chains that achieve different performance features such as fast cutting operations (e.g., complete a single cut at a fast speed), clean cutting operations, durability, etc. In other embodiments, the cutting tooth 76 may be ground to have a fleam grind.

[0081] In some embodiments, the rake angle A2 ranges between -90 and 90 degrees. In other embodiments, the rake angle A2 ranges between -5 and 50 degrees. In preferred embodiments, the rake angle A2 ranges between 2.5 and 12.5 degrees, in which high value rake angles of the specified range produce a chainsaw chain that provides fast cutting operations. As such, the rake angle A2 of the preferred embodiment is not dependent on the relief angle A3 so that the rake angle A2 can be independently changed. In further embodiments, the rake angle A2 ranges between 4 and 6 degrees, and may be 5 degrees.

[0082] In some embodiments, the relief angle A3 ranges between -40 and 80 degrees, in which the relief angle A3 is dependent on the rake angle A2 and a height of the cutter 68. In other embodiments, the relief angle A3 ranges between -5 and 50 degrees. In preferred embodiments, the relief angle A3 ranges between 2.5 and 12.5 degrees, in which a high value relief angle A3 of the specified range produces a chainsaw chain that provides fast cutting operations. As such, the relief angle A3 of the preferred embodiment is not dependent on the rake angle A2 so that the relief angle A3 can be independently changed. In other preferred embodiments, the relief angle A3 is 30 degrees or less. In additional embodiments, the reliefangle A3 ranges between 4 and 6 degrees, and may be 5 degrees. Moreover, the rake angle A2 and / or the relief angle A3 may have other values and ranges.

[0083] The rake face 102 of the cutting tooth 76 is substantially flush (i.e., aligns with) with the front portion 136 of cutting insert 108. The relief face 104 of the cutting tooth 76 is substantially flush (i.e., aligns with) with the top portion 132 of the cutting insert 108. As such, the relief face 104 of the cutting tooth 76 and the top portion 132 of the cutting insert 108 define a flat continuous relief surface 140 along a top portion of the cutting tooth 76. The continuous relief surface 140 provides strength to the cutting insert 108, and thereby increases the cutting life of the cutter 68. For example, the continuous relief surface 140 inhibits removal of the cutting insert 108 from the cutting tooth 76 when the cutting tooth 76 strikes a fastener embedded within a workpiece.

[0084] With reference back to FIG. 6, the feed limiter 80 defines a feed cutting height Hl of the cutter 68. Specifically, the feed cutting height Hl is defined between a feed limiter tip 142 and the cutting tip 100, measured perpendicular to the longitudinal axis 96. In some embodiments, the feed cutting height Hl ranges between -5 mm to 5 mm. In other embodiments, the feed cutting height Hl ranges between -0.5 mm and 3 mm. In further embodiments, the feed cutting height Hl preferably ranges between 0.5 mm and 0.9 mm, in which a high value feed cutting height Hl of the specified range produces a chainsaw chain that provides fast cutting operations. In more embodiments, the feed cutting height Hl is preferably 2 mm or less. In additional embodiments, the feed cutting height Hl ranges between 0.4 mm and 0.6 mm, and may be 0.5 mm. In another embodiment, the feed cutting height Hl ranges between 0.25 mm and 0.6 mm. In other embodiments, the feed cutting height Hl may have other values. The feed limiter 80 is provided as a relatively tall feed limiter to enable the cutter 68 to only remove a small amount of material from a workpiece with each cut. As such, the feed limiter 80 is set to control an impact magnitude at which the cutter 68 strikes a fastener embedded in the workpiece.

[0085] With reference back to FIG. 5, the cutter body 72 of the cutter 68 also defines a cutter thickness Tl. Specifically, the cutter thickness T1 is defined between a first face 144 of the cutter body 72 and a second face 148 of the cutter body 72 opposite the first face 144. The cutter thickness Tl is selected to help the cutter 68 make more cuts and prolong the cutting life of the cutter 68. In some embodiments, the cutter thickness Tl ranges between 0.040 inches and 0.070 inches. In preferred embodiments, the cutter thickness Tl rangesbetween 0.042 inches and 0.050 inches, in which a high value cutter thickness T1 of the specified range results in increased durability and cutting life in comparison to a conventional cutter. In additional embodiments, the cutter thickness T1 may be 0.050 inches. In further embodiments, the cutter thickness T1 may be no more than 0.063 inches or 0. 100 inches when the cutter 68 has a large sized cutting insert 108. Moreover, the cutter thickness T1 may have other values.

[0086] FIG. 8 illustrates another cutter 150 of the plurality of cutters 10. The cutter 150 is similar to the cutter 68 of FIG. 5; therefore, like structure will be identified by like reference number plus “100"’ and only the differences will be discussed hereafter.

[0087] The cutter 150 includes a cutter body 172, a cutting tooth 176, a feed limiter 180, a gullet 184 positioned between the feed limiter 180 and the cutting tooth 176, a toe 188, a heel 192, and one or more rivet holes 194. The cutting tooth 176 is set (i.e., bent) in a right direction of the cutter 150 and non-parallel to a vertical axis 198 defined by the cutter body 172. The cutting tooth 176 is oriented such that a cutting tip 200 of the cutting tooth 176 extends past a corresponding rivet 20 (FIG. 2), and thereby clears the rivet 20. Depending on the position of the cutter 150 along the chainsaw chain 7, the cutting tooth 176 may overlap and clear a portion of the guide bar 6 of the chainsaw 1 from the right direction or extend in the right direction away from the guide bar 6. As such, for certain positions of the cutter 150, it is necessary for the cutting tooth 176 to clear the guide bar 6 to make a cut in a workpiece.

[0088] The cutting tooth 176 may be set such that the cutting tip 200 (e.g., cutting edge 249 of the cutting tip 200) is disposed at a distance of 0.042 inches from a plane extending parallel to a second face 248 of the cutter body 172. In some embodiments, the cutting tip 200 is disposed at a distance, ranging between 0.025 inches and 0.050 inches, from the plane extending parallel to the second face 248. In preferred embodiments, the cutting tip 200 is disposed at a distance, ranging between 0.032 inches and 0.050 inches, from the plane extending parallel to the second face 248. In general, the cutting tip 200 is oriented at an angle, ranging between 10 degrees and 15 degrees, relative to the plane. A high value distance of the specified range achieves clearance over a corresponding rivet and allows the chainsaw chain 7 to produce a controlled cut. Ultimately, the distance, between the cutting tip 200 and the plane, should be greater than 0.032 inches so that a kerf of the chainsaw chain 7 is larger than a size of a corresponding rivet (depending on the size of the rivet). In further embodiments, the distance, between the cutting tip 200 and the plane extending parallel to thesecond face 248, ranges between 0 inches and 0. 1 inches. In another embodiment, a theoretical angular limit at which the cutting tip 200 is oriented relative to the plane ranges between 0 and 90 degrees.

[0089] FIG. 9 illustrates another a cutter 350 of the plurality of cutters 10. The cutter 350 is similar to the cutter 68 of FIG. 5; therefore, like structure will be identified by like reference number plus '‘300’’ and only the differences will be discussed hereafter.

[0090] The cutter 350 includes a cutter body 372, a cutting tooth 376, a feed limiter 380, a gullet 384 positioned between the feed limiter 380 and the cutting tooth 376, a toe 388. a heel 392. and one or more rivet holes 394. The cutting tooth 376 is set (i.e., bent) in a left direction of the cutter 350 and non-parallel to a vertical axis 398 defined by the cutter body 372. As such, the cutting tooth 376 is oriented such that a cutting tip 400 of the cutting tooth 376 extends past a corresponding rivet 20 (FIG. 2), and thereby clears the rivet 20. Depending on the position of the cutter 350 along the chainsaw chain 7, the cutting tooth 376 may overlap and clear a portion of the guide bar 6 of the chainsaw 1 from the left direction or extend in the left direction away from the guide bar 6. As such, for certain positions of the cutter 350, it is necessary for the cutting tooth 376 to clear the guide bar 6 to make a cut in a workpiece.

[0091] The cutting tooth 376 may be set such that the cutting tip 400 (e.g., cutting edge 449 of the cutting tip 400) is disposed at a distance of 0.042 inches from a plane extending parallel to a first face 444 of the cutter body 372. In some embodiments, the cutting tip 400 is disposed at a distance, ranging between 0.025 inches and 0.050 inches, from the plane extending parallel to the first face 444. In preferred embodiments, the cutting tip 400 is disposed at a distance, ranging between 0.032 inches and 0.050 inches, from the plane extending parallel to the first face 444. In further embodiments, the distance, between the cutting tip 400 and the plane extending parallel to the first face 444, ranges between 0 inches and 0.1 inches. In another embodiment, a theoretical angular limit at which the cutting tip 400 is oriented relative to the plane ranges between 0 and 90 degrees.

[0092] Referring back to FIG. 2. the chainsaw chain 7 is formed by coupling the plurality of cutters 10 to the plurality of drive links 14, and also coupling the plurality of drive links 14 to the plurality of tie straps 18. For example, one of the rivet holes 94 of the cutter 68 is aligned and coaxial with one of the rivet holes 32a of the drive link 24a, so that a rivet 20 canbe received through the aligned rivet holes 32a, 94 of the drive link 24a and the cutter 68. The rivet 20 may be deformed to permanently couple the cutter 68 to the drive link 24a. The same process can also be used to permanently couple the tie strap 48a and the drive link 24a together. In addition, the same process can be used to permanently couple the cutters 150, 350 of FIGS. 8 and 9 to a respective drive link 14.

[0093] To deform the rivet 20 such that the cutter 68, the drive link 14, and the tie strap 48a are coupled to each other, the rivet 20 can be forged. The rivet 20 includes a rivet head, a rivet end opposite the rivet head, and a rivet shaft disposed between the rivet head and the rivet end. Once the rivet 20 is received through corresponding rivet holes 32a, 56a, 94, either the drive link 24a, the tie strap 48a, or the cutter 68 is placed along the rivet shaft as the rivet head is positioned against a surface of either the tie strap 48a or the cutter 68. The rivet end can then be deformed, such that the rivet end enlarges to a diameter about two times larger than a diameter of the rivet shaft. After the rivet end has been deformed, the drive link 24a, the tie strap 48a, or the cutter 68 are then enclosed between the rivet head and the rivet end and permanently coupled to each other. Once the rivet 20 is completely deformed, the rivet 20 may cut into either the tie strap 48a or the cutter 68. As such, the drive link 24a is permitted to pivot about the rivet shaft of the rivet 20. The tie strap 48a and the cutter 68 are fixed, and therefore cannot pivot with respect to the rivet 20. In some embodiments, the rivet 20 may include a tapered collared portion, which a respective drive link 24a is placed along. In other embodiments, the rivet 20 may include an asymmetric shank portion. In additional embodiments, the rivet 20 may be a flush rivet to obtain the most benefit out of the kerf of the chainsaw chain 7. In further embodiments, the rivet 20 may not include a collared portion.

[0094] The plurality of cutters 10 of the chainsaw chain 7 is formed by cutters similar to the cutter 68 of FIGS. 5-7, the cutter 150 of FIG. 8, and the cutter 350 of FIG. 9. To form the cutting arrangement of the chainsaw chain 7, the cutters 68, 150, 350 are arranged to alternate with each other. In some embodiments, the chainsaw chain 7 may alternate between a group of set cutters (e.g., cutters 150, 350) and a group of unset cutters (e.g., cutter 68). In other embodiments, the chainsaw chain 7 may alternate between a set cutter (e.g., cutters 150, 350) and an unset cutter (e.g., cutter 68). For example, as illustrated in FIG. 2, the cutters 10 are arranged (starting from the left side of the drawing) in a repeating pattern of: (i) unset cutter positioned on the right side of the chainsaw chain 7. (ii) unset cutter positioned on the left side of the chainsaw chain 7, (iii) right set cutter positioned on the right side of the chainsawchain 7, (iv) left set cutter positioned on the left side of the chainsaw chain 7, (v) left set cutter positioned on the right side of the chainsaw chain 7, and (vi) right set cutter positioned on the left side of the chainsaw chain 7. Such an arrangement increases the overall kerf of the chainsaw chain 7 (compared to a chainsaw chain with only unset cutters or only cutters set to one side) and ensures at least one cutting tooth of a cutter cuts through each section of the kerf. In other embodiments, the chainsaw chain 7 may have other repeating or nonrepeating patterns of cutters 10. In another embodiment, the chainsaw chain 7 may alternate between a first set of cutters that are set in the right direction (e.g., cutter 150) and a second set of cutters that are set in the left direction (e.g., cutter 350). Each set of cutters is formed of a pair of cutters that are parallel to each other. At least one drive link of the plurality of drive links 14 is disposed between the pair of cutters to maintain the chainsaw chain 7 along the guide bar 6 of the chainsaw 1. The chainsaw chain 7 may also include a third set of cutters and a fourth set of cutters. The third set of cutters is formed of a pair unset cutters (e.g., cutter 68). The fourth set of cutters is formed of a pair of set cutters, in which one of the cutters is set in the left direction as the other cutter is set in the right direction. In additional embodiments, the chainsaw chain 7 may include a plurality of the first set of cutters, a plurality of the second set of cutters, a plurality of the third set of cutters, and a plurality of the fourth set of cutters.

[0095] FIG. 10 illustrates another embodiment of a chainsaw chain 500 that can be used with the chainsaw 1 of FIG. 1. The chainsaw chain 500 includes a plurality of cutters 504, a plurality of drive links 508, and a plurality’ of tie straps 512 configured to interconnect consecutive drive links of the plurality of drive links 508. A plurality of rivets 510 are provided to permanently couple the cutters 504. the drive links 508, and the tie straps 512 together to form the chainsaw chain 500. The drive links 508, the tie straps 512, and the rivets 510 may be similar to the drive link 24a, the tie strap 48a, and the rivets 20 discussed above.

[0096] FIG. 11 illustrates a cutter 516 of the plurality of cutters 504. The illustrated cutter 516 includes a cutter body 520 defining a first face 522 and a second face 523 opposite the first face 522, a cutting tooth 524, a feed limiter 528, a gullet 532, a toe 536, and a heel 540. The cutter body 520 includes one or more rivet holes 544 extending therethrough. The cutter body 520 defines a longitudinal axis 548 of the cutter 516 and a vertical axis 552 of the cutter 516. The longitudinal axis 548 extends through the rivet holes 544, while the verticalaxis is oriented perpendicular to the longitudinal axis 548. The illustrated cutting tooth 524 includes a cutting tip 556, a rake face 560 extending from the cutting tip 556. a primary relief face 564 extending from the cutting tip 556 opposite the rake face 560, and a secondary relief face 572 extending from the primary relief face 564 to an edge 576 of the cutter body 520 proximate the heel 540. Also, the cutting tooth 524 takes the size and shape of a cutting tooth from a saw blade (e.g.. hole saw blade, circular saw blade, and reciprocating saw blade).

[0097] With reference to FIG. 12, a cutting insert 580 is coupled to the cutting tooth 524 by various joining methods (e.g., resistance welding, laser welding, cladding, etc.) and forms at least a part of the cutting tip 556. The primary relief face 564 of the cutting tooth 524 is substantially flush with a top portion 584 of the cutting insert 580 such that the primary relief face 564 and the top portion 584 are oriented at a primary relief angle A4 relative to a primary relief axis 588 extending parallel to the longitudinal axis 548. In the illustrated embodiment, the secondary' relief face 572 is oriented at a secondary relief angle A5 relative to a secondary relief axis 590 extending parallel to the vertical axis 552. In an alternative embodiment, the secondary relief angle A5 is measured relative to the primary relief face 564. The secondary relief angle A5 is larger than the primary7relief angle A4. In other embodiments, the secondary relief angle A5 may be smaller than the primary relief angle A4. The secondary relief angle A5 is provided to allow a user to perform a plunge cutting operation with a nose 592 (FIG. 1) of the chainsaw 1. In such scenarios, the primary relief angle A4 may act as a feed limiter. In other embodiments, the primary relief face 564 and the secondary relief face 572 may be non-flat surfaces (i.e., curved surfaces) with a rounded edge formed therebetween.

[0098] In some embodiments, the primary' relief angle A4 ranges between -40 and 80 degrees, in which the primary' relief angle A4 is dependent on a rake angle of the cutter 516 and a height of the cutter 516. In other embodiments, the primary7relief angle A4 ranges between -5 and 50 degrees. In preferred embodiments, the primary relief angle A4 ranges between 2.5 and 12.5 degrees, in which a high value primary relief angle A4 of the specified range produces a chainsaw chain that provides fast cutting operations. As such, the primary relief angle A4 of the preferred embodiment is not dependent on the rake angle of the cutter 516 such that the primary relief angle A4 can be independently changed. In other preferred embodiments, the primary relief angle A4 is 30 degrees or less. In additional embodiments.the primary relief angle A4 ranges between 4 and 6 degrees. In further embodiments, the primary’ relief angle A4 may be 5 degrees.

[0099] In some embodiments, the secondary relief angle A5 ranges between 0 and 120 degrees to result in a portion of the cutter body 520 proximate the edge 576 being taller than the cutting insert 580. In other embodiments, the secondary’ relief angle A5 ranges between 0 and 70 degrees. In preferred embodiments, the secondary relief angle A5 ranges between 2.5 and 12.5 degrees, in which a high value secondary relief angle A5 of the specified range produces a chainsaw chain that provide fast cutting operations. In additional embodiments, the secondary- relief angle A5 ranges between 30 and 60 degrees. In further embodiments, the secondary relief angle A5 may be 35 degrees. Moreover, the primary relief angle A4 and the secondary relief angle A5 may have other values and ranges. The secondary relief face 572 is obliquely oriented relative to the primary relief face 564 such that the secondary' relief face 572 is beneficial for the plunge cutting operation.

[0100] FIG. 13 illustrates another cutter 616 of the plurality' of cutters 504. The cutter 616 is similar to the cutter 516 of FIG. 11 and 12; therefore, like structure will be identified by like reference number plus ‘TOO’’ and only the differences will be discussed hereafter.

[0101] The cutter 616 includes a cutter body 620 defining a first face 622 and a second face 623 opposite the first face 622, a cutting tooth 624, a feed limiter 628, a gullet 632, a toe 636, a heel 640, and one or more rivet holes 644. The cutter body 620 further defines a longitudinal axis 648 and a vertical axis 652. The cutting tooth 624 is set (i.e., bent) in a right direction of the cutter 616 and non-parallel to the vertical axis 652. A portion of the cutter 616, defined between the cutter body 620 and the cutting tooth 624, is bent such that a curved surface is formed. In other embodiments, more than one portion of the cutter 616 may also be bent while a planar portion is formed between the bent portions of the cutter 616. The cutting tooth 624 is oriented such that a cutting tip 656 of the cutting tooth 624 extends past a corresponding rivet 510 (FIG. 10), and thereby clears the rivet 510. Depending on the position of the cutter 616 along the chainsayv chain 7, the cutting tooth 624 may overlap and clear a portion of the guide bar 6 of the chainsayv 1 from the right direction or extend in the right direction away from the guide bar 6. As such, for certain positions of the cutter 616, it is necessary for the cutting tooth 624 to clear the guide bar 6 to make a cut in a workpiece.

[0102] The cutting tooth 624 may be set such that the cutting tip 656 (e.g., cutting edge 694 of the cutting tip 656) is disposed at a distance of 0.042 inches from a plane extending parallel to the second face 623 of the cutter body 620. In some embodiments, the cutting tip 656 is disposed at a distance, ranging between 0.025 inches and 0.050 inches, from the plane extending parallel to the second face 623. In preferred embodiments, the cutting tip 656 is disposed at a distance, ranging between 0.032 inches and 0.050 inches, from the plane extending parallel to the second face 623. In general, the cutting tip 656 is oriented at an angle, ranging between 10 degrees and 15 degrees, relative to the plane. In further embodiments, the distance, between the cutting tip 656 and the plane extending parallel to the second face 248, ranges between 0 inches and 0. 1 inches. In another embodiment, a theoretical angular limit at which the cutting tip 656 is oriented relative to the plane ranges between 0 and 90 degrees.

[0103] FIG. 14 illustrates another cutter 716 of the plurality of cutters 504. The cutter 716 is similar to the cutter 516 of FIGS. 11 and 12; therefore, like structure will be identified by like reference number plus '‘200” and only the differences will be discussed hereafter.

[0104] The cutter 716 includes a cutter body 720 defining a first face 722 and a second face 723 opposite the first face 722, a cutting tooth 724. a feed limiter 728, a gullet 732, a toe 736, a heel 740, and one or more rivet holes 744. The cutter body 720 further defines a longitudinal axis 748 and a vertical axis 752. The cutting tooth 724 is set (i.e., bent) in a left direction of the cutter 716 and non-parallel to the vertical axis 752. A portion of the cutter 716, defined between the cutter body 720 and the cutting tooth 724, is bent such that a curved surface is formed. In other embodiments, more than one portion of the cutter 716 may also be bent while a planar portion is formed between the bent portions of the cutter 716. The cutting tooth 724 is oriented such that a cuting tip 756 of the cuting tooth 724 extends past a corresponding rivet 510 (FIG. 10), and thereby clears the rivet 510. Depending on the position of the cuter 716 along the chainsaw chain 7. the cuting tooth 724 may overlap and clear a portion of the guide bar 6 of the chainsaw 1 from the left direction or extend in the left direction away from the guide bar 6. As such, for certain positions of the cuter 716, it is necessary for the cuting tooth 724 to clear the guide bar 6 to make a cut in a workpiece.

[0105] The cuting tooth 724 may be set such that the cuting tip 756 (e.g., cutting edge 794 of the cuting tip 756) is disposed at a distance of 0.042 inches from a plane extending parallel to the first face 722 of the cuter body 720. In some embodiments, the cuting tip 756is disposed at a distance, ranging between 0.025 inches and 0.050 inches from the plane extending parallel to the first face 722. In preferred embodiments, the cutting tip 756 is disposed at a distance, ranging between 0.032 inches and 0.050 inches, from the plane extending parallel to the first face 722. In general, the cutting tip 756 is oriented at an angle, ranging between 10 degrees and 15 degrees, relative to the plane. In further embodiments, the distance, between the cutting tip 756 and the plane extending parallel to the second face 248, ranges between 0 inches and 0. 1 inches. In another embodiment, a theoretical angular limit at which the cutting tip 756 is oriented relative to the plane ranges between 0 and 90 degrees.

[0106] The plurality of cutters 504 of the chainsaw chain 500 is formed by cutters similar to the cutter 516 of FIGS. 11 and 12, the cutter 616 of FIG. 13, and the cutter 716 of FIG. 14. To form the cutting arrangement of the chainsaw chain 500, the cutters 516, 616, 716 are arranged to alternate with each other. In some embodiments, the chainsaw chain 500 may alternate between a group of set cutters (e.g., cutters 616, 716) and a group of unset cutters (e.g., cutter 516). In other embodiments, the chainsaw chain 500 may alternate between a set cutter (e.g., cutters 616, 716) and an unset cutter (e.g., cutter 516). In another embodiment, the chainsaw chain 500 may alternate betw een multiple sets of cutters, in which each set of cutters is formed of a pair of cutters that are parallel to each other as a respective drive link 508 is disposed therebetween.

[0107] In one embodiment, the cutting arrangement of the chainsaw' chain 500 may be formed such that 50% of the plurality of cutters 504 are set cutters (e.g., cutters 616, 716) and 50% of the plurality of cutters 504 are unset cutters (e.g., cutter 516). In an additional embodiment, the cutting arrangement of the chainsaw' chain 500 may be formed such that 75% of the plurality of cutters 504 are set cutters (e.g., cutters 616, 716) and 25% of the plurality of cutters 504 are unset cutters (e.g., cutter 516). In a further embodiment, the cutting arrangement of the chainsaw chain 500 may be formed such that 25% of the plurality of cutters 504 are set cutters (e.g., cutters 616, 716) and 75% of the plurality of cutters 504 are unset cutters (e.g., cutter 516). In another embodiment, the cutting arrangement of the chainsaw chain 500 may be formed such that 25% of the plurality of cutters 504 are cutters (e.g., cutter 716) set in a left direction. 25% of the plurality of cutters 504 are cutters (e.g., cutter 616) set in a right direction, and 50% of the plurality of cutters 504 are unset cutters (e.g., cutter 516). In another embodiment, the cutting arrangement of the chainsaw chain 500may be formed such that 60% of the plurality of cutters 504 are cutters (e.g., cutter 716) set in a left direction. 20% of the plurality of cutters 504 are cutters (e.g., cutter 616) set in a right direction, and 20% of the plurality of cutters 504 are unset cutters (e.g., cutter 516). In another embodiment, the cutting arrangement of the chainsaw chain 500 may be formed such that 20% of the plurality of cutters 504 are cutters (e.g., cutter 716) set in a left direction, 60% of the plurality of cutters 504 are cutters (e.g., cutter 616) set in a right direction, and 20% of the plurality of cutters 504 are unset cutters (e.g., cutter 516).

[0108] With reference to FIG. 15, a method 800 for manufacturing the chainsaw chain 7 of FIG. 2 is depicted. At step 804, the plurality of drive links is provided. The plurality of drive links 14 is configured to engage the drive element of the chainsaw 1 to connect the chainsaw chain 7 to the chainsaw 1. Each drive link 14 may take the form of, for example, the drive link 24a of FIG. 3 A. At step 808, the plurality of cutters 10 is provided for cutting a workpiece during a cutting operation. Each cutter 10 may take the form of, for example, the cutters 68 of FIGS. 5-7. In other embodiments, each cutter 10 may take the form of the cutters 150, 350, 516, 616, 716 of FIGS. 8, 9, and 1 1-14. In still other embodiments, the plurality of cutters 10 may include a combination of the cutters 68, the cutters 150, and the cutters 350.

[0109] At step 812, the cutting insert 108 is coupled to the cutting tooth 76 of each cutter 10 in a specific orientation. Specifically, the cutting insert 108 is j oined to the cutting tooth 76 in an axial orientation such that the longitudinal axis 128 of the cutting insert 108 is oriented at the inclination angle Al. At step 816, the cutting insert 108 is ground to a desired shape. As such, the front portion 136 of the cutting insert 108 is oriented at the rake angle A2 and the top portion 132 of the cutting insert 108 is oriented at the relief angle A3. The top portion 132 of the cutting insert 108 is also oriented to be substantially flush with the relief face 104 of the cutting tooth 76. At step 820, a rivet 20 is inserted into the rivet hole 32a of each drive link 14 and the rivet hole 94 of each cutter 10 to couple the plurality of drive links 14 and the plurality of cutters 10 together. At step 824, the plurality of tie straps 18 is provided. Each tie strap 18 may take the form of, for example, the tie strap 48a of FIG. 4A. At step 828, another rivet 20 is inserted into the rivet hole 56a of each tie strap 18 to couple the plurality of drive links 14, the plurality of cutters 10, and the plurality of tie straps 18 together. In some embodiments, the step 820 and the step 828 may be combined into a single step.

[0110] In some embodiments, the method 800 may not include all of the steps described above or may include additional steps before, after, or between the depicted steps. In addition, the steps may be performed in other orders.

[0111] FIG. 16 illustrates another embodiment of a chainsaw chain 900. The chainsaw chain 900 includes a plurality of cutters 904 and a plurality of drive links 908. The illustrated chainsaw chain 900 does not include tie straps. The plurality of drive links 908 is similar to the drive link 24a of FIG. 3 A. The cutters 904 and the drive links 908 are each coupled to each other by rivets 914. The plurality of drive links 908 is positioned along a central portion of the chainsaw chain 900. as the plurality of cutters 904 is positioned along both sides of the plurality of drive links 908. The plurality of cutters 904 includes a first set of cutters 912a, a second set of cutters 912b, a third set of cutters 912c, and a fourth set of cutters 912d. Each set of cutters 912a-d is formed by a pair of cutters that are parallel to each other. As such, cutting teeth of each set of cutters 912a-d are longitudinally aligned. At least one drive link of the plurality of drive links 908 is disposed between a respective pair of cutters 904 to maintain the chainsaw chain 900 along the guide bar 6 of the chainsaw 1.

[0112] FIG. 17 illustrates one cutter 916 of the plurality of cutters 904. The cutter 916 includes a cutter body 920, a cutting tooth 924, a feed limiter 928, a gullet 932. a toe 936, and a heel 940. The cutter body 920 includes one or more rivet holes 944 extending therethrough. Each rivet hole 944 is configured to receive a respective rivet 914. The cutter body 920 defines a longitudinal axis 948 of the cutter 916 and a vertical axis 952 of the cutter 916. The longitudinal axis 948 of the cutter 916 extends through the rivet holes 944, while the vertical axis 952 is oriented perpendicular to the longitudinal axis 948. The cutting tooth 924 is coupled to and extends from an upper portion of the cutter body 920. More specifically, the cutting tooth 924 extends parallel to the feed limiter 928 and the vertical axis 952 such that the cutting tooth 924 is unset relative to the feed limiter 928. The feed limiter 928 is also coupled to and extends from the upper portion of the cutter body 920. The cutting tooth 924 includes a cutting tip 956, a rake face 960 extending from the cutting tip 956, a primary relief face 964 extending from the cutting tip 956 opposite the rake face 960, and a secondary relief face 968 extending from the primary relief face 964 to an edge 972 of the cutter body 920 proximate the heel 940. Also, the cutting tooth 924 takes the size and shape of a cutting tooth from a saw blade (e.g.. hole saw blade, circular saw blade, and reciprocating saw blade).

[0113] With reference to FIG. 18, a cutting insert 976 is coupled to the cutting tooth 924 by various joining methods (e.g., resistance welding, laser welding, cladding, etc.) and forms at least a part of the cutting tip 956. In some embodiments, the cutting insert 976 can be formed of carbide, while the cutting tooth 924 and the cutter body 920 can be formed of steel (e.g., high speed steel). In other embodiments, the cutting insert 976, the cutting tooth 924, and / or the cutter body 920 can be formed of other suitable materials. In additional embodiments, the cutting insert 976 is coupled to the cutting tooth 924 by brazing.

[0114] In the illustrated embodiment, the primary' relief face 964 of the cutting tooth 924 is substantially flush with a top portion 980 of the cutting insert 976 such that the primary relief face 964 and the top portion 980 are oriented at a primary relief angle A6 relative to a primary relief axis 984 extending parallel to the longitudinal axis 948. The secondary relief face 968 is oriented at a secondary' relief angle A7 relative to a secondary' relief axis 988 extending parallel to the vertical axis 952. In an alternative embodiment, the secondary' relief angle A7 is measured relative to the primary relief face 964. The secondary relief angle A7 is larger than the primary relief angle A6. The secondary relief angle A7 is provided to allow a user to perform a plunge cutting operation with the nose 592 (FIG. 1) of the chainsaw 1. In such scenarios, the primary' relief angle A6 may act as a feed limiter. In other embodiments, the primary relief face 964 and the secondary relief face 968 may be non-flat surfaces (i.e.. curved surfaces) with a rounded edge formed therebetween.

[0115] In some embodiments, the primary relief angle A6 ranges between -40 and 80 degrees, in which the primary relief angle A6 is dependent on a rake angle of the cutter 916 and a height of the cutter 916. In other embodiments, the primary relief angle A6 ranges between -5 and 50 degrees. In preferred embodiments, the primary relief angle A6 ranges between 2.5 and 12.5 degrees, in which a high value primary relief angle A6 of the specified range produces a chainsaw chain that provides fast cutting operations. As such, the primary relief angle A6 of the preferred embodiment is not dependent on the rake angle of the rake face 960 such that the primary relief angle A6 can be independently changed. In other preferred embodiments, the primary relief angle A6 is 30 degrees or less. In additional embodiments, the primary relief angle A6 ranges between 4 and 6 degrees. In further embodiments, the primary relief angle A6 may be 5 degrees.

[0116] In some embodiments, the secondary' relief A7 ranges between 0 and 120 degrees to result in a portion of the cutter body 920 proximate the edge 972 being taller than thecuting insert 976. In other embodiments, the secondary relief angle A7 ranges between 0 and 70 degrees. In preferred embodiments, the secondary relief angle A7 ranges between 2.5 and 12.5 degrees, in which a high value secondary relief angle A7 of the specified range produces a chainsaw chain that provide fast cuting operations. In additional embodiments, the secondary' relief angle A7 ranges between 30 and 60 degrees. In further embodiments, the secondary’ relief angle A7 may be 35 degrees. Moreover, the primary relief angle A6 and the secondary relief angle A7 may have other values and ranges. The secondary relief face 968 is obliquely oriented relative to the primary relief face 964 such that the secondary relief face 968 is beneficial for the plunge cuting operation.

[0117] The gullet 932 of the cuter 916 is defined between the cuting tooth 924 and the feed limiter 928. More specifically, the gullet 932 is defined by the rake face 960 of the cuting tooth 924, a planar face 992 of the feed limiter 928, and an arcuate face 994 defined within the cuter body 920 and disposed between the rake face 960 and the planar face 992. The planar face 992 is oriented at a gullet angle A8 relative to the vertical axis 952. In the illustrated embodiment, the gullet angle A8 is an oblique angle. In some embodiments, the gullet angle A8 ranges between 0 degrees and 75 degrees. In preferred embodiments, the gullet angle A8 preferably ranges between 25 and 60 degrees. As such, the gullet 932 is structured to reduce the occurrence of clogging the chainsaw chain 900 during operation of the chainsaw 1. In other embodiments, the gullet 932 may be disposed underneath the feed limiter 928 such that a portion of the feed limiter 928 overhangs the gullet 932 and provides more clearance.

[0118] FIG. 19 illustrates another cutter 1016 of the plurality of cuters 904. The cuter 1016 is similar to the cuter 916 of FIGS. 17 and 18; therefore, like structure will be identified by like reference number plus “100” and only the differences will be discussed hereafter.

[0119] The cuter 101 includes a cuter body 1020 defining a first face 1022 and a second face 1023 opposite the first face 1022, a cutting tooth 1024, a feed limiter 1028, a gullet 1032 positioned between the feed limiter 1028 and the cuting tooth 1024, a toe 1036, a heel 1040, and one or more rivet holes 1044. The cuting tooth 1024 is set (i.e., bent) in a right direction of the cutter 1016 and non-parallel to a vertical axis 1052 defined by the cuter body 1020. A portion of the cuter 1016, defined betyveen the cuter body 1020 and the cuting tooth 1024, is bent such that a curved surface is formed. In other embodiments, morethan one portion of the cutter 1016 may also be bent as a planar portion is formed between the bent portions of the cutter 1016. The cutting tooth 1024 is oriented such that a cutting tip 1056 of the cutting tooth 1024 extends past a corresponding rivet 914 (FIG. 16), and thereby clears the rivet 914. Depending on the position of the cutter 1016 along the chainsaw chain 7, the cutting tooth 1024 may overlap and clear a portion of the guide bar 6 of the chainsaw 1 from the right direction or extend in the right direction away from the guide bar 6. As such, for certain positions of the cutter 1016, it is necessary for the cutting tooth 1024 to clear the guide bar 6 to make a cut in a workpiece.

[0120] The cutting tooth 1024 may be set such that the cutting tip 1056 (e.g., cutting edge 1094 of the cutting tip 1056) is disposed at a distance of 0.042 inches from a plane extending parallel to the second face 1023 of the cutter body 1020. In some embodiments, the cutting tip 1056 is disposed at a distance, ranging between 0.025 inches and 0.075 inches, from the plane extending parallel to the second face 1023. In preferred embodiments, the cutting tip 1056 is disposed at a distance, ranging between 0.032 inches and 0.050 inches, from the plane extending parallel to the second face 1023. In general, the cutting tip 1056 is oriented at an angle, ranging between 10 degrees and 15 degrees, relative to the plane. In further embodiments, the distance between the cutting tip 1056 and the plane extending parallel to the second face 248 ranges between 0 inches and 0. 1 inches. In another embodiment, a theoretical angular limit at which the cutting tip 1056 is onented relative to the plane ranges between 0 and 90 degrees.

[0121] FIG. 20 illustrates another cutter 1116 of the plurality of cutters 904. The cutter 1116 is similar to the cutter 916 of FIGS. 17 and 18; therefore, like structure will be identified by like reference number plus “200” and only the differences will be discussed hereafter.

[0122] The cutter 1116 includes a cutter body 1120 defining a first face 1122 and a second face 1 123 opposite the first face 1122, a cutting tooth 1124, a feed limiter 1 128, a gullet 1132 positioned between the feed limiter 1128 and the cutting tooth 1124, a toe 1136, a heel 1140, and one or more rivet holes 1144. The cutting tooth 1124 is set (i.e., bent) in a left direction of the cutter 1116 and non-parallel to a vertical axis 1152 defined by the cutter body 1 120. A portion of the cutter 1116, defined between the cutter body 1120 and the cutting tooth 1124, is bent such that a curved surface is formed. In other embodiments, more than one portion of the cutter 1116 may also be bent while a planar portion is formed between thebent portions of the cutter 1116. The cutting tooth 1124 is oriented such that a cutting tip 1156 of the cutting tooth 1124 extends past a corresponding rivet 914 (FIG. 16), and thereby clears the rivet 914. Depending on the position of the cutter 11 16 along the chainsaw chain 7, the cutting tooth 1124 may overlap and clear a portion of the guide bar 6 of the chainsaw 1 from the left direction or extend in the left direction away from the guide bar 6. As such, for certain positions of the cutter 1116, it is necessary for the cutting tooth 1124 to clear the guide bar 6 to make a cut in a workpiece.

[0123] The cutting tooth 1124 may be set such that the cutting tip 1156 (e.g., cutting edge 1194 of the cutting tip 1156) is disposed at a distance of 0.042 inches from a plane extending parallel to the first face 1122 of the cutter body 1120. In some embodiments, the cutting tip 1 156 is disposed at a distance, ranging between 0.025 inches and 0.075 inches, from the plane extending parallel to the first face 1122. In preferred embodiments, the cutting tip 1156 is disposed at a distance, ranging between 0.032 inches and 0.050 inches, from the plane extending parallel to the first face 1122. In general, the cutting tip 1156 is oriented at an angle, ranging between 10 degrees and 15 degrees, relative to the plane. In further embodiments, the distance between the cutting tip 1156 and the plane extending parallel to the second face 248 ranges between 0 inches and 0. 1 inches. In another embodiment, a theoretical angular limit at which the cutting tip 1156 is oriented relative to the plane ranges between 0 and 90 degrees.

[0124] With reference back to FIG. 16, the first set of cutters 912a is formed by a pair of cutters that are similar to the cutter 916 of FIGS. 17 and 18. and thereby forms a pair of unset cutters. The second set of cutters 912b is formed by a pair of cutters that are similar to the cutter 1016 of FIG. 19 to thereby form a pair of cutters set in the right direction. The third set of cutters 912c is formed by a pair of cutters that are similar to the cutter 1116 of FIG. 20 to thereby form a pair of cutters set in the left direction. The fourth set of cutters 912d is formed by the cutters 1016, 1116 of FIGS. 19 and 20. As such, the fourth set of cutters 912d form a pair of cutters that are set in opposite directions. In other embodiments, the chainsaw chain 900 may include a set of cutters (i.e., a pair of cutters) formed by one unset cutter (e.g., cutter 68) and one cutter that is set in the right direction or the left direction (e.g., cutter 150 or cutter 350).

[0125] To form the cutting arrangement of the chainsaw chain 900, the sets of cutters912a-d are arranged to alternate with each other. For example, as illustrated in FIG. 16, thecuters 904 are arranged (starting from the left side of the drawing) in a repeating patern of: (i) the first set of cuters 912a, (ii) the second set of cuters 912b, (iii) the third set of cuters 912c, and (iv) the fourth set of cuters 912d. In some embodiments, the chainsaw chain 900 may have other repeating or non-repeating paterns of cuters 904. In other embodiments of the chainsaw chain 900, the cuting patern can alternate between a plurality of the first set of cuters 912a, a plurality of the second set of cuters 912b, a plurality’ of the third set of cuters 912c. and a plurality of the fourth set of cuters 912d.

[0126] In each embodiment of the chainsaw chain 900, the cuting patern does not include a plurality of tie straps. Tie straps are configured to interconnect consecutive drive links 908 together to create spacing between consecutive cuters 904. Without tie straps, the cuting patern of the chainsaw chain 900 consists of different sets of cuters 912a-d adjacent each other without a substantial gap defined therebetween. Therefore, assembling the chainsaw chain 900 without a plurality' of tie straps increases the number of components configured to perform cuting operations.

[0127] FIG. 21 illustrates another chainsaw chain 2000. The chainsaw chain 2000 includes a plurality of cuters 2004, a plurality of drive links 2008, and a plurality' of tie straps 2012 configured to interconnect consecutive drive links of the plurality of drive links 2008. The plurality of drive links 2008 is similar to the drive link 24a of FIG. 3 A. The plurality of tie straps 2012 is similar to the tie strap of 48a of FIG. 4A. The cuters 2004, the drive links 2008, and the tie straps 2012 are coupled to each other by rivets 2020. The plurality of drive links 2008 is positioned along a central portion of the chainsaw chain 2000, as the plurality’ of cuters 2004 is positioned along both sides of the plurality of drive links 2008.

[0128] The plurality of cutters 2004 includes a first set of cuters 2016a similar to the first set of cuters 912a of FIG. 16, a second set of cutters 2016b similar to the second set of cuters 912b of FIG. 16, a third set of cuters 2016c similar to the third set of cuters 912c of FIG. 1 , and a fourth set of cuters 2016d similar to the fourth set of cuters 912d of FIG. 16. Each set of cuters 2016a-d is formed by a pair of cuters that are parallel to each other. As such, cuting teeth of each set of cuters 2016a-d are longitudinally aligned. In some embodiments, the chainsaw chain 2000 may include a set of cuters formed by an unset cuter and a cuter set in the right direction or the left direction. At least one drive link of the plurality of drive links 2008 is disposed between a respective pair of cutters 2016a-d to maintain the chainsaw chain 2000 along the guide bar 6 of the chainsaw 1. In addition, theplurality of tie straps 2012 are defined as a pair of tie straps parallel with each other, such that a gap is defined therebetween for the arrangement of the drive links 2008 along the chainsaw chain 2000.

[0129] To form the cutting arrangement of the chainsaw chain 2000, the sets of cutters 2016a-d alternate with each other while a respective pair of tie straps 2012 is provided between consecutive cutters 2004. For example, as illustrated in FIG. 21, the cutters 2004 are arranged (starting from the left side of the drawing) in a repeating pattern of: (i) the first set of cutters 2016a, (ii) a pair of tie straps 2012, (iii) the second set of cutters 2016b, (iv) a pair of tie straps 2012, (v) the third set of cutters 2016c, (vi) a pair of tie straps 2012, and (vii) the fourth set of cutters 2016d. In some embodiments, the chainsaw chain 2000 may have other repeating or non-repeating patterns of cutters 2004. In other embodiments of the chainsaw chain 2000, the cutting pattern can alternate between a plurality of the first set of cutters 2016a, a plurality' of the second set of cutters 2016b, a plurality of the third set of cutters 2016c, and a plurality of the fourth set of cutters 2016d.

[0130] As such, each chainsaw chain 900, 2000 of FIGS. 16 and 21 contains multiple sets of dual cutters 912a-d, 2016a-d that are either set or unset. The sets of cutters 912a-d, 2016a- d are configured to produce a straight cutting path along a workpiece when performing a cutting operation. The sets of dual cutters 912a-d, 2016a-d also produce durable chainsaw chains 900, 2000 since each cutter 904, 2004 take less impact when arranged in a respective set of dual cutters. In addition, the sets of cutters 912d, 2016d provide further stability to the chainsaw chains 900, 2000. In particular, the sets of cutters 912d, 2016d reduce the occurrence of a chainsaw chain 900. 2000 walking through a cutting path formed along a workpiece during a cutting operation.

[0131] FIG. 22 illustrates another chainsaw chain 3000. The chainsaw chain 3000 includes a plurality of cutters 3004, a plurality of drive links 3008, and a plurality of tie straps 3012 configured to interconnect consecutive drive links of the plurality of drive links 3008. Each of the drive links 3008 is similar to the drive link 24a of FIG. 3 A. Each of the tie straps 3012 is similar to the tie strap of 48a of FIG. 4A. The cutters 3004, the drive links 3008. and the tie straps 3012 are coupled to each other by rivets 3020. The plurality of drive links 3008 is positioned along a central portion of the chainsaw chain 3000, and the plurality of cutters 3004 is positioned along both sides of the plurality of drive links 3008.

[0132] The plurality of cutters 3004 includes a first set of cutters 3016a similar to the fourth set of cutters 912d of FIG. 16 and a second set of cutters 3016b also similar to the fourth set of cutters 912d of FIG. 16. The plurality of cutters 3004 also include a first cutter 3020a similar to the cutter 916 of FIG. 17, a second cutter 3020b also similar to the cutter 916 of FIG. 17, a third cutter 3020c similar to the cutter 1016 of FIG. 19, and a fourth cutter 3020d similar to the cutter 1116 of FIG. 20.

[0133] To form the cutting arrangement of the chainsaw chain 3000, the sets of cutters 3016a, 3016b alternate with individual cutters 3020a-d while individual tie straps 3012 are disposed opposite a respective cutter 3020a-d. For example, as illustrated in FIG. 22, the cutters 3004 are arranged (starting from the left side of the drawing) in a repeating pattern of: (i) the first set of cutters 3016a, (ii) the first cutter 3020a and one tie strap 3012, (iii) the second cutter 3020b and one tie strap 3012, (iv) the second set of cutters 3016b, (v) the third cutter 3020c and one tie strap 3012, and (vi) the fourth cutter 3020d and one tie strap 3012. In other embodiments, the chainsaw chain 3000 may have other repeating or non-repeating patterns of cutters 3004.

[0134] FIG. 23 illustrates another chainsaw chain 4000. The chainsaw chain 4000 includes a plurality of cutters 4004, a plurality of drive links 4008, and a plurality’ of tie straps 4012 configured to interconnect consecutive drive links of the plurality of drive links 4008. Each of the drive links 3008 is similar to the drive link 24a of FIG. 3 A. Each of the tie straps 4012 is similar to the tie strap 48a of the FIG. 4A. The cutters 4004, the drive links 4008, and the tie straps 4012 are coupled to each other by rivets 4018. The plurality’ of drive links 4008 is positioned along a central portion of the chainsaw chain 4000, and the plurality of cutters 4004 is positioned along both sides of the plurality of drive links 4008.

[0135] The plurality of cutters 4004 includes a set of cutters 4016 similar to the fourth set of cutters 912d of FIG. 16 and multiple individual cutters 4020a-f that are respectively positioned a left side of the chainsayv chain 4000 (e.g., a left side of the plurality of drive links 4008) or a right side of the chainsaw’ chain 4000 (e.g., a right side of the plurality of drive links 4008). The individual cutters 4020a-f of the chainsaw chain 4000 are made of a first cutter 4020a, a second cutter 4020b, a third cutter 4020c. a fourth cutter 4020d, a fifth cutter 4020e, and a sixth cutter 4020f. The first cutter 4020a and the second cutter 4020b are similar to the cutter 916 of FIG. 17. The third cutter 4020c and the sixth cutter 4020f aresimilar to the cutter 1116 of FIG. 20. The fourth cutter 4020d and the fifth cutter 4020e are similar to the cutter 1016 of FIG. 19.

[0136] To form the cutting arrangement of the chainsaw chain 4000, the individual cutters 4020a-f alternate with each other while the set of cutters 4016 is provided before the individual cutters 4020a-f. For example, as illustrated in FIG. 23, the plurality of cutters 4004 is arranged (starting from left side of the drawing) in a repeating pattern of: (i) the set of cutters 4016, (ii) the first cutter 4020a on a left side of the chainsaw chain 4000 and one tie strap 4012 on a right side of the chainsaw7chain 4000, (iii) the second cutter 4020b on the right side of the chainsaw chain 4000 and one tie strap 4012 on the left side of the chainsaw chain 4000, (iv) the third cutter 4020c on the left side of the chainsaw chain 4000 and one tie strap 4012 on the right side of the chainsaw chain 4000, (v) the fourth cutter 4020d on the right side of the chainsaw chain 4000 and one tie strap 4012 on the left side of the chainsaw chain 4000, (vi) the fifth cutter 4020e on the left side of the chainsaw chain 4000 and one tie strap 4012 on the right side of the chainsaw chain 4000. and (vii) the sixth cutter 4020f on the right side of the chainsaw chain 4000 and one tie strap 4012 on the left side of the chainsaw chain 4000. In other embodiments, the chainsaw chain 4000 may have other repeating or non-repeating patterns of cutters 4004.

[0137] The set of cutters 4016 is occasionally disposed along the chainsaw chain 4000. As such, each cutting tooth of the set of cutters 4016 serve as projections for providing stability7and durability to the chainsaw7chain 4000 and inhibit a w obbling action from occurring. The addition of the individual cutters 4020a-f ensures that a kerf of the chainsaw chain 4000 is cleared during a cutting operation. In other words, the individual cutters 4020a-f ensure that each section of the kerf is cut through. In other embodiments, the set of cutters 4016 may be provided as the only pair of cutters along the chainsaw7chain 4000.

[0138] In additional embodiments, each feed limiter formed on the set of cutters 4016 may also be set in the same manner as a corresponding cutting tooth. Having feed limiters that are set in an opposite direction of the plurality of drive links 4008 may further provide the chainsaw chain 4000 with stability and durability to handle hard material.

[0139] FIG. 24 illustrates another chainsaw chain 5000. The chainsaw chain 5000 includes a plurality7of cutters 5004, a plurality7of drive links 5008, and a plurality of tie straps 5012 configured to interconnect consecutive drive links of the plurality of drive links 5008.Each of the drive links 5008 is similar to the drive link 24a of FIG. 3 A. Each of the tie straps 5012 is similar to the tie strap 48a of the FIG. 4A. The cutters 5004, the drive links 5008, and the tie straps 5012 are coupled to each other by rivets 5018. The plurality of drive links 5008 is positioned along a central portion of the chainsaw chain 5000, and the plurality of cutters 5004 is positioned along both sides of the plurality' of drive links 5008. The chainsayv chain 5000 further includes a set of outset tie straps 5019 further discussed herein below.

[0140] The plurality of cutters 5004 includes multiple individual cutters 5020a-f that are respectively positioned a left side of the chainsaw chain 5000 (e.g., a left side of the plurality of drive links 5008) or a right side of the chainsaw chain 5000 (e.g., a right side of the plurality of drive links 5008). The individual cutters 5020a-f of the chainsaw chain 5000 are made of a first cutter 5020a, a second cutter 5020b, a third cutter 5020c, a fourth cutter 5020d, a fifth cutter 5020e, and a sixth cutter 5020f. The first cutter 5020a and the second cutter 5020b are similar to the cutter 916 of FIG. 17. The third cutter 5020c and the sixth cutter 5020f are similar to the cutter 1116 of FIG. 20. The fourth cutter 5020d and the fifth cutter 5020e are similar to the cutter 1016 of FIG. 19. The set of outset tie straps 5019 is made of a first outset tie strap 5024 (FIG. 25) and a second outset tie strap 5064 (FIG. 26), and thereby forms a pair of outset tie straps that are parallel to each other. At least one drive link of the plurality’ of drive links 5008 is disposed between the pair of outset tie straps.

[0141] With reference to FIG. 25, the first outset tie strap 5024 includes a strap body 5028, one or more rivet holes 5032 extending through the strap body 5028, a toe 5036, and a heel 5040. Each rivet hole 5032 is configured to receive one of the rivets 5018 (FIG. 24). The strap body 5028 defines a longitudinal axis 5044 of the first outset tie strap 5024 and a vertical axis 5048 of the first outset tie strap 5024. The longitudinal axis 5044 extends through the rivet holes 5032, while the vertical axis 5048 is oriented perpendicular to the longitudinal axis 5044. The first outset tie strap 5024 further includes a projection 5052 extending from the strap body 5028. The projection 5052 is a non-cutting projection. As such, the projection 5052 does not including a cutting tooth or a cutting tip. In the illustrated embodiment, the projection 5052 is integrally formed with the strap body 5028. In other embodiments, the projection 5052 may be separate piece that is secured to the strap body 5028.

[0142] The projection 5052 of the first outset tie strap 5024 extends along a partial length of the first outset tie strap 5024 such that a planar surface 5056 of the strap body 5028extends a remaining length of the first outset tie strap 5024. In addition, the first outset tie strap 5024 has a partial gullet 5060 formed by a curved surface disposed between the planar surface 5056 and the projection 5052. As such, the planar surface 5056 transitions from the gullet 5060 and the projection 5052 extends from the gullet 5060. The projection 5052 of the first outset tie strap 5024 is set in a right direction of the first outset tie strap 5024 and nonparallel to the vertical axis 5048. As such, the projection 5052 is oriented to extend past a corresponding rivet 5018, and thereby clear the rivet 5018.

[0143] With reference to FIG. 26, the second outset tie strap 5064 includes a strap body 5068, one or more rivet holes 5072 extending through the strap body 5068, a toe 5076, and a heel 5080. Each rivet hole 5072 is configured to receive one of the rivets 5018 (FIG. 24). The strap body 5068 defines a longitudinal axis 5084 of the first outset tie strap 5024 and a vertical axis 5088 of the first outset tie strap 5024. The longitudinal axis 5084 extends through the rivet holes 5072. while the vertical axis 5088 is oriented perpendicular to the longitudinal axis 5084. The second outset tie strap 5064 further includes a projection 5092 extending from the strap body 5068. The projection 5092 is a non-cutting projection. As such, the projection 5092 does not include a cutting tooth or a cutting tip. In the illustrated embodiment, the projection 5092 is integrally formed with the strap body 5068. In other embodiments, the projection 5092 may be separate piece that is secured to the strap body- 5068.

[0144] The projection 5092 of the second outset tie strap 5064 extends along a partial length of the second outset tie strap 5064 such that a planar surface 5096 of the strap body 5068 extends a remaining length of the second outset tie strap 5064. In addition, the second outset tie strap 5064 has a partial gullet 5100 formed by a curved surface disposed between the planar surface 5096 and the projection 5092. As such, the planar surface 5096 transitions from the gullet 5100 and the projection 5092 extends from the gullet 5100. The projection 5092 of the second outset tie strap 5064 is set in a left direction of the second outset tie strap 5064 and non-parallel to the vertical axis 5088. As such, the projection 5092 is oriented to extend past a corresponding rivet 5018, and thereby clear the rivet 5018. When the set of outset tie straps 5019 are along the chainsaw chain 5000, then the projections 5052, 5092 extend outwardly from the plurality of drive links 5008.

[0145] With reference back to FIG. 24, the cutting arrangement of the chainsaw chain5000 is formed such that the individual cutters 5020a-f alternate with each other while the setof outset tie straps 5019 is provided before the individual cutters 5020a-f. For example, as illustrated in FIG. 24, the chainsaw chain 5000 is arranged (starting from left side of the drawing) in a repeating pattern of: (i) the set of outset tie straps 5019, (ii) the first cutter 5020a on a left side of the chainsaw chain 5000 and one tie strap 5012 on a right side of the chainsaw chain 5000, (iii) the second cutter 5020b on the right side of the chainsaw chain 5000 and one tie strap 5012 on the left side of the chainsaw chain 5000, (iv) the third cutter 5020c on the left side of the chainsaw chain 5000 and one tie strap 5012 on the right side of the chainsaw chain 5000, (v) the fourth cutter 5020d on the right side of the chainsaw chain 5000 and one tie strap 5012 on the left side of the chainsaw chain 5000, (vi) the fifth cutter 5020e on the left side of the chainsaw chain 5000 and one tie strap 5012 on the right side of the chainsaw chain 5000, and (vii) the sixth cutter 5020f on the right side of the chainsaw chain 5000 and one tie strap 5012 on the left side of the chainsaw chain 5000. In other embodiments, the chainsaw chain 5000 may have other repeating or non-repeating patterns of cutters 5004. The set of outset tie straps 5019 is occasionally disposed along the chainsaw chain 500 for providing stability and durability to the chainsaw chain 5000 and inhibits a wobbling action from occurring. The addition of the individual cutters 5020a-f ensures that a kerf of the chainsaw chain 5000 is cleared during a cutting operation.

[0146] FIG. 27 illustrates another chainsaw chain 6000. The chainsaw chain 6000 includes a plurality of cutter links 6004 and a lurality of drive links 6008. The cutter links 6004 and the drive links 6008 are coupled to each other by rivets 6010. The plurality of drive links 6008 is positioned along a central portion of the chainsaw chain 6000, and the plurality of cutter links 6004 is positioned along both sides of the plurality of drive links 6008. The plurality of cutter links 6004 includes a first set of cutter links 6012a. a second set of cutter links 6012b, a third set of cutter links 6012c, and a fourth set of cutter links 6012d.

[0147] With reference to FIG. 28, a cutter link 6020 of the plurality of cutter links 6004 is illustrated. The cutter link 6020 includes a cutter link body 6024 defining a first face 6026 and a second face 6027 opposite the first face 6026, a cutting tooth 6030, a toe 6034, and a heel 6038. The cutter link body 6024 includes one or more rivet holes 6042 extending therethrough. The cutter link body 6024 defines a longitudinal axis 6046 of the cutter link 6020 and a vertical axis 6050 of the cutter link 6020. The longitudinal axis 6046 extends through the rivet holes 6042. while the vertical axis 6050 is oriented perpendicular to the longitudinal axis 6046. The cutter link 6020 further includes a partial gullet 6052 formed bya curved surface defined between the cutter link body 6024 and the cutting tooth 6030. The cutter link 6020 does not include a feed limiter like one of the cutters described above. As such, the curved surface of the partial gullet 6052 transitions into a planar surface 6053 formed along an upper portion of the cutter link body 6024. The illustrated cutting tooth 6030 includes a cutting tip 6054, a rake face 6058 extending from the cutting tip 6054, a primary relief face 6062 extending from the cutting tip 6054 opposite the rake face 6058, and a secondary relief face 6066 extending from the primary relief face 6062 to an edge 6070 of the cutter link body 6024 proximate the heel 6038.

[0148] With reference to FIG. 29, a cutter link insert or a cutting insert 6074 is coupled to the cutting tooth 6030 by various joining methods (e.g.. resistance welding, laser welding, cladding, etc.) and forms at least a part of the cutting tip 6054. The primary relief face 6062 of the cutting tooth 6030 extends from the cutting insert 6074 such that the primary' relief face 6062 is oriented at a primary relief angle A9 relative to a primary relief axis 6078 extending parallel to the longitudinal axis 6046. The secondary relief face 6066 is oriented at a secondary relief angle A10 relative to a secondary' relief axis 6082 extending parallel to the vertical axis 6050. In an alternative embodiment, the secondary relief angle A10 is measured relative to the primary relief face 6062. The secondary relief angle A10 is larger than the primary’ relief angle A9. In other embodiments, the secondary relief angle A10 may be smaller than the primary relief angle A9. The secondary relief angle A10 is provided to allow a user to perform a plunge cutting operation with the nose 592 (FIG. 1) of the chainsaw 1. In such scenarios, the primary' relief angle A9 may act as a feed limiter.

[0149] In some embodiments, the primary relief angle A9 ranges between -40 and 80 degrees, in which the primary relief angle A9 is dependent on a rake angle of the cutter link 6020 and a height of the cutter link 6020. In other embodiments, the primary' relief angle A9 ranges between -5 and 50 degrees. In preferred embodiments, the primary relief angle A9 ranges between 2.5 and 12.5 degrees, in which a high value primary relief angle A4 of the specified range produces a chainsaw chain that provides fast cutting operations. As such, the primary relief angle A9 of the preferred embodiment is not dependent on the rake angle of the cutter link 6020 such that the primary’ relief angle A9 can be independently changed. In other preferred embodiments, the primary relief angle A9 is 30 degrees or less. In additional embodiments, the primary relief angle A9 ranges between 4 and 6 degrees. In further embodiments, the primary relief angle A9 may be 5 degrees.

[0150] In some embodiments, the secondary' relief A10 ranges between 0 and 120 degrees to result in a portion of the cutter link body 6024 proximate the edge 6070 being taller than the cutting insert 6074. In other embodiments, the secondary relief angle A10 ranges between 0 and 70 degrees. In preferred embodiments, the secondary relief angle A10 ranges between 2.5 and 12.5 degrees, in which a high value secondary7relief angle A10 of the specified range produces a chainsaw chain that provide fast cutting operations. In additional embodiments, the secondary relief angle A10 ranges between 30 and 60 degrees. In further embodiments, the secondary relief angle A10 may be 35 degrees. Moreover, the primary relief angle A9 and the secondary relief angle A10 may have other values and ranges. The secondary7relief face 6066 is obliquely oriented relative to the primary relief face 6062 such that the secondary relief face 6066 is beneficial for the plunge cutting operation.

[0151] With reference to FIG. 30, the cutter link body 6024 defines a cutter thickness T2 of the cutter link 6020. The cutter thickness T2 is defined between the first face 6026 and the second face 6027 of the cutter link body 6024. The cutting insert 6074 defines an insert thickness T3 measured transverse the longitudinal axis 6046. As such, a respective side of the cutting insert 6074 extends about 0.015 inches from the cutter link body 6024. The insert thickness T3is greater than the cutter thickness T2 so that the cutting insert 6074 is formed to overhang the cutter link body 6024. As such, the cutting insert 6074 is thicker than the cutter link body 6024 so that the chainsaw chain 6000 provides a fast cutting operation and reduces the time it takes to grind the cutting insert 6074 to a final state. Also, stability and durability7of the chainsaw chain 6000 is also retained due to the thickness of the cutting insert 6074. In some embodiments, the cutting insert 6074 is flush (i.e., aligns with) with the cutter link body 6024 such that the cutter thickness T2 is substantially equal to the insert thickness T3. In addition, the illustrated cutting insert 6074 includes at least one ground edge in the form of a first bevel edge 6086a and a second bevel edge 6086b located along opposite edges. In some embodiments, the at least one ground edge may be in the form of a rooftop like bevel edge (e.g., a bevel edge with an apex). In other embodiments, the at least one ground edge may be in the form of a non-bevel configuration (e.g., flat top grind, alternating top bevel configuration, triple chip configuration, alternating top bevel with raker configuration, and other non-bevel configuration). In additional embodiments, the cutting insert 6074 may have a coined section in which one portion of the cutting insert 6074 may be thinner than another portion of the cutting insert 6074. In other embodiments, the cutting insert 6074 may be formed with other grind configurations.

[0152] FIG. 31 illustrates another cutter link 6120 of the plurality of cutter links 6004. The cutter link 6120 is similar to the cutter link 6020 of FIGS. 28-30; therefore, like structure will be identified by like reference number plus 'TOO’’ and only the differences will be discussed hereafter.

[0153] The cutter link 6120 includes a cutter link body 6124 defining a first face 6126 and a second face 6127 opposite the first face 6126, a cutting tooth 6130, atoe 6134, a heel 6138, and one or more rivet holes 6142. The cutter link body 6124 defines a longitudinal axis 6146 of the cutter link 6120 and a vertical axis 6150 of the cutter link 6120. The cutter link 6120 further includes a partial gullet 6152. The cutting tooth 6130 of the cutter link 6120 is set (i.e., bent) in a right direction of the cutter link 6120 and non-parallel to the vertical axis 6150. The cutting tooth 6130 is oriented such that a cutting tip 6154 of the cutting tooth 6130 extends past a corresponding rivet 6010 (FIG. 27), and thereby clears the rivet 6010. In other embodiments, an insert thickness of a cutting insert 6174 of the cutting tooth 6130 may be sufficiently greater than a cutter thickness of the cutter link body 6124 such that a set cutting tooth 6130 is unnecessary because the cutting insert 6174 is thick enough to extend past the corresponding rivet 6010.

[0154] FIG. 32 illustrates another cutter link 6220 of the plurality of cutter links 6004. The cutter link 6220 is similar to the cutter link 6020 of FIGS. 28-30; therefore, like structure will be identified by like reference number plus “200” and only the differences will be discussed hereafter.

[0155] The cutter link 6220 includes a cutter link body 6224 defining a first face 6226 and a second face 6227 opposite the first face 6226, a cutting tooth 6230, a toe 6234, a heel 6238, and one or more rivet holes 6242. The cutter link body 6224 defines a longitudinal axis 6046 of the cutter link 6220 and a vertical axis 6250 of the cutter link 6220. The cutter link 6220 further includes a partial gullet 6252. The cutting tooth 6230 of the cutter link 6220 is set (i.e., bent) in a left direction of the cutter link 6220 and non-parallel to the vertical axis 6250. The cutting tooth 6230 is oriented such that a cutting tip 6254 of the cutting tooth 6230 extends past a corresponding rivet 6010 (FIG. 27), and thereby clears the rivet 6010.

[0156] With reference to FIG. 33, a drive link 6500 of the plurality of drive links 6008 is illustrated. The drive link 6500 includes a drive link body 6504, one or more rivet holes 6508 extending through the drive link body 6504, and a bottom scooping portion or a tang 6512positioned below the pair of rivet holes 6508. The rivet holes 6508 are each configured to receive a rivet 6010 (FIG. 27). so that the drive link 6500 can be coupled to a cutter link 6004. The tang 6512 extends downw ardly from the drive link body 6504. In the illustrated embodiment, the tang 6512 is integrally formed with the drive link body 6504. In other embodiments, the tang 6512 may be a separate piece that is secured to the drive link body 6504. The tang 6512 is defined by a curved gap formed within the drive link body 6504 and is configured to support the chainsaw chain 7 along the guide bar 6 of the chainsaw 1. The drive link 6500 further includes an opening 6516 proximate the tang 6512. The opening 6516 also carries and spreads lubricating fluid through the guide bar 6.

[0157] With reference to FIG. 34, the drive link 6500 includes a cutting tooth 6520 and a gullet 6522. The cutting tooth 6520 extends from the drive link body 6504 in a direction opposite the tang 6512 and configured to perform a cutting operation. The gullet 6522 is formed by a curved surface disposed between the cutting tooth 6520 and the drive link body 6504. The cutting tooth 6520 has a cutting tip 6524, a rake face 6528 extending from the cutting tip 6524, a primary relief face 6532 extending from the cutting tip 6524 opposite the rake face 6528, and a secondary relief face 6536 extending from the primary relief face 6532 to a planar edge 6540 of the drive link body 6504. A drive link insert or a cutting insert 6542 is coupled to the cutting tooth 6520 by various joining methods (e.g., resistance welding, laser welding, cladding, etc.) and forms at least a part of the cutting tip 6524. The primary relief face 6532 extends from the cutting insert 6542 and is oriented at a primary relief angle Al 1 relative to a horizontal relief axis 6544. The secondary relief face 6536 is oriented at a secondary' relief angle A12 relative to a vertical relief axis 6548. In alternative embodiment, the secondary relief angle A12 is measured relative to the primary relief face 6532. In the illustrated embodiment, the secondary relief angle Al 2 is larger than the primary relief angle Al l. In other embodiments, the secondary relief angle Al 2 may be smaller than the primary relief angle Al l. The secondary relief angle A9 is provided to allow a user to perform a plunge cutting operation with the nose 592 (FIG. 1) of the chainsaw 1. In such scenarios, the primary relief angle Al 1 may act as a feed limiter. In some embodiments, the primary relief angle Al 1 and the secondary relief angle Al 2 may have similar values to the primary relief angle A9 and the secondary' relief angle A10 discussed above with reference to FIG. 29. In other embodiments, the primary relief angle Al 1 and the secondary relief angle A12 may- have other values and ranges.

[0158] With reference to FIG. 35, the drive link body 6504 defines a drive link thickness T4 of the drive link 6500. The drive link thickness T4 is defined between a first face 6552 and a second face 6556 of the drive link body 6504. The cutting insert 6542 defines an insert thickness T5 greater than the drive link thickness T4. In some embodiments, the cutting insert 6542 is flush (i.e., aligns with) with the drive link body 6504 such that the drive link thickness T4 is substantially equal to the insert thickness T5. Also, the cutting insert 6542 includes at least one ground edge in the form of a first bevel edge 6560a and a second bevel edge 6560b (FIG. 33) located along opposite edges. The first and second bevel edges 6560a, 6560b are provided to prevent chipping of the cutting insert 6542. In other embodiments, the cutting insert 6542 may have a coined section in which one portion of the cutting insert 6542 may be thinner than another portion of the cutting insert 6542.

[0159] With reference back to FIG. 27, the first set of cutter links 6012a is formed by a pair of cutter links that are similar to the cutter link 6020 of FIGS. 28-30, and thereby form a pair of unset cutter links. The second set of cutter links 6012b is formed by a pair of cutter links that are similar to the cutter links 6120, 6220 of FIGS. 31 and 32. The second set of cutter links 6012b is formed by a pair of cutter links that are set in opposite directions and away from the plurality' of drive links 6008. The third set of cutter links 6012c is formed by a pair of cutter links that are similar to the cutter link 6020 of FIGS. 28-30. and thereby form another pair of unset cutter links. The fourth set of cutter links 6012d is formed by a pair of cutter links that are similar to the cutter links 6120, 6220 of FIGS. 31 and 32. The fourth set of cutter links 6012d is formed by another pair of cutter links that are set in opposite directions.

[0160] To form the cutting arrangement of the chainsaw chain 6000, the sets of cutter links 6012a-d are arranged to alternate with each other. For example, as illustrated in FIG. 27, the cutter links 6004 are arranged (starting from the left side of the drawing) in a repeating pattern of: (i) the first set of cutter links 6012a, (ii) the second set of cutter links 6012b, (iii) the third set of cutter links 6012c, and (iv) the fourth set of cutter links 6012d. In some embodiments, the chainsaw chain 6000 may have other repeating or non-repeating patterns of cutter links 6004. In other embodiments of the chainsaw chain 6000, the cutting pattern can alternate between a plurality of the first set of cutter links 6012a, a plurality of the second set of cutter links 6012b. a plurality of the third set of cutter links 6012c, and a plurality of the fourth set of cutter links 6012d.

[0161] In each embodiment of the chainsaw chain 6000, each cutter link 6004 does not include a feed limiter because each drive link 6008 has a cutting tooth 6520 so that a respective cutter link 6004 is allowed to serve as a conventional feed limiter for a following cutter link 6004 in a similar manner as a conventional reciprocating saw blade. Also, since the cutting inserts 6074, 6174, 6274 are formed to overhang a corresponding cutter link body 6024, 6124, 6224 and the cutting insert 6542 is formed to overhang a corresponding drive link body 6504, the beveled edges 6086a-b, 6186a-b, 6286a-b, 6560a-b are provided to inhibit chipping of the cutting inserts 6074, 6174, 6274 in a similar manner as cutting inserts arranged on a circular saw blade formed to cut metal. In addition, the overhanging cutting inserts 6074, 6174, 6274, 6542 causes the chainsaw chain 6000 produce fast cutting operations while also retaining durability due to the size.

[0162] With reference to FIGS. 36A and 36B, another drive link 7000 similar to the drive link 24a of FIG. 3A is illustrated. The drive link 7000 includes a drive link body 7004, one or more rivet holes 7008 extending through the drive link body 7004. and a bottom scooping portion or a tang 7012 positioned below the pair of rivet holes 7008. The drive link 7000 further includes an opening 7016 proximate the tang 7012 and a projection 7020 extending upwardly from the drive link body 7004 in a vertical direction. In other embodiments, the projection 7020 may be set (i.e., bent) in a right direction or a left direction of the drive link 7000. The opening 7016 carries and spreads lubricating fluid through the guide bar 6 (FIG. 1). The projection 7020 is a tapered projection with an enlarged portion 7024a formed on the drive link body 7004 and narrow portion 7024b extending from the enlarged portion 7024a to define an apex 7028. The projection 7020 serves as a conventional feed limiter for a cutter that may be arranged rearward of the drive link 7000 along a chainsaw chain. As such, the drive link 7000 releases clogged material when going around the nose 592 (FIG. 1) of the chainsaw 1. For example, as the drive link 7000 moves around the nose 592 (or other sharp turn), the projection 7020 can move (e.g., pivot) between two cutters in a set of cutters to leverage out material between the cutters. The drive link 7000 may be incorporated in the chainsaw chains 7, 500, 900, 2000, 3000, 4000, 5000, 6000 as discussed herein.

[0163] With reference to FIGS. 37A and 37B, another drive link 7050 similar to the drive link 24a of FIG. 3 A is illustrated. The drive link 7050 includes a drive link body 7054, one or more rivet holes 7058 extending through the drive link body 7054. a bottom scooping portion or a tang 7062 positioned below the pair of rivet holes 7058, and an opening 7066proximate the tang 7062. The opening 7066 carries and spreads lubricating fluid through the guide bar 6 (FIG. 1). The drive link 7050 further includes a first projection 7070 extending upwardly from the drive link body 7054 and a second projection 7074 extending from the drive link body 7054 in a direction perpendicular to the first projection 7070. Each projection is a tapered projection that respectively defines an apex 7078, 7082. Also, the first projection 7070 and the second projection 7074 are formed along the same side of the drive link 7050. As the drive link 7050 is driven around a sprocket (not shown) that is located in the nose 592 (FIG. 1) of the chainsaw 1, the first and second projections 7070, 7074 are configured to interact with another drive link positioned rearward of the drive link 7050 to clear material from a gullet of the rearward drive link. The drive link 7050 may incorporated in the chainsaw chains 7. 500, 900. 2000, 3000, 4000, 5000. 6000 as discussed herein.

[0164] With reference to FIGS. 38A and 38B, another drive link 7100 is illustrated. The drive link 7100 includes a drive link body 7104, one or more rivet holes 7108 extending through the drive link body 7104, and a bottom scooping portion or a tang 7112 positioned below the pair of rivet holes 7108. The rivet holes 7108 are each configured to receive a rivet 20 (FIG. 2), so that the drive link 7100 can be coupled to a respective cutter and / or a respective tie strap. The size of the rivet holes 7108 and the distance between the rivet holes 7108 are ultimately determined by a pitch of a chainsaw chain. In the illustrated embodiment, the rivet holes 7108 have a circular shape. In some embodiments, the rivet holes 7108 may be tapered. In other embodiments, the rivet holes 7108 may have chamfers at the entrances of each rivet hole 7108. The drive link 7100 further includes an opening 7116 proximate the tang 7112. The opening 7116 also carries and spreads lubricating fluid through the guide bar 6. The size and shape of the opening 7116 may vary from the illustrated shape of the opening 71 16.

[0165] The tang 7112 extends downwardly from the drive link body 7104. In the illustrated embodiment, the tang 7112 is integrally formed with the drive link body 7104. In other embodiments, the tang 7112 may be a separate piece that is secured to the drive link body 7104. The tang 7112 is defined by a curved gap formed within the drive link body 7104 and is configured to support the chainsaw chain 7 along the guide bar 6 of the chainsaw 1. The tang 7112 also engages a drive element moving within the guide bar 6 to drive the chainsaw chain 7 around the guide bar 6 and carry lubricating fluid (e.g.. oil) through the guide bar 6 to keep the chainsaw chain 7 lubricated. In the illustrated embodiment, a topportion of the drive link 7100 has the same thickness as a bottom portion of the drive link 7100. In the other embodiments, the bottom portion of the drive link 7100 may be thinner than the top portion of drive link 7100 to fit in chainsaws with a thin bar or for minimizing a kerf of a chainsaw chain.

[0166] Also, the drive link body 7104 of the drive link 7100 is formed with a first flat surface 7120, a second flat surface 7124, a third flat surface 7128, and a fourth flat surface 7132 along the upper portion of the drive link 7100 for measurement, manufacturing, or material handling purposes. The first and second flat surfaces 7120, 7124 are located on opposite ends (e.g., front and back) of the drive link body 7104. The third and fourth flat surfaces 7128, 7132 are located on a top side of the drive link 7100, opposite the tang 71 12. The third and fourth flat surfaces 7128, 7132 are spaced from each other such that a gullet 7136 is formed therebetween. In addition, a first comer cutout 7140 and a second comer cutout 7144 is formed along the upper portion of the drive link 7100 for measurement or material handling purposes. The first comer cutout 7140 is arranged between the first flat surface 7120 and the third flat surface 7128. The second comer cutout 7144 is arranged between the second flat surface 7124 and the fourth flat surface 7132. Each comer cutouts 7140, 7144 is formed as a curved surface. As such, the drive link 7100 may incorporated in the chainsaw chains 7, 500, 900. 2000, 3000, 4000, 5000, 6000 as discussed herein.

[0167] With reference to FIG. 39, another drive link 7150 is illustrated. The drive link 7150 includes a drive link body 7154, one or more rivet holes 7158 extending through the drive link body 7154, and a bottom scooping portion or a tang 7162 positioned below the pair of rivet holes 7158. The rivet holes 7158 are each configured to receive a rivet 20 (FIG. 2), so that the drive link 7150 can be coupled to a respective cutter and / or a respective tie strap. The drive link 7150 further includes an opening 7166 proximate the tang 7162. The opening 7166 also carries and spreads lubricating fluid through the guide bar 6. In addition, the drive link body 7154 is formed with a first flat surface 7170 and a second flat surface 7174 that are located on opposite ends (e.g., front and back) of the drive link body 7154.

[0168] Also, the drive link 7150 includes a rear or first feed limiter 7178 and a front or second feed limiter 7182 extending from the drive link body 7154. The first and second feed limiters 7178, 7182 are spaced from each other such that a gullet 7186 is defined therebetween. The feed limiters 7178, 7182 are oriented to control a path in which material travels during a cutting operation. As the drive link 7150 travels around the nose 592 of thechainsaw 1, the first and second feed limiters 7178, 7182 are configured to cut into the material to inhibit the chainsaw 1 from experiencing kickback and serve as anti-kickback features. As such, the drive link 7150 may incorporated in the chainsaw chains 7, 500, 900, 2000, 3000, 4000, 5000, 6000 as discussed herein.

[0169] FIGS. 40 and 41 illustrate another cutter 7916 that is similar to the cutter 916 of FIGS. 17 and 18; therefore, like structure will be identified by like reference number plus “7000” and only the differences will be discussed hereafter.

[0170] With reference to FIG. 40, the cutter 7916 includes a cutter body 7920, a cutting tooth 7924. a feed limiter 7928, a gullet 7932. a toe 7936. and a heel 7940. The cutter body 7920 includes one or more rivet holes 7944 extending therethrough. The cutting tooth 7924 includes a cutting tip 7956, a rake face 7960 extending from the cutting tip 7956, a primary relief face 7964 extending from the cutting tip 7956 opposite the rake face 7960, and a secondary relief face 7968 extending from the primary relief face 7964 to an edge 7972 of the cutter body 7920 proximate the heel 7940.

[0171] With reference to FIG. 41, a cutting insert 7976 is coupled to the cutting tooth 7924 by various joining methods (e.g., resistance welding, laser welding, cladding, etc.) and forms at least a part of the cutting tip 7956. The primary relief face 7964 of the cutting tooth 7924 is substantially flush with a top portion 7980 of the cutting insert 7976 such that the primary relief face 7964 and the top portion 7980 are oriented at a primary relief angle Al 3 relative to a primary relief axis 7984 extending parallel to the longitudinal axis 7948. The secondary relief face 7968 is oriented at a secondary relief angle A14 relative to a secondary relief axis 7988 extending parallel to the vertical axis 7952. In an alternative embodiment, the secondary' relief angle A14 is measured relative to the primary' relief face 7964. The secondary relief angle A14 is larger than the primary relief angle A13. The secondary relief angle A14 is provided to allow a user to perform a plunge cutting operation with the nose 592 (FIG. 1 ) of the chainsaw 1 . In such scenarios, the primary relief angle Al 3 may act as a feed limiter.

[0172] In some embodiments, the primary relief angle A13 ranges between -40 and 80 degrees, in which the primary relief angle A13 is dependent on a rake angle of the cutter 7916 and a height of the cutter 7916. In other embodiments, the primary relief angle Al 3 ranges between -5 and 50 degrees. In preferred embodiments, the primary relief angle Al 3 rangesbetween 2.5 and 12.5 degrees, in which a high value primary relief angle Al 3 of the specified range produces a chainsaw chain that provides fast cutting operations. As such, the primary relief angle Al 3 of the preferred embodiment is not dependent on the rake angle of the cutter 7916 such that the primary relief angle A13 can be independently changed. In other preferred embodiments, the primary relief angle Al 3 is 30 degrees or less. In additional embodiments, the primary relief angle A13 ranges between 4 and 6 degrees. In further embodiments, the primary relief angle Al 3 may be 5 degrees.

[0173] In some embodiments, the secondary' relief A14 ranges between 0 and 120 degrees to result in a portion of the cutter body 7920 proximate the edge 7972 being taller than the cutting insert 7976. In other embodiments, the secondary relief angle A14 ranges between 0 and 70 degrees. In preferred embodiments, the secondary relief angle A14 ranges between 2.5 and 12.5 degrees, in which a high value secondary relief angle Al 4 of the specified range produces a chainsaw chain that provide fast cutting operations. In additional embodiments, the secondary relief angle A14 ranges between 30 and 60 degrees. In further embodiments, the secondary relief angle A14 may be 35 degrees. Moreover, the primary relief angle Al 3 and the secondary' relief angle A14 may have other values and ranges. The secondary' relief face 7968 is obliquely oriented relative to the primary' relief face 7964 such that the secondary relief face 7968 is beneficial for the plunge cutting operation.

[0174] The gullet 7932 of the cutter 7916 is defined between the cutting tooth 7924 and the feed limiter 7928. More specifically, the gullet 7932 is defined by the rake face 7960 of the cutting tooth 7924, a planar face 7992 of the feed limiter 7928, and a curvilinear face 7994 defined within the cutter body 7920 and disposed between the rake face 7960 and the planar face 7992. The planar face 7992 is oriented at a gullet angle Al 5 relative to the vertical axis 7952. In the Illustrated embodiment, the gullet angle Al 5 is an oblique angle. As such, the gullet 7932 is structured to reduce the occurrence of clogging a chainsaw chain during operation of the chainsaw 1. In some embodiments, the gullet angle Al 5 ranges between 0 degrees and 75 degrees. In preferred embodiments, the gullet angle Al 5 preferably ranges between 25 degrees and 60 degrees. In some embodiments, the gullet 7932 may be disposed underneath the feed limiter 7928 such that a portion of the feed limiter 7928 overhangs the gullet 7932 and provides more clearance. In other embodiments, the gullet 7932 may be wider or a different shape than what is illustrated.

[0175] Feet 7996 are formed along a bottom portion of the cutter 7916 as flat surfaces. In the illustrated embodiment, the feet 7996 are evenly formed along the bottom portion of the cutter 7916. In some embodiments, the feet 7996 may be unevenly formed along the bottom portion of cutter 7916 to assist with performing a bucking cut operation and an angular cut operation. In addition, the feet 7996 are spaced from each other such that an arched surface 7998 is formed therebetween. The arched surface 7998 is formed on the cutter 7916 to provide clearance between the sprocket of the chainsaw 1 as a corresponding chainsaw chain is driven around the nose 592 of chainsaw 1. In other embodiments, a trapezoidal surface may be formed along the bottom portion of the cutter 7916. In additional embodiments, the cutter 7916 may include identification markings, lubricating features, cutouts for reducing w eight of the cutter 7916 and handling of the cutter 7916 during production, and cooling features (e.g., cutouts, slots, etc.) configured to distribute heat through the cutter 7916.

[0176] FIG. 42 illustrates another chainsaw chain 8000. The chainsaw chain 8000 includes a plurality of drive links 8004, a plurality of straps 8008. and a plurality of projections 8012 extending from a corresponding strap 8008. Each drive link 8004 is integrally formed with one strap of the plurality of straps 8008 to thereby form a combination of a drive link and a tie strap. As such, each projection 8012 is configured to cooperate with a respective drive link 8004 to interconnect consecutive drive links of the plurality of drive links 8004.

[0177] With reference to FIGS. 43A and 43B, one drive link 8016 of the plurality of drive links 8004 is illustrated. The drive link 8016 includes a drive link body 8020, a hole 8024 extending through the drive link body 8020. and a bottom scooping portion or a tang 8028 positioned below the hole 8024. The hole 8024 is configured to receive a respective projection 8012, so that the drive link 8016 can be coupled to a consecutive drive link 8004. The tang 8028 extends downwardly from the drive link body 8020. In the illustrated embodiment, the tang 8028 is integrally formed with the drive link body 8020. In other embodiments, the tang 8028 may be a separate piece that is secured to the drive link body 8020. The tang 8028 is defined by a curved gap formed within the drive link body 8020 and is configured to support the chainsaw chain 7 along the guide bar 6 of the chainsaw 1. The drive link 8016 further includes an opening 8032 proximate the tang 8028. The opening 8032 also carries and spreads lubricating fluid through the guide bar 6.

[0178] The drive link 8016 further includes a cutting tooth 8036 and a gullet 8040. The cutting tooth 8036 extends from the drive link body 8020 in a direction opposite the tang 8028 and is configured to perform a cutting operation. The gullet 8040 is formed by a curved surface disposed between the cutting tooth 8036 and the drive link body 8020. The cutting tooth 8036 has a cutting tip 8044, a rake face 8048 extending from the cutting tip 8044, a primary relief face 8052 (similar to the primary relief face 6532 of FIGS. 33 and 34) extending from the cutting tip 8044 opposite the rake face 8048, and a secondary relief face 8056 (similar to the secondary relief face 6536 of FIGS. 33 and 34) extending from the primary relief face 8052 to a planar edge 8058 (FIG. 43 A) of the drive link body 8020. A cutting insert 8060 (similar to the cutting insert 6542 of FIGS. 33 and 34) is coupled to the cutting tooth 8036 by various joining methods (e.g.. resistance welding, laser welding, cladding, etc.) and forms at least a part of the cutting tip 8044. The cutting tooth 8036 is set (i.e., bent) in a left direction of the drive link 8016. Another drive link 8064 (FIG. 42) of the plurality7of drive links 8004 has a cutting tooth 8068 set in a right direction of the drive link 8064.

[0179] With continued reference to FIGS. 43A and 43B, one strap 8076 of the plurality of straps 8008 is illustrated. The strap 8076 includes a strap body 8080 having a first end 8084 and a second end 8088 opposite the first end 8084. The first end 8084 of the strap body 8080 is integrally formed with the drive link body 8020 of the drive link 8016. In other embodiments, the strap body 8080 may be a separate piece such that the first end 8084 is secured to the drive link body 8020 by the various joining methods discussed above. The strap body 8080 extends in a direction away from the cutting tooth 8068 such that the second end 8088 is spaced from the planar edge 8058. A projection 8092 of the plurality of projections 8012 is integrally formed with and extends from the strap body 8080. In other embodiments, the projection 8092 may be a separate piece such that the projection 8092 is secured to the strap body 8080 by the various joining methods discussed above. The projection 8092 is configured to sen e as a rivet and be received within a hole of a consecutive drive link to couple the plurality of drive links 8004 together to form the chainsaw chain 8000.

[0180] The drive link 8016, the strap 8076, and the projection 8092 are integrally formed together to form a first combination cutter 8096 that may drivingly engage the guide bar 6 of the chainsaw 1 and have a rivet-like projection for coupling a consecutive drive link of theplurality of drive links 8004. As such, the illustrated combination cutter 8096 has the cutting tooth 8036 which is set in the left direction. A second combination cutter 8100 (FIG. 42) is formed and has the cutting tooth 8068 which is set in the right direction.

[0181] To form the cutting arrangement of the chainsaw chain 8000, the combination cutters 8096, 8100 are arranged to alternate with each other. For example, as illustrated in FIG. 42, the combination cutters 8096, 8100 are arranged (starting from the left side of the drawing) in a repeating pattern of: (i) the second combination cutter 8100, (ii) the first combination cutter 8096, (iii) the second combination cutter 8100, (iv) the first combination cutter 8096, (v) the second combination cutter 8100, (vi) the first combination cutter 8096. (vii) the second combination cutter 8100, (vii) the first combination cutter 8096, and (ix) the second combination cutter 8100. In some embodiments, the chainsaw chain 8000 may have other repeating or non-repeating patterns of combination cutters 8096, 8100. In other embodiments of the chainsaw chain 8000, the cutting pattern can alternate between a plurality of the first combination cutter 8096 and a plurality’ of the second combination cutter 8100.

[0182] FIGS. 44 and 45 illustrate another cutter 9916 that is similar to the cutter 916 of FIGS. 17 and 18; therefore, like structure will be identified by like reference number plus “9000” and only the differences will be discussed hereafter.

[0183] With reference to FIG. 44, the cutter 9916 includes a cutter body 9920, a cutting tooth 9924. a feed limiter 9928, a gullet 9932, a toe 9936, and a heel 9940. The cutter body 9920 includes one or more rivet holes 9944 extending therethrough. The cutting tooth 9924 includes a cutting tip 9956, a rake face 9960 extending from the cutting tip 9956, a primary relief face 9964 extending from the cutting tip 9956 opposite the rake face 9960, and a secondary’ relief face 9968 extending from the primary’ relief face 9964 to an edge 9972 (FIG. 45) of the cutter body 9920 proximate the heel 9940.

[0184] With reference to FIG. 45, a cutting insert 9976 is coupled to the cutting tooth 9924 by various joining methods (e.g., resistance welding, laser welding, cladding, etc.) and forms at least a part of the cutting tip 9956. The primary relief face 9964 of the cutting tooth 9924 is substantially flush with a top portion 9980 of the cutting insert 9976 such that the primary relief face 9964 and the top portion 9980 are oriented at a primary relief angle Al 6 relative to a primary relief axis 9984 extending parallel to the longitudinal axis 9948. The secondary relief face 9968 is oriented at a secondary relief angle A17 relative to a secondaryrelief axis 9988 extending parallel to the vertical axis 9952. In an alternative embodiment, the secondary- relief angle Al 7 is measured relative to the primary relief face 9964. The secondary relief angle A17 is larger than the primary relief angle A16. The secondary relief angle Al 7 is provided to allow a user to perform a plunge cutting operation with the nose 592 (FIG. 1) of the chainsaw 1. In such scenarios, the primary- relief angle Al 6 may act as a feed limiter.

[0185] In some embodiments, the primary relief angle Al 6 ranges between -40 and 80 degrees, in which the primary- relief angle Al 6 is dependent on a rake angle of the cutter 9916 and a height of the cutter 9916. In other embodiments, the primary relief angle Al 6 ranges between -5 and 50 degrees. In preferred embodiments, the primary relief angle Al 6 ranges between 2.5 and 12.5 degrees, in which a high value primary relief angle Al 6 of the specified range produces a chainsaw chain that provides fast cutting operations. As such, the primary relief angle Al 6 of the preferred embodiment is not dependent on the rake angle of the cutter 9916 such that the primary relief angle Al 6 can be independently changed. In other preferred embodiments, the primary relief angle Al 6 is 30 degrees or less. In additional embodiments, the primary relief angle Al 6 ranges between 4 and 6 degrees. In further embodiments, the primary- relief angle Al 6 may be 5 degrees.

[0186] In some embodiments, the secondary- relief Al 7 ranges between 0 and 120 degrees to result in a portion of the cutter body 9920 proximate the edge 9972 being taller than the cutting insert 9976. In other embodiments, the secondary- relief angle Al 7 ranges between 0 and 70 degrees. In preferred embodiments, the secondary relief angle A17 ranges between 2.5 and 12.5 degrees, in which a high value secondary relief angle A17 of the specified range produces a chainsaw chain that provide fast cutting operations. In additional embodiments, the secondary- relief angle Al 7 ranges between 30 and 60 degrees. In further embodiments, the secondary relief angle A17 may be 35 degrees. Moreover, the primaryrelief angle A16 and the secondary- relief angle A17 may have other values and ranges. The secondary relief face 9968 is obliquely- oriented relative to the primary relief face 9964 such that the secondary relief face 9968 is beneficial for the plunge cutting operation.

[0187] The gullet 9932 of the cutter 9916 is defined between the cutting tooth 9924 and the feed limiter 9928. More specifically, the gullet 9932 is defined by the rake face 9960 of the cutting tooth 9924, a planar face 9992 of the feed limiter 9928, and a curvilinear face 9994 defined within the cutter body 9920 and disposed between the rake face 9960 and theplanar face 9992. The planar face 9992 is oriented at a gullet angle Al 8 relative to the vertical axis 9952. In the illustrated embodiment, the gullet angle Al 8 is an oblique angle. As such, the gullet 9932 is structured to reduce the occurrence of clogging a chainsaw chain during operation of the chainsaw 1. In some embodiments, the gullet angle Al 8 ranges between 0 degrees and 75 degrees. In preferred embodiments, the gullet angle Al 8 preferably ranges between 25 degrees and 60 degrees. In some embodiments, the gullet 9932 may be disposed underneath the feed limiter 9928 such that a portion of the feed limiter 9928 overhangs the gullet 9932 and provides more clearance. In other embodiments, the gullet 9932 may be wider or a different shape than what is illustrated.

[0188] Feet 9996 are formed along a bottom portion of the cutter 9916 as flat surfaces. In the illustrated embodiment, the feet 9996 are evenly formed along the bottom portion of the cutter 9916. In some embodiments, the feet 9996 may be unevenly formed along the bottom portion of cutter 9916 to assist with performing a bucking cut operation and an angular cut operation. In addition, the feet 9996 are spaced from each other such that an arched surface 9998 is formed therebetween. The arched surface 9998 is formed on the cutter 9916 to provide clearance between the sprocket of the chainsaw 1 as a corresponding chainsaw chain is driven around the nose 592 of chainsaw 1. In other embodiments, a trapezoidal surface may be formed along the bottom portion of the cutter 9916. In additional embodiments, the cutter 9916 may include identification markings, lubricating features, cutouts for reducing weight of the cutter 9916, handling of the cutter 9916 during production, and cooling features (e.g., cutouts, slots, etc.) configured to distribute heat through the cutter 9916.

[0189] With continued reference to FIG. 45, the feed limiter 9928 includes a feed limiter body 10000 extending upwardly from the cutter body 9920 and a projection 10004 coupled to a top portion of the feed limiter body 10000. The feed limiter body 10000 extends parallel to the cutting tooth 9924 and the vertical axis 9952. In the illustrated embodiment, the projection 10004 is integrally formed with the top portion of the feed limiter body 10000 and has a linear shape. In other embodiments, the projection 10004 may be a separate piece that is secured to the top portion of the feed limiter body 10000. In additional embodiments, the projection 10004 may have a non-linear shape such as a curvilinear shape. In further embodiments, the projection 10004 may have other shapes and sizes. The projection 10004 extends from the feed limiter body 10000 in a direction parallel to a longitudinal axis 9948 such that the projection 10004 is positioned to overlap the gullet 9932. As such, at least aportion of feed limiter 9928 is arranged to overhang a portion of the gullet 9932 to increase durability’ of the cutter 9916 without reducing a size of the gullet 9932.

[0190] In some embodiments, the projection 10004 extends a distance from the feed limiter body 10000 and thereby overlaps at least 15% of the gullet 9932. In other embodiments, the projection 10004 extends a distance over the gullet 9932 and thereby overlaps at least 25% of the gullet 9932. In additional embodiments, the projection 10004 extends a distance over the gullet 9932 and thereby overlaps at least 40% of the gullet 9932. In further embodiments, the projection 10004 extends a distance over the gullet 9932 and thereby overlaps at least 50% of the gullet 9932. In another embodiment, the projection 10004 extends a distance over the gullet 9932 and thereby overlaps at least 60% of the gullet 9932.

[0191] Also, a gap is defined between the cutting insert 9976 and the projection 10004. As such, another distance is defined between the cutting insert 9976 and the projection 10004. A ratio of a distance of the projection 10004 extending from the feed limiter body 10000 to a distance defined between the cutting insert 9976 and the projection 10004 may range from 0.5 mm to 5 mm.

[0192] Each chainsaw chain, discussed herein above, defines by a pitch. An approximate pitch of a respective chainsaw chain is calculated using Equation 1. In one preferred embodiment, the pitch of a chainsaw chain is approximately 0.325 inches, and realistically the pitch is 0.324 inches. In another preferred embodiment, the pitch of a chainsaw chain is approximately 3 / 8 inches low profile, and realistically the pitch is 0.366 inches. A low profile pitch indicates to a user that a particular drive system (e.g., sprocket) of a chainsaw is used. In further embodiments, the pitch of a chainsaw chain may be 3 / 8 inches, ! inches, 0.404 inches, or 0.325 inches low profile. In additional embodiments, the pitch of a chainsaw chain may be a high value so that the chainsaw chain is operable to cut into material such as concrete. In another embodiment, the pitch of a chainsaw chain may be other values.Equation 1: Distance Between 3 Rivets 2

[0193] Each embodiment discussed herein above may include a coating (not shown) such that any type of coating and coating applications may be used on each component ofchainsaw chains, only on cuters, only on cuting teeth, or only on cuting inserts. In one example, a hard coating may be applied via physical vapor deposition (PVD) onto a cuting tooth of the cuters to enhance the durability of the cuting tooth and maintain sharpness of a corresponding cuting insert. In another example, a low friction coating may be applied onto cuters, drive links, rivets, and tie straps to reduce the amount of heat and friction produced by the operation of the chainsaw, and thereby result in a decrease in the utilization of lubrication (e.g., oil). In an additional example, a hard coating may be applied on drive links and the guide bar 6 of the chainsaw chain 1 to reduce abrasion and friction that occurs between the drive links and the guide bar 6. In further embodiments, black oxide or paint may be applied onto cuters, drive links, rivets, and / or tie straps. In other embodiments, anodization may be used on cuters, drive links, rivets, and / or tie straps.

[0194] Cuting inserts of each embodiment discussed herein above may be ground to other desired shapes. In one example, various bevel configurations may be formed on the cuting inserts. In another example, the cuting inserts may be ground to have a fleam-type grind. In an additional example, the cuting inserts may be ground to a final desired shape after a corresponding cutting tooth is set to help the corresponding chainsaw chain produce a straight cut. In a further example, the cuting inserts may be ground to a desired shape that is purposely suitable for a respective material such as metal or wood. In other examples, the cuting inserts may be ground to have non-flat grinds to thereby form concave surfaces along the cuting inserts.

[0195] In an initial state of the cuting inserts of each embodiment discussed herein above may have various shapes and sizes to permit different grind configurations, provide effective welding joints, and provide durability to a corresponding cuter. As such, in some embodiments, the cuting inserts may have a trapezoidal prism shape in an initial state. In other embodiments, the cuting inserts may have a cylindrical shape in an initial state and oriented in a standard orientation (e.g., horizontal orientation such that an end of a cylindrical cuting insert would be illustrated along the pocket 116 of FIG. 7). In additional embodiments, the cuting inserts may have a spherical shape in an initial state. In further embodiments, the cuting inserts may have other shapes in an initial state and arranged in other orientations. In another embodiment, the cuting inserts may have a shape that cooperates with the geometry of a corresponding cuting tooth and allows the cuting inserts to be fixed in place relative to the corresponding cutting tooth.

[0196] In addition, the cutting inserts of each embodiment discussed herein above may have various carbide grades. In one example, the cutting inserts may have a carbide grade with a high binder content value (e.g., H15F or H10F sold by Hyperion®) which results in exception welds for joining a respective cutting insert to a cutting tooth. In an additional example, the cutting inserts may have a carbide grade with a cobalt content that ranges between 2% and 20%. In a further example, the grade of a cutting insert may be other carbide grades not discussed herein.

[0197] Chainsaw chains of each embodiment discussed herein above may each include cutting inserts with different final grind shapes. For example, a respective chainsaw includes a first cutter having a first cutting insert and a second cutter having a second cutting insert. The first cutting insert has a first final state different than a second final state of the second cutting insert. As such, each chainsaw chain may form a cutting arrangement in which cutting inserts with different final states alternate with each other.

[0198] 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 disclosure are set forth in the following claims.

Claims

CLAIMSWhat is claimed is:

1. A chainsaw chain for a chainsaw, the chainsaw chain comprising: a plurality’ of drive links configured to connect the chainsaw chain to the chainsaw, each drive link including a drive link body and a pair of rivet holes extending though the drive link body; a plurality' of cutters configured to cut a workpiece during a cutting operation, each cutter including a cutter body having a pair of rivet holes extending therethrough, the cutter body defining a longitudinal axis extending through the pair of rivet holes and a vertical axis oriented perpendicular to the longitudinal axis, a cutting tooth coupled to the cutter body, the cutting tooth including a rake face and a relief face extending opposite the rake face, a feed limiter coupled to the cutter body and spaced from the cutting tooth, a gullet defined between the cutting tooth and the feed limiter, and a cutting insert coupled to the cutting tooth, the cutting insert includes a front portion and a top portion that is substantially flush with the relief face of the cutting tooth; and a plurality of rivets received within corresponding rivet holes of the plurality of drive links and the plurality' of cutters to couple the plurality' of drive links and the plurality' of cutters together.

2. The chainsaw chain of claim 1, wherein the top portion is oriented at a relief angle relative to a relief axis that is parallel to the longitudinal axis, and wherein the front portion is oriented at a rake angle relative to a rake axis that is parallel to the vertical axis.

3. The chainsaw chain of claim 2, wherein the relief angle ranges between 2.5 degrees and 12.5 degrees.

4. The chainsaw chain of claim 2, wherein the relief angle is 30 degrees or less.

5. The chainsaw chain of claim 1, wherein the front portion of the cutting insert is substantially flush with the rake face of the cutting tooth.

6. The chainsaw chain of claim 1 , wherein the feed limiter defines a feed cutting height between a feed limiter tip and a cutting tip of the cutting tooth, and wherein the feed cutting height is measured perpendicular to the longitudinal axis.

7. The chainsaw chain of claim 6, wherein the feed cutting height ranges between 0.5 mm and 0.9 mm.

8. The chainsaw chain of claim 6, wherein the feed cutting height is 2 mm or less.

9. The chainsaw chain of claim 1, wherein the relief face of the cutting tooth and the top portion of the cutting tooth define a flat continuous relief surface of the cutting tooth.

10. The chainsaw chain of claim 1, wherein the relief face of the cutting tooth is a primary relief face, and wherein the cutting tooth further includes a secondary relief face extending from the primary7relief face.

11. The chainsaw chain of claim 10. wherein the primary relief face of the cutting tooth and the top portion of the cutting insert are oriented at a primary relief angle relative to a primary relief axis extending parallel to the longitudinal axis, and wherein the secondary' relief face is oriented at a secondary relief angle relative to a secondary relief axis extending parallel to the vertical axis.

12. The chainsaw chain of claim 1 1, wherein the primary relief angle ranges between 2.5 degrees and 12.5 degrees, and wherein the secondary' relief angle ranges between 30 degrees and 60 degrees.

13. The chainsaw chain of claim 11, wherein the primary relief angle is 30 degrees or less, and wherein the secondary' relief angle ranges between 30 degrees and 60 degrees.

14. The chainsaw chain of claim 1, wherein at least a portion of the gullet is defined by a planar face of the feed limiter oriented at a gullet angle relative to the vertical axis, and wherein the gullet angle is an oblique angle.

15. The chainsaw chain of claim 14, wherein the gullet angle ranges between 0 degrees and 75 degrees.

16. The chainsaw chain of claim 1, wherein the cutting insert is coupled to the cutting tooth in an axial orientation.

17. The chainsaw chain of claim 1, further comprising a plurality of tie straps, wherein each tie strap includes a tie strap body and a rivet hole extending through the tie strap body, and wherein the plurality of rivets is also received within corresponding rivet holes of the plurality' of tie straps to couple the plurality' of drive links, the plurality of cutters, and the plurality of tie straps together.

18. A chainsaw chain for a chainsaw, the chainsaw chain comprising: a plurality of drive links configured to connect the chainsaw chain to the chainsaw; a plurality of cutters configured to cut a workpiece during a cutting operation; a first projection positioned on a first side of the plurality of drive links and extending in a first direction; and a second projection positioned on a second side of the plurality of drive links and extending in a second direction opposite the first direction such that the first projection and the second projection extending outwardly from the plurality of drive links.

19. The chainsaw chain of claim 18, further comprising a plurality of tie straps configured to interconnect consecutive drive links of the plurality of drive links, wherein the first projection is formed on a first tie strap of the plurality of tie straps, and wherein the second projection is formed on a second tie strap of the plurality of tie straps.

20. The chainsaw chain of claim 19, wherein the first projection extends a partial length of the first tie strap such that a first tie strap body forms a first planar surface extending a remaining length of the first tie strap, and wherein the second projection extends a partiallength of the second tie strap such that a second tie strap body forms a second planar surface extending a remaining length of the second tie strap.

21. The chainsaw chain of claim 20, wherein the first tie strap includes a first partial gullet disposed between the first projection and the first planar surface, and wherein the second tie strap includes a second partial gullet disposed between the second projection and the second planar surface.

22. The chainsaw chain of claim 19, further comprising a plurality7of rivets configured to couple the plurality of drive links, the plurality' of cutters, and the plurality of tie straps together.

23. The chainsaw chain of claim 18, wherein the first projection is formed as a first cutting tooth on a first cutter of the plurality of cutters, and wherein the second projection is formed as a second cutting on a second cutter of the plurality of cutters.

24. A chainsaw chain for a chainsaw, the chainsaw chain comprising: a plurality' of drive links configured to connect the chainsaw chain to the chainsaw, each drive link including a drive link body, a rivet hole extending through the drive link body, a tang extending from the drive link body and configured to engage a drive element of the chainsaw, and a projection extending from the drive link body in a direction opposite the tang; a plurality' of cutters configured to cut a workpiece during a cutting operation, each cutter including a cutter body having a rivet hole extending therethrough and a cutting tooth coupled to the cutter body; and a plurality of rivets received within corresponding rivet holes of the plurality of drive links and the plurality' of cutters to couple the plurality' of drive links and the plurality' of cutters together.

25. The chainsaw chain of claim 24, wherein the projection is a tapered projection.

26. The chainsaw chain of claim 24, wherein the projection has an enlarged portion formed on the drive link body and a narrow portion extending from the enlarged portion.

27. The chainsaw chain of claim 26, wherein the narrow portion tapers to define an apex of the projection.

28. The chainsaw chain of claim 24, wherein the projection is a first projection, and wherein each drive link further includes a second projection extending from the drive link body perpendicular to the first projection.

29. The chainsaw chain of claim 28, wherein each projection is a tapered projection defining an apex.

30. The chainsaw chain of claim 24. further comprising a plurality of tie straps, wherein each tie strap includes a tie strap body and a rivet hole extending through the tie strap body, and wherein the plurality of rivets is also received within corresponding rivet holes of the plurality' of tie straps to couple the plurality' of drive links, the plurality of cutters, and the plurality of tie straps together.

31. A chainsaw chain for a chainsaw, the chainsaw chain comprising: a plurality of drive links configured to connect the chainsaw chain to the chainsaw; a set of cutters configured to cut a workpiece during a cutting operation, the set of cutters including a pair of cutters parallel to each other with at least one drive link of the plurality of drive links is disposed between the pair of cutters; a plurality of other cutters configured to cut the workpiece during the cutting operation, each cutter of the plurality of other cutters being positioned on a first side of the plurality of drive links or a second side of the plurality of drive links; and a plurality of tie straps, each tie strap of the plurality of tie straps configured to interconnect consecutive drive links of the plurality of drive links and positioned opposite on an opposite side of the consecutive drive links from a cutter of the plurality of other cutters.

32. The chainsaw chain of claim 31. wherein one cutter of the pair of cutters includes a first cutting tooth, wherein another cutter of the pair of cutters includes a second cutting tooth, and wherein the first cutting tooth and the second cutting tooth are set relative to corresponding feed limiters in directions away from the plurality of drive links.

33. The chainsaw chain of claim 31, wherein one cuter of the pair of cuters includes a first cuting tooth, wherein another cuter of the pair of cuters includes a second cuting tooth, and wherein the first cuting tooth and the second cuting tooth are set relative to corresponding feed limiters in opposite directions.

34. The chainsaw chain of claim 31, wherein a cuting arrangement of the chainsaw chain is formed by a repeating patern of the set of cuters, a first cutter of the plurality of other cuters on the first side and a first tie strap of the plurality of tie straps on the second side, a second cutter of the plurality of other cuters on the second side and a second tie strap of the plurality of tie straps on the first side, a third cuter of the plurality' of other cuters on the first side and a third tie strap of the plurality of tie straps on the second side, and a fourth cuter of the plurality of other cuters on the second side and a fourth tie strap of the plurality of tie straps on the first side.

35. The chainsaw chain of claim 34, wherein one cuter of the pair of cuters includes a first cuting tooth, wherein another cuter of the pair of cuters includes a second cuting tooth, and wherein the first cuting tooth and the second cuting tooth are set relative to corresponding feed limiters in directions away from the plurality' of drive links.

36. The chainsaw chain of claim 31. further comprising a plurality of rivets configured to couple the plurality of drive links, the plurality of other cutters, and the plurality of tie straps together.

37. A chainsaw chain for a chainsaw, the chainsaw chain comprising: a plurality of drive links configured to connect the chainsaw chain to the chainsaw, each drive link including a drive link body, a pair of rivet holes extending though the drive link body, a tang extending from the drive link body and configured to engage a drive element of the chainsaw, a cuting tooth coupled to the drive link body, and a drive link insert coupled to the cutting tooth; and a plurality of cutter links configured to interconnect consecutive drive links, each cuter link includes a cuter link body having a pair of rivet holes extending therethrough, the cuter link body defining a longitudinal axis extending through the pair of rivet holes,a vertical axis oriented perpendicular to the longitudinal axis, and a first thickness measured transverse the longitudinal axis, a cutting tooth coupled to the cutter link body, and a cutter link insert coupled to the cutting tooth, the cutter link insert defining a second thickness greater than the first thickness.

38. The chainsaw chain of claim 37. wherein the cutting tooth includes a primary relief face extending from the cutter link insert and a secondary relief face extending from the primary relief face.

39. The chainsaw chain of claim 38. wherein the primary relief face of the cutting tooth is oriented at a primary relief angle relative to a primary relief axis extending parallel to the longitudinal axis, and wherein the secondary relief face is oriented at a secondary relief angle extending parallel to the vertical axis.

40. The chainsaw chain of claim 39. wherein the primary relief angle ranges between 2.5 degrees and 12.5 degrees, and wherein the secondary relief angle ranges between 30 degrees and 60 degrees.

41. The chainsaw chain of claim 39. wherein the primary relief angle is 30 degrees or less, and wherein the secondary relief angle ranges between 30 degrees and 60 degrees.

42. The chainsaw chain of claim 37, wherein the cutter link insert includes at least one ground edge formed thereon.

43. The chainsaw chain of claim 37, wherein each cutter link further includes a gullet defined between the cutting tooth and at least a portion of the cutter link body.

44. The chainsaw chain of claim 43. wherein the cutter link body includes a planar surface extending a partial length of the cutter link body, and wherein the gullet is defined between the cutting tooth and the planar surface.

45. The chainsaw chain of claim 37, wherein the cutting tooth of each drive link includes a primary’ relief face extending from the drive link insert and a secondary relief face extending from the primary relief face.

46. The chainsaw chain of claim 45, wherein the primary’ relief face of the cutting tooth is oriented at a primary relief angle relative to a horizontal relief axis, and wherein the secondary relief face is oriented at a secondary relief angle relative to a vertical relief axis.

47. The chainsaw chain of claim 46, wherein the primary’ relief angle ranges between 2.5 degrees and 12.5 degrees, and wherein the secondary relief angle ranges between 30 degrees and 60 degrees.

48. The chainsaw chain of claim 46, wherein the primary relief angle is 30 degrees or less, and wherein the secondary’ relief angle ranges between 30 degrees and 60 degrees.

49. The chainsaw chain of claim 37. wherein one portion of the cutter link insert is thinner than another portion of the cutter link insert.

50. The chainsaw chain of claim 37, wherein one portion of the drive link insert is thinner than another portion of the drive link insert.

51. The chainsaw chain of claim 37, wherein the drive link body defines a third thickness, and wherein the drive link insert defines a fourth thickness greater than the third thickness.

52. The chainsaw chain of claim 51, w herein the drive link insert includes at least one ground edge formed thereon.

53. The chainsaw chain of claim 37, wherein the plurality of cutter links is positioned along both sides of the plurality of drive links in parallel such that the cutting tooth of a cutter link positioned on a first side of the plurality' of drive links is longitudinally aligned with the cutting tooth of an adjacent cutter link on a second side of the plurality of drive links.

54. The chainsaw chain of claim 53. wherein the cutting tooth of the cutter link and the cutting tooth of the adjacent cutter link are set in opposite directions.

55. The chainsaw chain of claim 53, wherein the cutting tooth of the cutter link and the cutting tooth of the adjacent cutter link are unset.

56. The chainsaw chain of claim 53, further comprising a plurality of rivets received within corresponding rivet holes of the plurality of drive links and the plurality of cutter links to couple the plurality of drive links and the plurality of cutter links together.

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