Abstract:
The elastic drive belt system connects the belt directly to a drive shaft and driven pulley. The elastic drive belt has a plurality of longitudinal ribs on the traction side of the belt. The drive shaft has a plurality of grooves sized and arranged to receive and engage the longitudinal ribs on the belt to facility torque transfer and alignment. This system facilitates delivery of relatively high amounts of torque to the driven pulley using relatively low horsepower motors. In many applications, such as a sander, the elastic drive belt system eliminates the need to readjust the tension on the belt as it wears.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a continuation application of U.S. patent application Ser. No. 11/672,817, filed Feb. 8, 2007, currently pending; the entire disclosure of which is hereby incorporated by reference. 
     
    
     BACKGROUND OF INVENTION 
       [0002]    The present invention uses an elastic drive belt assembly containing tensile cord members with elastic properties that does not require retensioning as the belt wears. This elastic drive belt assembly can be used in many different applications, such as wooden floor sanders, floor cleaning machines, metal cutting and grinding equipment, compressors, pumps, wood working equipment, etc. 
         [0003]    Belt driven sanders for wooden floors have traditionally been produced for decades with conventional non-elastic drive belts with tensile cords passing around a drive and driven pulley. Since the tensile cords are inelastic they permanently elongate as they wear. This permanent elongation reduces the tension in the belt which often ultimately causes the belt to slip and not properly drive the sanding pad. Therefore, conventional belts have to be retensioned as the belt wears and stretches. Other prior art belt driven sanders use synchronous “timing” type belts with a drive pulley and a driven pulley. Pulleys for synchronous drives are more expensive than conventional pulleys since teeth are machined into them. Manufacturing variability in the pulleys also increase the probability (due to additional manufacturing variability) of machine induced vibration. In addition, to possibly increasing operator fatigue and component failures, vibration can also cause “chatter” which appears as undesirable marks on the wooden floor being sanded. 
         [0004]    Clarke® American Sanders has been producing sanders for wooden floors for decades. Some of these sanders are used to sand the wooden floor where it abuts a wall and are thus called “edgers” in the trade. One such sander is the Clarke American Super E Edger described in the Operators Manual and Parts and Service Manual included in the Information Disclosure Statement. The body of this Super E Edger is produced separately from the kick-toe extension so that the tension on the conventional drive belt can be adjusted as the belt stretches. This is an added expense in the manufacture of the sander. Specifically, there are elongate channels in the kick-toe extension that can be adjusted relative to the body with wing nuts or conventional nuts and bolts. Adjustment of a worn belt can be time consuming and often requires tools. There is a need to reduce/eliminate this time consuming adjustment procedure and reduce the cost of production for this type of sander and other belt driven products. 
         [0005]    Further, the Clarke Super E sander can produce noise in excess of about 95 dB(A). Since the noise scale is logarithmic, slight numeric reductions in the dB(A) value can significantly reduce the amount of emitted noise in the environment. 
         [0006]    Some vacuum cleaners, like the venerable Kirby® vacuum have used elastomeric drive belts wrapped around a drive shaft that has a slight taper to keep the drive belt in place. These Kirby drive belts do not have longitudinal ribs, nor does the drive shaft have grooves. The typical motor in a vacuum cleaner is thought to have a nominal rating of about 0.5 hp or less and the drive shaft is thought to have speeds of about 16-20,000 rpm. This results in a low transfer of torque of about 1.5 to about 3 inch pounds. There is still a need for a drive belt system that can transfer higher amounts of torque such as those needed in the sander industry and other high load applications. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention is an elastic drive belt assembly that includes a) a elastic drive belt possessing longitudinal ribs on the traction side of the elastic drive belt, b) a drive shaft with grooves sized and arranged to receive and engage the ribs on the elastic drive belt and c) a driven pulley. Since the elastic drive belt assembly does not permanently elongate, the belt does not need to be re-tensioned as it wears. Conventional non-elastic drive belts require adjustment as the belt wears and stretches. Costs for assembly and manufacture of products that utilize this elastic drive belt assembly should be less than some prior art designs that use non-elastic drive belts. Products that use this invention should require less maintenance because the elastic drive belt will not require readjustment as the belt wears and stretches. One specific application of this elastic drive belt assembly is a sander for wooden floors commonly referred to as an edger. In addition, the edger of the present invention should be quieter than some prior art edgers. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a perspective view of the sander for wooden floors viewed from the right front of the apparatus. 
           [0009]      FIG. 2  is a left side elevation view of the sander of  FIG. 1  and also illustrates an attached vac hose. 
           [0010]      FIG. 3  is a top view of the sander of  FIG. 1   
           [0011]      FIG. 4  is a bottom perspective view of the sander of  FIG. 1  with the bottom dust plate in place. 
           [0012]      FIG. 5  is identical to  FIG. 4  except the bottom dust plate has been removed. 
           [0013]      FIG. 6  is a left side section view of the sander, similar to  FIG. 2 . 
           [0014]      FIG. 7  is a section view of the sander taken along the line  7 - 7  of  FIG. 6 . 
           [0015]      FIG. 8  is a section view of the sander taken along the line  8 - 8  of  FIG. 6 . 
           [0016]      FIG. 9  is a section view of the drive assembly including the drive shaft, drive belt and the driven pulley. 
           [0017]      FIG. 10  is an enlarged section view of the grooves in the drive shaft and a ion of the elastic drive belt. 
           [0018]      FIG. 11  is a left side elevation view of the sander of  FIG. 2 , except a dust collection bag has been substituted for the vac hose. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0019]    Referring now to  FIGS. 1-3 , a sander for wooden floors is generally identified by the numeral  20  and is often referred to as an “edger”. The sander  20  includes a lower body  22  connected to a motor housing  90 . The lower body  22  is supported by a left caster assembly  24  and a right caster assembly  26 . The motor housing defines a left handle  28  and a right handle  30 . In the right handle is an on/off switch  32  and in the left handle is an optional motor speed switch  34 . A light assembly  36  is positioned in the upper part of the body so the light shines down on the floor in front of the sander. 
         [0020]    The sander is driven by an electric motor  38 , better seen in  FIG. 6 . An electric cord,  40  provides electricity to the electric motor and the light assembly. In normal sanding operation, the dust emitted during the sanding process passes through a vac hose  42  to a dust collection receptacle, not shown such as an industrial vacuum cleaner. Operators generally move from the left to the right while sanding a floor, so it is convenient to have the electric cord  40  and the vac hose  42  positioned on the left of the sander  20  to allow unencumbered movement to the right. In an alternative embodiment, better seen in  FIG. 11 , a removable dust collection bag is used in lieu of the vac hose and dust collection receptacle. The dust collection bag may also be referred to as a dust collection receptacle. A bumper  44  is positioned at the front of the sander to prevent damage to walls. A sanding disk  46 , better seen in subsequent figures rotates clockwise immediately below the bumper. Sanding paper  48  is attached to the sanding disk  46  by a bolt  54  and washer  55 . 
         [0021]    Referring now to  FIGS. 4-8 , the internal components of the sander are shown in various views. The sanding disk  46  is attached to the sanding disk driver  50  by a plurality of screws  52 . The sanding disk driver  50  threads onto the shaft  104  of the driven pulley  102 . Rotation of the drive shaft  56  imparts rotational motion via the elastic drive belt  100  to the sanding disk driver  50 , the sanding disk  46  and the sanding paper  48  which is in contact with the wooden floor. 
         [0022]    In  FIG. 4  the bottom dust plate  58  is attached to the body by screws  60 . In  FIG. 5 , the bottom dust plate has been removed to better show the flow of dust through the sander. An external dust containment wall  62  surrounds most of the perimeter of the rotating sanding paper  48 . The bottom dust plate  58  and the external dust containment wall  62  define a dust containment chamber  63 . A dust fan shroud  64  partially surrounds the dust fan blade element  66  and defines the inlet  68  for the dust fan assembly  70 . The dust fan blade element  66  mounts on the bottom of the motor drive shaft  56  and is secured in place by a retaining key  72  and ring  73 . 
         [0023]    The flow of dust through the sander  20  is best seen in  FIGS. 5 and 6 . Rotation of the dust fan blade element  66  inside the dust fan shroud  64  creates negative pressure at the inlet  68  of the dust fan assembly  70 . This negative pressure draws the dust from the dust containment chamber  63  through the inlet  68  as indicated by the flow arrows in  FIG. 6 . The dust then exits the dust fan assembly  70  through the outlet  74 , best seen in  FIGS. 6 and 8  and passes through the dust exhaust duct  76 , as shown by the flow arrows, through the vac hose to a dust collection receptacle, not shown or a dust collection bag, best seen in  FIG. 11 . 
         [0024]    Referring to  FIG. 8 , a motor cooling fan assembly  82  includes a cooling fan blade element  84 , motor cooling air inlets  86 , fan intake baffle  87 , a first motor cooling air outlet  88  and a second motor cooling air outlet  89 , better seen in  FIGS. 5 and 6 . The motor cooling air inlets  86  are located under the left and right handles  28  and  30  and are best seen in  FIGS. 4 and 5 . The electric motor  38  is positioned in the motor housing  90 , as best seen in  FIG. 6 . The cooling fan blade element  84  is mounted on the motor drive shaft  56 . Rotation of the motor drive shaft causes the cooling fan blade element to rotate which creates negative pressure at the motor cooling air inlets  86 . The negative pressure draws ambient air through the motor cooling air inlets  86  and between the motor  38  and the motor housing  90  as shown by the flow arrows in  FIG. 6 . The ambient air flowing past the motor components provides convective cooling and draws away heat, thus cooling the motor. The heated air then exits the body through the first motor cooling air outlet  88  and a second motor cooling air outlet  89  as shown by the air flow arrows in  FIG. 6 . The second motor cooling air outlet  89 , also seen in  FIG. 5  directs some of the motor cooling air towards the floor. Therefore, rotation of the motor drive shaft imparts rotational motion to both the cooling fan blade element  84  and the dust fan blade element  66 . Rotation of the cooling fan blade element  84  cools the electric motor  38  and rotation of the dust fan blade element  66  helps to control unwanted dust caused by the sander  20 . 
         [0025]    Further, applicants believe that the present invention will reduce the noise level during operation when compared with a prior art sander like the Clarke Super E Edger. This anticipated noise reduction should occur due to several reasons. First, the present invention uses a smaller diameter cooling fan blade element  84  and smaller diameter dust fan blade element  66  than some prior art devices. The smaller diameter means that the tip speed is less which in turn decreases the noise level. In one embodiment, the diameter of the cooling fan blade element  84  of the present invention is about 3.75 inches and the diameter of the cooling fan blade in the Super E Edger is about 4.35 inches. Second, the flow path of the cooling air is more tortuous in the present invention than some prior art devices. For every 90 degree change in direction that the cooling air takes, there is an approximate 3 dB(A) reduction in noise. The motor cooling air inlet  86  of the present invention is located under the handles of the sander, which is directed away from the operators ear, unlike some prior art devices. Furthermore, some of the motor cooling air discharge is directed towards the floor through second motor cooling air outlet  89 , best seen in  FIG. 5 , and some is directed out the side of the motor housing  90  through the first motor cooling air outlet  88 , best seen in  FIG. 6 . The diameter of the dust fan blade element  66  is about 3.75 inches and is less than the 5 inch diameter of the dust fan blade element in the Super E sander. Reduction in fan diameter reduces fan tip speed and noise. 
         [0026]    Referring now to  FIGS. 6-10 , an elastic drive belt  100  wraps around the motor drive shaft  56  and imparts rotational motion to the driven pulley  102 . The outside circumference  103  of the driven pulley  102  may be smooth as shown in these drawings to further reduce production costs. However, if more torque needs to be transferred, the outside circumference of the driven pulley may also have grooves sized and arranged to receive and engage the longitudinal ribs in the elongate belt. The shaft  104  of the driven pulley  102  extends through one or more bearing assemblies  106  into the dust containment chamber  63 . The driven pulley  102  and the pulley shaft  104  can be formed from separate components or formed as one component. Applicants form the driven pulley  102  and the pulley shaft  104  as one component. The elastic drive belt assembly generally identified by the numeral  108  as best seen in  FIGS. 9 and 10  includes the elastic drive belt  100 , the motor drive shaft  56 , and the driven pulley  103 . The elastic drive belt assembly  108  may be positioned outside the dust containment chamber  63 , the dust exhaust duct  76  and the dust flow path to reduce fouling and contamination by dust and other particles. Likewise, the elastic drive belt assembly  108  may be positioned outside the motor cooling air flow path to reduce fouling and other contamination. 
         [0027]    As best seen in  FIGS. 9 and 10 , the elastic drive belt  100  receives torque direct from the motor drive shaft  56 . The Poly V® 6 PJ 450 Flexonic, elastic drive belt may be suitable to use in this invention and is available off-the-shelf from Hutchinson located at 1835 Technology Drive, Troy, Mich. 48083. This belt from Hutchinson has six PJ section longitudinal ribs  110  on the traction side of the belt, an overall nominal length of about 450 mm, and elastic cords that when installed are stretched (elongated) approximately 3½% over its nominal length. The cross section of the six ribbed belt is about 0.55 inch wide (14 mm) and about 0.157 inch tall. 
         [0028]    The electric motor  38  in this sander has a nominal horsepower rating of about 1.8 hp. The nominal speed for the motor drive shaft  56  is in the range of about 12,000 rpm to about 14,000 rpm, having an optimal speed of about 13,500 rpm. The nominal speed for the sanding disk is in the range of from about 2,800 rpm to about 3,200 rpm with an optimal working speed of about 3,000 rpm for a 7 inch sanding disk. In other words, there is a speed reduction of about 4.63:1. A motor speed of 13,500 rpm allows for good dust fan performance for a 3.75 inch OD fan. 
         [0029]    The sanding disk  46  is driven by the elastic drive belt  100  that extends from the motor drive shaft  56  to a driven pulley  102 . Speed is reduced by using a driven pulley  102  that is 4.63 times larger than the OD of the motor drive shaft  56 . The nominal diameter of the motor drive shaft is 1 inch, but it is turned down to an effective diameter of about 0.787 inches (20 mm) where the belt is installed. The minimum diameter of a drive shaft that is suitable for the PJ section belt is about 0.8 inches (20 mm). However, Hutchinson makes other elastic drive belts with a plurality of longitudinal ribs that may also be suitable in this or other applications. For example, the PH cross-section belt from Hutchison may be able to take torque from a drive shaft having a diameter as small as 0.25 inches (about 7 mm). 
         [0030]    The motor drive shaft  100  is machined with six grooves  112  that complement the six ribs  110  in the PJ elastic drive belt from Hutchinson. The grooves  112  contact the sides of each rib  110  and when coupled with the angle of belt wrap defines the total area of contact needed to impart the torque required to drive the sanding pad. Applicant believes that the dimensions for the grooves  112  as suggested for V-Ribbed Belts, cross sections PJ and PH, in the Rubber Manufacturers Association draft Standard RMA IP-26 are suitable for use in this invention. The present invention produces about 8 inch-pounds of torque using a nominal 1.8 hp electric motor with a drive shaft speed of about 13,500 rpm. Other cross section type V-Ribbed elastic belts such as PK, PL, and PM may also be suitable for use in this invention. 
         [0031]    The OD of the driven pulley is 3.854 inches (97.9 mm) and is smooth. There are no sidewalls on the pulley. Grooves are not needed in the driven pulley because there is sufficient contact area (pulley OD and amount of belt wrap) with the bottom of the six belt ribs to transfer the torque from the belt to the pulley. However, grooves may be added to the driven pulley to transfer more torque. 
         [0032]    The elastic drive belt has a plurality of ribs  110  on the traction side of the elastic drive belt and a flat surface on the opposite side of the drive belt. A plurality of grooves  112  are formed in the motor drive shaft  56  and are sized and arranged to receive and engage with the ribs  110  on the traction side of the elastic drive belt. In most prior art applications, a separate pulley is placed on the motor drive shaft and the drive belt is driven by this pulley. The present invention eliminates the need for this drive pulley and therefore is more economical to produce than some prior art devices. Eliminating the drive pulley also decreases the probability of machine induced vibration which can increase component failures, operator fatigue, and the presence of undesirable marks emitted to the floor being sanded. Furthermore, the elastic drive belt eliminates the need to readjust the tension on the belt as it wears, thus saving further on production costs of the sander and operational maintenance. Productivity increases as maintenance and service time are decreased. 
         [0033]      FIG. 11  is a side elevation view of the sander  20  similar to the sander in  FIG. 2 , except a dust collection bag  114  has been substituted for the vac hose  42 . In  FIG. 11 , the sander  20  is running and the dust collection bag  114  is shown in the fully expanded position since it is pressurized from the exhaust air from the dust exhaust duct  76 . The dust collection bag  114  may sometimes also be referred to as a dust collection receptacle.