Patent Publication Number: US-7594455-B2

Title: Fastener removing tool

Description:
FIELD 
   The present disclosure relates to tools which are utilized in removing broken fasteners and repairing resultant holes. 
   BACKGROUND 
   Tools for removing broken fasteners are well known. For example, fastener extractors which extend over a fastener to be removed are disclosed in U.S. Pat. No. 6,598,498 to Pigford et al. and U.S. Pat. No. 6,877,402 to Pigford et al. In another example, a fastener extractor which extends into a hole drilled into a faster to be removed is disclosed in U.S. Pat. No. 7,152,509 to McCalley, Jr. et al. Each of these patents is incorporated herein by reference in its entirety. 
   SUMMARY 
   The present disclosure provides an improved fastener removing tool. The fastener removing tool includes an extractor portion, a main body, and a cutter portion. 
   The extractor portion has a generally annular shape with an axis defined therethrough. The extractor portion defines an inside surface adapted to grip and remove a fastener. The extractor portion further defines an outside surface having a cutting edge extending outwardly therefrom. The cutting edge is adapted to cut a bore when the tool grips and removes a fastener. 
   The main body is fixed relative to the extractor portion. The main body extends away from the extractor portion along the axis and defines an outer coupling surface about the axis. The outer coupling surface is adapted to engage with a driving tool for powering rotation of the fastener removing tool. 
   The cutter portion is fixed relative to the main body opposite the extractor portion. The cutter portion includes an annular base directly coupled to main body and oriented about the axis. The cutter portion further includes a plurality of cutting members extending axially away from the base. The cutting members define a plug forming space therebetween. 
   The present disclosure also provides a method of repairing a component having a broken fastener disposed therein. The method includes positioning an extractor end of a fastener removing tool over a broken fastener disposed in an hole of a component. The method further includes gripping and removing the broken fastener from the component while simultaneously cutting a counterbore in the component around the broken fastener. The method also includes cutting a plug with a cutter end of the fastener removing tool. The plug is substantially similar in size to the previously created counterbore. Additionally, the method includes inserting the plug into the hole of the component. 

   
     DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of an exemplary fastener removing tool according to the principles of the present disclosure; 
       FIG. 2  is a end view of the fastener removing tool of  FIG. 1 ; 
       FIG. 3  is another perspective view of the fastener removing tool of  FIG. 1 ; 
       FIG. 4  is another end view of the fastener removing tool of  FIG. 1 ; 
       FIG. 5  is a side view of the fastener removing tool of  FIG. 1 ; 
       FIG. 6  is a cross-sectional side view of the fastener removing tool of  FIG. 1  along the line  6 - 6  illustrated in  FIG. 5 ; and 
       FIG. 7  is another side view of the fastener removing tool of  FIG. 1 . 
   

   DETAILED DESCRIPTION 
   Referring to  FIGS. 1-7 , an exemplary fastener removing tool  20  is illustrated in detail. Fastener removing tool  20  extends between a first or extractor end  24  and a second or cutter end  26 . Fastener removing tool  20  further includes a main body  28  disposed between extractor and cutter ends  24 ,  26 . According to the principles of the present disclosure, extractor end  24 , cutter end  26 , and main body  28  are integrally formed. Additionally, fastener removing tool  20  is oriented along an axis A. As used herein, the terms “axial” or “axially” refer to a direction extending along axis A, and the terms “radial” or “radially” refer to directions perpendicular to axis A. 
   Fastener removing tool  20  is configured such that a driving tool or mechanism, such as a drill or drill press, (not shown) can engage main body  28  to power rotation of fastener removing tool  20  and, therefore, utilize one of extractor end  24  and cutter end  26 . In particular, both extractor end  24  and cutter end  26  are operated by rotation about axis A. In operation, extractor end  24  is configured to grip and remove a fastener disposed in a component, such as a piece of wood, and contemporaneously form a counterbore in the component around the fastener. Cutter end  26  is separately operated to cut a plug sized to fit into the counterbore formed while removing a fastener. 
   Referring in particular to  FIGS. 1-2 , extractor end  24  is illustrated in detail. Extractor end  24  has a generally cylindrical shape oriented about axis A. Extractor end extends between a first end  38  disposed opposite main body  28  and a second end  40  proximate main body  28 . Furthermore, extractor end  24  defines an inside surface  42  and an outside surface  44 . 
   With additional reference to  FIG. 6 , inside surface  42  is configured to grip a fastener for removal. Inside surface  42  defines a generally cylindrical aperture through extractor end  24  and about axis A. Furthermore, a plurality of gripping features  50  extending from inside surface  42 . As is well known in the art, gripping features  50  are oriented so as to secure a fastener relative to tool  20  as tool  20  rotates in a loosening direction for the fastener. For example, if the fastener has right-hand thread, tool  20  is configured to grip and secure the fastener while rotating in the counterclockwise direction. 
   Referring also to  FIG. 7 , outside surface  44  also defines a generally cylindrical shape about axis A. Outside surface  44  includes a main section  70  disposed proximate main body  28  and a sloped section  72  extending between first end  38  and main section  70 . Sloped section  72  is oriented so as to extend radially outwardly from first end  38  to main section  70 . Outer surface  44  further includes a boring edge  74  extending radially outwardly from sloped section  72 . Boring edge  74  is configured to face the loosening direction for the fastener configured to be removed by tool  20 . Accordingly, when fastener removing tool  20  rotates in the loosening direction, boring edge  74  operates to form a counterbore in the component in which the fastener is disposed. 
   Referring in particular to  FIG. 3-4 , cutter end  26  is illustrated in detail. Cutter end  26  includes an annular base  100  proximate main body  28 . Base  100  defines a generally cylindrical aperture  102  ( FIG. 6 ) oriented about axis A. Additionally, base  100  has a substantially similar size to main section  70  of outer surface  44  of extractor end  24 . 
   Cutter end  26  further includes a plurality of cutting members  110  extending axially from base  100 . In particular, exemplary tool  20  includes four cutting members  110 . Cutting members  110  are all shaped to be substantially similar or the same. Furthermore, cutting members  110  are each curved around axis A in a right-hand direction, and each of cutting members  110  define a cutting edge  112 . 
   Cutting members  110  are spaced apart about axis A. Moreover, a plug space  114  is defined between cutting members  110 . Plug space  114  determines the size of the plug created through operation of cutter end  26 . According to the principles of the present disclosure, cutter end  26  is configured such that plug space  114  corresponds with the size of the counterbore to be created through use of extractor end  24 . 
   Referring again to  FIGS. 1-7 , main body  28  defines an outer surface  130  having a plurality of adjacent, relatively flat coupling sections  132 . In particular, exemplary fastener removing tool  20  includes outer surface  130  having a hexagonal cross section and, thus, six coupling portions  132 . Outer surface  130  is configured for fastener removing tool  20  to engage with another tool, such as a driver, to power rotation of tool  20 . Exemplary fastener removing tool  20  includes outer surface  130  extending radially outside of extractor end  24  and cutter end  26 . Accordingly, another tool, such as a driver, can extend over one of extractor end  24  and cutter end  26  to utilize the other of extractor end  24  and cutter end  26 . 
   With particular reference to  FIG. 6 , main body  28  includes a generally cylindrical aperture  140  extending therethrough and about axis A. Aperture  140  is generally smaller in size to both inside surface  42  of extractor end  24  and aperture  102  of cutter end  26 . With inside surface  42  of extractor end  24  being larger than aperture  140 , and with outer surface  130  extending radially outside of extractor end  24 , main body  28  defines an inner ledge  142  and an outer ledge  144  proximate extractor end  24 . Similarly, with aperture  102  of cutter end  26  being larger than aperture  140 , and with outer surface  130  extending radially outside of extractor end  24 , main body defines an inner ledge  146  and an outer ledge  148  proximate cutter end  26 . 
   The present disclosure can vary in many ways. The components of a fastener removing tool according to the principles of the present disclosure can vary in relative size and orientation. Furthermore, the various components can vary in configuration without causing the tool to depart from the principles described above. Accordingly, it is to be understood that the present disclosure is merely exemplary in nature.