U.S. patent application number 09/884853 was filed with the patent office on 2002-02-07 for in-line sander.
This patent application is currently assigned to Porter-Cable/Delta, Porter-Cable/Delta. Invention is credited to Bosten, Donald Robert, Cooper, Randy Glen, Kriaski, John Robert, Smith, John Charles.
Application Number | 20020016143 09/884853 |
Document ID | / |
Family ID | 23537591 |
Filed Date | 2002-02-07 |
United States Patent
Application |
20020016143 |
Kind Code |
A1 |
Bosten, Donald Robert ; et
al. |
February 7, 2002 |
In-line sander
Abstract
An in-line sander comprising a sander body which houses a motor
coupled to an in-line oscillating mechanism. The in-line
oscillating mechanism is adapted and configured to move a sanding
pad in a linear oscillating motion. A corner or detail pad has a
substantially flat lower surface and a substantially pointed front
portion bounded laterally by two substantially-linear
corner-sanding edges having an included angle of less than 90
degrees. A forward end of this substantially pointed front portion
of the preferred corner or detail pad protrudes ahead of a front
end of the sander body throughout the linear oscillating motion of
the pad. The front portion of the preferred corner or detail pad
has particular application for sanding into corners of a carcass.
For example, with the preferred detail or corner pad installed,
when the sander is in use where three workpiece surfaces of a
carcass meet one another perpendicularly to form a corner,
sandpaper supported by the pad under the forward end of the pad
will effectively sand into the corner on any included surface of
the corner. A preferred embodiment of the present corner or detail
pad has at least one substantially linear side edge which is
aligned substantially parallel to the linear oscillating motion of
the sander. This substantially linear side edge of the pad
protrudes laterally at least as far as the maximum width of the
sander body. With such a configuration, when the sander is in use
where two workpiece surfaces meet one another at an included angle
along edges of less than 180 degrees, the surfaces of each
workpiece which form the included angle can be sanded up to the
adjoining workpiece surface by sandpaper supported by the pad under
the substantially linear side edge of the pad. An alternate
preferred sanding pad, sometimes referred to in the present
application as a shutter pad, has at least one extended
substantially linear side edge which is aligned substantially
parallel to the linear oscillating motion of the sander and which
extends laterally a conspicuous distance beyond the maximum width
of the sander body. With such a shutter pad configuration, when the
sander is in use on a project such as the louvers on a shutter,
where a lower workpiece upper surface is below an upper workpiece
by a distance greater than the thickness of the pad but is
inaccessible by the sander body, sandpaper supported by the pad
below the extended substantially linear side edge can be
effectively used on the inaccessible lower workpiece upper surface
within the conspicuous distance that the extended substantially
linear side edge protrudes laterally beyond the sander body.
Inventors: |
Bosten, Donald Robert;
(Jackson, TN) ; Kriaski, John Robert; (Jackson,
TN) ; Cooper, Randy Glen; (Milan, TN) ; Smith,
John Charles; (Jackson, TN) |
Correspondence
Address: |
MERCHANT & GOULD PC
P.O. BOX 2903
MINNEAPOLIS
MN
55402-0903
US
|
Assignee: |
Porter-Cable/Delta
Jackson
TN
|
Family ID: |
23537591 |
Appl. No.: |
09/884853 |
Filed: |
June 19, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09884853 |
Jun 19, 2001 |
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08990587 |
Dec 15, 1997 |
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6257969 |
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08990587 |
Dec 15, 1997 |
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08931196 |
Sep 16, 1997 |
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6042460 |
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08931196 |
Sep 16, 1997 |
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08851804 |
May 6, 1997 |
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5759094 |
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08851804 |
May 6, 1997 |
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08389277 |
Feb 9, 1995 |
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Current U.S.
Class: |
451/344 ;
451/357 |
Current CPC
Class: |
B24B 55/105 20130101;
B24B 23/04 20130101; B24D 9/08 20130101 |
Class at
Publication: |
451/344 ;
451/357 |
International
Class: |
B24B 023/00; B24B
027/08 |
Claims
What is claimed is:
1. An in-line sander comprising: an elongated sander housing
configured to be grasped by a user of the in-line sander; a sanding
pad holding portion defining an outwardly facing channel that opens
outward from the sander housing and that extends in a direction
generally along a length of the sander housing, the channel being
arranged and configured for receiving and holding a profiled
sanding pad; a motor housed within the housing; and an in-line
oscillating mechanism operatively coupled between the motor and the
sanding pad holding portion, the in-line oscillating mechanism
being arranged and configured to move the sanding pad holding
portion in a linear oscillating motion, the linear oscillating
motion being in the direction generally along the length of the
housing.
2. The in-line sander of claim 1, wherein the profiled sanding pad
is secured within the channel of the sanding pad holding portion,
and the profiled sanding pad has, in a plane substantially
perpendicular to the linear oscillating motion, a particular cross
sectional profile which defines, substantially consistently along
the length of the pad, a profile sanding area including portions
not aligned on a single common plane.
3. The in-line sander of claim 2, wherein the profiled sanding pad
is oriented such that a portion of the pad protrudes ahead of a
front end of the sander housing throughout the linear oscillating
motion.
4. The in-line sander of claim 2, wherein the sanding area of the
profiled sanding pad includes a curved sanding surface.
5. The in-line sander of claim 2, wherein the sanding area of the
profiled sanding pad includes a plurality of planar sanding
surfaces interconnected at discrete edges.
6. The in-line sander of claim 1, further comprising a plurality of
profiled sanding pads adapted to be interchangeably secured within
the channel of the sanding pad holding portion, each of the
profiled sanding pads having a different cross sectional
profile.
7. The in-line sander of claim 1, wherein the channel has a
generally U-shaped cross section.
8. The in-line sander of claim 1, wherein the sanding pad holding
portion includes a plurality of projections that extend into the
channel, the projections being arranged and configured for
assisting in retaining the profiled sanding pad within the
channel.
9. The in-line sander of claim 8, wherein the projections comprise
ridges.
10. The in-line sander of claim 9, wherein the ridges have an
opposing relationship.
11. The in-line sander of claim 10, wherein the ridges are arranged
in a substantially vertical orientation.
12. The in-line sander of claim 1, wherein the profiled-sanding pad
is frictionally retained within the channel of the pad holding
portion.
13. The in-line sander of claim 12, wherein the profiled sanding
pad has elastic characteristics, and portions of the profiled
sanding pad are deformed when the pad is inserted in the channel
such that the pad is frictionally retained in the channel.
14. The in-line sander of claim 13, wherein the pad holding portion
includes projections that extend into the outwardly facing channel,
the projections being arranged and configured to deform the
portions of the profiled sanding pad when the profiled sanding pad
is inserted within the outwardly facing channel.
15. The in-line sander of claim 2, wherein the sanding pad holding
portion comprises a pad frame on which the outwardly facing channel
is defined, the pad frame including means for detachably coupling
the pad frame to the in-line oscillating mechanism.
16. The in-line sander of claim 15, wherein the pad frame includes
substantially pointed front and back portions, and substantially
parallel portions located between the front and back portions.
17. The in-line sander of claim 1, wherein the channel of the
profiled sanding pad holding portion is defined by opposing first
and second holding members.
18. The in-line sander of claim 17, wherein the profiled sanding
pad is more elastic than the first and second holding members, and
the profiled sanding pad is arranged and configured to deform when
inserted between the first and second members.
19. The in-line sander of claim 18, wherein the first and second
holding members include a plurality of projections that extend into
the channel, the projections being arranged for assisting in
retaining the profiled sanding pad within the channel.
20. The in-line sander of claim 19, wherein the projections
comprise ridges.
21. The in-line sander of claim 20, wherein the ridges have an
opposing relationship.
22. The in-line sander of claim 21, wherein the ridges are arranged
in a substantially vertical orientation.
23. The in-line sander of claim 2, further comprising an abrasive
material attached to the profiled sanding pad.
24. The in-line sander of claim 23, wherein the abrasive material
comprises sandpaper.
25. The in-line sander of claim 12, wherein the profiled sanding
pad has a base end configured to be inserted in the channel of the
pad holding portion, the base end of the profiled sanding pad being
tapered.
26. The in-line sander of claim 1, wherein the pad holding portion
defines two spaced-apart outwardly facing channels extending
lengthwise along the sander housing, the channels being arranged
and configured for receiving and holding profiled sanding pads.
27. The in-line sander of claim 26, wherein the channels are angled
outward from one another.
28. An in-line sander comprising: a sander housing including an
elongated main portion and a head portion, the main portion being
configured to be grasped by a user of the sander, and the head
portion projecting laterally outward from one end of the main
portion, wherein the head portion forms a sanding end that is
laterally offset from the main portion such that finger clearance
is provided between the main portion and a surface to be sanded; a
pad holder located at the sanding end of the sander housing; a
profiled sanding pad positionable within the pad holder, the
sanding pad having a transverse cross sectional profile which
defines, substantially consistently along the length of the pad, a
sanding area corresponding to a profile to be sanded on a
workpiece, the sanding area including portions not aligned on a
single common plane; a motor housed within the housing; and an
in-line oscillating mechanism operatively coupled between the motor
and the pad holder, the in-line oscillating mechanism being
arranged and configured to move the pad holder in a linear
oscillating motion in a direction generally along the length of the
sander housing, whereby when the motor is actuated and the profiled
sanding pad is positioned in the pad holder, abrasive material
secured to the sanding area of the profiled sanding pad is adapted
to power sand the workpiece.
29. The in-line sander of claim 28, wherein the sanding area of the
profiled sanding pad includes a curved sanding surface.
30. The in-line sander of claim 28, wherein the sanding area of the
profiled sanding pad includes a plurality of planar sanding
surfaces interconnected at discrete edges.
31. The in-line sander of claim 28, further comprising a pad
holding portion located at the sanding end of the sander housing,
the pad holding-portion defining a downwardly facing channel in
which the profiled sanding pad is retained.
32. The in-line sander of claim 31, wherein the pad holding portion
includes projections that extend into the channel and that engage
and deform the profiled sanding pad.
33. The in-line sander of claim 32, wherein the projections
comprise opposing ridges.
34. The in-line sander of claim 31, wherein the channel has a
generally U-shaped cross section.
35. The in-line sander of claim 28, wherein the elongated main
portion of the sander housing is generally barrel-shaped.
36. The in-line sander of claim 35, wherein the elongated main
portion of the sander housing has a diameter equal to or less than
a maximum width of the sander housing.
37. The in-line sander of claim 28, wherein the abrasive material
is sandpaper.
38. An in-line sander comprising: an elongated sander housing
configured to be rasped by a user of the in-line sander; a sanding
pad holding portion defining an outwardly facing channel that opens
outward from the sander housing and that extends lengthwise along
the sander housing; means for connecting the sanding pad holding
portion to the sander housing; a profiled sanding pad; means for
frictionally retaining the profiled sanding pad within the
outwardly facing channel; a motor housed within the sander housing;
and means for operatively coupling the motor to the pad holding
portion such that the motor is configured to move the sanding pad
holding portion in a linear oscillating motion, the linear
oscillating motion being in a direction generally along the length
of the housing.
39. An in-line sander comprising: a sander housing including a
barrel-shaped portion and a head portion, the barrel-shaped portion
being configured to be grasped by a user of the sander, the
barrel-shaped portion being aligned along a longitudinal axis and
including a bottom side adapted to face a surface to be sanded by
the in-line sander, and the head portion projecting transversely
outward from one end of the barrel-shaped portion such that the
head portion forms a sanding end that is downwardly offset from the
bottom side of the barrel-shaped portion, wherein the offset
provides finger clearance between the bottom side of the
barrel-shaped portion and the surface to be sanded; a pad holder
located at the sanding end of the housing; a profiled sanding pad
positionable within the pad holder, the sanding pad including a
length aligned substantially parallel to the longitudinal axis of
the barrel-shaped portion, and the sanding pad having a transverse
cross sectional profile which is substantially uniform along the
length of the pad, and which defines a sanding area including
portions not aligned on a single common plane; a motor housed
within the housing; and an in-line oscillating mechanism
operatively coupled between the motor and the pad holder, the
in-line oscillating mechanism being arranged and configured to move
the pad holder in a linear oscillating motion in a direction
generally parallel to the longitudinal axis of the barrel-shaped
portion, whereby when the motor is actuated and the profiled
sanding pad is positioned within the pad holder, abrasive material
secured to the sanding area of the profiled sanding pad is adapted
to power sand a workpiece.
40. The in-line sander of claim 39, wherein the one end of the
barrel-shaped portion is sized and shaped to correspond with the
user's palm, and a gripping depression is defined between the
barrel-shaped portion and the head portion of the sander housing,
the gripping depression being arranged and configured for receiving
the user's fingers when the user's palm is placed on the one end of
the barrel-shaped portion.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of application ser. No.
08/851,804 filed on May 7, 1997, which is a file wrapper
continuation of application Ser. No. 08/389,277 filed on Feb. 9,
1995.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] The present invention relates to an in-line sander
comprising a sander body which houses a motor coupled to an in-line
oscillating mechanism. The in-line oscillating mechanism is adapted
and configured to move a sanding pad in a linear oscillating
motion.
[0003] One preferred sanding pad adapted and configured to be
coupled to the in-line oscillating mechanism is sometimes referred
to in the present application as a corner or detail sanding pad.
The preferred corner or detail pad has a substantially flat lower
surface and a substantially pointed front portion-bounded laterally
by two substantially-linear corner-sanding edges having an included
angle of less than 90 degrees. A forward end of this substantially
pointed front portion of the preferred corner or detail pad
protrudes ahead of a front end of the sander body throughout the
linear oscillating motion of the pad. The front portion of the
preferred corner or detail pad has particular application for
sanding into corners of a carcass. For example, with the preferred
detail or corner pad installed, when the sander is in use where
three workpiece surfaces of a carcass meet one another
perpendicularly to form a corner, sandpaper supported by the pad
under the forward end of the pad will effectively sand into the
corner on any included surface of the corner.
[0004] A preferred embodiment of the present corner or detail pad
has at least one substantially linear side edge which is aligned
substantially parallel to the linear oscillating motion of the
sander. This substantially linear side edge of the pad protrudes
laterally at least as far as the maximum width of the sander body.
With such a configuration, when the sander is in use where two
workpiece surfaces meet one another at an included angle along
edges of less than 180 degrees, the surfaces of each workpiece
which form the included angle can be sanded up to the adjoining
workpiece surface by sandpaper supported by the pad under the
substantially linear side edge of the pad.
[0005] An alternate preferred sanding pad, sometimes referred to in
the present application as a shutter pad, has at least one extended
substantially linear side edge which is aligned substantially
parallel to the linear oscillating motion of the sander and which
extends laterally a conspicuous distance beyond the maximum width
of the sander body. With such a shutter pad configuration, when the
sander is in use on a project such as the louvers on a shutter,
where a lower workpiece upper surface is below an upper workpiece
by a distance greater than the thickness of the pad but is
inaccessible by the sander body, sandpaper supported by the pad
below the extended substantially linear side edge can be
effectively used on the inaccessible lower workpiece upper surface
within the conspicuous distance that the extended substantially
linear side edge protrudes laterally beyond the sander body.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 illustrates a top left perspective view of a
preferred embodiment of the present sander configured with a corner
or detail sanding pad;
[0007] FIG. 2 illustrates a left side elevational view of the
sander shown in FIG. 1;
[0008] FIG. 3 illustrates a right side elevational view of the
sander shown in FIG. 1;
[0009] FIG. 4 illustrates a front elevational view of the sander
shown in FIG. 1;
[0010] FIG. 5 illustrates a back elevational view of the sander
shown in FIG. 1;
[0011] FIG. 6 illustrates a top plan view of the sander shown in
FIG. 1;
[0012] FIG. 7 illustrates a bottom plan view of the sander shown in
FIG. 1, including a bottom plan view of a preferred corner or
detail sanding frame (with a preferred corner or detail pad shown
in phantom) for use with the present sander;
[0013] FIG. 8 is a right side elevational cross sectional profile
(taken along cutting line 8-8 of FIG. 6) illustrating the preferred
sander, as well as a preferred profiled pad holding system coupled
to the sander;
[0014] FIG. 9 is a right side elevational cross section of a front
portion of the sander (taken along cutting line 9-9 of FIG. 6)
showing a portion of the preferred in-line oscillation system as
well as a preferred corner or detail sanding pad coupled to the
sander;
[0015] FIG. 10 is a front cross sectional view (taken along cutting
line 10-10 of FIG. 8) including a preferred holding system adapted
and configured for holding a single, selected profiled sanding
pad;
[0016] FIG. 10A is a front cross sectional view (taken along
cutting line 10A-10A of FIG. 8) including a preferred holding
system adapted and configured for holding two selected profiled
sanding pads;
[0017] FIG. 11 is a partial cutaway drawing including an
illustration of a portion of the preferred in-line oscillation
system;
[0018] FIG. 12 is an exploded lower perspective view including a
lower perspective view of two alternate preferred profiled pad
frames for respectively holding a single or two profiled pads, as
well as of a preferred corner or detail pad frame;
[0019] FIG. 13 is an exploded upper perspective view of portions of
the preferred in-line oscillation system and an upper perspective
view of a preferred corner or detail pad frame;
[0020] FIGS. 14 and 15 are perspective illustrations of partially
assembled portions of the preferred in-line oscillation system;
[0021] FIG. 16 is an exploded perspective view of components of the
preferred in-line oscillation system;
[0022] FIGS. 17 and 18 illustrate a preferred shutter pad frame and
pad;
[0023] FIGS. 19-21 illustrate a preferred pad frame for holding two
profiled pads;
[0024] FIGS. 22-24 illustrate a preferred pad frame for holding a
single profiled sanding pad;
[0025] FIGS. 25, 25A, 26, and 27 illustrate the preferred corner or
detail sanding pad frame and pad, including a preferred radius of
an at least slightly-convex, curved sanding edge of the preferred
corner or detail pad frame and pad; and
[0026] FIGS. 28-44 illustrate preferred profiled sanding pads which
can be selectively used with the present sander.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Although the tool or tool system referred to in the present
application is referred to as a "sander" which uses "sandpaper", it
will be recognized that other abrasive papers, abrasive materials,
or abrasive systems or the like can be used to replace the
"sandpaper" referred to without loss of generality.
[0028] The preferred system is a sanding system which can be
configured into many highly-versatile configurations. The present
sanding system is arranged and configured to alternatively and
selectably accept for use a corner or detail pad, a shutter pad,
and a wide variety of profiled pads. Such versatility is found in
no other sander.
[0029] To accomplish this, the present sanding system preferably
includes a pad frame system comprising a corner or detail pad frame
for supporting a corner or detail pad for sanding into the corners
of a carcass, a shutter pad frame for supporting a shutter pad
configured for operations such as sanding louvers of a shutter
blocked by other louvers on the shutter, and a profiled pad frame
for supporting a profiled pad configured to power sand
pre-configured profiles onto or sand such profiles previously
configured on a workpiece.
[0030] The preferred sander comprises a sander body 50 which houses
a motor 52 (see FIG. 8) coupled to an in-line oscillating mechanism
54.
[0031] A preferred sanding pad frame such as 56 or pad such as 56A
may be coupled to an in-line oscillating mechanism such as 54 for
movement in a linear oscillating motion. Such a sanding pad or pad
frame, which is sometimes referred to in the present application as
a corner or detail sanding pad or pad frame, typically has a
substantially flat lower surface 58 and a substantially pointed
front portion 60 bounded laterally by two substantially-linear
corner-sanding edges 62 having an included angle 64 of less than 90
degrees.
[0032] A forward end 66 of the substantially pointed front portion
60 of preferred pad frame 56, and the forward end 56B of preferred
pad 56A, protrudes ahead of a front end 68 of sander body 50
throughout the linear oscillating motion of pad frame 56.
[0033] The front portion 60 of preferred pad frame S6 and pad 56A
has particular application for sanding into corners of a carcass.
For example, with preferred pad frame 56 with pad 56A installed,
when the sander is in use where three workpiece surfaces (not
shown) of a carcass meet one another perpendicularly to form a
corner, sandpaper supported by pad 56A under the forward portion 60
of the pad will effectively sand into the corner on any included
surface of the corner.
[0034] In a preferred embodiment, the substantially-linear
corner-sanding edges 62 each define an at least slightly-convex,
curved sanding edge 70. It has been found that a radius 72 (see
FIG. 25) on the order of 15 inches is appropriate for defining the
at least slightly-convex, curved sanding edges 70 and that such
curved edges are useful when sanding into a corner. In such an
application, the at least slightly-convex, curved sanding edges 70
facilitate a controlled rotation of the forward end 66 of the
substantially pointed front portion 60 of the pad or pad frame into
the corner.
[0035] FIG. 25A further illustrates the preferred configuration of
pad frame 56. At the forward end 66 of preferred pad frame 56, two
tangents drawn along the at least slightly-convex, curved sanding
edges 70 form an angle 64A of approximately 80 degrees. At the
trailing edges of the substantially pointed front portion of
preferred pad frame 56, tangents drawn along the at least
slightly-convex, curved sanding edges 70 form an angle 64B of
approximately 64 degrees. This preferred configuration assists in
sanding within corners that are out of square. Sometimes nominally
90 degree corners in woodworking are off by plus or minus five
degrees or even more. Accordingly, in order to sand into a corner
that is closed by five degrees, the forward included angle of the
pad should be less than 85 degrees. For this reason, preferred
angle 64A shown in FIG. 25A was selected to be approximately 80
degrees, so that a corner of up to almost 80 degrees can be sanded.
Furthermore, for corners having walls bowed in toward the user, an
even smaller angle 64B of approximately 64 degrees was chosen, in
order to allow rotation of forward end of the pad and pad frame
into all portions of the corner.
[0036] Although the forward end 56B of preferred pad 56A is
substantially pointed, forward end 66 of the substantially pointed
front portion 60 of pad frame 56 preferably comprises a
substantially flattened portion 74 joining the two sanding edges at
the front end of the pad frame. When sanding into a corner,
substantially flattened portion 74 of the substantially pointed
front portion 60 of the pad frame helps prevent indenting of
workpieces by the front end of the pad frame.
[0037] In the preferred embodiment, sander body 50 has a maximum
width 76 (see FIGS. 6 and 7) on the order of 2.5 inches along the
length of the sander body, and preferred pad frame 56 has at least
one substantially linear side edge 78 which is aligned
substantially parallel to the linear oscillating motion. In this
preferred embodiment, the at least one substantially linear side
edge 78 of pad frame 56 protrudes laterally at least as far as the
maximum width 76 of sander body 50. With such a configuration, when
the sander is in use where two workpiece surfaces (not shown) meet
one another at an included angle along edges of less than 180
degrees, the surfaces of each workpiece which form the included
angle can be sanded up to the adjoining workpiece surface by
sandpaper supported by the pad under the at least one substantially
linear side edge 78 of the pad frame. Preferred pad frame 56 has
two substantially linear side edges 78 which are aligned
substantially parallel to the linear oscillating motion. Each
substantially linear side edge 78 of preferred pad frame 56
protrudes laterally at least as far as the maximum width 76 of the
corresponding side of sander body 50. With such a configuration,
when the sander is in use where two workpiece surfaces (not shown)
meet one another at an included angle along edges of less than 180
degrees, the surfaces of each workpiece which form the included
angle can be sanded up to the adjoining workpiece surface by
sandpaper supported by the pad under either substantially linear
side edge of the pad.
[0038] The substantially linear side edges of preferred pad 56A
define a pad width 80 (see FIGS. 6 and 7) which is slightly larger
than the maximum width 76 of the sander body. In the preferred
embodiment, preferred pad frame 56 has a width of approximately 2.5
inches. With such a configuration, the sander can be effectively
used on a workpiece surface (not shown) bounded by protruding
workpiece surfaces (not shown) only slightly further apart than the
maximum width of the sander body.
[0039] Preferred pad frame 56 further comprises a substantially
pointed rear portion 82 bounded laterally by two
substantially-linear corner-sanding edges having an included angle
of less than 90 degrees. In the preferred embodiment, substantially
pointed rear portion 82 is configured the same as preferred front
portion 60, and preferred pad frame 56 is adapted and configured to
be reversed end for end. With such a configuration, when sandpaper
supported by the front end of the pad becomes worn, the pad frame
can be reversed end for end so that the sandpaper at both
substantially pointed portions of the pad or pad frame can be used
easily and effectively.
[0040] When pad frame 56 is coupled to dust collection or vacuum
housing 166, dust collected through ports 84 is carried through a
dust channel 214 (see FIGS. 8 and 14) to a dust exhaust channel 216
(see FIG. 8) within dust exhaust housing 218 for collecting dust
generated by sandpaper coupled to lower surface 58 of frame
56A.
[0041] In the preferred system, vacuum housing 166 defines the
upper portion of dust channel 214 within housing 166, the lower
portion of vacuum housing being formed by the combination of a
vacuum housing cover 244 (see FIGS. 12 and 13) held in place by a
machine screw 246, and by the upper surface of any pad frame
coupled to the lower surface of housing 166.
[0042] In addition to dust collection through dust ports 84 located
through some versions of pad frames and pads (see, for example,
dust ports 84 in FIGS. 7, 12, 13, and 18), additional dust
collection capability is also available in the preferred system.
The preferred system comprises a sander vacuum housing 166 and pad
frame system which provides unique, continuous air flow for dust
collection in a sander coupled to a dust collection system such as
a separate vacuum cleaner or dust collector (not shown), while
providing the versatility of using a pad frame system. This
continuous air flow providing the additional dust collection
capability of the preferred system is effective independently of
whether dust ports such as 84 are located through the thickness of
pad frames or pads. In addition, the continuous air flow of the
preferred system helps ensure that dust which passes into dust
channel 214 or dust exhaust channel 216 or a collection hose does
not stagnate or unduly collect in or block such passages.
[0043] Furthermore, the preferred dust collection system helps
prevent a pad with dust ports such as 84 located through the
thickness of the pad frames or pads from essentially adhering to a
workpiece surface. Such a workpiece surface adherence could
otherwise occur through the substantial partial vacuum that is
created by an effective external vacuum cleaner or dust collector.
However, the continuous dust-collection air flow of the preferred
system substantially eliminates such an adherence of pads to a
workpiece surface.
[0044] The preferred dust collection system has particular
application to a pad frame system for supporting sanding pads
having varying characteristics or geometries, but it is not limited
to such a system of pad frames, nor is it limited to in-line
sanding systems. For example, the preferred dust collection system
has application to corner or detail sanding systems which employ
rotationally-oscillating, pivoting, or orbital sanding motions.
[0045] The preferred dust collection system comprises a vacuum
housing such as housing 166 adapted and configured to be coupled to
a motorized sanding mechanism of a sander so that the vacuum
housing moves in a sanding motion. In one preferred embodiment, the
vacuum housing defines at least the upper portion of a dust channel
such as dust collection channel 214 within the housing. The dust
channel in the vacuum housing is adapted and configured for
connection to a dust collection system.
[0046] The preferred dust collection system further comprises a pad
frame (e.g., a pad frame such as frame 56 described above, or pad
frames such as 88, 130, or 140, described below; see, for example,
FIGS. 12 and 18) arranged and configured to be coupled under the
vacuum housing in order to move the lower surface of an attached
frame so coupled in a sanding motion. The pad frame comprises a
relatively soft sanding pad, described below, for supporting
sandpaper.
[0047] The preferred dust collection system comprises a vacuum
housing which defines air flow dust ports 240 proximate the upper
surface of the attached pad frame in a lower portion of the vacuum
housing. Air flow dust ports such as 240 permit a continuous flow
of air during dust collection from a region outside the vacuum
housing proximate the upper surface of the attached pad frame,
through a vacuum housing dust channel such as 214, and to the
separate vacuum cleaner or dust collector.
[0048] With the preferred dust collection system, airborne dust
proximate air flow dust ports such as 240 will be drawn
continuously into the separate vacuum cleaner or dust
collector.
[0049] In alternate embodiments (not shown), dust ports such as 240
could be formed or defined entirely by a lower portion of a vacuum
housing such as 166 (e.g., by apertures defined completely by the
housing proximate the upper portion of a pad frame or pad), or dust
ports such as 240 could be defined by portions of the upper surface
of a pad frame or pad adjacent a lower portion of a vacuum
housing.
[0050] Preferred: sander body 50 comprises a substantially
barrel-shaped portion 86. The barrel-shaped portion of preferred
sander body 50 has a diameter substantially equal to or less than
the maximum width 76 of the sander body, so that the barrel-shaped
portion of the sander body is adapted and configured to be grasped
by a user's hand. As is explained further below, dust exhaust
housing 218 may be optionally removed. With dust exhaust housing
218 in place, a user's fingers can wrap around barrel-shaped
portion 86, and fit within a opening 242 located between
barrel-shaped portion 86 and dust exhaust housing 218.
[0051] An alternate preferred sanding pad or pad frame useful with
the present sander or sanding system is sometimes referred to in
the present application as a shutter pad or pad frame. FIGS. 17 and
18 illustrate a preferred shutter pad frame 88 and pad 88A, which
has at least one extended substantially linear side edge 90 which
is aligned substantially parallel to the linear oscillating motion
and which extends laterally a conspicuous distance 94 beyond the
maximum width of the sander body. In FIG. 17, line 96 represents a
top plan view projection of the maximum width of sander body 50
projected onto preferred pad frame 88 in order to illustrate the
conspicuous distance 94 beyond the maximum width of the sander body
that preferred pad frame 88 extends. With such a configuration,
when the sander is in use on a project such the louvers on a
shutter (not shown), where a lower workpiece upper surface (not
shown) is below an upper workpiece (not shown) by a distance
greater than a thickness 92 of the shutter pad and pad assembly but
is inaccessible by the sander body, sandpaper supported by the pad
below the at least one extended substantially linear side edge can
be effectively used on the inaccessible lower workpiece upper
surface within the conspicuous distance 94 that the at least one
extended substantially linear side edge 90 protrudes laterally
beyond the sander body.
[0052] In the preferred embodiment shown in FIG. 17, distance 94 is
approximately 1.6 inches. Other distances 94 could also be used. In
addition, a similar shutter pad or pad frame could have two
extended substantially linear side edges each protruding laterally
a conspicuous distance beyond each side of the sander body.
[0053] As with preferred pad frame 56, preferred sanding pad frame
88 defines dust ports 84 (see FIG. 17). When pad frame 88 is
coupled to dust collection housing 166, dust collected through
ports 84 is carried through a dust channel 214 (see FIGS. 8 and 14)
to a dust exhaust channel 216 (see FIG. 8) within dust exhaust
housing 218 for collecting dust generated by sandpaper coupled to
the lower surface of pad 88A.
[0054] Preferred substantially flat portions of corner or detail
pad frame 56 and preferred shutter pad frame 88 have a nominal
thickness 92 (see FIG. 18) of approximately 0.125 inch, although
other thicknesses could be used.
[0055] Pad frames such as 56, 88, 130, and 140 typically comprise
or are formed of a relatively hard, structural material. For
example, such pad frames can be formed of ABS polycarbonite
plastic.
[0056] Pads such as 56A and 88A may be attached to frames such as
56 and 88 by a cross-linked acrylic pressure sensitive adhesive
(PA). The pads may comprise either a substantially flat lower
surface adapted to secure sandpaper or the like to the bottom of
the pads with releasable pressure sensitive adhesive (such that the
pads might be referred to as PA pads), or the lower surface of the
pads such as 56A and 88A may comprise a hook and loop system (such
that the associated pads might be referred to as hook and loop
pads).
[0057] PA pads may be formed of neoprene foam rubber having a
thickness of, for example, 0.25 inch. The upper portion of hook and
loop pads may be formed of mini-cell urethane having a thickness,
for example of 0.20 inch. Other systems for securing an abrasive
surface or the like to the pads or pad frames could also be
used.
[0058] In the preferred sanding system, profiled sanding pads such
as pads 98-128 (see FIGS. 28-44) are adapted and configured to be
coupled to the in-line oscillating mechanism. Each profiled sanding
pad 98-128 has, in a plane substantially perpendicular to the
linear oscillating motion, a particular cross sectional profile
corresponding to a profile to be formed onto or to be sanded on a
workpiece. The cross sectional configuration typically extends
substantially consistently along the entire length of the profiled
pad. Pads 98-128 respectively define sanding surfaces 98S-128S,
with each such sanding surface having a profile corresponding to
the particular cross sectional profile desired. With such a system,
sandpaper secured to the sanding surface of a profiled sanding pad
will power sand the selected profile to be formed onto or to be
sanded on a workpiece (cross sectional profiles in addition to
those shown in FIGS. 28-44 may be employed, and that any such
configurations may include or be used to sand or form profiles
commonly formed onto or to be sanded on a workpiece, as well as
those not commonly formed or sanded).
[0059] Profiled pads such as pads 98-128 may be formed of nitrile
butadiene rubber (NBR) having a nominal hardness of 80 on the shore
scale. Other materials and hardness may also be employed. Varying
hardness can affect the amount of material removed by the pads.
Sandpaper can be secured to such pads using pressure sensitive or
other adhesives, or other approaches might be used to secure
abrasive to the sanding surfaces of pads 98-128.
[0060] Preferred profiled pads such as pads 98-128 for use with the
present system may have a length of approximately 2.75 inches,
although pads in other lengths may be configured as needs
dictate.
[0061] Preferred in-line oscillating mechanism 54 is adapted and
configured to selectively receive and move in a linear oscillating
motion at least one of a plurality of profiled sanding pads
selectable from a system of profiled sanding pads, and a preferred
sander comprises a system of profiled sanding pads such as pads
98-128. Each profiled sanding pad within the system is adapted and
configured to be selectively coupled to in-line oscillating
mechanism 54, and each profiled sanding pad has, in a plane
substantially perpendicular to the linear oscillating motion, a
distinct particular cross sectional profile corresponding to a
profile to be formed onto or to be sanded on a workpiece. The cross
sectional configuration of any profiled pad in the system typically
extends substantially consistently along the length of the pad, and
each profiled pad in the system defines a sanding surface 98S-128S
having a profile corresponding to the distinct particular cross
sectional profile of the pad. With such a system, sandpaper secured
to the sanding surface of any profiled pad in the system will, when
the corresponding pad is coupled to in-line oscillating mechanism
54, power sand the profile having the distinct particular cross
section of the selected pad.
[0062] In the preferred sanding system, in-line oscillating
mechanism 54 is adapted and configured to move in a linear
oscillating motion a plurality of profiled sanding pads selected
from the system of profiled sanding pads. In this embodiment, the
selected pads are typically coupled at spaced-apart locations onto
the in-line oscillating mechanism. With such an arrangement,
sandpaper secured to the sanding surfaces of the profiled pads
will, when the selected plurality pads are coupled to the in-line
oscillating mechanism, selectively and alternately power sand onto
the workpiece the profiles having the distinct particular cross
sections of the selected plurality of pads secured to the in-line
oscillating mechanism.
[0063] The preferred sanding system comprises a variety of pad
frames adapted and configured to be coupled to in-line oscillating
mechanism 54. In the preferred embodiment, this is accomplished
through a vacuum housing 166 which is coupled to the in-line
oscillating mechanism 54, and vacuum housing 166, which moves in
linear oscillating motion, is adapted and configured to be
selectively coupled to a plurality of sanding pads frames such as
corner or detail pad frame 56, shutter pad frame 88, or profiled
pad frames 130 or 140, which in turn are adapted and configured to
position one or more profiled pads 98-128 for in-line power
sanding. With such a system, the present sander or sanding system
can be alternately and selectively adapted and configured as either
a power corner or detail sander, a power shutter sander, or a power
profile sander.
[0064] Pads or pad frames such as 56, 130, and 140 are adapted and
configured in the preferred embodiment to be selectively and
conveniently connected to in-line oscillating mechanism 54 by
snapping the pad frames into the lower portion of vacuum housing
166. Each of preferred pad frames 56, 130, and 140 comprise two
in-line, upwardly-protruding vertical members 222 having at their
upper ends forward and back facing hooked portions 224 which are
secured within vacuum housing 166 by fixed or moveable flanges. A
rear-facing, hooked portion 224 on a rear vertical member 222 on
each pad frame engages with a forward-facing, fixed flange 226 (see
FIG. 9) formed within vacuum housing 166. A forward facing hooked
portion 224 on a front vertical member on each pad frame engages a
moveable, forward-facing flange 228 (see FIGS. 9 and 12) located on
the underside of a releasable sliding or locking button 230.
[0065] Releasable sliding button 230 is biased by a spring 232, and
is releasably secured into a front upper portion of vacuum housing
166 by biased, sliding side portions 234 on button 230, the biased,
sliding side portions 234 being received by grooves 236 defined by
the opening formed into the front upper portion of the vacuum
housing for receiving button 230.
[0066] Hooked members 238 formed on the ends of biased, sliding
side portions 234 of button 230 maintain the button in a normal,
installed position within vacuum housing 166. Button 230 can be
removed for replacement or the like by pulling the button outward
while simultaneously pushing the biased, sliding side portions 234
toward one another in order to release hooked members 238 from
grooves 236.
[0067] In normal operation of button 230 for releasing or more
easily installing a sanding pad frame, button 230 is pushed into
the vacuum housing. This inward movement of button 230 releases
front-facing, movable flange 228 within button 230 away from
rear-facing hook 224 on the front vertical member 222 of any
preferred sanding pad frame, thus allowing removal of the pad frame
from vacuum housing 166. Such removal is facilitated by moving the
pad frame simultaneously slightly forward and downward, in order to
also release the rear facing hook 224 on the rear vertical member
222 of the pad frame frontward and downward away from forward
facing permanent flange 226, thus releasing the pad frame.
[0068] A new pad frame can be inserted onto vacuum housing 166 by
simply inserting the pad frame vertical members 222 up into the
vacuum housing so that the rear facing hook 224 on the rear
vertical member 222 engages forward facing, permanently-placed
flange 226, while engaging the rear-facing hook 224 on the front
vertical member 222 up and into the movable front-facing flange 228
on releasable spring-biased button 230.
[0069] In addition to being secured by vertical members 222 as
described above, preferred pad frames 56, 88, 130, and 140 each
comprise four stability projection members 248. In the preferred
embodiment, two of stability projection members 248 are located
toward the front portion of each pad frame and bear snugly up
against the inside of the front interior walls of vacuum housing
166, and two of the stability projection members 248 are located
toward the rear portion of each pad frame and bear snugly up
against vacuum housing cover 244 bearing surfaces 250, which are
geometrically symmetrical to the front interior walls of vacuum
housing 166. This snug interface between projection members 248 and
the interior side of the front walls of vacuum housing 166 and
bearing surfaces 250 substantially eliminate in-line movement of
the pad frames or pads with respect to the vacuum housing.
[0070] One profiled pad holding system 130 (see, for example, FIGS.
10, 12, and 22-24) useful with the present sanding system is
adapted and configured to hold a single profiled sanding pad such
as any one of pads 98-128. In the preferred system, pads 98-128
have an upper portion defining a particular holding cross sectional
configuration 98H-128H preferably extending substantially
consistently along the length of the pad. Preferred holding system
130 defines a single, substantially downward-facing channel 132
having first and second sides 134 and 136 respectively configured
to secure any one of holding cross sectional configurations
98H-128H of the profiled pads.
[0071] Preferred profiled sanding pad holding system 130 further
defines substantially-vertically-oriented ridges 138 on the inner
surfaces of sidewalls 134 and 136 of substantially downward-facing
channel 132 to assist in securing the holding cross sectional
configurations of the profiled pads. It has been found that ridges
138 may be configured with a 0.015 inch flat on the tip of the
ridges, and each ridge has concave radial sides. Other
configurations could also be used. In addition, different
arrangements entirely could be used, e.g., a T-slot
configuration.
[0072] Profiled sanding pad holding system 130 preferably is
further arranged and configured so that, when the profiled sanding
pad is coupled to the in-line oscillating mechanism, at least a
portion of the particular cross sectional profile 131 (see, for
example, FIG. 8) protrudes ahead of front end 68 of the sander body
throughout the linear oscillating motion of the pad. With such an
arrangement, when sandpaper is secured to at least the portion 131
of the particular cross sectional profile which protrudes ahead of
the front end of the sander body throughout the linear oscillating
motion of the pad, the protruding portion can be used to power sand
the profile to be formed onto or to be sanded on a workpiece on a
surface which is otherwise blocked from access by the sander
body.
[0073] An alternate profiled sanding pad holding system 140 (see
FIGS. 12 and 19-21) defines two substantially downward-facing
channels 142 and 144. In the preferred embodiment, each channel 142
and 144 comprises first and second sidewalls 148 and 150 aligned
lengthwise in-line with the linear oscillating motion. Sidewalls
148 and 150 are configured to secure the holding cross sectional
configurations of the profiled pads. As with channel 132, channels
142 and 144 preferably comprise substantially-vertically-oriented
ridges 138 on the inner surfaces of sidewalls 148 and 150 to assist
in securing the holding cross sectional configurations of the
profiled pads in the channels.
[0074] In the preferred configuration of alternate profiled sanding
pad holding system 140 (see FIGS. 10A, 12, and 19-21), the two
substantially downward-facing channels 142 and 144 are each angled
at least slightly outward from one another and are located so that
any of the preferred profiled sanding pads 98-128 secured within
either of the two channels has at least a portion of the pad
sanding surface projecting laterally past the sander body maximum
width (see FIG. 10A). Using the profiled sanding pad orientation
achieved through preferred alternate pad holding system 140, with
sandpaper secured to the sanding surfaces of selected pads mounted
in channels 142 and 144, at least a portion of selected particular
cross sectional profiles can with power sanding be formed onto or
sanded on a workpiece surface that might otherwise be blocked by
the sander body.
[0075] It is further preferred that the configuration of alternate
profiled sanding pad holding system 140 comprise the two
substantially downward-facing channels each being located such that
any profiled sanding pad secured within either of the two channels
may be positioned so that at least a portion of the pad sanding
surface protrudes ahead of the front end of the sander body
throughout the linear oscillating motion of the pad. This is
accomplished through placement of the forward end of channels 142
and 144 as far forward on holding system 140 as the forward end of
channel 132 is placed on holding system 130 (see FIG. 12).
Accordingly, with holding system 140 mounted to the sander, the
forward portion of channels 142 and 144 are located ahead of the
front end 68 of the sander body, similarly to the position of the
forward portion of channel 132 shown in FIG. 8. Therefore, with
sandpaper secured to the sanding surfaces of selected pads mounted
in the forward portions of channels 142 and 144, at least a portion
of selected particular cross sectional profiles can with power
sanding be formed onto or sanded on a workpiece surface that might
otherwise be inaccessible by the sander body.
[0076] While motor 52 is illustrated in FIG. 8 as an electric motor
controlled by power switch 51 (see FIG. 1) and powered by line
voltage coupled through power cord boot 53, the motor could be an
electric motor powered by a rechargeable battery system, or it
could be an air-powered motor. In the preferred embodiment, motor
52 typically has a nominal speed of approximately 18,000
revolutions per minute, and a three-to-one gear ratio may be used
to turn the horizontal motor output vertically and to reduce the
speed of rotation so that a nominal in-line stroke speed of
approximately 6,000 strokes per minute (spm) is achieved. A stroke
length of approximately 0.080 inch has been found acceptable in
combination with the nominal stroke speed of approximately 6000
spm.
[0077] In developing the present system, the assignee of the
present system experimented with a stroke length of approximately
0.060 inch with a stroke speed of approximately 18,000 spm, as well
as with a stroke length of approximately 0.125 inch at stroke speed
of approximately 9,000 spm. The small 0.060 inch stroke length at
the relatively high speed of 18,000 spm resulted in relatively
little material removal with some sanding pad configurations, and
the larger stroke length of 0.125 at the speed of 9,000 spm
typically caused aggressive removal of material but was found more
difficult to control in some circumstances and to be relatively
noisy. The selected stroke length of 0.080 inch at 6,000 spm was
found to provide a combination of control, stock removal, and
quietness. Other stoke lengths and speeds may also be acceptable,
including variable stroke speed attained through the use of motor
speed control.
[0078] Motor 52 powers the present in-line oscillating mechanism 54
through a set of face gears including a pinion face gear 152 (see
FIG. 8) mounted on the end of motor shaft 154, which is secured
into rotational position by bearings 156 having outer races secured
within sander body 50. Pinion face gear 152 meshes with a
horizontal face gear 158, which is shown schematically in, for
example FIGS. 8, 11, 13, and 15.
[0079] Face gear 158 is coupled to vertical drive shaft 160 held
rotationally in place at the upper end of the shaft by an upper
bearing 162 having an outer race coupled to a bearing housing 164
secured within sander body 50. Vertical drive shaft 160 is held
rotationally in place at a lower portion of the shaft by a lower
bearing 163, which has an outer race secured within a cavity 179
(see FIG. 13) of a bearing plate 174 by an o-ring 184 (see FIGS. 8
and 10). Bearing plate 174 is firmly attached to sander body 50 by
two machine screws 180 (see FIG. 10), each of which thread into a
tapped hole 182 (see FIGS. 11 and 15), one on each side of bearing
plate 174 (note: FIG. 13 is schematic and does not show a tapped
hole 182 on the visible side of bearing plate 174). The lower
portion of vertical drive shaft 160 is coupled to a scotch yoke
mechanism that causes vacuum housing 166 to move in a linear
oscillating motion.
[0080] Vacuum housing 166 comprises four substantially vertical
risers 168, each of which include at an upper portion a bronze
bushing 170. The four bronze bushings 170 secured in the upper
portion of vertical risers 168 provide sliding support to dowel
pins 172, which pass through and are firmly attached to bearing
plate 174. Accordingly, vacuum housing 166, supported by the four
vertical risers 168 with bronze bushings sliding on dowel pins 172,
is caused to move in a liner oscillating motion by a scotch yoke
mechanism, which will now be described.
[0081] A lower portion of drive shaft 160 comprises an eccentric
shaft portion 186, which guides the inner race of vacuum-housing
drive bearing 188. The outer race of vacuum-housing drive bearing
188 rides within an elongated opening 190 defined by a vacuum
housing drive plate 192, 193 (note: a first embodiment of the
vacuum housing drive plate, labeled 192, is shown in FIGS. 12, 13,
and 14; a second embodiment of the vacuum housing drive plate,
labeled 193, is shown in FIG. 16). The vacuum housing drive plate
is secured to the vacuum housing by two machine screws 194 (see
FIG. 8), the lower portion of machine screws 194 being secured by
hex nuts 196 set within recesses 198 on the underside of vacuum
housing 166 (see FIG. 12).
[0082] Elongated opening 190 defined by the vacuum housing drive
plate has a width along the linear oscillating motion substantially
equal to the outer diameter of vacuum-housing drive bearing 188,
which rides within elongated opening 190.
[0083] The length of elongated opening 190 across the linear
oscillating motion is substantially greater than the outer diameter
of vacuum housing drive bearing 188. This shape of elongated
opening 190 causes the outer race of vacuum-housing drive bearing
188, which is eccentrically mounted on drive shaft portion 186, to
move the vacuum housing in the in-line oscillating motion.
[0084] Sander body vibration which might otherwise be caused by the
in-line oscillating motion of the vacuum housing and attached pad
frame and pad is substantially offset by a counterweight 200, 201
(note: a first embodiment of the counterweight, labeled 200, is
shown in FIGS. 11, 13, and 15; a second embodiment of the
counterweight, labeled 201, is shown in FIG. 16). The counterweight
is caused to move with an in-line oscillating motion 180 degrees
out of phase with the in-line movement of the vacuum housing, as
will now be described in more detail.
[0085] A lower portion of drive shaft 160 just above eccentric
drive shaft portion 186, comprises a second eccentric portion 202
which is eccentrically out of phase by 180 degrees with eccentric
portion 186. Eccentric portion 202 guides the inner race of a
counterweight drive bearing 204. The outer race of counterweight
drive bearing 204 rides within an elongated opening 206 (see FIGS.
13 and 16) defined by the counterweight.
[0086] Elongated opening 206 defined by the counterweight has a
width along the linear oscillating motion substantially equal to
the outer diameter of counterweight drive bearing 204, which rides
within elongated opening 206. The length of elongated opening 206
across the linear oscillating motion is substantially greater than
the outer diameter of counterweight drive bearing 204. This shape
of elongated opening 206 causes the outer race of counterweight
drive bearing 204, which is eccentrically mounted on drive shaft
portion 202, to move the counterweight in an in-line oscillating
motion, 180 degrees out of phase with the inline oscillating motion
of vacuum housing 166.
[0087] The counterweight is guided in an in-line oscillating motion
by two bushings 208 (see FIG. 16), which ride within slots 210
elongated in line with the in-line oscillating motion (note: slots
210 are offset in counterweight embodiment 200, as shown in FIGS.
11, 13, and 15, and are aligned in counterweight embodiment 201, as
shown in FIG. 16). Bushings 208 are held in place for guiding the
counterweight by machine screws 212 (FIG. 8) secured to the vacuum
housing drive plate.
[0088] With the weight of the counterweight and the combined weight
of vacuum housing 166 and any pad frame and corresponding attached
pad and abrasive being substantially equal, vibration of sander
body 50 in a user's hand is substantially reduced or
eliminated.
[0089] Vacuum housing 166 defines dust channel 214 (see FIGS. 8 and
14) for guiding dust collected through dust ports 84 and air flow
dust ports 240 to a dust exhaust channel 216 within dust exhaust
housing 218. A dust collection hose (not shown) may be connected on
one end fitting 219 on the exit end of dust exhaust housing 218 and
on the other end to a suitable separate vacuum cleaner or dust
collector for collecting dust created by the sander.
[0090] A rear portion 256 (see FIGS. 8, 9, and 14) of the vacuum
housing assembly (the assembly of vacuum housing 166 and vacuum
housing cover 244) fits into the upstream or forward end of dust
exhaust housing 218. A sliding interface between the exterior walls
of portion 256 and the interior walls of dust exhaust housing 218
permits portion 256 of the vacuum housing assembly to move in an
in-line oscillating motion within forward end of dust exhaust
housing 218.
[0091] Dust exhaust housing 218 may be optionally removed by
loosening thumb screw 220, which then permits housing 218 to be
removed, such as to provide a lighter or more maneuverable sander
(e.g., when no dust collection is desired, or in tight operating
conditions). In the preferred embodiment, when thumb screw 220 is
loosened, dust exhaust housing 218 is easily removed by pulling
housing 218 down and away from the front of the sander (when
installed, the forward portion of housing 218 is held in place by a
pin 258 which fits into an corresponding hole in the sander
body).
[0092] The present invention is to be limited only in accordance
with the scope of the appended claims, since persons skilled in the
art may devise other embodiments still within the limits of the
claims. For example, many of the preferred features of the present
sander or sander systems described in the present application are
not limited to an in-line sander.
* * * * *