Patent Abstract:
Disclosed is a method and apparatus for collecting debris produced by a tool from a work location on a work surface. The apparatus comprises an enclosure surrounding and defining the work location within an interior thereof and an outer body located to the outside of the enclosure. The enclosure is spaced apart from the work surface by a gap distance wherein the enclosure and the outer body enclose and define chamber therebetween. The apparatus further comprises a port passing through the outer body so as to place the chamber in fluidic communication with a vacuum source. The method comprises containing the debris at the work location within the interior of the enclosure, drawing the debris between the enclosure and the surface into the chamber and suctioning the debris out of the chamber through a collection port.

Full Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of Invention The present invention relates to debris collection in general and in particular to a method and apparatus for containing and collecting debris from a worksite surface produced by a working tool. 
         [0002]    2. Description of Related Art 
         [0003]    In construction or renovation, it is frequently necessary to cut, drill or core though walls formed of concrete, brick and other building materials. Such drilling and other material cutting operations are known to produce debris from the material upon which they operate. Such debris may be in the form of dust, chips and the like, or drilling fluid and suspended particles, also known as slurry when the tool operation is lubricated or cooled by a drilling or cutting fluid. 
         [0004]    Such debris is undesirable in many locations such as indoors where dust may cause breathing difficulties for occupants. Additionally, liquid entrained drilling debris, or slurry, may be difficult to clean up after it has escaped the drilling area. Such liquid and dust may be damaging to the surrounding area as well as other equipment or objects. 
         [0005]    One previous method to contain and remove the debris from the work location is to surround the work location with plastic or another impermeable material so as to collect the debris for disposal. Such methods typically tape or otherwise adhere a plastic sheet around the area for such purpose. These methods are disadvantageously time consuming and cumbersome to install at a given location due to the need to tape or adhere the entire periphery of the plastic sheet. Additionally, such methods are known to leak at locations not properly taped or where the surface to which they are adhered are uneven. 
         [0006]    Another attempt to address the above difficulty has been to provide a shield or cover attached to the tool. Such a shield may have a vacuum source attached thereto so as to suction any debris from within the chamber formed by the shield. Disadvantageously, such shields are required to be attached to each tool before use and are therefore limited to a single tool use without time consuming adaptation or modification for use with different tools. The use of tool mounted shields may also require the shield and therefore the tool to remain in place after the tool operation has completed in order to continue removing debris from the work location which further increases the time required to perform the task that is to be performed by the tool. Examples of such shields may be found in U.S. Patent Application Publication No. US2007/0264091 to Bleicher et al. 
         [0007]    Other devices have been proposed which define an area around the tool which contains the debris and in which the debris is removed therefrom by a vacuum or the like. Examples of such devices may be found in U.S. Pat. No. 5,983,445 to Baker. Such devices often require a means to secure the device to the work surface such as a separate vacuum source or dividing the debris removal vacuum source. Such division of a single vacuum source may reduce the effectiveness of the debris removal. Additionally, for use with wet tool operations such as concrete coring, the liquid debris or slurry may be prone to running down the works surface, such as a wall. Any liquid or slurry running down the wall may not be collected by such a device and may be permitted to escape between the wall and the device or pooled to be released when the device is removed from the wall. 
       SUMMARY OF THE INVENTION 
       [0008]    According to a first embodiment of the present invention there is disclosed an apparatus for collecting debris produced by a tool from a work location on a work surface. The apparatus comprises an enclosure surrounding and defining the work location within an interior thereof and an outer body located to the outside of the enclosure. The enclosure is spaced apart from the work surface by a gap distance wherein the enclosure and the outer body enclose and define a chamber therebetween. The apparatus further comprises a port passing through the outer body so as to place the chamber in fluidic communication with a vacuum source. 
         [0009]    The outer body may support and space the enclosure apart from the work surface. The enclosure may form a central bore extending between a tool entry opening and the work location. The central bore may be cylindrical. The enclosure may be formed of a tubular wall. 
         [0010]    The outer body may comprise a shell. The shell may have an inner bore sized to closely surround and engage the enclosure and an outer edge engageable upon the work surface. The outer edge may include a gasket for sealably engaging upon the work surface. 
         [0011]    The apparatus may further comprising a connector for selectably securing the shell to the enclosure so as to selectably vary the gap distance as desired by a user. The connector may comprise internal shell threading in the inner bore engageable with corresponding enclosure threading on an outer surface of the enclosure. The connector may comprise a compression fitting. The inner bore may include a radially compressible member radially engageable upon the enclosure. The radially compressible member may be radially compressed by a compression ring. 
         [0012]    The port may comprise a bore passing through the outer body. The bore may be defined by a tube extending through the outer body. The tube may be adapted to connect to a vacuum hose. 
         [0013]    According to a first embodiment of the present invention there is disclosed a method for collecting debris produced by a tool from a work location on a surface. The method comprises containing the debris at the work location within the interior of an enclosure, drawing the debris between the enclosure and the surface into a chamber located to the outside of the enclosure and suctioning the debris out of the chamber through a collection port. The chamber is defined by the enclosure and a shell extending therearound. 
         [0014]    The suctioning may form a partial vacuum within the chamber. The partial vacuum may retain the enclosure and the shell proximate to the surface. 
         [0015]    Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    In drawings which illustrate embodiments of the invention wherein similar characters of reference denote corresponding parts in each view, 
           [0017]      FIG. 1  is a perspective view of an apparatus for collecting debris according to a first embodiment. 
           [0018]      FIG. 2  is a cross sectional view of the apparatus of  FIG. 1  as taken along the line  2 - 2 . 
           [0019]      FIG. 3  is an exploded perspective of the apparatus of  FIG. 1  having a radially compressible connection between the shell and enclosure according to a further embodiment. 
           [0020]      FIG. 4  is a detailed cross-sectional view of a radially compressible connection between the shell and enclosure according to a further embodiment. 
           [0021]      FIG. 5  is a perspective view of apparatus having a non-circular outline for collecting debris according to a further embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0022]    Referring to  FIGS. 1 and 2 , an apparatus for collecting debris according to a first embodiment of the present invention is shown generally at  10 . The apparatus  10  comprises an enclosure  12  and an outer body  30  extending therearound. The enclosure or inner sleeve has an inner surface  14  defining a central cavity  22  and an exterior surface  16  having threading  24  or the like thereon. The apparatus is applied to a work surface  8  to which a work operation is to be performed. The apparatus  10  defines and encloses a work location  6  within the central cavity  22  on the work surface  8 . Debris produced at the work location  6  is contained by the apparatus  10  and drawn away from the work location for disposal as will be more fully described below. The work operation may comprise any known operation such as, drilling, chiselling, coring, sanding and the like. 
         [0023]    The enclosure  12  comprises a cylindrical member having interior and exterior surfaces,  14  and  16 , respectively extending between entrance and exit ends,  18  and  20 , respectively. The exterior surface  16  includes threading  24  thereon. As illustrated, the central cavity  22  formed by the enclosure  12  extends through the apparatus so as to provide access to the work location  6  from the entrance end  18 . In such a way, a tool (not shown) may be passed through the central cavity  22  from the entrance end  18  to the work location  6 . 
         [0024]    The outer body  30  comprises a shell having an inner hub  32  and annular disk portion  34  extending therefrom. An outer skirt  36  extends from the distal edge of the annual disk portion  34  to abut against the work surface  8  at a distal edge  37  thereof. The inner hub  32  defines an inner bore  33  and includes internal threading  38  that are matable with the exterior threading  24  of the enclosure  12 . The internal and exterior threading  38  and  24  form a connector  40  between the outer body  30  and enclosure  12  so as to permit the two to be selectably coupled to each other at a position as desired by the user. As illustrated in  FIG. 2 , this permits a user to selectably space the exit end  20  of the enclosure  12  apart from the work surface  8  by a gap distance generally indicated at  42 . The outer body  30  and enclosure  12  define an annular cavity  44  therebetween for collection of the drilling fluids and solid particles. The outer body  30  also includes a collection funnel  46  and outlet port  48  at a bottom edge thereof. The outlet port  48  is sized to the connected to a vacuum source such as a wet dry shop vacuum or the like. 
         [0025]    In operation, the user locates the apparatus  10  against a surface  8  such as a wall or the like that is to be drilled or otherwise worked on and connects a vacuum source to the outlet port  48 . This creates a partial vacuum within the annular cavity  44  so as to retain the apparatus  10  against the work surface  8 . The partial vacuum within the annular cavity  44  also serves to draw drilling fluids, and the like particles from the central cavity  22  produced at the work location  6  into the annular cavity  44  in a direction generally indicated a  50 . The drilling fluid and drilling particles may then be collected within the collection funnel  46  and drawn out of the apparatus through the outlet port  48 . By threadably rotating the enclosure  12  relative to the outer body  30 , enclosure  12  may be axially moved relative to the outer body in a direction generally indicated at  52  thereby adjusting the gap distance  42  between the exit end  20  of the enclosure and the work surface  8 . In this way, the user may adjust and select the desired gap distance  42  depending upon the work being performed upon the work location  6  as well as the conditions of the work surface itself. 
         [0026]    The apparatus may be sized to provide a central cavity  22  of sufficient size for the work activity to be performed. By way of non-limiting example, the central cavity may have a diameter of between 2 and 12 inches (51 and 305 mm) although it will be appreciated that other diameters may be useful as well. The apparatus may be formed of any suitable material such as, by way of non-limiting example, metal, plastics, wood, ceramics or composite materials. The apparatus may be sized to permit the gap distance  42  to be adjusted depending upon the needs of the user. By way of non-limiting example, the gap may be adjustable to a wide dimension, such as 1 inch (25 mm) for applications producing large debris particles or where the work surface  8  is rough so as to ensure the distal edge  37  of the outer body  30  engages the works surface as opposed to the exit end  20  of the enclosure  12  engaging the work surface  8 . In other applications the gap distance  42  may be reduced to a narrow dimension of ⅛ of an inch (3 mm), by way of non-limiting example for applications producing smaller debris particles such as dust or slurry. 
         [0027]    The apparatus  10  may also include gaskets or other sealing materials between the distal edge  37  of the outer body  30  and the work surface  8 . Although the outer body is illustrated and described above as having a disk portion  34  and an outer skirt  36  extending therefrom, it will be appreciated that the disk portion and outer skirt  36  may be formed continuously with each other in a continuously curved wall extending from the inner bore  33  to the distal edge  37 . In such embodiments the outer body  30  may have a toroidal shape. 
         [0028]    Turning now to  FIG. 3 , an alternative embodiment of the present invention is illustrated having a compression connection between the enclosure  12  and the outer body  30 . The compression connection comprises a flexible inner flange  60  extending from the outer body  30 . being formed of a pliable material and having inner and outer surfaces,  62  and  64 , respectively. The enclosure  12  is received within the interior of the flexible inner flange  60 . A radial compression member  66  is applied around to the outer surface  64  of the flexible inner flange. The radial compression member is adapted to be tightened or otherwise radially reduced in size so as to radially compress inwardly upon the flexible inner flange  60 . Under radial compression from the radial compression member  66 , the flexible inner flange  60  will be radially deformed inwardly so as to bias the flexible inner flange upon the enclosure and thereby to grip or retain the enclosure at the desired location. 
         [0029]    The flexible inner flange may be formed of a thinner section of material than the remainder of the outer body. Alternatively the flexible inner flange  60  may be formed of a pliable material such as natural and synthetic rubbers, silicon, plastics and other elastic materials, by way of non-limiting example. In other embodiments, the flexible inner flange  60  may be sized to closely engage the enclosure  12  in an interference fit so as to frictionally retain the enclosure at a location relative to the outer body without the use of a separate compression member. As illustrated in  FIG. 3  the radial compression member  66  may comprise a band of rigid material  68  having a diameter reducing gear  70  such as a screw applied thereto, which is commonly known as a hose clamp. 
         [0030]    In other embodiments, the radial compression member may comprise a band of material extending substantially around the flexible inner flange  60  and screw or rod  80  spanning opposed ends  82  of the band as illustrated in  FIG. 4 . The rod may have an eccentrically connected cam  84  at one end connected to a lever  86  such that rotation of the cam by the lever reduces the space between the opposed ends  82  of the band  68  so as to radially compress the flexible inner flange  60  therein. Additionally, in some embodiments the flexible inner flange  60  may comprise a plurality of fingers  90  extending axially along the inner bore  33  in parallel to the radial compression member  66  as illustrated in  FIG. 4 . The fingers  90  may be separated from each other by gaps or slots  92  therebetween so as to surround the enclosure. The fingers  90  may be biased inwardly upon the enclosure  12  by the radial compression member  66  so as to grip the enclosure at the desired location. Optionally, the enclosure  12  may also include one or more spacers, generally indicated at  52  adapted to space the exit end  20  of the enclosure away from the work surface  8 . The spacers  52  may comprise spacing screws  54  or the like having distal ends  56  extending parallel to the enclosure  12  so as engage the work surface  8  and maintain the desired gap distance  42 . As illustrated in  FIG. 2 , the spacing screws  54  may be connected to the enclosure by a block  58  or the like proximate to the exit end  20  of the enclosure. 
         [0031]    It will also be appreciated that the apparatus may also have a non-circular shape as illustrated in  FIG. 5 . The outer body  30  may have any outline shape as desired by the user including, by way of non-limiting example square, triangular, oval or irregular. Additionally, the enclosure  12  may also have a non-circular shape, such as, by way of non-limiting example square, triangular, oval or irregular. As illustrated in  FIG. 5 , the outer body and enclosure are substantially rectangular with the inner bore  33  of the inner hub  32  also being substantially rectangular to correspond to the outline of the enclosure  12 . In such embodiments the connector may comprise set screws  96  and the like for securing the enclosure  12  to the outer body  30 . Also as illustrated in  FIG. 5 , the enclosure  12  may optionally be positioned to one side of the outer body such that the cavity  44  between the outer body and the enclosure extends only partially around the enclosure. As illustrated in  FIG. 5 , in such embodiments, it is preferable that the outlet port  48  be positioned at a bottom of the apparatus so as to facilitate removal of liquid debris. It will also be appreciated that for a substantially circular shaped apparatus having the enclosure  12  located to one side of the outer body  30 , the cavity  44  formed between the outer body  30  and the enclosure  12  will be u-shaped. Such embodiments may be desirable for work that is to be performed in close proximity to other structures extending from the work surface. 
         [0032]    While specific embodiments of the invention have been described and illustrated, such embodiments should be considered illustrative of the invention only and not as limiting the invention as construed in accordance with the accompanying claims.

Technology Classification (CPC): 1