Abstract:
A buffing ball is made from two layers of tufted wool or synthetics cut to identical  FIG. 8  shape and secured to the outer surface of a spherical member, preferably by stitching.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority from U.S. Provisional Patent Application Ser. No. 60/888,783, filed Feb. 8, 2007. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates to power-driven rotary devices for buffing and finishing surfaces, such as painted or clear coat finishes, and more particularly, to such a buffing and polishing device in a spherical shape using tufted wool (or wool-like materials) or wool yarn. 
         [0003]    Buffing pads and the like made of natural wool, polymeric foams, and other synthetic materials have long been used to buff and polish surfaces. Conventional flat-faced pads have evolved to include pads with curved faces and other surface treatments intended to enhance performance. Also known in the prior art are buffing, polishing and finishing pads which have a generally spherical shape. These spherical buffing and polishing balls have been made from polymeric foam materials which are uniquely cut and compressed to form a spherical shape. Such spherical buffing balls have gained wide acceptance because of their utility in fishing contoured surfaces and in permitting operators to reach into and through small openings and other recesses and crevices that were typically difficult to reach with pads having generally flat operating faces. 
         [0004]    However, it would be useful to have a power-driven rotary buffing and polishing ball that uses natural wool or other wool-like materials, in addition to known buffing balls made of polymeric foam materials. 
       SUMMARY OF THE INVENTION 
       [0005]    In accordance with the present invention, a sphere of a suitable material is covered with a tufted wool, and a driving stub shaft is attached to the center sphere to provide connection to a powered driver for rotary buffing and polishing. The center sphere may be made of a wide range of materials, including hard metal or plastics, softer plastics, and even foam. The tufted wool covering preferably comprises a scrim fabric of jute, cotton, synthetics or other suitable backing material to which the wool fibers are attached in a conventional tufting process. The tufted wool is cut into two identical figure eight patterns which are attached to the inner sphere in a manner similar to the manufacture of a baseball. Thus, the figure eight sheets can be stitched together, but the figure eight sheets may also be attached to the sphere in another manner, such as bonding with glue or the like. The size of the center sphere may vary widely and the length of the wool fibers on the tufted sheets may also vary widely from relatively short to quite long nap. The stitching pattern is significant because the inherent curvature of the seam minimizes or eliminates rotational “thumping” that is often produced in rotary buffing tools having extended linear seams. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is a side view of a tufted wool buffing ball of the present invention shown attached to a powered driver. 
           [0007]      FIG. 2  is a plan view of the back sides of the two figure eight tufted wool covers used to make the buffing ball of  FIG. 1 . 
           [0008]      FIG. 3  is a cut-away view of one embodiment of the  FIG. 1  buffing ball. 
           [0009]      FIG. 4  is a cut-away view of another embodiment of the  FIG. 1  buffing ball. 
           [0010]      FIG. 5  is a sectional view through the buffing ball taken on line  5 - 5  of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0011]    A spherical buffing ball  10  includes an outer covering of tufted wool  11 , as shown in  FIG. 1 . The tufted wool cover  11  is made from two identical figure eight cover pieces  12  that are conveniently sewn together and attached to enclose and cover a center sphere  13  (shown in  FIGS. 3-5 ). A short drive shaft  14  is attached to the sphere  13  to provide connection to a conventional powered driver  15  as shown in  FIG. 1 . 
         [0012]    Each of the cover pieces  12  includes a scrim fiber layer  16  to which the wool fibers  11  are attached in a conventional tufting process. The figure eight shape of the cover pieces is the same as the cover pieces of cowhide or the like which are used to cover a conventional baseball. The scrim layer  16  may be of woven jute, cotton, or other materials, including synthetics. Similarly, the tufted wool may be replaced by or blended with synthetic fibers, just as tufted wool and tufted synthetics are used in the manufacture of rugs and carpets. 
         [0013]    The center sphere  13  (and correspondingly the cover pieces  12 ) can be of any size to suit the needs of the user. The sphere  13  may be made of a wide variety of materials ranging from very hard to very soft. Thus, hard metal spheres can be used, as well as a wide range of plastics from hard to quite soft, and the sphere  13  may even be made of a polymeric foam or similar highly compressible material. A range of core softness will affect the way the buffing ball  10  conforms to the working surface. The sphere  13  shown in  FIG. 5  is formed from two semi-spherical halves  18  glued or otherwise secured together. 
         [0014]    In accordance with one method for making a buffing ball  10  of the present invention, the two cover pieces  12  are sewn together as with a stitched seam  17 , except for portions along a common edge that provide an opening large enough to allow the center sphere  13  to be inserted therethrough. After the center sphere is inserted, the stitching may be completed to finish the covering. Alternately, the opening may be positioned to surround the drive shaft  14  and the unstitched portions glued to the surface of the sphere  13 . See  FIG. 3 . 
         [0015]    It is also possible to attach the cover pieces  12  to the sphere  13  by bonding with a suitable adhesive as shown in  FIG. 4 . However, the stitched baseball-like attachment of the cover pieces  12  is presently preferred. 
         [0016]    In the embodiment described herein, the cover pieces  12  are made of tufted wool using a conventional scrim fabric backing. However, sliver knit wool or natural sheepskin cover pieces may also be used. In addition, the wool fibers may be attached in an untwisted form thereby providing the outer surface of the buffing ball  10  with a longer fiber and more fuzzy appearance. Further, blends of wool with acrylic or polyester or even all synthetic fibers can be used. 
         [0017]    The spherical wool buffing ball  10  of the present invention follows the recent development and successful introduction of the polymeric foam buffing ball. However, in certain finishing operations, wool provides the user the ability to provide a finish that cannot be achieved with polymeric foam materials.