Tools for the removal of helically coiled wire inserts are well known.

Generally, these tools have a tapered blade with a pair of knife edges that are driven into the inner diameter threads of the insert. Such as tool is described in U. S. Patent No. 6,171,040. When using these tools to extract an insert, however, the insert and the parent material surrounding it is often permanently damaged.

Another type of removal tool for helically coiled wire inserts is described in U. S. Patent No. 4,553,303 and includes a mandrel having a threaded lead portion and a pivotable pawl inserted in a groove below the threaded portion so that the pawl can engage a notch in the trailing end of the insert in order to extract the insert from the tapped hole. This pivotable pawl automatically engages the insert when the mandrel is pulled back, allowing the mandrel to extract the insert. Although this known extraction tool does not damage the parent material of the insert, it is a relatively complicated design and suffers from increased risks of malfunction. Further, because each insert requires a tool of complimentary size, a set of tools taught by the aforementioned patent is relatively expensive.

An improved extraction and adjustment tool for helically coiled wire inserts is described in co-pending U. S. Patent Application Serial No.

09/596,035, which is incorporated herein by reference. While the extraction and adjustment tool described therein is believed to be a significant advancement over the prior art, it is particularly suited for use with inserts already having a notched coil end.

SUMMARY OF THE INVENTION An extraction tool for helically coiled wire inserts includes a mandrel with a threadless lead portion having a stationary tooth for forming a notch in a trailing end of the insert. Upon formation of the notch, the extraction tool can thereafter be utilized for extracting the insert from a tapped hole. The extraction tool may include a handle portion having a bushing for selective reception of a mandrel adapted to fit a particular-size helically coiled wire insert or may be used in association with a power tool to effectuate removal of the insert. Once the extraction tool is inserted into the internal diameter of the insert and a notch is formed, the stationary tooth engages the notch in the trailing end of the insert to extract the wire insert.

DESCRIPTION OF THE DRAWINGS Figure 1 is a front view of a notch-forming extraction tool for helical inserts according to the invention; Figure 2 is a partial sectional view of the notch-forming extraction tool of Figure 1; Figure 3 is a partial side view of a lead end of the notch-forming extraction tool of Figure 1; Figure 4 is a partial top view of the lead end of the notch-forming extraction and adjustment tool of Figure 1; Figure 5a is an end view of the lead end of the notch-forming extraction tool of Figure 1; Figure 5b is an end view of an alternative embodiment of the lead end of the notch-forming extraction tool according to the invention; Figure 6 is a partial sectional view of the lead end of the notch-forming extraction tool as shown in Figures 1-4,5a and 5b prior to forming a notch in a helically coiled wire insert installed in a bore of a parent material ; Figure 7 is a partial sectional view of the lead end of the notch-forming extraction tool as shown in Figure 6 forming a notch in a helically coiled wire insert in a bore of a parent material ;

Figure 8a is a partially sectioned top view of the lead end of the notch- forming extraction tool as shown in Figure 7 engaging the inner diameter of the helically coiled wire insert; Figure 8b is a partially sectioned top view of the lead end of the notch- forming extraction tool as shown in Figure 5b engaging the inner diameter of the helically coiled wire insert; Figure 9 is a partial sectional view of the lead end of the notch-forming extraction tool as shown in Figure 1 removing a helically coiled wire insert from the bore of a parent material; Figure 10 is a perspective view of a series of notch-forming extraction tools having alternatively sized lead ends; Figure 11 is a side view of a screw-lock type insert for use with the notch-forming extraction tool of Figure 1; Figure 12 is a sectional view of the screw-lock type insert along line 12- 12 of Figure 11; and Figure 13 is a partial sectional view of the lead end of the notch- forming extraction tool as shown in Figures 1-4,5a and 5b engaging the inner diameter of the screw-lock type insert of Figures 11-12 in a bore of a parent material.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT With reference to the drawings, and to Figures 1 and 2 in particular, an extraction tool 10 for use in association with helically coiled wire inserts is shown. Helical inserts are used, for example, where a steel fastener having conventional threads is desired to be fastened into a material of relatively softer alloy, such as aluminum. The helical inserts may be of either the tang, tangles or screw-lock type. Extraction tool 10 of the present invention may include a manually driven handle 22 at one end and a coupler 24 at an opposite end. Coupler 24 selectively receives a mandrel 30 of the extraction tool 10 and supports mandrel 30 in removing a helical insert 14 in tapped hole 16 of a parent material 18, as illustrated in Figures 6,7,9 and 13.

Alternatively, the extraction tool 10 may be a bit or mandrel that is power driven by a motor, such as with a power drill or screw driver (not shown).

As shown in Figure 2, the mandrel 30 includes a first end 32 for insertion into coupler 24, which selectively compresses a bushing 28 on first end 32. Coupler 24 includes a nut portion 50 having an internal screw thread for tightening on an external screw thread cut in end portion 26 of handle 22.

When fully tightened on end portion 26, nut portion 50 of coupler 24 compresses bushing 28 against first end 32 of mandrel 30, thereby securing mandrel 30 to handle 22. Preferably, the diameter of mandrel 30 pilots on the inner diameter of tapped hole 16.

As best illustrated with reference to Figures 3 and 4, at an end opposite the first end 32, the mandrel 30 includes a second end 34, which has a leading portion 38 having a larger diameter portion 36 and a smaller diameter portion 37. Larger diameter portion 36 approximates an inner diameter of helical insert 14 when insert 14 is installed in tapped hole 16 and expanded against parent material 18. More specifically, larger diameter portion 36 is slightly smaller than the inner diameter of insert 14 in its installed state, thereby facilitating axial insertion of leading portion 38 into an installed insert 14. Larger diameter portion 36 partially extends about the circumference of the leading portion 38. Specifically, larger diameter portion 36 extends about three quarters of the circumference of the leading portion 38 and includes an inclined surface 41 at one end and a tooth 42 at an opposite end. A void 39 between inclined surface 41 and tooth 42 exposes smaller diameter portion 37. Finally, a ramped leading edge 40 of the second end 34 caps smaller diameter portion 37 and facilitates insertion of mandrel 30 into insert 14.

As shown in Figures 3,4,5a and 5b, a central longitudinal axis 58 extends through the axial center of the second end 34. As best shown in Figure 5a, the central longitudinal axis 58 is defined by the intersection of a first longitudinal plane 60 and a second longitudinal plane 62. The axis and planes are illustrated for the explanation below.

As shown in Figures 7-9, insert 14 includes a notch 12 on a trailing end 13. As shown best in Figure 8, notch 12 includes a lead wall portion 54 and a

pair of camming surfaces 52a and 52b for locating the tooth or pawl of an extraction tool. As described below, the extraction tool 10 according to the invention not only forms this notch 12, but also uses this notch 12 for removing helical insert 14.

To this end, as illustrated in Figure 5a, the tooth 42 formed at one end of the larger diameter portion 36 is adapted to form and engage the notch 12 in trailing end 13 of helical insert 14. More specifically, tooth 42 includes a face 43, a ramp 44 and a shoulder 45.

As best shown in Figure 3, face 43 angles outwardly toward ramped leading edge 40 at an angle a, preferably approximately 3 degrees from normal N1, which is in a plane disposed perpendicularly to central longitudinal axis 58. An acceptable angle a according to the invention is preferably between 1 and 15 degrees. As shown in Figure 4, face 43 also angles from ramp 44 to shoulder 45 at an angle p, preferably approximately between 3 and 5 degrees from normal N2, which is in a plane disposed perpendicularly to central longitudinal axis 58. An acceptable angle ß according to the invention is preferably between 1 and 15 degrees. As best shown in Figure 5a, shoulder 45 angles from the first longitudinal plane 60 an at angle x, preferably approximately 12 degrees. An acceptable angle % according to the invention is preferably between 5 and 15 degrees.

As shown in Figures 3-5a, a first cutting edge 43a is formed at the intersection of face 43 and the top of tooth 42 and a second cutting edge 43b is defined by the intersection of face 43 and shoulder 45. Cutting edges 43a and 43b define a compound angle capable of cutting a notch in an insert 14, as will be discussed below.

A variation of the invention is shown in Figure 5b, wherein a tooth 42'is formed at one end of the larger diameter portion 36. Like tooth 42, tooth 42'is adapted to form and engage a notch in the trailing end 13 of helical insert 14.

More specifically, tooth 42'includes shoulders 45a, 45b flanking a face 43'.

Like face 43 for tooth 42, as best shown in Figure 3, face 43'angles outwardly toward ramp leading edge 40 at an angle I, preferably

approximately 3 degrees from normal N1, which is in a plane disposed perpendicularly to central longitudinal axis 58. An acceptable angle I according to the invention is preferably between 1 and 15 degrees. Also like face 43 of tooth 42, as shown in Figure 4, face 43'angles from shoulder 45a to shoulder 45b at an angle, preferably approximately between 3 and 5 degrees from normal N2, which is in a plane disposed perpendicularly to central longitudinal axis 58. An acceptable angle ß according to the invention is preferably between 1 and 15 degrees. As best shown in Figure 5b, shoulders 45a, 45b angle approximately 12 degrees from a longitudinal plane such as the first longitudinal plane 60. An acceptable angle according to the invention is preferably between 5 and 15 degrees.

Similar to the cutting edge illustrated for tooth 42 of Figures 3-5a, a first cutting edge 43a'is formed at the intersection of face 43'and the top of tooth 42'and a second cutting edge 43b'is defined by the intersection of face 43' and shoulder 45b. Cutting edges 43a'and 43b'define a compound angle capable of cutting a notch in an insert 14, as will be described below.

To form the notch 12, ramped leading edge 40 of leading portion 38 is coaxially aligned with helical insert 14, as shown in Figure 6. The second end 34 is inserted to the required depth in the tapped hole 16. An axial driving force, shown as arrow D in Figure 6, is exerted on extraction tool 10 to force cutting edges 43a and 43b to strike a portion of trailing end 13 of insert 14.

The downward driving force may be created manually, such as by striking a hammer against the tool 10, or through the use of a power tool (not shown), such as a pneumatically or electrically powered system.

As shown in Figure 7, cutting edges 43a and 43b strike trailing edge 13 and shear material from trailing end 13 away to define notch 12 in a shape complimentary to tooth 42. The angled surfaces of face 43 and shoulder 45 are shaped to move the sheared material away from insert 14 such that the material can easily be removed.

Upon formation of notch 12, extraction tool 10 can be used to extract insert 14, as shown in Figures 8a, 8b and 9. The extraction of the insert can be performed while tooth 42 remains engaged with notch 12 following notch-

forming procedures. Otherwise, if, for example, a worker wishes to disengage the tooth 42 from notch 12 so that the extraction tool 10 can be used for another task, the tooth 42 may be disengaged from notch 12 and re-engaged at a later time. The re-engagement of tooth 42 with notch 12 can be accomplished due to the shape of tooth 42. Specifically, ramp 44 of tooth 42 allows camming on surfaces 52a and 52b of newly formed notch 12 to facilitate location of the tooth 42 in the notch 12 of the insert 14.

In either case, when the tooth 42 is engaged with the notch 12, left- hand rotation of mandrel 30 contracts insert 14 about leading portion 38 of mandrel 30. More specifically, shoulder 45 strikes lead wall 54, forcing insert 14 to tighten about leading portion 38, whereby insert 14 is no longer expanded against parent material 18. Once contracted, continued left-hand driving force of mandrel 30 against insert 14 permits removal. To disengage tooth 42 from notch 12 following removal, slight right-hand rotation (approximately 1/4 turn) of mandrel 30 will disengage tooth 42 from notch 12 by camming ramp 44 along surface 52b.

Figure 8b illustrates the tooth 42', as discussed above, engaging an insert 14. More specifically, the tooth 42'engages a notch 12', which is formed similar to notch 12. That is, upon coaxially aligning the ramp leading edge 40 of leading portion 38 of extraction tool 10, and inserting the second end 34 to required depth in the tapped hole 16, an axial driving force is exerted on extraction tool 10 to force cutting edges 43a'and 43b'to strike a portion of trailing end 13 of insert 14. The cutting edges 43a'and 43b'share material from trailing end 13 away to define notch 12'in a shape complimentary to tooth 42'. The angled surfaces of face 43'and shoulders 45a and 45b are shaped to move the shared material away from the insert 14 such that the material can be easily removed. As before, extraction tool 10 can be used to extract insert 14 following notch formation. Also as before, when the tooth 42'is engaged with the notch 12', left-hand rotation of mandrel 30 contracts insert about leading portion 38 of mandrel 30. More specifically, shoulder 45a strikes lead wall 54, forcing insert 14 to tighten about leading portion 38, whereby insert 14 is no longer expanded against parent material

18. Once contracted, continued left-hand driving force of mandrel 30 against insert 14 permits removal. To disengage tooth 42'from notch 12'following removal, insert 14 must be slid axially from mandrel 30 until tooth 42 disengages the notch 12'.

With reference to Figures 11-13, a screw-lock type insert 14'is illustrated. The insert 14'includes a reduced coil 15, preferably disposed intermediately among the series of coils of insert 14'. As shown best in Figure 12, reduced coil 15 has a generally hexagonal inner diameter including mid- grip flats 17. The smaller diameter portion 37 of leading portion 38 is adapted to pilot on mid-grip flats 17 of the screw-lock type insert 14', as best shown in Figure 13. The engagement of the smaller diameter portion 37 on mid-grip flats 17 of reduced coil 15 facilitates removal of screw-lock type insert 14'.

To use extraction tool 10, the user simply inserts second end 34 of mandrel 30 into an insert 14'installed in tapped hole 16 of parent material 18 until tooth 42 strikes the trailing end 13 of the insert 14'to cut a notch 12. This process is the same as that described with reference to insert 14 and, as such, will not be repeated here.

Upon formation of the notch 12, when tooth 42 is engaged with notch 12, tooth 42 is positioned to remove insert 14'through left-hand rotation of tooth 42. As previously described with reference to an insert 14, the extraction of insert 14'can be done while the tooth 42 and notch 12 are continuously engaged, or when the tooth 42 and notch 12 are disengaged and later re- engaged. The process of re-engaging the tooth 42 with notch 12 is the same as that described with reference to insert 14 and, as such, will not be repeated here.

As before, when the tooth 42 is engaged with the notch 12, left-hand rotation of mandrel 30 contracts insert 14'about leading portion 38 of mandrel 30. Once shoulder 45 strikes lead wall 54, insert 14'tightens about leading portion 38, whereby insert 14'is no longer expanded against parent material 18. Continued left-hand driving force of mandrel 30 against insert 14'permits removal of the insert from tapped hole 16. To disengage tooth 42 from notch

12 following removal, slight right-hand rotation (approximately 1/4 turn) of mandrel 30 will disengage tooth 42 from notch 12.

Extraction tool 10 allows notch-forming and removal of helical inserts 14,14'after installation in a tapped hole 16 of parent material 18. Extraction tool 10 provides notch-forming and removal of insert 14,14'without causing damage to the parent material 18. Accordingly, extraction tool 10 provides a relatively simple and inexpensive way to form a notch and remove an incorrectly installed or damaged insert.

While the aforementioned extraction tool 10 has been described as including a single mandrel 30, it is preferred to provide a series of mandrels 30 of different sizes corresponding to different-sized inserts 14,14', as shown in Figure 10. Thus, a notch-forming extraction tool set 10 includes a single tool body 20 for removing different-sized inserts 14,14'by simply selecting a mandrel 30,30', 30", or 30"'corresponding in size to the insert 14,14'to be removed. Coupler 24 provides simple connection of a selected mandrel 30 to handle 22. Further, mandrel 30 includes first end 32, which is sized for use with various commercial types of handles or other types of mechanical holders. As shown, mandrel body is generally circular in cross-section, but can be made any shape, such as square or hexagonal, for example.

Accordingly, mandrel 30 according to the invention can be used independently of body 20 of extraction tool 10.

Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the present invention can be implemented in a variety of forms. Therefore, while this invention has been described in connection with particular examples thereof, the true scope of the invention should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, specification, and following claims.