NON-CIRCULAR HOLE SAW DEVICE AND METHOD OF OPERATION

Abstract

An axially mounted non-circular hole saw device follows a lateral, oscillating cutting motion to cut a non-circular kerf in a workpiece. The device adapts to variously styled power tools. The device couples to a power tool at an axial orientation through a mounting portion. The axial disposition of the device relative to the power tool enables the axial vibratory force generated by the power tool to convert to a lateral, oscillating cutting motion followed by the device. This cutting motion forms a clean non-circular kerf, offsets vibrations during cutting, and minimizes debris formed during cutting. A cutting portion has a non-circular shape. The cutting portion includes a base edge and a teeth edge. A bridge traverses the base edge for stability. A mounting portion extends perpendicularly from the bridge portion. The mounting portion includes a gap defined by slots that couple to a coupling mechanism from the power tool.

Claims

1. A non-circular hole saw device, the device comprising: a cutting portion defined by a generally non-circular shape, the cutting portion comprising a base edge and an oppositely disposed teeth edge, the teeth edge comprising a plurality of teeth disposed in an aligned, spaced apart relationship; a bridge portion defined by a pair of short ends and a pair of long sides, the bridge portion disposed to traverse the base edge of the cutting portion, whereby the generally normal disposition of the bridge portion in relation to the cutting portion helps enhance structural integrity of the hole saw device and helps minimize vibratory effects of the hole saw device while in operation; and a mounting portion configured to enable mounting of the device, the mounting portion comprising a tab, the tab extending generally perpendicular from the bridge portion, the tab forming a gap having a gap perimeter, the gap perimeter defined by a plurality of slots, whereby the generally perpendicular disposition of the tab in relation to the bridge portion enables axial mounting of the hole saw device.

2. The device of claim 1, wherein the generally non-circular shape includes at least one of the following shapes: a square, a rectangle, a triangle, a trapezoid, a star, and a rhombus.

3. The device of claim 1, wherein the plurality of teeth are arranged in a plurality of repeating segments.

4. The device of claim 1, wherein the bridge portion is generally broad.

5. The device of claim 1, wherein the tab forms a plurality of apertures disposed around the gap perimeter.

6. The device of claim 1, wherein the tab is configured to form a tapered terminus.

7. The device of claim 1, wherein the plurality of slots have uneven lengths.

8. The device of claim 1, wherein the mounting portion is disposed generally perpendicular to the bridge portion.

9. The device of claim 1, wherein the mounting portion is substantially flat.

10. The device of claim 1, wherein the device comprises welded metal.

11. The device of claim 1, wherein the device comprises abrasive or corrosion resistant coatings or impregnation.

12. The device of claim 1, wherein the workpiece includes at least one member selected from the group consisting of: drywall, electric panels, wood, metal studs, foam, paper, polymer, masonry, ceramics, clay, teeth, and organic substrates.

13. A non-circular hole saw device, the device consisting of: a cutting portion defined by a generally non-circular shape, the generally non-circular shape including at least one of the following shapes: a square, a rectangle, a triangle, a trapezoid, a star, and a rhombus, the cutting portion comprising a base edge and an oppositely disposed teeth edge, the teeth edge comprising a plurality of teeth disposed in an aligned, spaced apart relationship; a bridge portion traversing the base edge of the cutting portion, whereby the generally normal disposition of the bridge portion in relation to the cutting portion helps enhance structural integrity of the hole saw device and helps minimize vibratory effects of the hole saw device while in operation; and a mounting portion configured to enable mounting of the device, the mounting portion comprising a tab, the tab extending generally perpendicular from the bridge portion, the tab forming a gap having a gap perimeter, the gap perimeter defined by a plurality of slots, the tab further forming a plurality of apertures disposed around the gap perimeter, whereby the generally perpendicular disposition of the tab in relation to the bridge portion enables axial mounting of the hole saw device.

14. The device of claim 13, wherein the mounting portion is substantially flat.

15. The device of claim 13, wherein the device comprises welded metal.

16. The device of claim 13, wherein the device comprises abrasive or corrosion resistant coatings or impregnation.

17. A method for operation of a non-circular hole saw device, the method comprising: providing a non-circular hole saw device, the hole saw device comprising a cutting portion for cutting, a bridge portion for stabilizing the cutting portion, and a mounting portion for mounting to a power tool; coupling the mounting portion to the power tool, such that the device is axially disposed to the power tool, whereby the axial disposition of device relative to the power tool enables the axial vibratory force generated by the power tool to convert to a lateral, oscillating cutting motion followed by cutting portion; aligning the cutting portion with a predetermined area of a work piece; actuating the power tool; following the lateral, oscillating cutting motion while cutting a kerf in the workpiece, whereby the lateral, oscillating cutting motion forms a clean non-circular kerf, offsets vibrations from the cutting, and minimizes debris that is formed during cutting; and cleaning the surface of the kerf in the workpiece.

Description

DESCRIPTION OF THE DRAWINGS

[0036] The invention will now be described, by way of example, with reference to the accompanying drawings, in which:

[0037] FIG. 1 illustrates a perspective view of an exemplary axially mounted hole saw device, in accordance with an embodiment of the present invention;

[0038] FIG. 2 illustrates an elevated side view of the axially mounted hole saw device shown in FIG. 1, in accordance with an embodiment of the present invention;

[0039] FIG. 3 illustrates an elevated forward view of the axially mounted hole saw device shown in FIG. 1, in accordance with an embodiment of the present invention; and

[0040] FIG. 4 illustrates a flowchart of an exemplary method for operation of an axially mounted hole saw device, in accordance with an embodiment of the present invention.

[0041] Like reference numerals refer to like parts throughout the various views of the drawings.

DETAILED DESCRIPTION OF THE INVENTION

[0042] The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. For purposes of description herein, the terms “upper,” “lower,” “left,” “rear,” “right,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in FIG. 1. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

[0043] At the outset, it should be clearly understood that like reference numerals are intended to identify the same structural elements, portions, or surfaces consistently throughout the several drawing figures, as may be further described or explained by the entire written specification of which this detailed description is an integral part. The drawings are intended to be read together with the specification and are to be construed as a portion of the entire “written description” of this invention as required by 35 U.S.C. §112.

[0044] In one embodiment of the present invention presented in FIGS. 1-4, an axially mounted non-circular hole saw device 100 and method 200 of operation provides a unique saw blade that is configured to form non-circular holes in a workpiece while cutting in a lateral, oscillating cutting motion. The axially mounted non-circular hole saw device 100, hereafter “device 100” adapts to different styles of power tools, and also configured to follow a lateral, oscillating cutting motion while cutting a kerf in a workpiece. Device 100 is configured to couple to a power tool at an axial orientation. The axial disposition of the device 100 relative to the power tool enables the axial vibratory force generated by the power tool to convert to a lateral, oscillating cutting motion followed by the device 100.

[0045] There are numerous advantageous that the lateral, oscillating cutting motion of device 100 offers. For one, a clean kerf is formed in the workpiece. Another advantage is that a clean non-circular kerf is formed. Another advantage is that vibrations during cutting are offset. As a result of the minimization of vibrations, debris that is formed during the cutting process is reduced.

[0046] As referenced in FIG. 1, the device 100 comprises a cutting portion 102 that can be configured to form at least one non-circular shape. The non-circular shape of the cutting portion 102 allows for eclectic operational uses of the device 100. In one embodiment, a generally square perimeter shape of the cutting portion 102 forms a square electrical gap 114, such as used for residential light switches. In some embodiments, the non-circular shape may include, without limitation, a square, a rectangle, a triangle, a trapezoid, a star, and a rhombus.

[0047] In some embodiments, cutting portion 102 may include a base edge 104 and a teeth edge 106. Teeth edge 106 may include a plurality of teeth 108a, 108b, 108c that are arranged in repeating segments to perform the cutting action on the workpiece. Base edge 104 is disposed opposite teeth edge 106. In one embodiment, a sidewall extends from base edge 104 to teeth edge 106. Suitable materials for cutting portion 102 may include, without limitation, steel, tungsten alloy, carbon metal, iron, and metal alloys. The cutting portion 102 may also be treated with an abrasive or corrosion resistant coatings or impregnation.

[0048] Looking now at FIG. 2, device 100 further comprises a bridge portion 118 that traverses the base edge 104 of the cutting portion 102. Bridge portion 118 is generally broad, which enhances the structural integrity of cutting portion 102 and helps minimize vibratory effects from the power tool while cutting the workpiece.

[0049] In one alternative embodiment, bridge portion 118 may be configured to be partially or fully enclosed with or without the perforation of base edge 104. While fully enclosed, bridge portion 118 may include a vacuum port that receives a vacuum assembly to suck excessive dust and debris from the cutting operation. The vacuum assembly provides a means of sterile, central dust free cutting operation. Further, the vacuum port may be designed with or without a counterweight fixed on the opposing side of cutting portion 102.

[0050] As illustrated in FIG. 3, device 100 may further comprise a mounting portion 110 that is adaptable to detachably couple to different styles of power tools. Mounting portion 110 may include a tab 112 that extends perpendicularly from the base edge 104 of the cutting portion 102. Tab 112 terminates at a tapered terminus 120. Tab 112 is defined by a gap 114 having a gap perimeter 122. Gap perimeter is defined by a plurality of slots 116a, 116b, 116c and a plurality of apertures 124a, 124b, 124c, 124d, 124e, 124f that help interlock mounting portion 110 with a power tool. Tab 112 may also form a tapered terminus that couples directly into a power tool.

[0051] In one embodiment, the power tool includes a coupling mechanism, such as a drill chuck that enables the power tool to detachably couple to device 100 through gap 114. The slots 116a, 116b, 116c in the perimeter of gap 114 are configured to align and misalign with a plurality of protrusions from the coupling mechanism of the power tool. In one embodiments, the lengths of slots 116a-c are different. This coupling means enables rotatable locking and detachment of device 100 from the power tool.

[0052] In operation, device 100 is used to cut a non-circular section out of a work piece. Device 100 is used with a power tool, such as a drill, to cut circular holes in a work surface. Those skilled in the art will recognize that these types of holes are commonly used by electricians to cut holes through a hard metallic work surface on an electrical panel. The workpiece may include, without limitation, drywall, electric panels, wood, metal studs, foam, paper, polymer, masonry, ceramics, clay, and organic substrates.

[0053] As referenced in FIG. 1, the hole saw device 100 is an “open hole” style saw blade that cuts gaps in various workpieces and substrates. Those skilled in the art will recognize that a hole saw is often used in the construction industry for drilling holes that have a diameter of larger than 9/16″. Most commonly, hole saws are utilized for providing holes in drywall, electric panels, wood, and metal studs. The holes for such endeavors must be drilled accurately and quickly. This enables the workpiece to be smooth around the area of the drilled hole.

[0054] As FIG. 2 shows, device 100 comprises a cutting portion 102 that may be configured into at least one non-circular shape. Cutting portion 102 may include a base edge 104 and a teeth edge 106. Teeth edge 106 may include a plurality of teeth 108a, 108b that are arranged in repeating segments to perform the cutting action on the workpiece. Though in other embodiments, any serrated configuration for teeth 108a, 108b may be used. In one embodiment, cutting portion 102 is welded metal. In another embodiment, cutting portion 102 comprises abrasive or corrosion resistant coatings or impregnation.

[0055] The unique non-circular shape of cutting portion 102 allows for eclectic operational uses of device 100. In some embodiments, the cutting portion 102 is scalable, so as to cut non-circular holes ranging in size from ⅝″ to 6″ in diameter, but is mostly utilized for drilling holes larger than 1″ diameter.

[0056] In one exemplary non-circular shape of cutting portion 102, a generally square perimeter shape of cutting portion 102 forms a square electrical gap, such as used for residential light switches. In another example, a generally rectangular perimeter shape may form a kerf for a circuit box that is set behind a wall. In yet another example, a star perimeter shape may be used to cut a depression in a tooth for setting gold fillings. In any case, the cutting is generally smooth, with minimal vibratory effects from the power tool.

[0057] Cutting portion 102 is configured to follow a lateral, oscillating cutting motion while cutting a kerf in a workpiece. Because device 100 couples to the power tool at an axial orientation, the axial disposition of device 100 relative to the power tool enables the axial vibratory force generated by the power tool to convert to a lateral, oscillating cutting motion followed by cutting portion 102. This lateral, oscillating cutting motion provides numerous advantageous for operation on the workpiece, and especially forming a kerf in the workpiece. The lateral, oscillating cutting motion forms a clean non-circular kerf, offsets vibrations from the cutting, and minimizes debris that is formed during cutting.

[0058] Looking back at FIG. 1, device 100 comprises a bridge portion 118 that traverses the base edge 104 of the cutting portion 102. Bridge portion 118 is defined by a pair of short ends 126a, 126b and a pair of long sides 128a, 128b. Bridge portion 118 is generally broad from side 128a to side 128b.

[0059] For example, as bridge portion 118 traverses the gap formed across the base edge 104 of cutting portion 102, about 20% of the gap may be covered. The general broadness of bridge portion 118 enhances structural integrity of cutting portion 102 and helps minimize vibratory from the power tool effects while cutting the workpiece. In one embodiment, bridge portion 118 is welded metal. In another embodiment, bridge portion 118 comprises abrasive or corrosion resistant coatings or impregnation.

[0060] As illustrated in FIG. 3, device 100 may further comprise a mounting portion 110 that is adaptable to detachably couple to different styles of power tools. Mounting portion 110 may include a tab 112 that extends perpendicularly from the base edge 104 of the cutting portion 102. Tab 112 is generally flat and rigid, so as to from a stable connection with the coupling mechanism of the power tool. In one embodiment, tab 112 is defined by a gap 114 having perimeter that is defined by a plurality of slots 116a, 116b, 116c. Tab 112 may form a plurality of apertures disposed around the gap perimeter. Tab 112 extends up from bridge portion, up to a terminus 120.

[0061] In one exemplary mounting adaptation, a power tool (not shown) mounts to device for non-circular sawing of a hole. The power tool includes a coupling mechanism, such as a drill chuck, that enables the power tool to detachably couple to the gap 114 in tab 112. The slots 116a, 116b, 116c in the perimeter of gap 114 are configured to align and misalign with a plurality of protrusions from the coupling mechanism of the power tool. This coupling means enables rotatable locking and detachment of device 100 from the power tool. In one embodiment, mounting portion 110 is welded metal. In another embodiment, mounting portion 110 comprises abrasive or corrosion resistant coatings or impregnation.

[0062] FIG. 4 illustrates a flowchart of an exemplary method 200 for operation of a non-circular hole saw device. Method 200 may include an initial Step 202 of providing a non-circular hole saw device, the hole saw device comprising a cutting portion, a bridge portion, and a mounting portion. Method 200 may further comprise a Step 204 of coupling the mounting portion to the power tool, such that the device is axially disposed to the power tool, whereby the axial disposition of device relative to the power tool enables the axial vibratory force generated by the power tool to convert to a lateral, oscillating cutting motion followed by cutting portion.

[0063] In some embodiments, a Step 206 includes aligning the cutting portion with a predetermined area of a work piece. A Step 208 comprises actuating the power tool. A Step 210 includes following the lateral, oscillating cutting motion while cutting a kerf in the workpiece, whereby the lateral, oscillating cutting motion forms a clean non-circular kerf, offsets vibrations from the cutting, and minimizes debris that is formed during cutting. A final Step 212 includes cleaning the surface of the kerf in the workpiece.

[0064] Since many modifications, variations, and changes in detail can be made to the described preferred embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalence.