Abstract:
Disclosed is a sander tool suited for sanding planar surfaces, and mechanisms enabling the pivoting of an ergonomic handle. Also disclosed is a sander tool having a detachable pole for use in reaching areas located outside the user&#39;s normal reach.

Description:
FIELD  
       [0001]     The invention generally pertains to the field of construction tools, and more particularly to sander tools having a pivoting handle mechanism, to aid in the sanding of surfaces.  
       BACKGROUND  
       [0002]     Sanding tools are used to finish surfaces, such as seams between drywall panels where excess drywall compound has been applied, or in smoothing other surfaces perhaps as a preliminary step to further finishing steps such as applying paints, varnishes or adhesives.  
         [0003]     A problem exists, however, when sanding surfaces within a room which contains both wall sections which are easily within reach, as well as surfaces which one cannot easily reach without some sort of assistance. This problem has been previously solved through the use of such items which elevate the user, such as drywall stilts, drywall benches, ladders, and the like. These solutions, because they place the user at an elevated position, place the user at risk of being injured by a fall. In addition, it is cumbersome to lug around this additional equipment and time consuming to set up and change positions using these devices. Other solutions involve the use of separate hand sander devices for the vertical surfaces which are within reach, and then a separate sanding tool having a pole attached for the out-of-reach surfaces, such as ceilings. The problem with this last approach is in having twice the number of tools necessary to finish the surfaces. Not only does the user have to keep track of and carry these extra items to each jobsite, but he or she has to be careful to maintain the same type and grit of sandpaper loaded in each so that the resulting surface finishes match one another.  
         [0004]     The applicants&#39; Sander Tool Apparatus, the subject of U.S. Pat. No. 4,885,876, provides for interchangeable top structures of a sanding tool—one with a handle for sanding surfaces within the user&#39;s reach, and one with a universal joint and threaded pole coupler, in addition to a threaded pole, for reaching distally located surfaces.  
         [0005]     The present disclosure discloses a sander tool which solves many of these problems that are associated with existing sander tools. It will be appreciated that the disclosure may disclose more than one invention. The invention(s) is(are) pointed out with particularity in the claims annexed hereto and forming a part hereof.  
       BRIEF SUMMARY  
       [0006]     The invention(s) generally relate to sander tools suited for sanding planar surfaces.  
         [0007]     A preferred embodiment of a sander tool includes an ergonomically shaped handle which is pivotally connected to a housing which includes a unit base and a unit pedestal. The handle pivots about a first pivotal axis through a wide range of angles to accommodate a variety of comfortable arm, wrist, and hand positions for the sanding of surfaces.  
         [0008]     In one embodiment, the ergonomic handle includes an upper portion, an intermediate portion, and a lower portion. The upper portion is suitable for gripping by the user; the intermediate portion extends downward at both a first and a second end with an open area between the first and second ends to allow for the placement of the user&#39;s hand between the upper portion and the lower portion. The lower portion of the handle contains the first pivotal axis, defined by a pair of handle pivot cones, and is pivotally attached to a pivotal handle mounting surface of the housing.  
         [0009]     A preferred embodiment of a sander tool also includes sandpaper retention mechanisms for releasably retaining the sandpaper on the back surface of a unit base.  
         [0010]     In one embodiment, the retention mechanism includes a sandpaper retainer pivotally connected to a housing about a third pivotal axis. In addition, latches, integrally molded with the housing member, are provided for releasably latching the sandpaper retention mechanism in a closed position.  
         [0011]     One advantage of one embodiment of the sander tool is that it saves the user the inconvenience of suffering strained arm, hand, and finger muscles and ligaments which readily occurs with standard hand sanders.  
         [0012]     Another preferred embodiment of a sander tool includes a pivoting pole assembly which additionally allows the user to conveniently sand surfaces which are not within reach by simply attaching a pole to a pivotal pole connector. The pivoting pole is preferably connected to a pivotal pole connector located inside an upper portion of a handle through the use of mating threads, although other suitable fastening methods might be utilized.  
         [0013]     One embodiment relates to a kit assembly including a sander tool with a pivotal pole connector and a pole, whereby the sander tool can be readily converted from a hand sander to a pole sander upon releasable attachment of the pole to the pivotal pole connector. Another embodiment relates to a kit assembly including a sander tool with sheets of sandpaper. Yet another embodiment relates to a kit assembly including a sander tool, a pole, and sheets of sandpaper.  
         [0014]     The above-mentioned advantages of the various embodiments are only representative and illustrative. The invention(s) is (are) pointed out with particularity in the claims annexed hereto and forming a part hereof. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]      FIG. 1  is a perspective view of a preferred embodiment of a sander tool.  
         [0016]      FIG. 2  is an exploded view of the embodiment shown in  FIG. 1  with a pivoting handle and a pivoting pole connector.  
         [0017]      FIG. 3  is a side view of the embodiment shown in  FIG. 1  showing both sandpaper retainers pivoted to an open position so that sandpaper may be loaded on to sandpaper retaining spikes.  
         [0018]      FIG. 4  is a front view of the embodiment shown in  FIG. 1  showing the range of motion of the pivoting handle (shown in broken lines).  
         [0019]      FIG. 5  is a perspective view of the embodiment shown in  FIG. 1  of a sander tool showing a pole attached to the pivoting pole connector which allows the user to sand out-of-reach surfaces.  
         [0020]      FIG. 6  is a side view of the embodiment shown in  FIG. 1  showing the range of motion of the pivoting pole connector (shown in broken lines).  
         [0021]      FIG. 7  is a plan view of the embodiment shown in  FIG. 1 . 
     
    
     DETAILED DESCRIPTION  
       [0022]     Referring to the drawings, wherein like reference numerals generally designate identical or corresponding parts throughout the several views, and more particularly to  FIGS. 1 and 2 , there is shown a preferred embodiment of a sander tool having many components, designated generally by the numeral  20 .  
         [0023]     The sander tool  20  includes a housing  70  to which a handle  30  is pivotally attached at a first pivotal axis  22  which is located in a longitudinal direction of the sander tool  20 . The housing  70  includes a unit base  40 , which has a substantially planar bottom side, and a unit pedestal  50  which is attached to the top side of the unit base  40 . Preferably, the sander tool is three inches wide and of such a length that a user can cut a standard 9″*11″ piece of sandpaper in thirds and has no waste of the sandpaper. The handle  30  pivots about the first pivotal axis  22  through a wide range of angles to accommodate a variety of comfortable arm, wrist, and hand positions for the sanding of surfaces. In addition, the handle includes an upper portion  74 , an intermediate portion  76 , and a lower portion  78 . The upper portion  74  is suitable for gripping by the user; the intermediate portion  76  extends downward at both a first and a second end with an open area between the first and second ends to allow for the placement of the user&#39;s hand between the upper portion  74  and the lower portion  78 . The lower portion  78  of the handle  30  contains the first pivotal axis  22 , defined by a pair of pivotal cones  38 , and is pivotally attached to a pivotal handle mounting surface  52  of the unit pedestal  50  of the housing  70 . As shown in  FIG. 2 , the preferred embodiment of the sander tool  20  is made to be conveniently assembled through the use of resilient snap-fit features on the components, and thus does not require screws, and the like in the assembly of the sander tool  20 . Other embodiments, however, may include threaded screws or other fasteners in assembly.  
         [0024]     Embodiments optionally include a foam pad  90  attached to the planar bottom side of the unit base  40 . The foam pad  90  is made from a foam material such as polyethylene or urethane foams, for example, and is preferably at least 1/16″ thick. The foam pad  90  helps accommodate imperfections in the sanding surfaces and may be adhesively mounted to the unit base  40  using common adhesives, or preferably double-sized adhesive tape.  
         [0025]     Sandpaper retention mechanisms are located at each end of the housing  70 , as shown in  FIG. 3  (without the sandpaper). In the preferred embodiment, a sandpaper retainer  60  is pivotally connected at a third pivotal axis  26  to each end of the housing  70 . In addition, a resilient latch  64  is integrally molded with the unit base  40  of the housing  70  for releasably latching the sandpaper retainer  60  in a closed position. The latch  64  is outwardly biased for engagement with the sandpaper retainer  60 . Sandpaper retaining spikes  66  are also integrally molded into the unit base  40 , and mating sandpaper retainer bosses (not shown), which secure the sandpaper on the sandpaper retaining spikes  66 , are integrally molded into the sandpaper retainer  60 .  
         [0026]      FIG. 4  shows an angle Ψ (from vertical, as shown) through which the handle  30  may rotate about the first pivotal axis  22  (which has a direction perpendicular to  FIG. 4 ), in either direction. In the embodiment shown, the handle may rotate through an angle Ψ of about 60° in either direction from vertical, although other embodiments may include rotation through an angle Ψ of 90° in either direction from vertical. It is preferred that the angle Ψ be through an angle of at least 60° in either direction of vertical; more preferably the angle Ψ may be through an angle of at least 30° in either direction from vertical; most preferably the angle Ψ may be through an angle of at least 20° from vertical.  
         [0027]     Referring now to  FIG. 5 , a perspective view of the sander tool  20  with a pole  80  pivotally connected to the handle  30  by a pivotal pole connector  36 . The pivotal pole connector  36  is conveniently recessed within the upper portion  74  of the handle  30  so that its  36  outer surface is flush with the handle  30  so that the pivotal pole connector  36  does not interfere with gripping the handle  30  while using the sanding tool  20  on surfaces in close proximity to the user.  
         [0028]     In order to sand surfaces located at a distance from the user, the user simply rotates the pivotal pole connector  36  upward slightly, attaches the pole  80 , which in the embodiment shown is threaded, to the pivotal pole connector  36 , by, for example, threading the pole into an internally threaded cylindrical receptacle  72  located at either end of the pivotal pole connector  36 . Other embodiments include a pole  80  connected to a sander tool  20  using quick-release connectors, for example, bayonet-type fittings, snap-fit connectors, and the like.  
         [0029]      FIG. 6  shows an angle Φ (from horizontal) through which the pivotal pole connector  36  may rotate about a second pivotal axis  24  in either direction. The second pivotal axis  24  is orthogonal to the first pivotal axis  22 . In the embodiment shown, the pivotal pole connector  36  may rotate through an angle Φ of 30° in either direction from horizontal, although other embodiments may include rotation through an angle Φ of 90° in either direction from horizontal.  
         [0030]     Additionally, a preferred embodiment has a thin wall construction thereby providing a light weight sander. In addition to being light weight, the sander tool includes reinforcement structure such that it is strong and rigid. The components are preferably molded from plastic compounds, although die-casting methods would additionally work using appropriate metal alloys. It will be appreciated that the unit base and unit pedestal structures are designed so that in molding, there is no need for cams, which results in faster molding and a lower mold cost. In addition, the sander tool is preferably held together through the use of snap-fit joints, although other assembly techniques involving such methods as sonic welding and/or the use of fasteners, such as threaded fasteners is contemplated and may be used.  
         [0031]     In addition, level of friction between the bearing surfaces, may be tailored through various mechanisms well known to skilled artisans, so that, for example, the components are free standing. This applies to the components of all three pivotal axes  22 ,  24 , and  26  of the pivotal sander  20  in the case where a pole is not attached.  
         [0032]     In one embodiment of the present invention, the sander tool  20 , and the threaded pole  80  might be sold as a kit assembly, thereby effectively providing two sander tools in one kit. The kit may additionally include sheets of sandpaper.  
         [0033]     In use, sandpaper is first secured to the pivotal sander  20 . To secure sandpaper, the latch  64  is depressed, the sandpaper retainer  60  is lifted, as shown in  FIG. 3 , and the end of the sandpaper piece is pushed downward so that sandpaper retaining spikes  66 , integrally molded into the unit base  40 , pierce through the sandpaper. Then the sandpaper retainer  60  is pushed back into place, the latch re-engages the sandpaper retainer  60 , and sandpaper retainer bosses (not shown) located on the underside of the sandpaper retainer  60  hold that end of the sandpaper in place. The same procedure is then repeated at the other end of the pivotal sander, and the unit is operational.  
         [0034]     Next, if the user wishes to sand surfaces located within arm&#39;s reach, he or she grips the pivotal sander  20  by the upper portion  74  of the handle  30 , with fingers freely extending within the intermediate portion  76 , positions the bottom side of the unit base  40  on the surface to be sanded, and moves the unit back and forth while applying pressure, preferably along the longitudinal (lengthwise) axis of the unit, until the desired surface finish is achieved. Using various grit sizes of sandpaper may be required for efficiently obtaining the desired result, depending upon the particular circumstances.  
         [0035]     Alternately, if the user wishes to sand surfaces located at a distance, he or she threads a threaded pole into the pivotal pole connector  36  of the handle  30  until tight. Next, he or she positions the bottom side of the unit base  40  on the surface to be sanded, and moves the unit back and forth while applying pressure, preferably along the longitudinal (lengthwise) axis of the unit, until the desired surface finish is achieved.  
         [0036]     It should be understood that even though these numerous characteristics and advantages of various embodiments have been set forth in the foregoing description, together with details of the structure and function of the embodiments, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principals of the invention(s) claimed in the appended claims to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.