Patent Publication Number: US-2003228833-A1

Title: Power tool and method of operating same

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
     [0001] This application is a continuation-in-part of pending application No. 29/162,046, filed Jun. 7, 2002, which is hereby incorporated herein by reference in its entirety. 
    
    
     
       BACKGROUND OF THE INVENTION  
       [0002] This invention relates generally to a power tool and, more particularly, to an electrically-powered polisher capable of rotating a pad to polish a workpiece.  
       [0003] The tool industry offers a variety of power tools for performing work on various types of workpieces. One common shortcoming, however, is that the power tools do not offer handles with enhanced gripping surfaces for an operator to use to grip the tool. For example, many power tools, such as polishers, are used outdoors in hot climates where operation of the tool often causes the operator to sweat, and possibly even involve operation of the tool in damp environments, such as, for example, near a recently washed vehicle. This often results in the operator having a difficult time in gripping and/or controlling the power tool due to a lack of enhanced gripping surfaces.  
       [0004] In addition, current power tool configurations may force the operator to continually hold a trigger in the “on” position in order to actuate the power tool. This forces the operator to expend more energy while operating the tool and can result in making the operator sweat more, thereby, complicating the already difficult task of maintaining a firm grip on the power tool.  
       [0005] Furthermore, the use of accessories in conjunction with the operation of the power tool may also be necessary. For example, power tools tend to leave residual particles from the workpiece or from substances used on the workpiece that could be picked up at the time of operation. It would be advantageous if the accessories were readily available or proximate to the power tool itself. This would promote maintaining a clean and obstacle free work environment.  
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0006]FIG. 1 is a perspective view of a power tool embodying features of the present invention;  
     [0007]FIG. 2 is a front elevational view of the power tool of FIG. 1;  
     [0008]FIG. 3 is a left side elevational view of the power tool of FIG. 1;  
     [0009]FIG. 4 is a plan view of the power tool of FIG. 1;  
     [0010]FIG. 5 is a bottom view of the power tool of FIG. 1;  
     [0011]FIG. 6 is an exploded view of the power tool of FIG. 1;  
     [0012]FIG. 7 is a cross-sectional view of the power tool of FIG. 1 taken along line  7 - 7  in FIG. 2;  
     [0013]FIG. 8 is a cross-sectional view of the power tool of FIG. 1 taken along line  8 - 8  in FIG. 3;  
     [0014]FIG. 9 is a partial perspective view of an alternate power tool embodying features of the present invention; and  
     [0015]FIG. 10 is a partial exploded view of the power tool of FIG. 9. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
     [0016] In FIGS.  1 - 8 , there is illustrated a power tool  20  embodying features of the present invention for working (e.g., waxing, buffing, polishing, etc.) on a workpiece. The power tool  20  includes a housing  22 , first and second handles  24  and  26 , respectively, connected to the housing  22 , and a work element, such as a pad  28 , for working on a desired workpiece, such as the body of an automobile or hull of a boat. The power tool  20  includes a symmetrical design about a vertical reference plane (not shown) extending centrally from the forward end of the tool  20   a  to a rearward end  20   b  (see FIGS. 3 and 4). The cross-section illustrated in FIG. 7 is taken along the vertical reference plane.  
     [0017] In a preferred embodiment, the tool  20  has a clamshell design with a first clamshell member  20   c  and a second clamshell member  20   d  which, when connected to each other, define a parting line  20   e  which extends in the vertical reference plane about which the tool  20  is generally symmetrical, as shown in FIGS. 4 and 6. As further illustrated in FIG. 6, the clamshell members  20   c  and  20   d  are secured together by a number of screws  21  which are recessed into bores defined by second clamshell member  20   d  and thread into internally threaded bores or post members  21   a  defined by first clamshell member  20   c . The clamshell members  20   c  and  20   d  can be made of any suitably lightweight material and, in a preferred embodiment, are molded plastic parts.  
     [0018] As illustrated in FIGS.  1 - 4 , the housing  22  is generally cylindrical in shape and includes a front portion  22   a , rear portion  22   b , top portion  22   c , bottom portion  22   d  (FIG. 7), and first and second side portions  22   e - f , respectively. Collectively the housing portions  22   a - f  define an internal cavity  30  within which at least a portion of motor  32  is disposed (see FIG. 7). The first handle  24  extends from the upper rear portion  22   b  of housing  22  and the second handle  26  extends from the upper front portion  22   a  of housing  22 . In addition, the bottom portion  22   d  of housing  22  is generally flat and the upper portion  22   c  forms a slightly convex arcuate surface. Furthermore, the edges of the housing  20  are generally arcuate to facilitate a generally smooth transition from one housing portion to another. For example, the edge between rear portion  22   b  and bottom portion  22   d  is rounded as illustrated in FIG. 7.  
     [0019] The upper portion  22   c  of housing  22  also includes a raised arcuate rim or wall portion  22   g  near the rear of the housing which defines a vent or passage to the cavity  30 , such as the elongated slot opening  22   h  illustrated in FIG. 1. The wall portion  22   g  curves along the periphery of the top surface  22   c  so that it remains flush with the rear housing portion  22   b  (see FIG. 3) and has gusset members  22   i  and  22   j  extending forward from the ends of the wall portion  22   g . In a preferred embodiment, the gusset members  22   i  and  22   j  each have two parallel gusset walls which taper downward to the top surface  22   c  of housing  22  as they extend toward the front  20   a  of the tool  20 .  
     [0020] As mentioned above, and illustrated in FIGS. 6, 7 and  8 , the housing portions  22   a - f  define a cavity within which motor  32  is disposed. The motor  32  is secured to the housing  22  using a mounting plate  34  and is supported and/or aligned laterally by ribs  22   k  which extend from the inner surface of at least one of the housing portions  22   a - g . As illustrated, several of the ribs  22   k  include an arcuate edge that compliments the body of the motor  32 . The mounting plate  34  includes a generally flat and rectangular plate structure  34   a  having a circular upstanding wall  34   b , a centrally located hub portion  34   c  (FIG. 7) and tabs  34   d  and  34   e  which extend outward from opposing side portions of the plate  34   a.    
     [0021] The circular wall  34   b  of mounting plate  34  extends upward from the plate structure  34   a  and forms an annular wall about a fan (not shown) which is positioned therein and driven by the motor shaft  32   a  in order to circulate air through, and cool, the motor  32 . The annular wall  34   b  includes notches  34   f  to assist in the circulation of air through the tool  20 . For example, in the embodiment illustrated in FIGS. 6 and 7, the motor  32  rests on the upper edge of the circular wall  34   b  and rotates the fan located therein in order to draw air through the vent  22   h  located in upper housing portion  22   c , down through holes in the top of the motor  32 , out the notches  34   f  of the mounting plate  34 , and eventually out of the cavity  30  via passages  22   n  located in the lower half of first and second side portions  22   e  and  22   f  (see FIGS.  1 - 3 ). The circulation of air cools the motor  32  during operation, which aids in preventing the overheating of motor  32 .  
     [0022] The hub portion  34   c  of mounting plate  34  extends upward and downward from the center of the plate structure  34   a  and defines a bore through which the motor shaft  32   a  is disposed and a socket within which bearing  36  is nested. As illustrated in FIG. 8, the motor output shaft  32   a  passes through the bearing  36  and bore of the hub portion  34   c . The bearing  36  assists the motor in operating more efficiently by aligning and guiding the rotational operation of the output shaft  32   a  and reducing the frictional forces encountered thereby. As will be discussed in further detail below, a portion of the hub  34   c  extending below the plate structure  34   a  helps to align the motor  32  with the bottom  22   d  of housing  22  and helps mount the plate  34  within cavity  30 .  
     [0023] The tabs  34   d  and  34   e  of mounting plate  34  define bores into which elongate screws or bolts (not shown) are thread in order to mount and secure the motor  32  to the mounting plate  34 . More particularly, the threaded bolts are fed through tab structures  32   b  and  32   c  (see FIGS.  6 - 7 ), which are located adjacent the top of the motor  32  and aligned with the mounting plate tabs  34   d  and  34   e , and are thread into the mounting plate tabs  34   d - e . In the embodiment illustrated in FIG. 7, the motor tab structures  32   b  and  32   c  have recessed portions into which the bolt heads are nested, and the mounting plate tabs  34   d  and  34   e  have recessed portions into which nuts are nested. Preferably, the recesses of the mounting plate tabs  34   d  and  34   e  will be complimentary in shape to the nuts in order to prevent the nuts from rotating while nested therein to assist in tightening the elongate bolts.  
     [0024] The motor  32  and mounting plate  34  are secured to the housing  22  by sliding at least a portion of the mounting plate  34  into a slot defined by the inner surface of at least one of the housing portions  22   a - g . As illustrated in FIG. 6, and in a preferred embodiment, the corners of plate structure  34   a  are inserted into slots  22   m  defined by the lower most rib  22   k  extending from the inner surfaces of first and second side portions  22   e - f  and the inner surface of bottom portion  22   d . The bottom portion  22   d  further defines a circular opening within which the portion of hub  34   c  extending down below the plate structure  34   a  is disposed. Thus, this portion of hub  34   c  and the opening in the bottom portion  22   d  help align and maintain the motor  32  and mounting plate  34  in their desired location within the cavity  30  of the housing  22 . In addition, the slot and insert configuration between the housing  22  and the mounting plate  34  help prevent the motor  32  from rotating once in position so that maximum torque may be supplied to a work element, such as pad  28 . In alternate embodiments, the plate structure  34   a  and bottom portion  22   d  may have additional openings aligned with one another for assisting in the circulation of air over the motor  32 .  
     [0025] Extending downward below the housing  22  is an arcuate shield or skirt member  40 , which forms an annular wall about the exposed end of the motor shaft  32   a  and at least a portion of counterweight  38  (see FIG. 8). The shield  40  is connected to the lower portion  22   d  of housing  22  and, in a preferred embodiment, is made integral therewith.  
     [0026] The motor  32  is mechanically connected to the pad assembly  28  to drive it in an orbital path below the housing  22 . More particularly, the motor output shaft  32   a  extends through the bottom portion  22   d  of housing  22  and is threaded into a first threaded bore  38   a  defined by the counterweight  38 . As illustrated in FIGS.  6 - 8 , the counterweight  38  is connected to the pad assembly  28  by a bolt, such as left handed bolt  42 , which threads into a second threaded bore  38   b  in the counterweight  38 . The second counterweight bore  38   b  is parallel to, and located generally adjacent to, the first counterweight bore  38   a . Thus, rotation of the output shaft  32   a  results in a corresponding rotation in the counterweight  38  and the pad assembly  28  connected thereto.  
     [0027] As further illustrated in FIGS.  6 - 8 , the pad assembly  28  preferably consists of a pad support  44 , a first pad  28   a , a second pad  28   b , and a third pad  28   c . The pads  28   a - c  are overlaid and connected to one another and to the pad support  44  by an adhesive (not shown) and, preferably, include a closed polyethylene pad, an ether foam pad, and a closed micro-cell polyethylene pad, respectively. The preferred pads  28   a - c  have a thickness of ¼″, ⅝″ and ⅛″ respectively. In alternate embodiments, however, various types and sizes of pads may be used. For example, varying combinations of the above mentioned pads may be used in either a two pad configuration or in a single pad configuration, rather than a three pad coil figuration.  
     [0028] The pad support  44  has a generally planar disc portion  44   a  supporting a circular hub portion  44   b  extending upward from the center of the disc and an annular wall  44   c  extending upward from the disc portion  44   a  intermediate the edge of the disc portion  44   a  and hub portion  44   b . A plurality of gusset members extend along the sides of the hub portion  44   b  down to the disc portion  44   a  (see FIG. 6). As mentioned above, the annular wall  44   c  is positioned intermediate the outer perimeter of the disc  44   a  and the hub portion  44   b  and is preferably located about two-thirds of the radial distance from the center of the disc  44   a  toward the perimeter of the disc  44   a . Thus, the counterweight  38  rotates within the annular wall  44   c  of the pad support  44 , and the annular wall  44   c  remains under cover of the shield  40 . With such a configuration, the skirt member  40  and the annular wall  44   c  of the pad support  44  combine to prevent, or at least hinder, direct access to the counterweight  38 .  
     [0029] The hub portion  44   b  of pad support  44  defines a hollow center region that houses bearings  46   a - b  and spacer  48 . The bolt  42  extends through the central openings in the bearings  46   a - b  and the spacer  48  and is threaded into the second bore  38   b  of the counterweight  38 . The first pad  28   a , the second pad  28   b  and the third pad  28   c  also have central openings or passageways through which the bolt  42  passes in order to be threaded into the counterweight  38 . The end of bolt  42  includes an enlarged head to secure the pad support  44 , bearings  46   a - b  and spacer  48 , to the tool  20 . During operation, the pad assembly  28  will orbitally rotate about the z-axis of the tool (defined by output shaft  32   a ) when the motor  32  drives the shaft  32   a  and the counterweight  38 .  
     [0030] For maintenance purposes, at least one small opening or notch  44   d  may be defined by the annular wall  44   c  of the pad support  44  so that a hand tool or other instrument can be inserted into the interior region between the pad support  44  and the skirt member  40  to prevent the counterweight  38  from rotating while the bolt  42  is being unscrewed and removed film the counterweight  38 . This enables the pad assembly  28  to be removed from the tool  20  for access to the counterweight  38  and other internal components (e.g., the motor shaft  32   a , bearing  46   a , etc.). Such access may be required to repair or replace parts, including the counterweight  38  and pad assembly  28  or those parts internal thereto.  
     [0031] The counterweight  38  includes a first horizontal portion  38   c , which defines bores  38   a  and  38   b  of the counterweight  38 . More particularly, the first horizontal portion  38   c  is generally rectangular in shape and cross-section and has bores  38   a - b  disposed therein between first and second ends of the structure. The first bore  38   a  is internally threaded for receiving the motor output shaft  32   a  and has a sleeve or collar extending upward from the top surface of the horizontal portion  38   c  in order to increase the length of the bore  38   a . The second bore  38   b  is internally threaded for receiving the bolt  42  connecting the pad assembly  28  to the tool  20  and has a sleeve or collar extending downward from the bottom surface of the horizontal portion  38   c  in order to increase the length of the bore  38   b . The lengthened bores  38   a  and  38   b  increase the amount of the shaft  32   a  and bolt  42  disposed therein, which subsequently strengthens the mechanical connection made between the counterweight  38  and shaft  32   a  and between counterweight  38  and bolt  42 .  
     [0032] A second horizontal portion  38   e  is connected to the first horizontal portion  38   c  via a generally vertical interconnecting portion  38   d . More particularly, the interconnecting portion  38   d  connects the second horizontal portion  38   e  such that it is generally parallel to the first horizontal portion  38   c . Collectively, the connecting portion  38   d  and second horizontal portion  38   e  form a generally L shaped structure having a central opening  38   f  (FIG. 6) that generally divides the connecting portion  38   d  and second horizontal portion  38   e  into two parallel legs which allows for a desired reduction in counterweight mass.  
     [0033] A first end member  38   g  extends from the second horizontal portion  38   e  on the end opposite the interconnecting portion  38   d . The first end member  38   g  is arcuately shaped about the end of the second horizontal portion  38   e , with the end of the second horizontal portion  38   e  being connected to the inner curved surface of the end member  38   g  and the end member  38   g  having a generally rectangular cross-section at any given point there along. The radius of curvature of the end portion  38   g  preferably corresponds to that of the annular wall  44   c  of pad support  44  so that the end member  38   g  can rotate within the annular wall  44   c  without interference by the wall  44   c.    
     [0034] A second end member  38   h  is connected to the first horizontal portion  38   c  on the side opposite the interconnecting member  38   d . Thus, the first and second end members  38   g  and  38   h  are located on opposite sides of the counterweight  38 . The second end member  38   h  is generally rectangular in shape and is generally centered off of the end of the first horizontal portion  38   c . This configuration allows the counterweight  38  to be made out of less material, but yet supply a sufficient amount of revolutions per minute (RPMs) to orbit the pad assembly  28  as desired.  
     [0035] As illustrated in FIGS. 1 and 3- 6 , the first handle  24  includes a pair of elongated members  24   a  and  24   b  which project outward from the rear portion  22   d  of the housing  22  near the top thereof. This shape provides an operator with a plurality of locations to facilitate an effective grip to maintain control over the tool  20 . More particularly, the first and second side members  24   a  and  24   b  connect along the parting line  20   e  to form the handle  24 . The side portions  24   a  and  24   b  are secured together by screws  21  or other fasteners which are inserted into recessed bores located in the right side portion  24   b  of handle  24 . The first handle  24  has a longitudinal axis that is generally perpendicular to the z-axis and within the vertical reference plane discussed above. In a preferred embodiment, the handle  24  has a generally oval-shaped cross-section at any given point and a distal end  24   c  which is enlarged with respect to the remainder of the handle  24 . In addition, the upper surface of the handle  24   d  is generally flat compared to the remainder of the contour, which, as shown by the lower surface  24   e  is generally arcuate to provide an operator with a more comfortable grip and to account for the differing hand sizes of operators.  
     [0036] The enlarged end  24   c  allows the operator to “feel” the end of the handle without the need to visually locate it. This allows the operator to focus more on the workpiece rather than requiring the operator to break visual contact with the workpiece to determine the location of the end of the handle  24 . For example, the enlarged end  24   c  provides the handle with a structural end stop for an operator to feel. Furthermore, the enlarged end  24   c  can also assist an operator in drawing the tool  20  backward when working on a workpiece.  
     [0037] Internally, the first and second side portions  24   a - b  of handle  24  include a plurality of ribs  24   f  which both strengthen the handle  24  and support the recesses and threaded posts into which screws  21  are inserted and thread. Furthermore, the handle  24  and the rear portion  22   b  of housing  22  define a socket within which actuator  50  is disposed. In the embodiment illustrated in FIGS. 6 and 7, the actuator  50  includes a trigger member  52 , which is generally rectangular in shape and cross-section and has a generally hollow interior.  
     [0038] The trigger  52  has an inward concave lower surface  52   a  which is to be engaged for actuation by at least one of an operator&#39;s fingers. Located on opposite side walls of the trigger  52  are gudgeons  52   b  (FIG. 6) which are inserted into complimentary bores defined by posts  22   p  extending inward from the inner surfaces of the clamshell members  20   c  and  20   d  of tool  20 . Thus, the trigger  52  is able to pivot about the axis defined by the gudgeons  52   b . Furthermore, located within the trigger  52  is a pedestal  52   c  having a recessed upper surface within which an end of spring  54  is nested. The pedestal  52   c  further includes a centrally located post  52   d  which extends upward from the center region of the recessed upper surface of pedestal  52   c  and is used to actuate pushbutton  56 . More particularly, the other end of spring  54  is positioned over the button of pushbutton switch  56  like a sleeve. The pushbutton switch is mounted in the first handle  24  above the end of the trigger  52  having post member  52   d , with the spring  54  biasing the trigger  52  (and post  52   d ) out of engagement with the switch  56 . In the embodiment illustrated, switch  56  consists of a pushbutton switch which is a push on-push off type switch, such as pushbutton switch model No. J188B manufactured by Judco Manufacturing Inc. of Harbor City, Calif. The switch  56  regulates power supplied to the motor  32  and is movable between an active position, or “on” state, to allow power to the motor  32  and a de-active position, or “off” state, to prohibit power to the motor  32 .  
     [0039] The switch  56  is actuated between active and de-active positions via the post  52   d  of trigger  52 . More particularly, when the trigger  52  is squeezed by the operator, it pivots about the axis defined by the gudgeons  52   b . This drives the post  52   d  towards the pushbutton  56  and compresses the spring  54  between the body of the pushbutton  56  and the pedestal  52   c . As a result, the post  52   d  is pressed into contact with the pushbutton  56 . Thus, the operator may activate or deactivate the tool  20  by pivoting or squeezing the trigger  52 . Once released, the spring  54  returns the trigger  52  to its biased position out of engagement with the switch  56 .  
     [0040] In alternate embodiments, however, other types of actuators  50 , with alternate features, may be used. For example, the actuator  50  may include a momentary on switch and/or a locking momentary on switch which can be temporarily locked in the “on” position. In one embodiment, a locking momentary on pushbutton, such as pushbutton switch HELI KP-D1 manufactured by Changzhou Create Electric Appliance Co. Ltd. of Changzhou, China, may be used. To accommodate such an actuator, one of the side portions  24   a - b  of first handle  24  may define an opening, such as aperture  24   g  illustrated in FIGS. 1 and 3- 4 , through a lock member is disposed for selectively locking the momentary on switch into the “on” position. In a preferred embodiment, the operator may lock the actuator into the “on” position by pivoting the trigger  52  into the “on” position, depressing a locking pushbutton disposed in aperture  24   g  to lock the trigger in the “on” position, and releasing the trigger  52 . The locking pushbutton prevents the trigger  52  from being fully returned to its biased “off” position, thereby temporarily locking the actuator  50  in the “on” state. The tool  20  may then be deactivated by pivoting (or squeezing) the trigger again toward the “on” position until the spring activated lock pushbutton disengages the trigger so that the trigger may be returned to its biased “off” position. In yet other embodiments, other actuators and actuator features may be incorporated into the tool  20  as are known in the art.  
     [0041] As illustrated in FIGS. 6 and 7, the rear portion  24   c  of handle  24  includes a power cord  58  for supplying power to the tool  20  (i.e., for supplying power to the apparatus from a power supply external to the power tool). Preferably, the power cord  58  has two conductive and shielded wires  58   a  and  58   b  and an outer insulator jacket  58   c  (e.g., a double insulation wiring configuration). The rear handle portion  24   c  made up of side portions  24   a  and  24   b  includes two semi-circular notches  60  located on each side portion  24   a - b  which cooperate to form a strain relief  61  for the power cord  58 . More particularly, the notches  60  form a rounded collar about a flange portion  58   d  of the insulator jacket  58   c  (see FIG. 7). This helps to prevent the power cord  58  from being separated from the handle  24  and power tool  20 . The preferred strain relief  61  also includes a clamp mechanism, such as block  60   c , which has a curved bottom surface and bores located on opposite ends. The power cord  58  rests ill a curved cradle  60   d  and the block  60   c  is fastened down over the power cord  58  via screws  60   e  to clamp the power cord  58  in the cradle  60   d , with the curved surface of the block  60   c  engaging and compressing the outer jacket  58   c  in order to provide additional strain relief for the power cord  58 .  
     [0042] One end of the power cord  58  includes an electrical connector, such as male plug member  58   e , which can be connected to various types of power supplies, either directly or via an extension cord (not shown). On the other end of the power cord  58 , wire  58   a  is connected to electronic circuitry located within the tool  20 , such as a terminal of full wave rectifier  62 , which is fastened to the inner surface of clamshell member  20   c  via screw  62   a . The other wire, wire  58   b , is connected to a terminal of the pushbutton switch  56 . A second terminal of the pushbutton  56  is electrically connected by a wire to a second terminal on the rectifier  62 , and additional wiring electrically connects third and fourth terminals on the rectifier  62  to first and second terminals on motor  32  in order to complete the electrical circuit between the power supply, rectifier  62 , motor  32  and actuator  50 . Thus, when the tool  20  is connected to a power supply and actuator  50  is placed into the “on” position, power will be supplied to the motor  32  in order to drive the work element  28  connected to the tool  20 . When the actuator  50  is placed into the “off” position, no power will be supplied to the motor  32 , and the apparatus  20  will remain in an inoperative or de-active state.  
     [0043] In the alternate embodiment discussed above using the HELI KP-D1 switch, both wires  58   a - b  may be connected to input terminals of the switch and output wires from the switch may be connected to the rectifier  62 . Additional wires from the rectifier would then be electrically connected to the motor  32  in order to complete the electrical circuit between the power supply, rectifier  62 , motor  32  and actuator  50 . Thus allowing the tool  20  to be operated with a momentary on pushbutton switch rather than a push on-push off type switch. As mentioned above, it should be understood that alternate actuators and wiring schemes may be used in order to operate the power tool  20 .  
     [0044] As illustrated in FIGS.  1 - 7 , the second handle  26  has a generally block-shaped configuration which projects outward from the front portion  22   a  of the housing  22  near the top thereof in order to provide the operator with a forward handle to facilitate an effective grip to help maintain control over the tool  20 . More particularly, the first and second side portion is  26   a  and  26   b  (see FIG. 6) connect along the parting line  20   e  to form the second handle  26 . The side portions  26   a - b  are secured together by at least one of the screws  21  connecting the clamshell members  20   c - d , which again are inserted into recessed bores located in the right side portion  26   b  of handle  26  and thread into threaded post members extending from the left side portion  26   a  of handle  26 . The second handle  26  has a longitudinal axis that is generally perpendicular to both the z-axis and the longitudinal axis of the first handle  24 . In a preferred embodiment, the handle  24  has a generally rectangular cross-section and a distal end portion  26   c  which is enlarged with respect to the remainder of the handle  26 . In addition, the upper surface of the handle  26   d  is generally flat or planer (see FIGS. 3 and 7) while the lower surface  26   e  is convexly curved to provide an operator with a more comfortable grip. The second handle  26  is wider and shorter than the first handle  24  and is most often gripped with an operator&#39;s palm and/or fingers wrapped around the front or distal end portion  26   c  of the handle  26  rather than around the sides of the handle, as is the case with respect to the rear handle  24 .  
     [0045] In addition, the enlarged end portion  26   c  of handle  26  is wider and thicker than the remainder of handle, which provides the operator with more surface area to grip the tool  20 . Thus, the enlarged end  26   c  helps facilitate a stronger grip and control over the tool  20 . Furthermore, the enlarged end  26   c  can also assist the operator in directing the tool  20  forward and backwards, as well as side-to-side, when working on a workpiece. Like the first handle  24 , the interior of the first and second side portions  26   a  and  26   b  of handle  26  include a plurality of ribs  26   f , which both strengthen the handle  26  and support the recesses and threaded posts into which at least one of the screws  21  is thread.  
     [0046] As illustrated in FIGS.  1 - 6 , both the first and second handles  24  and  26  have outer elastomer surfaced grips  64  to facilitate enhanced gripping for control over the tool  20 . In a preferred embodiment, the elastomer grips  64  are provided on the upper surfaces  24   d  and  26   d  of handles  24  and  26  to facilitate enhanced gripping control over the power tool  20 . The elastomer grip is preferably added by way of an injection overmolding process. More particularly, the handles  24  and  26  are preferably formed by a plastic injection molding process, which is later followed by injection of a grip layer material to form grip  64 . A preferred material for the elastomer grip  64  is an elastomer/plastic blend, such as, for example, SANTOPRENE, which is a product of Advanced Elastomer Systems, L.P. of Akron, Ohio. The overmolded grip may be formed with a smooth outer surface or with a textured outer surface and provides a non-slip rubber (or rubber-like) gripping surface for the operator&#39;s hand to grasp. Preferably, the operator will grip the top surface  24   d  of the first handle  24  with his or her palm and wrap his or her thumb off to one side of the handle  24  and fingers off to the other side of the handle  24 . In contrast, the operator will preferably grip the top surface  26   d  of the second handle  26  with his or her palm and wrap his or her fingers around the forward end  26   c  of the handle  26 , leaving his or her thumb off to the side of the handle  26 . In alternate embodiments, additional portions of the handles  24  and  26  (or the entire surface of the handles) may be covered with an elastomer overmolding. For example, an overmolded grip portion may be included on the lower surface  24   e  of first handle  24 . Furthermore, in yet other embodiments, only one of the handles  24  or  26  may include the elastomer grip  64 .  
     [0047] It should be understood that other materials may be used for the overmolding portions. For example, other thermal plastic elastomers or elastomer/plastic blends, such as rubber, nylon, butyl, EPDM, poly-trans-pentenarmer, natural rubber, butadiene rubber, SBR, ethylene-vinyl acetate rubber, acrylate rubber, chlorinated polyethylene, neoprene and nitrile rubber, may also be used for the overmolded grip  64 . Another material which may be used for the overmolding is HERCUPRENE, which is manufactured by the J-Von Company of Leominster, Mass.  
     [0048] It should also be understood that alternate embodiments of the apparatus  20  may be provided with no elastomer overmolding whatsoever. For example, the tool  20  may be provided with a simple smooth plastic handle, or a textured plastic handle, created from a plastic injection molding process. More particularly, the overmolding may be replaced with a textured surface, such as Rawal #MT-11605, a mold texturization process provided by Mold-Tech/Rawal of Carol Stream, Ill. Similarly, other mold texturization processes may be used to create a variety of textured surfaces.  
     [0049] Turning now to FIGS.  9 - 10 , there is illustrated an alternate embodiment of tool  20  embodying features in accordance with the present invention. In this embodiment, the tool  20  includes an accessory  66 , which can be stored on the tool  20  and used in conjunction therewith. For convenience, features of alternate embodiments illustrated in FIGS.  9 - 10  that correspond to features already discussed with respect to the embodiments of FIGS.  1 - 8  are identified using the same reference numeral in combination with an apostrophe (′) merely to distinguish one embodiment from the other, but otherwise such features are similar.  
     [0050] More particularly, the tool in FIGS.  9 - 10 , hereinafter  20 ′, includes a recess, such as elongated slot  68  defined by handle  24 ′, for receiving and maintaining an accessory, such as a brush like tool  66  illustrated therein. The slot  68  is preferably rectangular in shape and is deep enough to allow at least a majority of the brush  66  to be inserted therein. In the embodiment illustrated, the slot  68  is deep enough to allow the brush  66  to be fully inserted therein so that the top of the brush  66  is flush with, or recessed below, the upper handle surface  24   d ′ of tool  20 ′. The slot  68  may also include recessed groove portions  68   a  and  68   b , which provide access to a portion of the brush  66  so that the operator may more easily remove the brush  66  from slot  68 . The brush  66  is preferably of a shape that corresponds in a complimentary fashion to the slot  68  and includes a grippable feature, such as a groove  66   a  along its upper surface to further assist the operator in removing the brush  66  from slot  68 . Extending out from the lower surface of the brush  66  are bristles  66   b  which may be used to sweep up or away residual particles of the workpiece or materials used on the workpiece, such as dry wax. The brush  66  may also be provided with a releasable locking mechanism, such as resilient shoulder portions  66   c  and  66   d , which may secure the brush  66  into slot  68  by filling the space created below corresponding ridge members  68   c  and  68   d  located in the slot  68 . With such a configuration, the accessory may be moved between a locked location on the tool  20 ′ (see FIG. 9) and an unlocked position remote from the tool  20 ′ (see FIG. 10) so that the accessory may be used in conjunction therewith. In alternate embodiments, an accessory item, may be located in the second handle  26 ′ instead of, or in addition to, being located in the first handle  24 ′.  
     [0051] Although certain example methods and apparatus have been described herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus, and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents.