U.S. patent application number 12/370656 was filed with the patent office on 2009-08-20 for polishing tool.
Invention is credited to Michael Gearald BURNETT, Jerry De Green, Jeffrey Kalman, Craig Saunders, James William Webster, JR..
Application Number | 20090209181 12/370656 |
Document ID | / |
Family ID | 40955567 |
Filed Date | 2009-08-20 |
United States Patent
Application |
20090209181 |
Kind Code |
A1 |
BURNETT; Michael Gearald ;
et al. |
August 20, 2009 |
POLISHING TOOL
Abstract
An apparatus for polishing a surface comprising: a polishing
head comprising a plurality of flap assemblies; and a shaft
attached to the plurality of flap assemblies for rotatably driving
the polishing head.
Inventors: |
BURNETT; Michael Gearald;
(Houston, TX) ; Green; Jerry De; (Windsor, OH)
; Kalman; Jeffrey; (Cleveland Heights, OH) ;
Saunders; Craig; (Rocky River, OH) ; Webster, JR.;
James William; (Houston, TX) |
Correspondence
Address: |
SHELL OIL COMPANY
P O BOX 2463
HOUSTON
TX
772522463
US
|
Family ID: |
40955567 |
Appl. No.: |
12/370656 |
Filed: |
February 13, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61029059 |
Feb 15, 2008 |
|
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|
61048019 |
Apr 25, 2008 |
|
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Current U.S.
Class: |
451/344 ;
451/358; 451/526 |
Current CPC
Class: |
B24D 13/045 20130101;
B24B 23/02 20130101 |
Class at
Publication: |
451/344 ;
451/526; 451/358 |
International
Class: |
B24D 13/16 20060101
B24D013/16; B24D 13/00 20060101 B24D013/00; B24B 23/02 20060101
B24B023/02 |
Claims
1. An apparatus for polishing a surface comprising: a polishing
head comprising a plurality of flap assemblies; and a shaft
attached to the plurality of flap assemblies for rotatably driving
the polishing head.
2. The apparatus of claim 1 wherein the flap assembly comprises an
upper material layer and a lower material layer with at least one
stiffener element between the upper material layer and the lower
material layer.
3. The apparatus of claim 2 wherein the at least one stiffener
element is smaller than the upper material layer and the lower
material layer such that at least an unsupported length L of the
upper material layer and the lower material layer extend outward
from the at least one stiffener element.
4. The apparatus of claim 2 wherein the upper material layer and
the lower material layer comprise a microfiber material.
5. The apparatus of claim 2 wherein the stiffener element comprises
a foam material.
6. The apparatus of claim 1 further comprising a handle assembly
acting cooperatively with the shaft to support the polishing
head.
7. The apparatus of claim 6 wherein the handle assembly comprises a
housing and a folding handle pivotally attached to the housing.
8. The apparatus of claim 6 wherein the shaft extends through the
handle assembly.
9. The apparatus of claim 6 further comprising a handle shaft
extending through the housing coupled to the shaft.
10. The apparatus of claim 2 wherein the upper material layer and
the lower material layer each have a shape comprising a first width
at a first section and a tapering width section.
11. The apparatus of claim 2 wherein the upper material layer and
the lower material layer comprise a main section and a bulbous
tip.
12. The apparatus of claim 2 wherein at least one of the upper
material layer and the lower material layer has a cutout extending
through the at least one of the upper material layer and the lower
material layer.
13. The apparatus of claim 2 wherein the at least one of the upper
material layer and the lower material layer comprises a textured
surface.
14. The apparatus of claim 2 wherein the upper material layer and
the lower material layer each comprise an internally arched lower
edge.
15. The apparatus of claim 2 wherein the stiffener element
comprises an open cell foam material.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/029,059, filed on Feb. 15, 2008, and U.S.
Provisional Application No. 61/048,019, filed on Apr. 25, 2008,
which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present application relates to a rotary tool for
polishing a surface.
BACKGROUND OF THE INVENTION
[0003] Rotary polishing tools are available for polishing various
surfaces. Such tools commonly have a substantially uniform size and
shape making it difficult for a single polishing head to polish
surfaces having varying sizes and shapes. For example, U.S. Pat.
No. 7,203,989 B2, discloses a buffing and polishing ball made of a
compressible polymeric foam material is formed by slitting a body
of foam material in a substantially uncompressed state (1) from an
outside surface of the body in a direction generally perpendicular
to the rotational axis and (2) on circumferentially spaced planes
that extend generally radially from the outside surface of the body
to define a plurality of foam fingers. A fastening system is used
to compress and hold a center portion of the foam body in a
direction along the rotational axis such that the uncompressed
outer ends of the finger assume a generally spherical ball.
[0004] In addition, U.S. Pat. No. 5,560,744 discloses a buffing
apparatus including a buffing assembly including a stack of buffing
wheels with or without spacers between the rings, compressed under
high pressure. Each wheel includes a clinch ring which in turn
secures an annulus of fabric extending radially therefrom. Each
spacer includes a ring; they may be the remnants of used buffing
wheels. The wheels and spacers, if any, are contiguous forming an
inner cylindrical surface of the rings. Steel straps extend axially
along this inner surface, the straps being secured by metal
inert-gas welding to the rings at the ends of the stack. The
pressure between the buffing wheels and any spacers of the stacks
is so high as to suppress any tendency of the wheels or spacers to
slip circumferentially with respect to each other when the stack is
under high tangential force in use. The straps serve to be engaged
by the keys of a drive shaft to drive the buffing apparatus.
[0005] Such shapes are not generally suitable for polishing small
cavities as well as large substantially flat surfaces.
SUMMARY OF THE INVENTION
[0006] In one embodiment, the present invention provides an
apparatus for polishing a surface comprising: a polishing head
comprising a plurality of flap assemblies; and a shaft attached to
the plurality of flap assemblies for rotatably driving the
polishing head.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] For a detailed understanding of embodiments of the present
invention, reference is made to the following detailed description
of example embodiments, taken in conjunction with the accompanying
drawings, in which like elements have been given like numerals,
wherein:
[0008] FIG. 1 is a view of an example embodiment of a polishing
tool for polishing a surface;
[0009] FIG. 2 is a view of another example embodiment of a
polishing tool for polishing a surface;
[0010] FIG. 3A is a view of an example of a polishing head;
[0011] FIG. 3B is a cross-section of the polishing head of FIG.
3A;
[0012] FIG. 4 is an exploded view of an example of upper and lower
material layers with at least one stiffener element between the
upper and lower material layers;
[0013] FIG. 5 is a cross-section of a flap assembly showing upper
and lower material layers with stiffener elements;
[0014] FIG. 6 is a cross-section of a plurality of stacked flap
assemblies;
[0015] FIG. 7 is a view of another shape for a material layer;
[0016] FIG. 8A is a view of an example of a material layer having a
substantially circular bulbous tip;
[0017] FIG. 8B is a view of substantially elliptical bulbous
tip;
[0018] FIG. 9A is an exploded view of one example of a flap
assembly;
[0019] FIG. 9B is a view of the assembled flap assembly of FIG.
9A;
[0020] FIG. 10 is a view of another flap assembly;
[0021] FIG. 11 is a view of one example of a flap material layer
having a textured surface; and
[0022] FIG. 12 is a view of another example of a flap material
layer having a textured surface.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Referring to FIG. 1, in one example embodiment, a polishing
tool 10 comprises a polishing head 20 coupled to a handle assembly
30. Polishing tool 10 may be coupled to a rotary power device 40 to
rotate polishing head 20. In one example embodiment, polishing head
20 comprises a plurality of flap assemblies 21 attached to a shaft
22 extending at least partially upward through the center of
polishing head 20.
[0024] In the example embodiment shown in FIG. 1, shaft 22 extends
through an axial bore (not shown) in housing 31, and protrudes out
of the bottom of housing 31. The bore in housing 31 acts to support
and guide shaft 22 during rotary motion of shaft 22. The protruding
portion of shaft 22 may be coupled to chuck 41 of rotary power
device 40. In one example, rotary power device 40 is a cordless
portable drill. Alternatively, corded electric drills or air driven
rotary devices may be used. Folding handle 32 is pivotally attached
to housing 31 by a pin 33. As shown, handle 32 may be folded around
housing 31 in position 32', or may be extended as shown. When
extended, handle 32 may provide better support and control of the
polishing tool as the polishing head interacts with a surface to be
polished.
[0025] Housing 31 may be made of a plastic material, a metal
material, or a combination of a plastic material and a metal
material. Likewise, shaft 22 may be made from a plastic material, a
metal material, or a combination of a plastic material and a metal
material. Suitable plastic materials may comprise polyethylenes,
polycarbonates, nylons, polypropylenes, polyvinylcarbonates,
polyurethanes, and polyethylene terephthalate (PET). Suitable metal
materials may comprise steel, aluminum, aluminum alloys, brass, and
bronze.
[0026] In another embodiment, see FIG. 2, polishing tool 110
comprises a polishing head 120 coupled to a handle assembly 130.
Polishing head 120 comprises a plurality of flap assemblies 21
attached to shaft 122. Shaft 122 extends below polishing head 120
and is sized to attach to handle assembly 130 at coupling 27.
Coupling 27 connects shaft 122 to handle shaft 28. Handle shaft 28
extends through an axial bore (not shown) in housing 31. Handle
shaft 28 may be attached to rotary power device 40 by chuck 41.
Shaft 122 and handle shaft 28 may be made from plastic materials,
metal materials, and combinations thereof as previously described.
Folding handle 32 is pivotally attached to housing 31 by a pin 33.
As shown, handle 32 may be folded around housing 31 in position
32', or may be extended as shown. When extended, handle 32 may
provide better support and control of the polishing tool as the
polishing head interacts with a surface to be polished.
[0027] FIG. 3A shows a view of polishing head 20. It will be
appreciated that the difference between polishing head 20 and
polishing head 120 is the difference in length of shafts 22 and
122. The following description of the arrangement and construction
of the plurality of flap assemblies 21 applies to both polishing
head 20 and polishing head 120. Referring also to FIGS. 3B-5, each
flap assembly 21 may comprise an upper material layer 51 and a
lower material layer 53 with two stiffener elements 52 located
between upper material layer 51 and lower material layer 53. In one
embodiment, the width W of upper material layer 51 and lower
material layer 53 is in the range of about 4.5 inches (114 mm) to
about 5 inches (127 mm). FIG. 4 shows an exploded partial view of
one example of the construction of flap assembly 21. FIG. 5 is a
cross-section of a flap assembly showing upper and lower material
layers with stiffener elements. In FIG. 4, only one stiffener
element 52 and a cutaway upper material layer 51 are shown for
clarity above a full lower material layer 53. Upper material layer
51 and lower material layer 53 may comprise a cloth material and/or
a foam material. In one embodiment upper material layer 51 and
lower material layer 53 comprise a polyester and polyamide
microfiber fabric. Alternatively, natural fiber materials may be
used, including felt, wool, mohair, cotton, and linen. In one
example, stiffener element 52 may be made of an elastomer or
plastic foam material having a stiffness greater than the stiffness
of upper material layer 51 and lower material layer 53. Stiffener
element 52 provides sufficient rigidity to force upper material
layer 51 and lower material layer 53 of flap assembly 21 to extend
substantially radially outward from shaft 22 during rotation of
polishing head 20. Alternatively, at least one unstiffened material
layer (not shown) may be interleaved between flap assemblies
21.
[0028] In one embodiment, upper material layer 51 and lower
material layer 53 may be attached to stiffener 52 by any suitable
technique, for example, by an adhesive, by stitching, or a
combination of adhesive and stitching. As shown in FIGS. 4 and 5,
stiffener element 52 is located inboard from the edge of material
layers 51 and 53, such that a predetermined length L of unsupported
material makes first contact with the workpiece surface. The
flexible, unsupported material may enhance the polishing action of
the material when the material interacts with the workpiece
surface. There is a gap H between the stiffeners 52 in each flap
assembly. Gap H provides access for stitching multiple layers
together as shown in FIG. 3B and FIG. 6, where a plurality of flap
assemblies 21 are stacked and stitched together along stitch lines
A and B that may extend along the length of upper material layer 51
and lower material layer 53. The stitched stack allows for
insertion of shaft 22 between two flap assemblies 21, see FIG. 3B.
The attached flap assemblies may be attached to shaft 22, for
example, using an adhesive. In other embodiments, upper material
layer 51 and lower material layer 53 may comprise multiple layers
of material attached together by adhesive and/or stitching.
[0029] The upper and lower material layers 51 and 53 may be shaped
having varying widths such that both small and large workpiece
features may be polished using the same polishing head. For
example, FIG. 4 shows a substantially bullet shaped layer having a
large relatively constant width section P1 for polishing relatively
flat surfaces, and a smaller tapered width section P2 for polishing
smaller surfaces and/or cavities. In use on automotive surfaces,
for example, the large relatively constant width section P1 may be
used for polishing, for example, fenders, hoods, and trunk lids.
The smaller tapered width section P2 may be more useful for
polishing, for example, around door handles and/or within wheel
spokes.
[0030] FIG. 7 presents another example shape for a material layer
60 for the polishing head wherein the edges S1 and S2 taper
substantially linearly from a relatively small width at each end to
a relatively large width W near the center of each side.
[0031] FIG. 8A shows another example shape for a material layer 70
for the polishing head. Layer 70 comprises a main section 71 for
polishing large surfaces, and a bulbous tip 72 for polishing small
areas and openings. In the example embodiment shown, there are at
least three polishing areas S3, S4, and S5 of differing shapes for
polishing a variety of different surfaces on a workpiece. In FIG.
8A, bulbous tip 72 is substantially round having a radius R. In one
embodiment, the radius R is about 0.5 inch (13 mm). In another
embodiment, see FIG. 8B, a bulbous tip 75 may have an elliptical
shape.
[0032] FIGS. 9A and 9B show another example embodiment of a flap
assembly 110 that may be used with polishing heads 20 and/or 120,
described previously. Flap assembly 110 may comprise an upper
material layer 90 and a lower material layer 91 with stiffener
elements 95 located between upper material layer 90 and lower
material layer 91. In one example, material layers 90 and 91 may
comprise a polyester and polyamide microfiber fabric, a felt
material, a wool material, a mohair material, a cotton material, a
linen material, and combinations thereof. Stiffener elements 95 may
comprise an elastomer or a plastic foam material having a stiffness
greater than the stiffness of upper material layer 90 and lower
material layer 91. In one example, upper material layer 90 and
lower material layer 91 may comprise a textured pattern 98. For
example, textured pattern 98 may be formed into the material.
Textured pattern 98 may comprise a hexagonal pattern, as shown.
Alternatively, textured pattern 98 may comprise any suitable
geometric pattern.
[0033] Upper material layer 90 and lower material layer 91 may be
attached to stiffeners 95 by any suitable technique, for example,
by an adhesive, by stitching, or a combination of an adhesive and
stitching. A plurality of flap assemblies 110 may be assembled
together using the techniques described previously with reference
to FIG. 3B and FIG. 6. The assembled flap assemblies may be
attached to shaft 22 or shaft 122 as described previously.
[0034] In another example, referring to FIG. 10, a flap assembly
121 may have a cutout 96 located on one side of a centerline 94 of
an upper material layer 93 such that a foam stiffener element 95 is
accessible through cutout 96. The placement of cutout 96 on one
side allows the foam stiffener element material to be accessed for
polishing a surface when the rotary power device is driven in a
first direction, and the material layer is accessible for buffing
when the rotary power device is driven in an opposite second
direction. Any number of such cutout flap assemblies 121 may be
assembled together, as described previously. In one example,
stiffener element 95 may comprise an open cell plastic foam
material that holds a polishing compound, for example a polishing
wax, during the polishing process. It will be understood that a
similar cutout may be formed in lower material layer 91.
[0035] FIG. 11 shows one example of material layers 90 or 91 having
a textured pattern, for example, a textured pattern 98 formed in
the material layer. In the example shown, a hexagonal pattern may
be formed in the material layer. In one example, an outline
perimeter 97 may be raised with respect to a hexagonal surface 99.
Alternatively, hexagonal surface 99 may be raised with respect to
outline perimeter 97. The portion that is not raised, that is the
lower feature, may provide a collection area for dirt and/or used
polishing compound collected on the material layers during the
polishing and/or buffing process. As indicated previously, any
suitable textured geometric pattern may be used.
[0036] FIG. 12 shows an example of an upper or lower material layer
100 that has an internally arched lower edge 102 that may provide
for increased hand clearance when used in an assembled polishing
head, for example polishing heads 20 and 120, described
previously.
[0037] The foregoing description is intended for illustration and
should not be construed as limiting the scope of the invention in
any way. Those skilled in the art will recognize many variations
that may be made without departing from the scope of the disclosed
invention.
* * * * *