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Hole Saw and Mandrel Assembly

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Hole Saw and Mandrel Assembly Europaisches Patentamt 19 J) European Patent Office Office europeen des brevets (Tj) Publication number : 0 455 420 A2 12 EUROPEAN PATENT APPLICATION (2?) Application number : 91303751.1 (a) Int. CI.5 : B23B 51/04 (2) Date of filing : 25.04.91 (So) Priority : 04.05.90 US 532527 (72) Inventor : Cain, William 100 Brookside Road Orange, Massachusetts 01364 (US) (43) Date of publication of application : Inventor : Emond, Ernest 06.11.91 Bulletin 91/45 28 River Road Millers Falls, Massachusetts 01349 (US) Karl @ Designated Contracting States : Inventor : Glawischnig, DE FR GB IT SE 98 Shelburne Center Road Shelburne Falls, Massachusetts 01370 (US) Inventor : Grant, Robert @ Applicant : RULE INDUSTRIES, INC. 31 Columbian Avenue 70 Blanchard Road Athol, Massachusetts 01331 (US) Burlington, MA 01803 (US) @) Representative : Woodward, John Calvin et al VENNER SHIPLEY & CO. 368 City Road London EC1V 2 OA (GB) (54) Hole saw and mandrel assembly. (57) A one piece hole saw assembly with mandrel permanently affixed to the hole saw cup. The mandrel contains a hollow shaft, a locking flange and reinforcing flange which are integ- rally formed as by machining. The locking flange of the mandrel mates with a locking hole or slot in the top surface of the hole saw cup. The reinforcing flange on the mandrel is welded during manufacture to the top surface of the hole saw cup. A pilot drill bit is inserted into the shaft core and welded to the shaft. The resulting product is a one piece hole saw assembly inten- ded for use by simple insertion of the mandrel or shaft end of the pilot drill into the chuck of a conventional electric drill. O CM m m £L Lil Jouve, 18, rue Saint-Denis, 75001 PARIS 1 EP 0 455 420 A2 2 BACKGROUND OF THE INVENTION cap. (Col. 4, lines 54 to 58). The hole saw is perma- nently secured to the bottom of the end cap by a con- Field of the invention tinuous circumferential TIG weld between the bottom of the end cap and the top surface of the cylindrical The present invention relates to hole saws for 5 hole saw. (Col. 5, lines 3 to 9). These two welds pro- power driven hole sawing operation. The present vide the necessary strength for withstanding the high invention particularly relates to a hole saw wherein the forces and stresses exerted during the hole sawing hole saw and accompanying mandrel form a single in- operation. (Col. 5, lines 6 to 9). A pilot drill bit is slid tegral unit. into the core of the arbor shaft prior to use. The drill w bit is held firmly in place in the arbor shaft by a set Description of the prior art screw which penetrates the shaft wall and connects with the drill bit. The set screw must be manually tight- Hole saws conventionally in use are formed of a ened. cylindrical cutting blade which is separately attached The arbor constructions of the type disclosed in to a mandrel or arbor just prior to use. The mandrel 15 U.S. patents 3,999,869 and 4,148,593 have the shaft is inserted into the jaws of the chuck of conven- advantage that they may be reused when the hole tional electric power drills. Such electric drills are typi- saw blade becomes worn. That is, the worn blade is cally equipped with a "Jacobs" three jaw chuck. removed from the arbor and another one secured In U.S. patent 3,999,869 a hole saws arbor con- thereto in its place. The arbor constructions, disclosed struction is disclosed having a longitudinally grooved 20 in these two references are heavy duty, permit high shank which telescopes into an enlarged body. The torque transmission and consequently allow sawing longitudinal grooves form engaging surfaces for the of even hard metals, e.g. metals which are not easily chuck jaws of conventional electric drills. A circular machined as well as soft thick metals, e.g. low carbon hole saw blade for cutting wood, plastic or metal is steel metals having thicknesses greater than 1/32 manually screwed to the base of the shank just prior 25 inch. The hole saw blade, however, must be sepa- to use of the hole saw. A drill bit, used to start the hole, rately mounted on the arbor before operation. The in- is placed within the shank core and secured thereto tegral arbor construction disclosed in U.S. patent by a set screw. The arbor construction disclosed in 4,077,737 has the disadvantage that two continuous this reference is designed for use in relatively small welds, each at different points on the shaft, are drills, e.g. drills having 1/4 inch to 1/2 inch capacity 30 required to complete the construction. This adds to chucks. the cost of manufacture. Also the design shown in this In U.S. patent 4,148,593 a heavy duty arbor con- latter reference has the disadvantage that it requires struction for hole saws is disclosed. As in U.S. patent the tightening of a set screw to hold the pilot drill in 3,999,869 the base of the arbor is threaded so that a place prior to use. circular hole saw of desired diameter can be screwed 35 Accordingly it is principal objective of the present to the arbor base just prior to use. The arbor, has a invention to provide a one piece hole saw assembly longitudinally grooved shaft inserted into an electric which may be inserted into a conventional electric drill chuck and a quick disconnect drive collar which drill. is slkJeabty mounted on the shaft. After the hole saw Another objective is to provide a hole saw assem- of desired diameter is manually screwed onto the 40 bly which is relatively inexpensive to manufacture but arbor base, the drive collar is manually slid down the yet is strong enough to withstand the torsional stres- Bhaft until drive pins attached to the underside of the ses encountered during the sawing operation. A collar engage receiving holes on the top surface of the related objective is to provide a one piece hole saw hole saw. Engagement of the drive collar to the hole assembly suitable for cutting holes in wood and met- saw helps to transmit torque to the hole saw and lock 45 als which are easily machinable. up of the hole saw on the arbor during operation. The arbor design disclosed in this reference has the dis- SUMMARY OF THE INVENTION advantage that the arbor is expensive and hole saw blades must be manually attached to the arbor prior The hole saw assembly of the present invention to use. so is composed of a mandrel permanently affixed to a In U.S. patent 4,077,737 an integral hole saw and cylindrical hole saw cup. The assembly is a one piece arbor construction is disclosed. The arbor is formed of unit and thus avoids the need to manually attach the a longitudinal shank telescoping into an intermediate mandrel to the hole saw prior to use. The hole saw drive plate which in turn telescopes into a circular end assembly fits into chucks of conventional hand held sap. The top of the end cap is permanently secured 55 electric drills. The mandrel is composed of a hollow to the intermediate drive plate by a circumferential shaft, a reinforcing flange and a locking flange all of continuous tungsten inert gas (TIG) weld between the which are preferably formed as an integral part of the intermediate drive plate and the top surface of the end mandrel, for example, by machining. The mandrel 3 EP 0 455 420 A2 4 shaft proximally terminates at one end with the locking forms a very desirable "D" shape for locking hole 80. flange. The reinforcing flange is preferably located However, locking hole 80 may be of other shapes above the locking flange when the end of the shaft wherein at least one edge is straight, for example furthest from the locking flange is pointed upwards. locking hole 80 may be of triangular, rectangular, pen- The mandrel is affixed to the hole saw cup by inserting 5 tagonal, hexagonal or higher order polygonal shape. the locking flange into a mating locking hole or slot Locking hole 80 could even be circular but as located in the top surface of the hole saw cup. The aforementioned it is preferable that at least one of its locking flange has at least one straight edge to pre- edges be straight. The expanse of straightedges, for vent the mandrel from rotating in the locking hole. The example 82A and 82B should preferably be between reinforcing flange is welded to the top surface of the 10 25 to 75 percent, typically about 50 percent of the total hole saw cup after the locking flange is inserted into circumference of locking hole 80. Locking hole 80 the locking hole. A pilot drill bit is inserted into the shaft penetrates at least substantially through cup surface core so that the bit tip protrudes slightly from the cut- 22 and preferably penetrates entirely through surface ting edge of the hole saw cup. Thereupon the bit is 22. welded to the shaft. 15 The locking flange 60 protrudes from the under- The resulting product is a one piece hole saw side surface of reinforcing flange 50. Locking flange assembly which is ready for use by insertion of the 60 is of proper size and shape that it will fit snugly into exposed end of the mandrel shaft or shaft end of the hole 80.
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