U.S. patent application number 16/844577 was filed with the patent office on 2021-10-14 for sanding tool attachment.
This patent application is currently assigned to ACME UNITED CORPORATION. The applicant listed for this patent is ACME UNITED CORPORATION. Invention is credited to Richard S. Constantine, George W. Woodruff, III.
Application Number | 20210316415 16/844577 |
Document ID | / |
Family ID | 1000005302675 |
Filed Date | 2021-10-14 |
United States Patent
Application |
20210316415 |
Kind Code |
A1 |
Constantine; Richard S. ; et
al. |
October 14, 2021 |
SANDING TOOL ATTACHMENT
Abstract
A sanding tool system including a sanding plate with a metal
composition having a first layer composed of a corrosive inhibitor
and a second layer composed of an abrasive material. The sanding
plate also has one or more evacuation ports extending through the
metal composition, one or more recesses extending partially into at
least the second layer of the metal composition, a retaining lip
extending around a perimeter of the metal composition, and a
connector attached to the first layer. The system additionally
includes a sanding tool removably attached to the sanding plate via
the connector.
Inventors: |
Constantine; Richard S.;
(Monroe, CT) ; Woodruff, III; George W.;
(Shrewsbury, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ACME UNITED CORPORATION |
FAIRFIELD |
CT |
US |
|
|
Assignee: |
ACME UNITED CORPORATION
FAIRFIELD
CT
|
Family ID: |
1000005302675 |
Appl. No.: |
16/844577 |
Filed: |
April 9, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B24B 23/005
20130101 |
International
Class: |
B24B 23/00 20060101
B24B023/00 |
Claims
1. A sanding tool attachment, comprising: a metal composition
having a first layer composed of a corrosive inhibitor and a second
layer composed of an abrasive material; one or more evacuation
ports extending through the metal composition; one or more recesses
extending partially into at least the second layer of the metal
composition; and a retaining lip extending around a perimeter of
the metal composition.
2. The attachment of claim 1, wherein the abrasive material is
comprised of diamonds.
3. The attachment of claim 2, wherein the diamonds are
microcrystalline.
4. The attachment of claim 2, wherein the diamonds are arranged in
multiple layers.
5. The attachment of claim 1, wherein the corrosive inhibitor is
nickel.
6. The attachment of claim 1, wherein at least one of a hook strip
or a loop strip of a hook and loop connector is attached to the
first layer.
7. The attachment of claim 6, further comprising a sanding tool
having at least one of a hook strip or a loop strip of a hook and
loop connector, wherein the hook and loop connector of the first
layer is attachable to the hook and loop connector of the sanding
tool.
8. The attachment of claim 7, wherein the sanding tool is composed
of at least one of hydrophobic foam rubber and porous fiber.
9. The attachment of claim 1, wherein one or more torsional springs
are connected to the metal composition.
10. The attachment of claim 9, wherein each torsional spring
comprises a metal coating.
11. The attachment of claim 9, wherein each torsional spring has a
rounded end curved toward the first layer.
12. The attachment of claim 9, further comprising a sanding tool
connected to the first layer by compression from the torsional
spring.
13. A sanding tool system, comprising: a sanding plate comprising:
a metal composition having a first layer composed of a corrosive
inhibitor and a second layer composed of an abrasive material; one
or more evacuation ports extending through the metal composition;
one or more recesses extending partially into at least the second
layer of the metal composition; a retaining lip extending around a
perimeter of the metal composition; and a connector attached to the
first layer; and a sanding tool removably attached to the sanding
plate via the connector.
14. A method for creating a sanding tool attachment, comprising the
steps of: generating a die having a first portion and a second
portion; placing a metal composition within the second portion of
the die; covering the metal composition with the first portion;
pressing the first portion and the second portion of the die
together; removing metal composition from the die and then
pre-plating the metal composition with a corrosive inhibitor; and
electroplating the metal composition with diamonds of a first size
distribution after it is pre-plated.
15. The method of claim 14, wherein the corrosive inhibitor is
nickel.
16. The method of claim 14, wherein the diamonds are
microcrystalline.
17. The method of claim 14, further comprising the steps of
electroplating the metal composition with diamonds of a second size
distribution.
18. The method of claim 14, wherein the metal composition is
steel.
19. The method of claim 14, wherein the die is generated with a 3D
printer.
20. The method of claim 14, wherein the first portion has one or
more protrusions extending toward the second portion, forming
evacuation ports in the metal composition.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates to a sanding tool attachment
and, more particularly, to a steel plate with a diamond embedded
surface for attachment to a sanding tool.
2. Description of Related Art
[0002] Sandpaper and other abrasive products are generally known
and used in a variety of industries for removing material from
surfaces of various materials, e.g., wood, in order to smooth the
surfaces, roughen the surfaces, and/or prepare them for subsequent
treatment after one or more top layers of material are removed.
These products are consumable and generally have a short work life
due to the high degree of wear and tear caused by use. As such,
these products rapidly deteriorate, which results in a quickly
diminishing service life and performance. Frequently changing out
worn out pads in order to maintain a sufficient level of
performance is generally a tedious and costly process.
[0003] Moreover, attaching sandpaper to sanding tools can be
painful for several reasons. First, the sandpaper must be cut to
size, which dulls the cutting tool. Second, folding the sandpaper
can crease it and leave an uneven fold that ultimately mars the
surface to be sanded. Furthermore, sandpaper can tear upon any
proud nail, drywall screw, or corner edge. Handling and applying
sandpaper is unaesthetic to human ears, producing a
"nails-on-chalkboard" effect. As mentioned above, sandpaper must be
replaced with regularity, consuming time and money. Finally,
sandpaper does not evacuate debris, meaning that during the sanding
process, debris builds up and the sandpaper must be replaced.
[0004] Therefore, there is a need for a low-cost, long-lasting
sanding tool attachment as a replacement for sandpaper.
BRIEF SUMMARY OF THE INVENTION
[0005] Embodiments of the present invention are directed to a
sanding tool attachment. According to one aspect, the attachment
includes a substrate having a first layer composed of a corrosive
inhibitor and a second layer composed of an abrasive material. The
attachment also includes one or more evacuation ports extending
through the substrate, one or more recesses extending partially
into at least the substrate, and a retaining lip extending around a
perimeter of the substrate.
[0006] According to another aspect, the attachment includes at
least one of a hook strip or a loop strip of a hook and loop
connector attached to the first layer. A sanding tool having at
least one of a hook strip or a loop strip of a hook and loop
connector is attachable to the hook and loop connector of the first
layer.
[0007] According to a similar aspect, the attachment includes one
or more torsional springs extending from the substrate. A sanding
tool is connected to the first layer by compression of the
torsional spring.
[0008] According to an additional aspect, the present invention is
a sanding tool system. The sanding tool system includes a sanding
plate with a metal composition having a first layer composed of a
corrosive inhibitor and a second layer composed of an abrasive
material. The sanding plate also has one or more evacuation ports
extending through the metal composition, one or more recesses
extending partially into at least the metal composition, a
retaining lip extending around a perimeter of the metal
composition, and a connector attached to or extending from the
first layer. The system additionally includes a sanding tool
removably attached to the sanding plate via the connector.
[0009] According to yet another aspect, the present invention is a
method for creating a sanding tool attachment. The method includes
the steps of: (i) generating a die having a first portion and a
second portion; (ii) placing a metal composition within the second
portion of the die; (iii) covering the metal composition with the
first portion; (iv) pressing the first portion and the second
portion of the die together; (v) removing metal composition from
the die and then electroplating the metal composition with a
corrosive inhibitor; and (vi) electroplating the metal composition
with diamonds of a first size distribution after it is
electroplated with the corrosive inhibitor.
[0010] These and other aspects of the invention will be apparent
from and elucidated with reference to the embodiment(s) described
hereinafter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0011] The present invention will be more fully understood and
appreciated by reading the following Detailed Description in
conjunction with the accompanying drawings. The accompanying
drawings illustrate only typical embodiments of the disclosed
subject matter and are therefore not to be considered limiting of
its scope, for the disclosed subject matter may admit to other
equally effective embodiments. Reference is now made briefly to the
accompanying drawings, in which:
[0012] FIG. 1 is a table of some varieties of electric sanding
tools;
[0013] FIG. 2A is a perspective view of a design for a sanding tool
attachment die;
[0014] FIG. 2B is a top view of a metal composition within a bottom
portion of the die;
[0015] FIG. 2C is a top perspective view of the top portion of the
die;
[0016] FIG. 2D is a side perspective view of the closed die in a
press;
[0017] FIG. 2E is a top view of the metal composition within the
bottom portion of the die after it is pressed;
[0018] FIG. 2F is a top view of the metal composition removed from
the die;
[0019] FIG. 3 is a table comparing microscopic images of
conventional sandpaper and a diamond embedded plate;
[0020] FIG. 4 is a table comprising microscopic images of a
multi-layered diamond embedded plate;
[0021] FIG. 5A is a cross-sectional view of a Palm shaped sanding
plate attached to a sanding tool;
[0022] FIG. 5B is a cross-sectional view of an Orbital shaped
sanding plate or a Corner shaped sanding plate attached to a
sanding tool;
[0023] FIG. 5C is a cross-sectional view of a Detail shaped sanding
plate attached to a sanding tool;
[0024] FIG. 6A is a top view schematic representation of a Corner
shaped sanding plate;
[0025] FIG. 6B is a perspective view schematic representation of a
Corner shaped sanding plate;
[0026] FIG. 6C is another top view of a Corner shaped sanding
plate;
[0027] FIG. 7A is a top view schematic representation of an Orbital
shaped sanding plate;
[0028] FIG. 7B is a perspective view schematic representation of an
Orbital shaped sanding plate;
[0029] FIG. 7C is another top view of an Orbital shaped sanding
plate;
[0030] FIG. 8A is a top view schematic representation of a Palm
shaped sanding plate;
[0031] FIG. 8B is a perspective view schematic representation of a
Palm shaped sanding plate;
[0032] FIG. 8C is another top view of a Palm shaped sanding
plate;
[0033] FIG. 9A is a top view schematic representation of a Detail
shaped sanding plate;
[0034] FIG. 9B is a perspective view schematic representation of a
Detail shaped sanding plate;
[0035] FIG. 9C is another top view of a Detail shaped sanding
plate;
[0036] FIG. 10A is a bottom view of a plurality of embodiments of a
sanding plate with one or more connectors attached;
[0037] FIG. 10B is a bottom view of a Palm shaped sanding plate
with an attached connector:
[0038] FIG. 10C is a bottom view of a Detail shaped sanding plate
with an attached connector;
[0039] FIG. 10D is a bottom view of a Corner shaped sanding plate
with an attached connector;
[0040] FIG. 10E is a bottom view of an Orbital shaped sanding plate
with an attached connector;
[0041] FIG. 11A is a bottom view of the sanding plates in FIG. 10
attached to electric sanding tools;
[0042] FIG. 11B is a top view of a Palm shaped sanding plate
attached to an electric sanding tool;
[0043] FIG. 11C is a top view of a Corner shaped sanding plate
attached to an electric sanding tool;
[0044] FIG. 11D is a top view of an Orbital shaped sanding plate
attached to an electric sanding tool;
[0045] FIG. 12 is a bottom view of a Detail shaped sanding plate
attached to an electric sanding tool;
[0046] FIG. 13 is a bottom view of a Palm shaped sanding plate
attached to an electric sanding tool;
[0047] FIG. 14A is a cross-sectional view of a torsional
spring;
[0048] FIG. 14B is a cross-sectional view of the torsional spring,
in the compressed position, attached to the sanding plate and
compressing the sanding tool;
[0049] FIG. 14C is a perspective view of a metal coating of the
torsional spring;
[0050] FIG. 14D is a side view of the torsional spring attached to
the sanding plate and compressed by the sanding tool; and
[0051] FIG. 14E is a cross-sectional view of the torsional spring,
sanding plate, and sanding tool in FIG. 14D
[0052] FIG. 15 is a top view of a Palm shaped sanding plate with an
attached connector, according to an alternative embodiment;
[0053] FIG. 16 is a bottom view of the Palm shaped sanding plate
with the attached connector of FIG. 15;
[0054] FIG. 17 is a bottom perspective view of the Palm shaped
sanding plate with the attached connector of FIG. 15;
[0055] FIG. 18 is a side perspective view of a Palm shaped sanding
tool; and
[0056] FIG. 19 is a top perspective view of the Palm shaped sanding
plate of FIG. 15 attached to the Palm shaped sanding tool.
DETAILED DESCRIPTION OF THE INVENTION
[0057] Aspects of the present invention and certain features,
advantages, and details thereof, are explained more fully below
with reference to the non-limiting examples illustrated in the
accompanying drawings. Descriptions of well-known structures are
omitted so as not to unnecessarily obscure the invention in detail.
It should be understood, however, that the detailed description and
the specific non-limiting examples, while indicating aspects of the
invention, are given by way of illustration only, and are not by
way of limitation. Various substitutions, modifications, additions,
and/or arrangements, within the spirit and/or scope of the
underlying inventive concepts will be apparent to those skilled in
the art from this disclosure.
[0058] Referring now to the figures, wherein like reference
numerals refer to like parts throughout, FIG. 1 shows a table of
current electric sanding tools 100. The present invention is a
sanding tool attachment. The sanding tool attachment is designed to
be connected to electric sanding tools 100, such as those shown in
FIG. 1. The electric sanding tools 100 vary by grit and shape. The
grit designates an approximate number of abrasive grains per linear
inch: an inverse of coarseness and roughness. The sanding tool
attachments described herein can have any known grit measure. The
current electric sanding tools 100 shown in FIG. 1 are available
with a grit of 80, 120, 220 and 400.
[0059] As shown in FIG. 1, there are four sanding tool shapes:
Palm, Orbital, Corner, and Detail. The Palm shaped sanding tool
100A is rectangular with evacuation ports 102 extending through the
sanding tool near its edges. The Orbital shaped sanding tool 100B
is rounded or circular, as shown. The evacuation ports 102 on the
Orbital shaped sanding tool 100B are arranged radially through the
sanding tool 100B between the center of the sanding tool and the
outer circumference. The Corner shaped sanding tool 100C is a
flat-iron shape with one straight edge and two rounded edges that
come to a point. The evacuation ports 102 on the Corner shaped
sanding tool 100C are arranged as radially as possible, with some
extending through the sanding tool 100C near its edges. Finally,
the Detail shaped sanding tool 100D is triangular with no
evacuation ports 102.
[0060] Still referring to FIG. 1, the method of connecting a
sanding tool attachment to a current electric sanding tool 100
depends on the shape and size of the electric sanding tool 100. As
shown in FIG. 1, sanding tool attachments for Orbital shaped and
Corner shaped electric sanding tools 100B, 100C are connected to
the sanding tools 100B, 100C using hook and loop connectors. The
sanding tool attachments for Palm shaped and Detail shaped electric
sanding tools 100A, 100D use alternative methods for connection,
such as a compression clip and sticker, respectively. However, this
is not a preferred as it creates unnecessary variability and cost,
creating a division between traditional sandpaper users (via the
Palm shaped sanding tool 100A) and sanding discs (via the Orbital
and Corner shaped sanding tools 100B, 100C). In a preferred
embodiment, the Palm shaped sanding tool 100A and the Detail shaped
sanding tool 100D comprise hook and loop connectors for attaching
to the sanding tool attachment to provide uniformity. Uniformity
decreases costs across the industry. optimized the evacuation ports
to fit most of the major sanding brands.
[0061] Turning now to FIGS. 2A-2F, there are shown various views at
each step of the process for manufacturing a sanding tool
attachment. First, in FIG. 2A, a design for a sanding tool
attachment die 200 is rendered. In the depicted embodiment, the die
200 for a 3D sanding tool attachment is created in a computer
program, such as CAD. After a design is created, the die 200 is
formed using a 3D printer, for example. According to an embodiment,
the die 200 is formed in Onyx material. According to another
embodiment, the die 200 is printed using a MarkForged Mark II 3D
printer. In an alternative embodiment, the die 200 is a stamping
die and particularly, a metal stamping die. However, a 3D printer
reduces the cost and time for creating the die 200 and provides a
faster mechanism for feedback (e.g., for creating multiple
variations of the die 200 or correcting mistakes in the die
200).
[0062] To create the sanding tool attachment, an abrasive device
substrate 300 is placed within a bottom portion 202 of the die 200,
as shown in FIG. 2B. In an embodiment, the substrate 300 is a metal
composition, such as cold-rolled steel or any other type of metal
that can adhere to electroplated nickel. The metal composition 300
can have any thickness as long as it does not significantly impede
the vibration (i.e., dampen) amplitude of the sanding tool 100.
However, as carbon content increases the metal becomes harder to
form and cut. With the metal composition 300 in place within the
bottom portion 202 of the die 200, a top portion 204 of the die 200
is placed over the metal composition 300, as shown in FIG. 2C.
[0063] In the embodiment shown in FIG. 2C, the top portion 204 of
the die 200 comprises optional embossments 206. With the top
portion 204 of the die 200 installed, the die 200 is pressed closed
(e.g., via a press 400), as shown in FIG. 2D. Thereafter, the die
200 is opened by removing the top portion 204 and revealing the
metal composition 300, as shown in FIG. 2E.
[0064] The metal composition 300 is then removed from the die 200,
as shown in FIG. 2F. As shown in FIG. 2F, the metal composition 300
now comprises a lip 302. The lip 302 extends around the perimeter
of the metal composition 300. The lip 302 prevents lateral movement
and thereby significantly increases torsional strength. After the
metal composition 300 is transformed within the die 200, it is
coated with an anti-corrosion layer material and diamonds are
embedded thereon to create a sanding tool attachment, such as a
sanding plate.
[0065] According to an embodiment, the metal composition 300 is
pre-plated (i.e., electroplated) with nickel under vertical sulfate
chloride at 40-50 Amps for 10 minutes. The nickel pre-plating acts
as a corrosive inhibitor, which aids in elongated the work life of
the metal composition 300. The evacuation ports 102 can be used
during the manufacturing process to assist in providing an
electrical connection to an electroplating rack.
[0066] To transform the metal composition 300 into a sanding tool
attachment, such as a sanding plate, the pre-plated metal
composition 300 is then electroplated with nickel and diamonds
(e.g., 20 g base diamonds) under horizontal sulfate chloride at
40-50 Amps for a 10 minutes stir. Thus, the resulting sanding plate
uses diamonds as an abrasive material. Diamond embedded coating is
preferable to traditional sandpaper, which utilizes silicon
carbide, because diamond size and distribution is more uniform.
Electroplated diamonds are also more secure in a base film than
silicon carbide is in resin. Even further, the electroplated base
file (containing the diamonds) leaves less residue than silicon
carbide resin of traditional sandpaper.
[0067] After electroplating the metal composition 300 with nickel
and diamonds, a hard coat (e.g., 20 g) is added at 40-50 Amps for a
final burial of 15-60 minutes, depending on the preferred grit. The
hard coat is a base layer of extra-extra-coarse to coarse diamonds
surrounded by lighter "appendages" of fine diamonds. For a final
burial of 60 minutes, the grit can be 80 or 120. For a final burial
of 30 minutes, the grit can be 220, and for a final burial of 15
minutes, the grit can be 400. The purpose of the hard coat is to
increase removal rate while maintaining RMS roughness.
[0068] Turning now to FIG. 3, there is shown a table comparing
microscopic images of conventional sandpaper and a diamond plate
(i.e., an embodiment of a sanding plate). As shown in FIG. 3, the
grit of the diamond plate is within a range of: XX, DIAFLAT 95, X,
and C, which correspond to grits 80, 120, 220, and 400,
respectively. Thus, the size and quantity of diamonds have been
optimized to match the grit performance of a 80 grit, 120 grit,
etc. However, the diamond plate is essentially indestructible, and
the diamond grit has been optimized to match or exceed the
performance of traditional sandpaper.
[0069] Referring now to FIG. 4, there is shown a table comprising
microscopic images of a multi-layered diamond plate. They
multi-layered diamond plate is created by mixing grits. In
particular, the multi-layered diamond plate is created through the
addition of multiple layers of diamond with each layer having its
own distinct size distribution to create a stronger bond to the
base substrate (e.g., metal composition 300). For example, for the
X+F grit, the plate is pre-plated at 40-50 Amps for 10 minutes, as
described above. Then, the plate is stirred in 20 g X DP004 and
D-plated at 40-50 Amps for 10 minutes. Thereafter, the plate is
then stirred in 20 g F DP002, followed by a burial at 40-50 Amps
for 30 minutes. A similar process is used for each of the other
grits, XX+F, DIAFLAT95+F, and C+F, as shown in FIG. 4,
electroplating mixed grits by density and buoyancy. In addition to
creation of a stronger bond to the base substrate, mixing grits
increases the surface area of the diamond plate and improves heat
transfer. As a result of improved heat transfer, the diamond plate
generates much less heat than alumina oxide on traditional
sandpaper and less swarf will get clogged in the grit.
[0070] Turning now to FIGS. 5A-5C, there are shown side view
schematic representations of the sanding tool attachment 500 (e.g.,
diamond plate or other sanding plate) connected to a sanding tool
100. In FIG. 5A, a sanding plate 500 is shown attached to a Palm
shaped sanding tool 100A. In the depicted embodiment, the Palm
shaped sanding tool 100A has a base composed of hydrophobic foam
rubber and the sanding plate 500 has a nickel surface. A hook and
loop connector 10 is shown between the sanding tool 100A and the
sanding plate 500. In the depicted embodiment, a hook strip 12 of
the hook and loop connector 10 is attached to the sanding tool 100A
with adhesive 14 and a loop strip 16 of the hook and loop connector
10 is attached to the sanding plate 500 (at the nickel
(non-diamond) side) with adhesive 14. In an embodiment, the hook
and loop strips 12, 16 are fabricated from nylon.
[0071] In FIG. 5B, an embodiment of an Orbital shaped sanding tool
100B or Corner shaped sanding tool 100C. According to the
embodiment shown in FIG. 5B, the sanding tools 100B, 100C have a
base composed of the hook material 12 of the hook and loop
connector 10. The loop 16 of the hook and loop connector 10 is
attached to the sanding plate 500 (at the nickel (non-diamond)
side) with adhesive 14. In the embodiment shown in FIG. 5C, a base
of a Detail shaped sanding tool 100D is composed of porous fiber.
As with the embodiment shown in FIG. 5A, the Detail shaped sanding
tool 100D is attached to the hook 12 of the hook and loop connector
10 and the sanding plate 500 is attached to the loop 16 of the hook
and loop connector 10. The hook 12 and loop 16 of the hook and loop
connector 10 are attached to the respective sanding tool 100D and
sanding plate 500 (at the nickel (non-diamond) side) using adhesive
14.
[0072] In the embodiments shown in FIGS. 5A-5C and described above,
the hook strips and loop strips can be attached to the sanding tool
100 and sanding plate 500 without interference with the evacuation
ports 102, 502. Further, the adhesive described above can be
self-adhering backing on each of the hook and loop strips.
[0073] Referring now to FIGS. 6A and 6B, there are shown top and
perspective views schematic representations, respectively, of a
Corner shaped sanding plate 500C. As shown, the Corner shaped
sanding plate 500C comprises one or more evacuation ports 502
extending through its diamond surface 510. In the depicted
embodiment, there are three large evacuation ports 502 near each
corner (i.e., where any two edges intersect). As also shown in the
depicted embodiment, smaller evacuation ports 504 extend radially
from an approximate center of the sanding plate 500C.
[0074] FIG. 6A-6B additionally shows even smaller recesses 506
extending into the sanding plate 500C. These smaller recesses 506
can be produced through laser scribing. Through laser scribing, a
partial cut is performed on the sanding plate 500C into the diamond
surface 510, resulting in a recess 506 and not a port (i.e., hole)
502, 504. The recesses 506 also extend radially from an approximate
center of the sanding plate 500C. Finally, as shown in FIG. 6B, the
sanding plate 500C has a retaining lip 508 extending entirely
around its perimeter. The embodiment shown in FIG. 6C is similar to
the embodiment shown in FIGS. 6A-6B, but the Corner shaped sanding
plate 500C does not comprise recesses 506 in the diamond surface
510.
[0075] FIGS. 7A-7B show top and perspective views schematic
representations, respectively, of an Orbital shaped sanding plate
500B. The Orbital shaped sanding plate 500B comprises large
evacuation ports 502 extending radially around an approximate
center of the sanding plate 500B. In the depicted embodiment, the
large evacuation ports 502 are near the perimeter or outer edge of
the sanding plate 500B. The sanding plate 500B additionally
comprises smaller evacuation ports 504, which also extend radially
around an approximate center of the sanding plate 500B. Finally,
the sanding plate 500B shown in FIGS. 7A-7B comprises smaller
recesses 506 (as described above and created by laser scribing)
extending radially around the approximate center of the sanding
plate 500B and into its diamond surface 510. The smaller evacuation
ports 504 are positioned between the larger evacuation ports 502
and the smaller recesses 506. As with the embodiment shown in FIGS.
6A-6B, the Orbital shaped sanding plate 500B also comprises a
retaining lip 508 extending around the outer perimeter (i.e.,
circumference) of the sanding plate 500B. The embodiment shown in
FIG. 7C is similar to the embodiment shown in FIGS. 7A-7B, but the
Orbital shaped sanding plate 500B does not comprise recesses 506 in
the diamond surface 510.
[0076] Turning now to FIGS. 8A-8B, there are shown top and
perspective views schematic representations, respectively, of a
Palm shaped sanding plate 500A. The Palm shaped sanding plate 500A
comprises one or more large evacuation ports 502 near its corners
(i.e., where two perimeter edges meet). The sanding plate 500A
additionally comprises smaller evacuation ports 504, which extend
between large evacuation ports 502 of sanding plate 500A, as shown.
The sanding plate 500A shown in FIGS. 8A-8B also comprises smaller
recesses 506 (as described above and created by laser scribing)
extending radially around the approximate center of the sanding
plate 500A and into the diamond surface 510. As with the previously
described embodiments of the sanding tool attachments, the Palm
shaped sanding plate 500A comprises a retaining lip 508 extending
around its outer perimeter. The embodiment shown in FIG. 8C is
similar to the embodiment shown in FIGS. 8A-81, but the Palm shaped
sanding plate 500A does not comprise recesses 506 in the diamond
surface 510.
[0077] FIGS. 9A-9B show top and perspective views schematic
representations, respectively, of a Detail shaped sanding plate
500D. The Detail shaped sanding plate 500D comprises one or more
large evacuation ports 102 near its corners (i.e., where two
perimeter edges meet). The sanding plate 500D additionally
comprises smaller evacuation ports 504, which may extend through
the diamond surface 510 of the sanding plate 500D at or near the
corners. The smaller evacuation ports 504 can be in a corner
without a larger evacuation port 502, as shown, or both can be
utilized in the same corner. The sanding plate 500D also comprises
smaller recesses 506 (as described above and created by laser
scribing) extending into the diamond surface 510 between the
evacuation ports 502, 504. As with the previously described
embodiments of the sanding plate 500D, the Detail shaped sanding
plate 500D comprises a retaining lip 508 extending around its outer
perimeter. The embodiment shown in FIG. 9C is similar to the
embodiment shown in FIGS. 9A-9B, but the Palm shaped sanding plate
500D does not comprise recesses 506 in the diamond surface 510.
[0078] Referring now to FIGS. 10A-13, there are shown various views
of embodiments of the sanding plate 500 connected to and
disconnected from corresponding sanding tools 100. In FIG. 10A,
embodiments of the sanding plates 500 are shown, each with one or
more connectors 20 for attaching to a sanding tool 100. In the
depicted embodiment, the connector 20 is a torsional spring. FIGS.
10B and 10C show a sanding plate 500 with a hook strip 12 of a hook
and loop connector 10 attached to the loop strip 16 of the hook and
loop connector 10. The sanding plate 500 in FIG. 10B is a Palm
shaped sanding plate 500A and the sanding plate 500 in FIG. 10C is
a Detail shaped sanding plate 500D. In FIGS. 10B and 10C, the loop
strip 16 is attached to the Palm and Detail shaped sanding plates
500A, 500D with adhesive. For example, the loop strip 16 is shown
attached (e.g., via adhesive) to a Corner shaped sanding plate 500C
in FIG. 10D and to an Orbital shaped sanding plate 500B in FIG.
10E. The hook strip 12 is removably attached or otherwise connected
to the loop strip 16, such as shown in FIGS. 10B and 10C.
[0079] The sanding plates 500 are shown connected to the sanding
tools 100 via the torsional springs 20 in FIGS. 11A-13. FIG. 11A
shows a Palm shaped electric sanding tool 100A, an Orbital shaped
electric sanding tool 100B, a Corner shaped electric sanding tool
100C and a Detail shaped electric sanding tool 100D. FIG. 11B shows
a top view of a Palm shaped sanding plate 500A attached to the Palm
shaped electric sanding tool 100A. Likewise, FIG. 11C shows a top
view of a Corner shaped sanding plate 500C attached to the Corner
shaped electric sanding tool 100C. Also, FIG. 11D shows a top view
of an Orbital shaped sanding plate 500B attached to the Orbital
shaped electric sanding tool 100B.
[0080] Turning now to FIGS. 14A-14E, there are shown various views
of the torsional spring 20. In FIG. 14A shows a side view of the
torsional spring 20. The torsional spring 20 is composed of a metal
material. The flexible material can also be coated in metal (e.g.,
metal coating 30 in FIG. 14C). In an embodiment, the flexible
material has anti-corrosion characteristics to increase the
longevity of the torsional spring 20. As shown in FIG. 14A, the
flexible metal is curled, forming a rounded (or circular) end 22.
In particular, the rounded end 22 forms an Archimedean spiral.
[0081] The torsional spring 20 is shown connected to a sanding
plate 500 and compressing a sanding tool 100, in FIG. 14B. In
particular, the torsional spring 20 is attached to the sanding
plate 500 via its flat end 24 such that the flexible metal curves
toward the sanding tool 100, as shown. Thus, the rounded end 22 of
the torsional spring 20 compresses against a side 104 of the
sanding tool 100. Specifically, FIG. 10-13 show the torsional
spring 20 attached to the sanding plates 500 and connecting them to
the sanding tools 100. When the rounded end 22 of the torsional
spring 20 extends along the side 104 of the sanding tool 100, the
torsional spring 20 is in a compression position, as shown in FIG.
14B.
[0082] As shown in FIG. 14D, the torsional spring 20 is attached to
a sanding plate 500 being compressed by a sanding tool 100. In the
depicted embodiment, there is a torsional spring 20 on opposing
sides 104 of the sanding tool 100. The torsional spring 20 does not
dampen vibratory operation but secures the sanding plate 500 to the
sanding tool 100. FIG. 14E shows a cross-sectional view of the
embodiment shown in FIG. 14D. The sanding tool 100 is shown with a
torsional spring 20 having a metal coating 30 connected thereto.
Attached to the torsional spring 20 is a layer of mono-crystalline
and/or micro-crystalline diamond (e.g., sanding plate 500). An
evacuation port 102, 502 is shown extending from the sanding tool
100 and through the torsional spring layers 20, 30 and diamond
layer, sanding plate 500.
[0083] Referring to FIGS. 15-19, there are shown various views of a
Palm shaped sanding plate 500A, according to an alternative
embodiment. As shown in FIG. 15, the sanding plate 500A has large
evacuation ports 502 at or near its four corners. In the depicted
embodiment, there are four large evacuation ports 502 at or near
each corner of the sanding plate 500A. Further, the sanding plate
500A comprises smaller evacuation ports 504. In the depicted
embodiment, the smaller evacuation ports 504 are between adjacent
corners of the sanding plate 500A and thus, between large
evacuation ports 502. In FIG. 15, there are two separate groups of
three smaller evacuation ports 504. As also shown in the depicted
embodiment, the sanding plate 500A comprises rectangular or square
recesses 512 at the corners of the sanding plate 500A and in
between at least some of adjacent corners of the sanding plate
500A. The large evacuation ports 502 and smaller evacuation ports
504 are grouped (as described above) in each recess 512. In the
embodiment shown in FIG. 15, four large evacuation ports 502 are
grouped together in one recess 512 and three smaller evacuation
ports 504 are grouped together in another recess.
[0084] As with the sanding plate 500A embodiments described above,
the sanding plate 500A shown in FIG. 15 comprises a diamond surface
510 and also includes a retaining lip 508 extending around the
outer perimeter of the sanding plate 500A. The sanding plate 500A
shown in FIG. 15 also has a connector 30 attached thereto. FIG. 16
shows a bottom view of the Palm shaped sanding plate 500A with the
connector 30 attached to the retaining lip 508. The connector 30 in
FIGS. 15-19 is a strap. The strap 30 is connected to the retaining
lip 508. In an embodiment, the strap 508 is connected to an edge
514 (FIG. 15) extending from the retaining lip 508 and in another
embodiment, in FIG. 17, the strap 30 is attached directly to the
retaining lip 508. The strap 508 is either woven through a slot 516
in the edge 514, as shown in FIG. 15, or through a slot 516 in the
retaining lip 508, as shown in FIG. 17.
[0085] FIG. 18 shows a side perspective view of a Palm shaped
sanding tool 100A. The sanding tool 100A comprises a spring-loaded
clip 106. To connect the Palm shaped sanding plate 500A to the Palm
shaped sanding tool 100A, the strap 30 shown in FIGS. 15-17 is
placed through the spring-loaded clip 106 and locked therein, as
shown in FIG. 19. The sanding plate 500A can be removed from the
sanding tool 100A by engaging the spring-loaded clip 106 again and
releasing the strap 30 therefrom. The strap 30 shown in FIGS. 15-19
can be used in conjunction with any embodiment of the sanding plate
500, including the Orbital, Corner, and Detail shaped sanding
plates 500B, 500C, 500D, and sanding tool 100, including the
Orbital, Corner, and Detail shaped sanding tools 100B, 100C, 100D,
described above.
[0086] While embodiments of the present invention has been
particularly shown and described with reference to certain
exemplary embodiments, it will be understood by one skilled in the
art that various changes in detail may be effected therein without
departing from the spirit and scope of the invention as defined by
claims that can be supported by the written description and
drawings. Further, where exemplary embodiments are described with
reference to a certain number of elements it will be understood
that the exemplary embodiments can be practiced utilizing either
less than or more than the certain number of elements.
* * * * *