SANDING SYSTEM FOR A CONSTRUCTION TOOL

A sanding system for sanding a working surface includes a vacuum portion having spaced-apart first and second inlets for recovering debris produced from the sanding process. A sanding portion is reciprocated relative to the vacuum portion to sand the working surface. As the sanding portion moves, it alternatively covers and uncovers the first and second inlets so that only one inlet is uncovered at a time. The uncovered inlet thus directs increased suction force towards the working surface to more effectively recover sanding debris. Optionally, an alignment heel is coupled in a spaced and aligned arrangement relative to the sanding portion to promote stability and uniform contact pressure between the sanding portion and the working surface.

FIELD OF THE INVENTION

The present invention relates generally to construction tools and tool accessories, and particularly to tools and tool accessories adapted to sand or smooth a surface.

BACKGROUND OF THE INVENTION

Many construction applications require sanding or smoothing a working surface, such as the surface of a wooden board or the surface of drywall compound at a seam between adjacent drywall panels. The sanding process involves placing an abrasive article, such as a sanding sheet or block, into contact with the working surface, and then moving the abrasive article to level or smooth portions of the working surface by removing material from the working surface. It can be beneficial to maintain a desired angle of contact between the abrasive article and working surfaces while sanding to avoid inadvertently creating gouges or other noticeable imperfections in the working surface. Material removed from the working surface may take the form of particulate matter which can permeate through the surrounding environment, often times coming to rest on undesired nearby non-working surfaces, such as countertops or furniture.

SUMMARY OF THE INVENTION

The sanding system of the present invention is adapted to be attached or incorporated into a powered self-moving tool, such as an electric reciprocating power tool, that actuates a sanding portion of the sanding system to sand or smooth a working surface, such as a wooden board or cured drywall compound located along a seam (such as at an inside corner) between adjacent drywall panels. A vacuum portion defines a pair of spaced apart inlets that recover dust and debris produced from the sanding process. While sanding, the sanding portion is moved to cover one inlet at a time, leaving the other inlet uncovered. As a result, the location of the uncovered inlet continuously alternates between the locations of each inlet. Because at least one inlet is always covered, the uncovered inlet will have increased suction power, thus resulting in effective recovery of dust and debris from continuously alternating areas of the working surface. An alignment heel that is spaced apart from the sanding and vacuum portions can be moved along the working surface to ensure proper contact and uniform pressure is maintained between the sanding portion and the working surface to reduce the likelihood of inadvertently creating gouges or other imperfections during the sanding process.

According to one form of the invention, a sanding system for sanding a working surface includes a vacuum portion having first and second vacuum inlets that direct a suction force to recover dust and debris from the working surface being sanded. A sanding portion to which an abrasive article (such as sandpaper) may be secured is movable relative to the vacuum portion between first and second positions. In the first position, the first vacuum inlet is at least partially covered by the sanding portion and the second vacuum inlet is at least partially uncovered, and in the second position the second vacuum inlet is at least partially covered by the sanding portion and the first vacuum inlet is at least partially uncovered.

In one aspect, the sanding portion includes a pair of backing surfaces oriented at an angle relative to one another and connected along a longitudinal axis. Optionally, the backing surfaces are oriented at a 90 degree angle relative to one another to more effectively sand adjacent surfaces at and/or near an internal corner.

In another aspect, the backing surfaces include tapered portions that are oriented at an angle of less than 90 degrees relative to one another.

In yet another aspect, the first and second vacuum inlets are located entirely inboard of the sanding portion in both latitudinal and transverse directions.

In still another aspect, the sanding system includes an attachment that protrudes through a hole defined by the vacuum portion to connect the sanding portion to a reciprocating part of a reciprocating power tool.

In a further aspect, the vacuum portion may be secured to a non-reciprocating part of the reciprocating power tool.

In yet a further aspect, the sanding system includes an alignment heel that is spaced apart from the sanding and vacuum portions, and is secured to the non-reciprocating part of the power tool. The alignment heel slides along the working surface during the sanding process to aid in maintaining a desired alignment and uniform pressure between the sanding portion and the working surface. The alignment heel and the sanding portion each terminate along a common longitudinal axis. Optionally, the alignment heel includes a pair of surface guides angled relative to one another and connected along the common longitudinal axis. Additionally, the surface guides may have the same angle relative to one another as the backing surfaces have relative to one another, such as 90 degrees.

According to another form of the invention, a sanding system for sanding a working surface includes an alignment heel with a surface guide that may slide along the working surface substantially without removing material from the working surface. The alignment heel is spaced apart from and coupled to a sanding portion having a backing surface, where the sanding portion is used to sand the working surface. Both the surface guide and the backing surface are coplanar in a contact plane.

In one aspect, the surface guide includes a pair of surface guides angled relative to one another and connected along a common longitudinal axis.

In another aspect, the sanding portion includes a pair of backing surfaces angled relative to one another and connected along the common longitudinal axis. The backing surfaces may have the same angle relative to one another as the surface guides have relative to one another, which may optionally be 90 degrees, such that both the backing surfaces and the surface guides make slidable contact with a pair of adjacent surfaces at and/or near an internal corner.

In yet another aspect, the surface guide is a felt surface that slides along the working surface.

In still another aspect, the alignment heel may be attached to a non-moving portion of a power tool, and the sanding portion may be attached to a moving portion of the power tool.

In a further aspect, the alignment heel includes a retention feature that frictionally engages with the non-moving portion of the power tool to secure the power tool to the alignment heel.

Thus, the sanding system of the present invention provides an effective way to sand a working surface, such as dried drywall compound or “mud” located along a wall seam. The sanding system includes a sanding portion that moves relative to a vacuum portion to cover and uncover one vacuum inlet at a time in an alternating fashion, the vacuum portion having a pair inlets spaced apart from one another. This results in increased suction power at alternating positions (the position of each inlet) to more effectively recover dust and debris from the working surface. The precision and quality of the sanding process is enhanced by an alignment heel spaced from the sanding and vacuum portions. The alignment heel slidably contacts the working surface to improve the stability and alignment of the sanding portion relative to the working surface, thereby reducing the likelihood of creating inadvertent gouges or other imperfections in the working surface due to uneven contact or pressure between the sanding portion and the working surface.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings and the illustrative embodiments depicted therein, a sanding system20is adapted to uniformly sand and recover sanding debris from a working surface such as the surface of a wall22shown inFIG.1. A sanding portion24provides an area for securing an abrasive article, such as sandpaper, and is attachable to a reciprocating part26of a reciprocating power tool28. Power tool28reciprocates sanding portion24against the surfaces of wall22to smooth and flatten portions of wall22by abrading or removing excess material forming ridges, bumps, or other protrusions extending outward from wall22. A vacuum portion30attached to a non-reciprocating part32of power tool28defines a pair of spaced apart inlets34a,34b(FIGS.10and11) for suctioning sanding debris from wall22. Inlets34a,34bare individually and alternatively covered and uncovered by sanding portion24as it reciprocates, such as shown inFIGS.7A and7C, to allow for the more effective removal of sanding debris from wall22. An alignment heel36, also connected to the non-reciprocating part32of power tool28, is spaced apart from both sanding and vacuum portions24,30and slides along the surface of wall22to facilitate proper alignment and even pressure between sanding portion24and wall22, thereby reducing the likelihood of inadvertently creating undesirable gouges and other imperfections on wall22.

Referring now toFIGS.2-4,8, and9, sanding portion24includes a pair of backing surfaces or pads38,40that are angled relative to one another at a sanding angle and connected at a sanding tip42extending along a common longitudinal axis. Pads38,40are oriented at an approximately 90 degree angle relative to one another at contact portions38a,40athat meet to define tip42to allow sanding portion24to effectively sand internal corners, such as internal corner22aof wall22shown inFIG.1. Tapered end portions38b,40bof pads38,40are oriented at less than a 90 degree angle relative to one another to ensure tip42and contact portions38a,40aare unobstructed to reach and make full contact with corner22aand proximate adjacent portions22b,22cof wall22. An abrasive article, such as a sheet of sandpaper, can be secured to pads38,40through various methods including hook and loop fastening features or spring-loaded clamps. It will be appreciated that backing pads having varying geometric profiles for sanding other surface areas may be utilized in sanding system20. For example, a single planar backing pad could be used to sand a flat portion of wall22not located near a corner.

Vacuum portion30includes an enclosure44located inboard of sanding portion24in both a latitudinal direction and a transverse direction, such as shown inFIGS.2-4and8-11. A distal side44aof enclosure44defines forward inlet34aand rearward inlet34bin a spaced arrangement, where inlets34a,34bare fluidly connected to an interior volume of enclosure44. Inlets34a,34bshare a common latitudinal plane with the common longitudinal axis of sanding tip42, discussed above, such that inlets34a,34bare centered with respect to sanding portion24in the transverse direction (FIGS.7A and7B). An elongated through-hole or access hole46extends through enclosure44in the latitudinal direction and is not fluidly connected to the interior volume of enclosure44. A posterior side44bof enclosure44is fluidly connected to a rigid elongated tube or duct48. Duct48may be connected to a vacuum via a vacuum tube or hose50to fluidly connect vacuum portion30to the vacuum. Duct48is secured to a connector52by extending through a receiving hole defined by connector52. Connector52includes a U-shaped shoulder56and an adjustable strap58that can be selectively secured and detached between a pair of arms56a,56bof shoulder56. Non-reciprocating part32of power tool28can be received by shoulder56and secured in place by strap58to attach vacuum portion30to non-reciprocating part32of power tool28. It should be appreciated that a vacuum portion may include more than one enclosure, in which each enclosure may define one or more inlets. Additionally, a vacuum hose may be routed along and/or adjacent to a shoulder and/or a connector.

With reference toFIGS.2,4,5,8, and9, alignment heel36includes a pair of surface guides60,62that are angled relative to one another at a guide angle and meet to define a guide tip64extending along the common longitudinal axis that is shared by tip42of sanding portion24as discussed above. Guides60,62are oriented at an approximately 90 degree angle relative to one another such that outer sides60a,62aof each guide60,62can fully engage with and slide along wall portions22b,22cand corner22aof wall22. Guides60,62also have inner sides60b,62bthat are connected to an upright anterior portion66to collectively define a saddle68or receiving area for part of non-reciprocating part32of power tool28, such as a removable battery attachment. It should be understood that surface guides may curve and/or transition in a non-linear fashion to meet and form a curved and/or truncated guide tip within the scope of the present invention, such that the guide tip may take the form of a rounded fillet or chamfer, for example. Likewise, it should also be understood that backing surfaces of a sanding portion may meet to form a sanding tip in a similar or identical fashion. A protrusion or outwardly extending feature of power tool28may be secured to anterior portion66via frictional engagement with a retention cavity70to secure power tool28to alignment heel36. The frictional engagement of the protrusion or outwardly extending feature of power tool28in retention cavity70may be similar to that of a press fit connection, or may be easily releasable by a user. In alternative embodiments, an alignment heel may include one or more retention cavities having geometry that differs from retention cavity70, or may include one or more protrusions to engage with varying geometric characteristics of different power tools.

Anterior portion66also includes a pair of upright supports72a,72blocated on opposite sides of retention cavity70. Supports72a,72beach define a pair of bolt holes74for securing a hose mount76that supports and directs vacuum hose50away from power tool28and sanding system24to limit potential interference or obstruction by vacuum hose50in the sanding process. Hose mount76may be secured to either support72a,72bdepending on a user's preference. Alternatively, a clamp or clip fastener could be used to secure vacuum hose50to alignment heel36.

As shown inFIGS.2and3, sanding portion24is selectively attachable to reciprocating part26of power tool28via an attachment in the form of a curved shank78. Curved shank78has a longitudinal leg78aand a latitudinal leg78b, the latter extending through access hole46to connect to sanding portion24. Latitudinal leg78bincludes a series of latitudinally spaced-apart connective features in the form of through-holes or threaded through-holes configured to receive a threaded bolt (which may be inserted and/or threaded through the through-holes into a nut) to allow sanding portion24to be secured to latitudinal leg78bat various latitudinal locations depending on user preference. It will be understood that a curved shank or attachment may vary depending on the configuration or type of tool to which a sanding portion is being attached, or the varying characteristics of a sanding portion itself. Reciprocating part26of power tool28is typically powered by an electromechanical or pneumatic force (such as is provided by a battery, an electrical outlet, or an air compressor, for example) to move back and forth in a longitudinal direction. The reciprocating movement of reciprocating part26similarly causes shank78to reciprocate in the longitudinal direction, where access hole46is elongated in the longitudinal direction to accommodate the reciprocating motion of latitudinal leg78b. The reciprocating motion of shank78is transferred to sanding portion24, thus enabling sanding portion24to reciprocate against a surface in order to sand, smooth, and/or flatten portions of the surface. It should be appreciated that an attachment may be secured to a sanding tool in a manner that varies from what has been described above. For example, an enclosure may include one or more connective features to which an attachment may be secured, such that the attachment would still secure a sanding portion to a reciprocating portion of a power tool.

Sanding portion24reciprocates through a neutral or central position (FIGS.6B and7B), a first or forward position (FIGS.6A and7A), and a second or rearward position (FIGS.6C and7C) relative to vacuum portion30while sanding wall22. In the central position ofFIGS.6B and7B, both inlets34a,34bare covered. In the forward position ofFIGS.6A and7A, forward inlet34ais covered and rearward inlet34bis uncovered. In the rearward position ofFIGS.6C and7C, forward inlet34ais uncovered and rearward inlet34bis covered. Accordingly, forward inlet34aor rearward inlet34bmay be covered by sanding portion24, where the uncovered inlet34aor34balternates depending on whether sanding portion is in the forward position or the rearward position. As a result, the majority of the suction force generated by a vacuum attached to vacuum portion30will be imparted through only a single inlet34aor34bwhile sanding portion24is in the forward or rearward position, thus resulting in increased suction power through the uncovered inlet as compared to if both inlets34a,34bwere uncovered.

Because inlets34a,34bare spaced apart near opposing ends of enclosure44, the suction force is rapidly and continuously redirected between alternating locations based on the frequency of reciprocation of sanding portion24. These characteristics result in increased suction power at both inlets34a,34bto more effectively recover dust and debris from the working surface as the user is sanding the working surface. Material abraded away or otherwise separated from the working surface during the sanding process is suctioned or vacuumed into inlets34a,34bto enter enclosure44. From enclosure44, the material moves through duct48and then vacuum hose50. Vacuum hose50may be fluidly connected to a vacuum such as a shop vacuum having a reservoir to store recovered material. It should be appreciated that an alternative vacuum portion may include more than two inlets and/or inlets that are arranged in a different configuration such that a sanding portion still moves to alternatively cover and uncover one or more inlets at various locations.

The above-described debris collection process is achieved in part due to the position of vacuum portion30relative to sanding portion24. As previously noted, enclosure44is located inboard of sanding portion24in both the latitudinal direction and the transverse direction, and inlets34a,34bare defined by distal side44aof enclosure44. As shown inFIGS.2and4, distal side44aof enclosure44is slightly spaced from sanding portion24such that pads38,40do not make physical contact with inlets34a,34b. Therefore, sanding portion24moves to cyclically cover and uncover the inlets34a,34bin an alternating fashion. AlthoughFIGS.7A-7Cshow that one or both inlets34a,34bare covered or obscured by sanding portion24at different positions, the inlets are not necessarily sealed closed, such that there can be continuous airflow through inlets34a,34beven when covered or partially covered. Thus, inlets34a,34bare considered to be substantially covered when at least a majority of their surface areas are covered or overlaid by sanding portion24, even though there may be continuous airflow into the inlets34a,34bwhen so covered. Likewise, inlets34a,34bare substantially uncovered when a majority of their surface areas are uncovered or not overlaid by sanding portion24. These characteristics improve the effectiveness of debris recovery by inlets34a,34bin part because inlets34a,34bare located relatively close to the working surfaces while using a corner sanding attachment such as sanding portion24. Additionally, the positions of sanding portion24and vacuum portion30provide a spatially compact configuration of components that both sand and recover debris from a working surface. It should be appreciated that an alternative sanding system may include a sanding portion moves to completely cover (and/or seal) and uncover vacuum portion inlets. It should also be appreciated that the advantages of the invention may be achieved when the cyclical motion of sanding portion24moves to at least partially cover and at least partially uncover inlets34a,34b.

Alignment heel36includes surface guides60,62to provide sanding system20with a second area of contact with wall22that is spaced from and aligned with sanding portion24(the first area of contact). Outboard portions of alignment heel36and sanding portion24terminate in common contact planes. That is, the outer sides60a,62aof each guide60,62are coplanar, in respective contact planes, with respective contact portions38a,40aof sanding portion24. Guides60,62are also made of or covered with a smooth and/or soft material, such as felt, to allow them to slide along a working surface without scratching, damaging, or otherwise substantially removing material from working surface, but that also provides guides60,62with a suitable level of friction to prevent sudden movements or inadvertent slipping of guides60,62relative to the working surface during the sanding process. As a result, alignment heel36promotes proper alignment and uniform contact between sanding portion24and wall22by both stabilizing and constraining undesired movements of sanding portion24. As discussed above, a sanding portion may be equipped with backing pads having varying geometric profiles that are designed for sanding surface areas other than an internal corner. Similarly, an alignment heel may also be equipped with surface guides having geometry that varies depending on the particular backing pads being used for sanding such that any given combination of backing pads/surface guides each terminate in an outboard direction in one or more common contact planes.

Accordingly, the sanding system of the present invention provides an effective way to sand a working surface while simultaneously vacuuming away sanding dust or debris, and maintaining desired alignment with the surface(s) being sanded. A sanding portion is attached to a power tool that reciprocates or moves the sanding portion to sand the working surface. The sanding portion moves relative to a vacuum portion during the sanding process to alternatively cover and uncover a pair of spaced apart inlets that are used to recover debris from the working surface. An alignment heel is spaced apart from and aligned with the sanding portion to promote stability and uniform contact pressure between the sanding portion and the working surface during the sanding process.