Abstract:
A tool element for cutting a workpiece includes a shank adapted for connecting the tool element to a power tool, and a first cutting portion fixedly coupled to the shank and including a first cutting edge having a first diameter and a second cutting edge having a second diameter. A second cutting portion is removably coupled to the first cutting portion. The second cutting portion includes a third cutting edge having a third diameter and a fourth cutting edge having a fourth diameter. The second diameter is smaller than the first diameter, the third diameter is smaller than the second diameter, and the fourth diameter is smaller than the third diameter.

Description:
RELATED APPLICATIONS 
       [0001]    The present application is a continuation of U.S. patent application Ser. No. 13/026,499, filed Feb. 14, 2011, now U.S. Pat. No. 8,109,700 which is a continuation of U.S. patent application Ser. No. 11/539,379, filed Oct. 6, 2006, now U.S. Pat. No. 7,909,547 which claimed the benefit of U.S. Provisional Patent Application No. 60/724,400, filed Oct. 8, 2005, the entire contents of which are hereby incorporated by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention generally relates to tool elements and, more particularly, to bits, auger bits, concrete bits, etc. 
       BACKGROUND 
       [0003]    With a bit, such as, for example, an auger bit, the tip portion cuts the work piece, and the remainder of the bit generally removes material cut from the work piece. The cutting tip portion may wear, requiring some action by the user (e.g., sharpening of the cutting portion(s), replacement of the entire bit, etc.). 
         [0004]    A user will typically select a tool element, such as, for example, a bit, an auger bit, a concrete bit, etc., based on one or more of price (in many cases), durability (e.g., against nail impacts), ability to re-sharpen numerous times (e.g., quick on-site repair or via sharpening service, etc.), etc. On a job site, many users have a container(s) filled with dulled or damaged bits, auger bits, etc., which may be held until a cost effective re-sharpening service is found. Many of these bits may be damaged beyond repair (bent shafts, broken feed screws, damaged cutting edge, etc.). However, users do not typically view these products as disposable. For example, due to the expense of an auger bit, a user will make a significant effort to repair the bit. 
       SUMMARY 
       [0005]    In some independent aspects and in some constructions, a tool element, such as, for example, a bit, an auger bit, a concrete bit, etc., may generally include a body and a cutting portion removably and/or replaceably connected to the body. 
         [0006]    In some independent aspects and in some constructions, a tool element for cutting a workpiece is provided and includes a body including a shank for connecting the tool element to a power tool and a cutting element removably connectable to the body. 
         [0007]    In some independent aspects and in some constructions, a tool element, such as, for example, a bit, an auger bit, a concrete bit, etc., may generally include a body and a cutting tip portion connected to the body, the body being formed of a first material and/or first process, the cutting tip portion being formed of a second material and/or second process different than the first material and/or first process. 
         [0008]    In some independent aspects and in some contructions, a tool element for cutting a workpiece is provided and includes a body including a shank for connecting the tool element to a power tool, the body being made of a first material, and a cutting element removably connectable to the body, the cutting element being made of a second material different than the first material. 
         [0009]    In some independent aspects and in some constructions, a tool element assembly, such as, for example, a bit, an auger bit, a concrete bit, etc., may generally include a body, a first cutting portion removably connectable to the body, and a second cutting portion removably connectable to the body, the first cutting portion and the second cutting portion being different. 
         [0010]    In some independent aspects and in some constructions, a tool element for cutting a workpiece is provided and includes a body including a shank for connecting the tool element to a power tool, a first cutting element removably connected to the body, and a second cutting element separate from the first cutting element and being removably connected to the body. 
         [0011]    In one construction, the invention provides a tool element for cutting a workpiece. The tool element includes a shank adapted for connecting the tool element to a power tool, and a first cutting portion fixedly coupled to the shank and including a first cutting edge having a first diameter and a second cutting edge having a second diameter. A second cutting portion is removably coupled to the first cutting portion. The second cutting portion includes a third cutting edge having a third diameter and a fourth cutting edge having a fourth diameter. The second diameter is smaller than the first diameter, the third diameter is smaller than the second diameter, and the fourth diameter is smaller than the third diameter. 
         [0012]    In another construction, the invention provides a tool element for cutting a workpiece. The tool element includes a first cutting portion including a first cutting edge having a first diameter, a second cutting edge having a second diameter, a shank extending from a first end of the first cutting portion to define a central axis, and an aperture formed along the central axis adjacent a second end of the first cutting portion. A second cutting portion includes a third cutting edge having a third diameter, a fourth cutting edge having a fourth diameter, and a shaft extending from the second cutting portion along the central axis. A locking mechanism is formed as part of the aperture and the shaft to selectively couple the first cutting portion to the second cutting portion while inhibiting rotation and axial movement of the first cutting portion with respect to the second cutting portion along the central axis. The first diameter, the second diameter, the third diameter, and the fourth diameter are not equal to one another. 
         [0013]    In another construction, the invention provides a tool element for cutting a workpiece. The tool element includes a first cutting portion including a first cutting edge having a first diameter, a second cutting edge having a second diameter, a shank extending from a first end of the first cutting portion to define a central axis, and a polygonal aperture formed along the central axis adjacent a second end of the first cutting portion, the first cutting edge and the second cutting edge being substantially parallel to the central axis. A second cutting portion includes a third cutting edge having a third diameter, a fourth cutting edge having a fourth diameter, and a polygonal shaft extending from the second cutting portion along the central axis, the third cutting edge, and the fourth cutting edge being substantially parallel to the central axis. A ball detent mechanism is formed as part of the aperture and the shaft to selectively couple the first cutting portion to the second cutting portion while inhibiting rotation and axial movement of the first cutting portion with respect to the second cutting portion along the central axis. The second diameter is smaller than the first diameter, the third diameter is smaller than the second diameter, and the fourth diameter is smaller than the third diameter. 
         [0014]    Independent features and independent advantages of the present invention will become apparent to those skilled in the art upon review of the detailed description and drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]      FIGS. 1-4  are perspective views of a tool element, such as, for example, an auger bit. 
           [0016]      FIGS. 5-8  are perspective views of another construction of a tool element, such as, for example, an auger bit. 
           [0017]      FIG. 9  is a cross-sectional view of a portion of the tool element shown in  FIGS. 5-8 , taken along line  9 - 9 . 
           [0018]      FIGS. 10-12  are alternative constructions of the cross-sectional view of a portion of the tool element shown in  FIGS. 5-8 . 
           [0019]      FIG. 13  is a perspective view of yet another construction of a tool element, such as, for example, an auger bit. 
           [0020]      FIGS. 14-17  are perspective views of a further construction of a tool element, such as, for example, an auger bit. 
           [0021]      FIGS. 18-20  are perspective views of another construction of a tool element, such as, for example, an auger bit. 
       
    
    
       [0022]    Before any independent features and 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 the construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. 
         [0023]    Although references are made below to directions, such as left, right, up, down, top, bottom, front, rear, forward, back, etc., in describing the drawings, the references are made relative to the drawings (as normally viewed) for convenience. These directions are not intended to be taken literally or to limit the present invention in any form. 
         [0024]    The use of “including”, “having”, and “comprising” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The use of letters to identify elements of a method or process is simply for identification and is not meant to indicate that the elements should be performed in a particular order. 
       DETAILED DESCRIPTION 
       [0025]    Constructions of a tool element  20 , such as, for example, a bit, an auger bit, a Selfeed bit, a boring bit, a Bellhanger bit, an electrician&#39;s bit, a cable bit, a Forstner bit, a concrete bit, a hammer bit, a core bit, a large hole system bit, etc., are illustrated in the figures. Independent aspects of the illustrated bits may be incorporated in other tool elements, such as, for example, hole saws, hole saw arbors, pilot drills, saw blades, grinding wheels, chisels, etc. 
         [0026]    With reference to  FIGS. 1-4 , the bit  20  generally includes a body  24 , a shank  28  for connecting the bit  20  to a power tool, and a cutting element or portion  32  removably and/or replaceably connected to the body  24 . In the illustrated construction, the cutting portion  32  and the body  24  twist together to connect to one another. In this manner, the body  24  and the cutting portion  32  have complementary surfaces that allow the body  24  and the cutting portion  32  to be twisted and secured together. The connection between the body  24  and the cutting portion  32  is sufficient to withstand normal operating conditions of the bit  20 , but facilitates removability of the cutting portion  32  from the body  24  when a user desires such removal. In some independent aspects and in illustrated constructions, the body  24  may be formed of a first material and/or first process and the cutting portion  32  may be formed of a second material and/or second process different than the first material and/or first process. In some independent aspects and in illustrated constructions, the bit  20  also includes a second cutting portion or feed screw  36  removably connectable to the body  24  and the first cutting portion  32 . In the illustrated construction, the feed screw  36  is threaded into an opening  39  defined in the cutting portion  32 . In some constructions, the feed screw  36  can assist in removably and/or replaceably connecting the first cutting portion  32  to the body  24  by passing completely through the cutting portion  32  and threading to the body  24  to compress the cutting portion  32  between the feed screw  36  and the body  24 , thereby securing the cutting portion  32  to the body  24 . The feed screw  36  and the first cutting portion  32  are formed separately from one another and may be formed of the same material or may be formed of a different material. 
         [0027]    Because the first and second cutting portions  32 ,  36  cut the work piece, they may wear over time. Accordingly, one or both of the first and second cutting portions  32 ,  36  may be removed from the body  24  and replaced with a new or sharpened first and/or second cutting portions  32 ,  36 . After replacement of the first and/or second cutting portions  32 ,  36 , a user may continue using the bit  20  after only a relatively short interruption. 
         [0028]    In some independent aspects and in some constructions, either or both the first and second cutting portions  32 ,  36  may be formed of a relatively harder material (but more expensive material) to resist wear, and the remainder of the bit  20  may be formed from less hard material (and less expensive material) to reduce the overall cost of the bit  20 . 
         [0029]    Also, in some constructions, the body  24  of the bit  20  may be cable of receiving different types of cutting portions constructed to cut different types of materials or combination of materials (wood, wood with embedded nails, concrete, etc.). The different cutting portions may be substitutably connectable to the body  24  of the bit  20  to provide optimized cutting of a selected work piece of a specific material, combination of materials, etc. 
         [0030]    With reference to  FIGS. 5-8 , an alternative construction of a bit  20 A is illustrated. Like elements are identified with like reference numbers “A”. The bit  20 A is similar to the multiple part bit system shown in  FIGS. 1-4 , but the body  24 A and the cutting portion  32 A of the bit  20 A slide together to form a complete bit. The bit  20 A includes the body  24 A, the first cutting portion  32 A, and the second cutting portion  36 A. The parts of the bit  20 A include complementary structure to limit, impede, inhibit, resist and/or prevent relative rotation of the parts. 
         [0031]    With further reference to  FIGS. 5-8  and additional reference to  FIG. 9 , a hex-shaped projection  40  is formed on the body  24 A and a complementary hex-shaped recess  44  is formed in the cutting portion  32 A. Alternatively, the hex-shaped projection may be formed on the cutting portion  32 A and the hex-shaped recess may be formed in the body  24 A. Inter-engagement of the hex-shaped structures  40 ,  44  limits, impedes, resists, inhibits and/or prevents relative rotation of the parts. 
         [0032]    With reference to  FIGS. 10-12 , other complementary structures, such as, for example, square, triangle, non-circular, eccentric, partially flat, etc., may be provided to limit, impede, resist, inhibit and/or prevent relative rotation of the parts. In other constructions, other complementary structure formed on other portions of the bit (e.g., the bit threads, etc.) may be provided to limit, impede, resist, inhibit and/or prevent relative rotation of the parts. 
         [0033]    Referring back to  FIGS. 5-8 , the body  24 A and cutting portion  32 A are screwed together with the removable and/or replaceable feed screw  36 A. The feed screw  36 A includes a threaded rear portion  38 A which is inserted through the opening  39 A in the cutting portion  32 A and threadedly engageable in a threaded recess  26 A in the body  24 . 
         [0034]      FIG. 13  illustrates another construction of a multiple part bit system. Like elements are identified with like reference numbers “B”. In this construction, the body  24 B has external threads  48  defined in an outer surface thereof and the cutting portion  32 B has internal threads  52  defined therein complimentary to the external threads  48  on the body  24 B. The cutting portion  32 B threads onto and off of the body  24 B to facilitate removal and replacement of the cutting portion  32 B. The body  24 B may include a stop  56  engageable by the cutting portion  32 B when the cutting portion  32 B is completely threaded onto the body  24 B. The stop  56  inhibits the cutting portion  32 B from rotating relative to the body  24 B during operation of the bit  20 B. In some constructions, the cutting portion  32 B includes two parts  32 B′,  32 B″ and the body  24 B has two sets of external threads, course threads  48 ′ and fine threads  48 ″. In such constructions, the first cutting portion  32 B′ is threaded onto the body  24 B first and the second cutting portion  32 B″ is threaded onto the body  24 B second until it mates with the first cutting portion  32 B′. The second cutting portion  32 B″ is threaded onto the fine threads  48 ″, which facilitates finer adjustment of the second cutting portion  32 B″ relative to the first cutting portion  32 B′ to ensure proper mating of the two cutting portions  32 B′,  32 B″. 
         [0035]    With reference to  FIGS. 14-17 , another alternative construction of a multiple part bit system is illustrated. Like elements are identified with like reference numbers “C”. In this construction, the cutting portion  32 C is relatively small. Such a cutting portion  32 C may be made of a relatively higher grade material. The end  60  of the body  24 C adjacent the cutting portion  32 C has a sharp edge or projection  64  and the cutting portion  32 C includes a recess  68  defined in a surface thereof. To connect the cutting portion  32 C to the body  24 C, the edge or projection  64  is positioned in the recess  68 , the feed screw  36 C is inserted through the opening  39 C in the cutting portion  32 C, threaded into the threaded recess  26 C in the body  24 C, and tightened to compress the cutting portion  32 C between the body  24 C and the feed screw  36 C. The engagement between the edge or projection  64  and the recess limits, impedes, resists, inhibits and/or prevents relative rotation of the body  24 C and the cutting portion  32 C. 
         [0036]    In some constructions, a bit may include a replaceable cutting edge and/or feed screw. Such a construction is not limited to just the physical cutting edge or screw but may include a replaceable end. With reference to  FIGS. 18-20 , another alternative construction of a multiple part bit system is illustrated. Like elements are identified with like reference numbers “D”. One option may be a step like bit cutting portions  32 D. In such a construction, the cutting portions  32 D may be defined as the first 1″ to 3″ of the actual cutting end of the bit  20 D, and this end could be interchangeable with 4″, 6″ and 18″ long cutting portions. The bit  20 D includes a spur  72  that provides a very clean, smooth edged hole. Spurs  72  are sometimes susceptible to damage. In some constructions, the bit  20 D may be useable with a removable and/or replaceable spur. Such a spur may eliminate the need to manufacture, sell and/or purchase both styles (an auger bit with a spur and an auger bit without a spur) and may be sold separately to those users needing a clean hole. The bit  20 D may also include a carbide tip replaceable cutting edge and/or feed screw. Each of the cutting portions  32 D include and opening  76  initiating at an end thereof and extending through a side of the cutting portions  32 D. The opening  76  allows cut debris to be transferred from the cutting position, out the side of the cutting portions  32 D, and away from the cutting position. The cutting portions  32 D can be connected to each other in a variety of manners including threading, snap-fit, tongue and groove, ball-detent, etc. 
         [0037]    It should be understood that each bit construction disclosed herein is capable of having features shown and described in other bit constructions. Also, the bit constructions are capable of having other features. For example, in some constructions, the bit may have a flute design which, rather than having a flat surface, may provide a “twist bit like” flute. Such a bit may provide a smaller surface area in contact with work piece (e.g., wood), resulting in less drag on the work piece. Also for example, in some constructions, the bit may have an improved cutting edge and may have improved re-sharpenability of the cutting edge. The tip portion may be removable for re-sharpening and, during re-sharpening, may be replaced with a tip portion having a sharpened edge. If off-site re-sharpening is required, only the worn tip portions need to be taken for re-sharpening. Further for example, in some constructions, the bit may be provided with a feed screw which may be relatively larger and/or taller. In any case, in independent aspects, the bit may be a better value product due, in part, to one or more of the convenience of a replaceable tip, the flexibility to switch to carbide tip, an overall lower cost, etc. 
         [0038]    Typical users of these tool elements include electricians, plumbers, mechanical contractors, general contractors, metal fabricators, HVAC/sheet metal, MRO, utilities, municipalities, remodelers, service trades, manufacturing/assembly, stick builders, drywallers, cable installers, pest control, automotive aftermarket, woodworkers, DIYers and others. The tool elements may be distributed through electrical, contractor/tool specialty, industrial, plumbing/heating, welding, hardware, rental, home center, catalog, or other channels. 
         [0039]    In many industries, these tool elements have a high usage, in remote locations, at all times (of the day, week, year) and in all weather conditions. In other industries and/or with other users, usage of the tool elements may be lower and cost may be a more important factor. 
         [0040]    In the utility industries, users are typically drilling through holes in wood power poles and may prefer a spur bit which leaves clean hole for through bolts. An electrician is typically using a tool element to run wire, conduit, Romex, etc., through wood, and a plumber typically uses a tool element to run copper, PVC, ABS pipe, etc., through wood. 
         [0041]    With municipalities, these tool elements are used for a wide variety tasks, such as, for example, mass transit, subway track repair, road and/or barrier repairs and installation, street sign installation, etc. Remodelers and landscape maintenance workers may use the tool elements for miscellaneous plumbing and/or electrical installations and repairs such as pre-drilling holes to fasten retaining wall timbers together, etc. 
         [0042]    With cable installers, small diameter auger bits are typically used for cable and phone lines. Cost may be extremely important because these users are often subcontractors, are paid by the job, and can be required to provide their own tools. Do-it-yourselfers (DIYers) typically consider overall cost and/or cost of replacement as important factors. 
         [0043]    In any case, the tool elements or bits may dull after extended use, the tooth and/or feed screw may damage (e.g., when impacting imbedded objects), and/or the spur, if provided, may dull quickly or be easily damaged. However, in each case, the shaft and auger are not normally damaged during use. Labor costs may be extreme if the tool element fails (inconvenient and expensive to replace the bit, inconvenient to send the bit for re-sharpening, etc.). In independent aspects, the illustrated constructions may provide a tool element with a convenient, easy and/or cost effective way to sharpen the tip portion (by replacement), replace cutting edge/feed screw, etc. 
         [0044]    One or more portions of the tool element, the manufacture of the tool element and the operation of the tool element may be similar to that shown and described in U.S. Pat. No. 6,874,978, issued Apr. 5, 2005; the entire contents of which is hereby incorporated by reference. 
         [0045]    The embodiments described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present invention.