# US RE49,842 E1 · Flaring and swaging bits, and methods using same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US RE49,842 E1 - Document ID: USRE49842E1 - Status: Granted - Kind: E1 - Application number: 18/115,993 - Filed: 2023-03-01 - Granted: 2024-02-20 - Earliest claimed: 2013-09-30 - Assignees: Diversitech Corporation - Applicants: Diversitech Corporation - Inventors: Bruno Anjos - Web page: https://patentgrep.com/patent/USRE49842E1 ## CPC - B21D 39/08: Tube expanders - B21D 19/08: by single or successive action of pressing tools, e.g. vice jaws - B21D 41/021: {by means of tube-flaring hand tools} - B21D: WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL (working or processing of wire B21F) ## Abstract Embodiments provide improved flaring and swaging bits, and methods for flaring and swaging. ## Claims ### Claim 1 A rotary insert, comprising: a shank portion; a stopper portion coupled to the shank portion such that a T-shape is formed thereby; and a tip opposite the shank portion, the tip having a base coupled to the stopper portion, the tip extending away from the stopper portion along an axis of symmetry, the tip having a tip end spaced apart from the stopper portion, the tip comprising a first face disposed opposite a second face, the first face and the second face defining a continuous outer edge, the continuous outer edge extending from the tip end to the base; the continuous outer edge intersecting the axis of symmetry at the tip end; the outer edge having a maximum radius relative to the axis of symmetry at the base, the continuous outer edge from the tip end to the base tapering outward relative to the axis of symmetry; from the tip end to the base the tip having at least one stage portion, the continuous outer edge curved toward the tip end in the at least one stage portion; and the stopper portion having a stopper radius greater than the maximum radius of the tip, wherein, the tip widens an open end portion of a metal tube when (1) the shank portion is inserted into a chuck of a drill or an electric screwdriver, (2) spun via the drill or the electric screwdriver, and (3) inserted into the open end portion of the metal tube while spinning so as to sufficiently heat the open end portion of the metal tube via friction generated between the tip that is spinning and the open end portion of the metal tube and thereby widen the open end portion of the metal tube using a hot process, the drill or the electric screwdriver is not a tailstock, and the tip is insertable into the open end portion of the metal tube up to the stopper portion. ### Claim 2 (depends on 1) The rotary insert of claim 1, wherein the continuous outer edge comprising at least two stage portions, in each of the at least two stage portions the continuous outer edge having different curvature. ### Claim 3 (depends on 1) The rotary insert of claim 1, wherein the rotary insert formed as is a single element. ### Claim 4 (depends on 1) The rotary insert of claim 1, wherein the rotary insert comprising metal. ### Claim 5 (depends on 1) The rotary insert of claim 1, wherein the rotary insert comprising ceramic. ### Claim 6 (depends on 1) The rotary insert of claim 1, wherein the tip further comprising a flared bottom portion, the flared bottom portion affixed between the stopper portion and the at least one stage portion, at least two edges of the flared bottom portion sloping from the tip to the stopper portion. ### Claim 7 (depends on 1) The rotary insert of claim 1, wherein the tip has rounded edges being which are equal in diameter. ### Claim 8 (depends on 1) The rotary insert of claim 1, wherein the at least one stage portion comprising only one stage portion. ### Claim 9 (depends on 1) The rotary insert of claim 1, wherein the at least one stage portion comprising two stage portions. ### Claim 10 A system, comprising: a rotary insert comprising: a shank portion; a stopper portion coupled to the shank portion such that a T-shape is formed thereby; and a tip opposite the shank portion, the tip having a base coupled to the stopper portion, the tip extending away from the stopper portion along an axis of symmetry, the tip having a tip end spaced apart from the stopper portion, the tip comprising a first face disposed opposite a second face, the first face and the second face defining a continuous outer edge, the continuous outer edge extending from the tip end to the base; the continuous outer edge intersecting the axis of symmetry at the tip end; the outer edge having a maximum radius relative to the axis of symmetry at the base, the continuous outer edge from the tip end to the base tapering outward relative to the axis of symmetry; from the tip end to the base the tip having at least one stage portion, the continuous outer edge curved toward the tip end in the at least one stage portion; the stopper portion having a stopper radius greater than the maximum radius of the tip; and a drill or an electric screwdriver having a chuck engaging the shank portion to enable the tip to widen an open end portion of a metal tube when (1) the shank portion is inserted into the chuck of the drill or the electric screwdriver, (2) spun via the drill or the electric screwdriver, and (3) inserted into the open end portion of the metal tube while spinning so as to sufficiently heat the open end portion of the metal tube via friction generated between the tip that is spinning and the open end portion of the metal tube and thereby widen the open end portion of the metal tube using a hot process, wherein, the drill or the electric screwdriver is not a tailstock, and the tip is insertable into the open end portion of the metal tube up to the stopper portion. ### Claim 11 (depends on 10) The system of claim 10, wherein the continuous outer edge comprising at least two stage portions, in each of the at least two stage portions the continuous outer edge having different curvature. ### Claim 12 (depends on 10) The system of claim 10, wherein the rotary insert formed as is a single element. ### Claim 13 (depends on 10) The system of claim 10, wherein the rotary insert comprising metal. ### Claim 14 (depends on 10) The system of claim 10, wherein the rotary insert comprising ceramic. ### Claim 15 (depends on 10) The system of claim 10, further comprising a flared bottom portion, the flared bottom portion affixed between the stopper portion and the tip, at least two edges of the flared bottom portion sloping from the tip to the stopper portion. ### Claim 16 (depends on 10) The system of claim 10, wherein the tip has rounded edges being which are equal in diameter. ### Claim 17 (depends on 10) The system of claim 10, wherein the at least one stage portion comprising only one stage portion. ### Claim 18 (depends on 10) The system of claim 10, wherein the at least one stage portion comprising two stage portions. ### Claim 19 A method for flaring a an open end portion of a metal tube, the method comprising: coupling a rotary insert to a chuck of a rotary power tool, wherein the rotary power tool is a drill or an electric screwdriver, wherein the rotary power tool is not a tailstock, wherein the rotary insert comprising: a shank portion; a stopper portion coupled to the shank portion such that a T-shape is formed thereby; a tip opposite the shank portion, the tip having a base coupled to the stopper portion, the tip extending away from the stopper portion along an axis of symmetry, the tip having a tip end spaced apart from the stopper portion, the tip comprising a first face disposed opposite a second face, the first face and the second face defining a continuous outer edge, the continuous outer edge extending from the tip end to the base; the continuous outer edge intersecting the axis of symmetry at the tip end; the outer edge having a maximum radius relative to the axis of symmetry at the base, the continuous outer edge from the tip end to the base tapering outward relative to the axis of symmetry; from the tip end to the base the tip having at least one stage portion, the continuous outer edge curved toward the tip end in the at least one stage portion; and the stopper portion having a stopper radius greater than the maximum radius of the tip; inserting the tip of the rotary insert into a cavity defined by an interior surface of a the open end portion of the metal tube while the rotary insert is coupled to the chuck of the rotary power tool; and rotating the rotary insert by spinning the shank portion via the chuck of the rotary power tool to cause friction between the tip and the interior surface of the open end portion of the metal tube, to increase the diameter of at least a portion of the metal tube including the open end portion, to create a flare of the open end portion of the metal tube, and to increase structural quality of the metal tube from heat provided to the metal tube via friction generated between the tip that is spinning and the open end portion of the metal tube using a hot process, wherein, rotating the rotary insert occurs as the tip of the rotary insert is inserted into the cavity defined by the interior surface of the open end portion of the metal tube, and the tip is insertable into the open end portion of the metal tube up to the stopper portion. ### Claim 20 A method for swaging a an open end portion of a metal tube, the method comprising: coupling a rotary insert coupled to a chuck of a rotary power tool, wherein the rotary power tool is a drill or an electric screwdriver, wherein the rotary power tool is not a tailstock, wherein the rotary insert comprising: a shank portion; a stopper portion coupled to the shank portion such that a T-shape is formed thereby; a tip opposite the shank portion, the tip having a base coupled to the stopper portion, the tip extending away from the stopper portion along an axis of symmetry, the tip having a tip end spaced apart from the stopper portion, the tip comprising a first face disposed opposite a second face, the first face and the second face defining a continuous outer edge, the continuous outer edge extending from the tip end to the base; the continuous outer edge intersecting the axis of symmetry at the tip end; the outer edge having a maximum radius relative to the axis of symmetry at the base, the continuous outer edge from the tip end to the base tapering outward relative to the axis of symmetry; from the tip end to the base the tip having at least one stage portion, the continuous outer edge curved toward the tip end in the at least one stage portion; and the stopper portion having a stopper radius greater than the maximum radius of the tip; inserting the tip of the rotary insert into a cavity defined by an interior surface of a the open end portion of the metal tube while the rotary insert is coupled to the chuck of the rotary power tool; and rotating the rotary insert by spinning the shank portion via the chuck of the rotary power tool to cause friction between the tip and the interior surface of the open end portion of the metal tube, to increase the diameter of at least a portion of the metal tube including the open end portion, to create a swage of the open end portion of the metal tube, and to increase structural quality of the metal tube from heat provided to the metal tube via friction generated between the tip that is spinning and the open end portion of the metal tube using a hot process, wherein, rotating the rotary insert occurs as the tip of the rotary insert is inserted into the cavity defined by the interior surface of the open end portion of the metal tube, and the tip is insertable into the open end portion of the metal tube up to the stopper portion. ### Claim 21 (depends on 1) The rotary insert of claim 1, wherein the tip widens the open end portion of the metal tube by or including flanging. ### Claim 22 (depends on 10) The system of claim 10, wherein the tip is enabled to widen the open end portion of the metal tube by or including flanging. ### Claim 23 (depends on 19) The method of claim 19, wherein the tip has only one stage portion. ### Claim 24 (depends on 19) The method of claim 19, wherein the tip has two stage portions. ### Claim 25 (depends on 19) The method of claim 19, wherein the rotary insert is a single element. ### Claim 26 (depends on 19) The method of claim 19, wherein each of the shank, the stopper, and the tip includes metal. ### Claim 27 (depends on 19) The method of claim 19, wherein each of the shank, the stopper, and the tip includes ceramic. ### Claim 28 (depends on 20) The method of claim 20, wherein the tip has only one stage portion. ### Claim 29 (depends on 20) The method of claim 20, wherein the tip has two stage portions. ### Claim 30 (depends on 20) The method of claim 20, wherein the rotary insert is a single element. ### Claim 31 (depends on 20) The method of claim 20, wherein each of the shank, the stopper, and the tip includes metal. ### Claim 32 (depends on 20) The method of claim 20, wherein each of the shank, the stopper, and the tip includes ceramic. ### Claim 33 A rotary insert, comprising: a shank portion; a stopper portion coupled to the shank portion such that a T-shape is formed thereby; and a tip opposite the shank portion, the tip having a base coupled to the stopper portion, the tip extending away from the stopper portion along an axis of symmetry, the tip having a tip end spaced apart from the stopper portion, the tip comprising a first face disposed opposite a second face, the first face and the second face defining a continuous outer edge, the continuous outer edge extending from the tip end to the base; the continuous outer edge intersecting the axis of symmetry at the tip end; the outer edge having a maximum radius relative to the axis of symmetry at the base, the continuous outer edge from the tip end to the base tapering outward relative to the axis of symmetry; from the tip end to the base the tip having at least one stage portion, the continuous outer edge curved toward the tip end in the at least one stage portion; and the stopper portion having a stopper radius greater than the maximum radius of the tip, wherein, the tip widens an open end portion of a metal tube when (1) the shank portion is inserted into a chuck of a drill or an electric screwdriver, (2) spun via the drill or the electric screwdriver, and (3) inserted into the open end portion of the metal tube while spinning so as to sufficiently heat the open end portion of the metal tube via friction generated between the tip that is spinning and the open end portion of the metal tube and thereby widen the open end portion of the metal tube using a hot process, the drill or the electric screwdriver is not a tailstock, the tip is insertable into the open end portion of the metal tube up to the stopper portion, the rotary insert is a single element, the rotary insert comprises metal, and the at least one stage portion comprises only one stage portion. ### Claim 34 (depends on 33) The rotary insert of claim 33, wherein the tip widens the open end portion of the metal tube by or including flanging.