Abstract:
A device and method to sand sink bowl flanges has an abrasive, a disk, a motor, a stand, a frame and a separate arm, holders, and a switch. An abrasive coats the disk. The motor rotates the disk in a nearly vertical plane. The motor rests upon the stand and the frame. The frame attaches to a floor and a wall. The arm in front of the frame positions a sink bowl in holders. An operator depresses a foot switch activating the motor, and then advances the arm, placing the flange of the sink bowl upon the rotating disk until smooth.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application is a non-provisional application of and claims priority to provisional application Serial No. 60/401,528, filed on Aug. 8, 2002, the disclosure of which is herein incorporated by reference in its entirety.  
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. Field of the Invention  
           [0003]    The present invention relates to a bowl sander for use as a sanding machine in connection with composite sink bowls. The bowl sander has particular utility in connection with a substantially vertical rotating disk.  
           [0004]    2. Description of the Prior Art  
           [0005]    Bowl sanders are desirable to advance a sink bowl into a sander with minimal force applied by a worker. Prior art designs provided a table covered with sandpaper. The conventional design allows a worker to lift a sink bowl, to place it upon a sanding table, and then to move the sink bowl across the table until the flanges of the sink bowl become smooth. Because of the size of a sink bowl, one or more workers often lean over the sanding table posing a safety risk. Prior art designs also provide a sander with an attached table. Using these designs, the worker places a sink bowl upon a table and pushes the sink bowl into the sander at a predetermined angle. Another typical design provides a sander that moves across a fixed workpiece. In summary, prior art requires one or more workers to lean upon a sink bowl over a sanding table in order to sand the flanges of a sink bowl.  
           [0006]    The present art overcomes the limitations of the prior art. That is, the art of the present bowl sander allows a worker to position a sink bowl upon a sander without the worker leaning over a sanding table. The present art further allows an arm to bear the weight of a sink bowl.  
           [0007]    The difficulty in providing smooth flanges of sink bowls while protecting workers is shown by the operation of a typical device. The present invention overcomes this difficulty. Sink bowls have a large awkward shape with a flange around the sink opening. To attain a smooth sink bowl flange, workers sand the entire flange as a unit. A typical sanding device takes the form of a table covered in strips of sandpaper. Placing a sink bowl upon a typical device and moving the sink bowl, requires one or more workers to lean over the sanding table. For a smooth bowl flange, workers move the sink bowl about the sanding table while simultaneously applying pressure to the sink bowl. A worker risks lifting and bending injuries.  
           [0008]    The use of sanding machines is known in the prior art. For example, U.S. Pat. No. 2,294,047 to Pollock discloses a tire-abrading machine. However, the Pollock &#39;047 patent does not pivot a tire about a horizontal axis, and does not fix the position of the motor.  
           [0009]    U.S. Pat. No. 4,228,618 to Jensen discloses a rotary disk sander that has a tilting table. However, the Jensen &#39;618 patent does not advance a work piece with an arm, and additionally does not fix the position of the motor.  
           [0010]    Similarly, U.S. Pat. No. 4,574,530 to Handler et al. discloses a drill powered abrasive machine that sands workpieces. However, the Handler &#39;530 patent does not advance a work piece into the sander, and cannot operate with an integral motor.  
           [0011]    Then, U.S. Pat. No. 1,404,605 to Hansen discloses a surface-grinding machine having a tilting table. However, the Hansen &#39;605 patent does not grasp a workpiece, and cannot advance a workpiece into the sander.  
           [0012]    U.S. Pat. No. 4,246,727 to Weissman discloses a device that positions a holder containing a gem. However, the Weissman &#39;727 patent does not have a sander oriented vertically, and cannot grasp a gem at more than one point.  
           [0013]    Similarly, U.S. Pat. No. 4,536,992 to Hennenfent et al. discloses a lapping system to shape electronic parts. However, the Hennenfent &#39;992 patent does not have a vertically oriented sander, and cannot operate in the absence of slurry.  
           [0014]    Lastly, U.S. Pat. No. 3,631,639 to Day &amp; McCandless discloses a device that grinds valve stems on engines. However, the Day &amp; McCandless &#39;639 patent does not grasp and advance a valve stem into the grinder, and has the additional deficiency of mounting upon a reference point.  
           [0015]    While the above-described devices fulfill their respective, particular objectives and requirements, the aforementioned patents do not describe a bowl sander that grasps a sink bowl and advances a sink bowl so held into a sander while improving worker safety. The Pollock &#39;047 patent makes no provision for pivoting about a horizontal axis. The Jensen &#39;618 and Handler &#39;530 patents lack provision for advancing a workpiece with an arm. While the Hansen &#39;605 patent does not grasp a workpiece. The Weissman &#39;727 and Hennenfent &#39;992 patents make no provision for a vertically oriented sander. The Day &amp; McCandless &#39;639 patent does not advance a valve stem into the grinder. Therefore, a need exists for a new and improved bowl sander that can operate a substantially vertical rotating disk. In this regard, the present invention substantially fulfills this need. In this respect, the bowl sander according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in doing so provides an apparatus primarily developed for the purpose of operating a substantially vertical rotating disk.  
         SUMMARY OF THE INVENTION  
         [0016]    In view of the foregoing disadvantages inherent in the known types of sanders now present in the prior art, the present invention provides an improved bowl sander, and overcomes the above-mentioned disadvantages and drawbacks of the prior art. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved bowl sander and method which has all the advantages of the prior art mentioned heretofore and many novel features that result in a bowl sander which is not anticipated, rendered obvious, suggested, or even implied by the prior art, either alone or in any combination thereof.  
           [0017]    The present art overcomes the prior art limitations by holding a sink bowl upon an arm and then advancing the arm towards a substantially vertical sanding disk. A sink bowl has a substantially hemispherical shape with a perimeter flange. The flange joins to a countertop with an adhesive. Smooth flanges make a stronger joint between the flange and a countertop. To attain this, the present invention essentially comprises a disk with an abrasive, a flange, a motor, a gearbox, a frame, a spine, an arm and a holder. The disk has a generally round shape in a substantially vertical plane, a thickness sufficient to maintain rigidity of the disk, a first face and an opposite second face. The abrasive has sufficient roughness to abrade composite sink bowls and adheres to the first face of the disk. The flange has a centered collar perpendicular to the plate and joins to the second face of the disk. The motor drives a shaft for operating the bowl sander and has a distantly connected foot switch. Coaxial to the motor, the gearbox connects to the collar and reduces the rotation of the shaft to a desired rate. The substantially rigid frame supports the gearbox and the motor by a base, two legs, and a header. The spine extends perpendicular from the base and is generally centered upon the bowl sander. The arm has a socket and a pivoting connection to the spine opposite the base. The holder fits within the socket while the socket readily exchanges different forms of the holder. The holder supports a sink bowl for sanding by the bowl sander.  
           [0018]    There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be better appreciated.  
           [0019]    The invention may also include a frame with braces, stiffeners, and a spine; an arm with a pin connecting to the spine; a holder with a stem, fingers, and stubs; fingers having an L or T shape; an abrasive of sandpaper or sand glued to the disk; and a socket that fits over the arm and the holder. Additional features of the invention will be described hereinafter and which will form the subject matter of the claims attached.  
           [0020]    Numerous objects, features and advantages of the present invention will be readily apparent to those of ordinary skill in the art upon a reading of the following detailed description of presently preferred, but nonetheless illustrative, embodiments of the present invention when taken in conjunction with the accompanying drawings. In this respect, before explaining the current embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.  
           [0021]    As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and the scope of the present invention.  
           [0022]    It is therefore an object of the present invention to provide a new and improved bowl sander that has all of the advantages of the prior art sanders and none of the disadvantages.  
           [0023]    It is another object of the present invention to provide a new and improved bowl sander that may be easily and efficiently manufactured and marketed.  
           [0024]    An even further object of the present invention is to provide a new and improved bowl sander that has a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale, thereby making such bowl sander economically available to the solid surface industry.  
           [0025]    Still another object of the present invention is to provide a new bowl sander that provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.  
           [0026]    Even still another object of the present invention is to provide a bowl sander with a substantially vertical rotating disk. This allows a smooth flange of a sink bowl in one step.  
           [0027]    Still yet another object of the present invention is to provide a bowl sander with a substantially vertical rotating disk. This makes it possible to grasp sink bowls of various shapes.  
           [0028]    Still yet another object of the present invention is to provide a bowl sander with a substantially vertical rotating disk. This makes it possible to improve worker safety.  
           [0029]    Lastly, it is an object of the present invention to provide a new and improved method of sanding a sink bowl, the steps comprising: 1) assembling a frame proximate to a shop wall and floor; 2) attaching a motor and gearbox to the frame; 3) connecting an abrasive disk to the gear box; 4) placing an arm into a spine extending from the frame; 5) placing a holder into a socket on the arm opposite the spine; 6) positioning a sink bowl within the holder; 7) pushing the holder with the sink bowl towards the abrasive disk; 8) contacting the sink bowl upon the rotating abrasive disk until the flange of the sink bowl becomes smooth; 9) pulling the holder away from the abrasive disk; and, 10) removing the sink bowl from the holder.  
           [0030]    These together with other objects of the invention, along with the various features of novelty that characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0031]    The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:  
         [0032]    [0032]FIG. 1 shows a side view of the preferred embodiment of the bowl sander in the first position and the second position, and constructed in accordance with the principles of the present invention.  
         [0033]    [0033]FIG. 2 shows a front view of the bowl sander.  
         [0034]    [0034]FIG. 3 shows a rear view of the bowl sander.  
         [0035]    [0035]FIG. 4 a  shows a detailed front view of an alternate embodiment of the holder of the bowl sander. FIG. 4 b  shows a detailed front view of a further alternate embodiment of the holder. FIG. 4 c  shows a detailed front view of a still further alternate embodiment of the holder.  
         [0036]    [0036]FIG. 5 shows an alternate embodiment of the bowl sander suitable for a dust collector. 
     
    
       [0037]    The same reference numerals refer to the same parts throughout the various figures.  
       DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0038]    Referring now to the drawings, and particularly to FIGS.  1 - 5 , a preferred embodiment of the bowl sander of the present invention is shown and generally designated by the reference numeral  10 .  
         [0039]    A sink bowl  12  has a substantially hemispherical shape with a perimeter flange F. The flange F joins to a countertop with an adhesive. Smooth flanges F make a stronger joint between the flange F and a countertop. The bowl sander  10  orients the sink bowl  12  so that the flanges F are substantially perpendicular to the plane defined by the surface of the earth, such as a floor. The present art holds a bowl upon an arm  44  and then advances the arm  44  towards a substantially vertical sanding disk  14 .  
         [0040]    In FIG. 1, a new and improved bowl sander  10  of the present invention for substantially vertical rotating disk  14  is illustrated and will be described. A holder  48  with three or more fingers  68  and one or more stubs  70  maintains the position of the sink bowl  12 . The holder  48  has alternate embodiments to hold sink bowls  12  of various shapes such as oval, rectangular, circular, single bowl, double bowl and the like as described in FIGS. 4 a ,  4   b , &amp;  4   c . The fingers  68  support the rim of the sink bowl  12  and orient the flange F parallel to the sanding disk  14 . The stubs  70  extend from the stem  66  or the interior of one or more fingers  68 , fit into the drain hole D of a sink bowl  12 , initially orient the sink bowl  12  in the holder  48 , and then support the weight of the sink bowl  12  during operation of the invention. The fingers  68  join together at a stem  66  as shown in FIG. 2. A gap exists between the fingers  68  sized to admit a sink bowl  12 . A worker may exchange the embodiments of the holder  48  for various shaped sink bowls  12 . The arm  44  is parallel with the flange F of the sink bowl  12 . The arm  44  has a first end with a socket  46  coaxial with the longitudinal axis of the arm  44 , and a second opposite end with a hinge  64 . The socket  46  receives the stem  66  of the holder  48 .  
         [0041]    At the second end, the arm  44  pivotably connects to the spine  42 . Pivotably means to allow rotation but not translation of a joint. The spine  42  traverses the floor perpendicular to the base  36 . The spine  42  has a first end that connects to the arm  44  at the hinge  64  and an opposite second end. The second end of the spine  42  joins to the base  36 , substantially at the center of the base  36 . The base  36  attaches to the floor for the purpose of securing the bowl sander  10 . The base  36  has one or more sides  52  connected into a polygonal shape defining a plane. In the preferred embodiment, the base  36  forms a rectangular shape. Where the spine  42  attaches is denoted the front  50  of the base  36 . At each corner of the front  50  and a side  52 , a leg  38  extends upward and away from the floor at a predetermined angle. The two legs  38  connect to the ends of a header  40 . The header  40  attaches to a wall or other substantial object to secure the bowl sander  10 . Opposite the front  50 , the base  36  has a rear  54 . Adjacent to the motor  26  and gearbox  32 , one or more braces span between the legs  38  and support the combined gearbox  32  and motor  26  as shown in FIG. 3. The first brace  56  extends to both legs  38  and beneath the gearbox  32 . The second brace  58  extends to both legs  38  and above the gearbox  32 . The base  36 , legs  38 , header  40 , and braces  56 ,  58  form a frame  34 . Centered in the frame  34 , a first stiffener  60  spans between the rear  54  of the base  36  and the first brace  56 . A second stiffener  62  extends from the second brace  58  to the header  40  while centered in the frame  34 . The first stiffener  60  and the second stiffener  62  stabilize the motor  26  and gearbox  32 , and stiffen the frame  34 .  
         [0042]    In FIG. 3, the motor  26  acts in concert with a gearbox  32  that connects directly to the disk  14 . The longitudinal axis of the motor  26  parallels the rear  54  side  52  of the base  36  while the longitudinal axis of the gearbox  32  parallels the spine  42 . In an alternate embodiment, the longitudinal axes of the motor  26  and of the gearbox  32  are coaxial and parallel to the spine  42 . Upon application of power to the motor  26 , the motor  26  rotates a shaft  28  and through the gearbox  32 , rotates the disk  14  at a predetermined rate of rotation. The substantially vertical disk  14  has an abrasive  20  affixed to its first face  16  suitable for sanding bowl flanges F, shown in FIG. 2 and a flange  22  affixed to its opposite second face  18  suitable for mounting the disk  14  to the gearbox  32 , shown in FIGS. 1 &amp; 3. Clamps C hold sandpaper upon the first face  16  as the abrasive  20 . The first face  16  of the disk  14  is opposite the gearbox  32 . A collar  24  extends perpendicular and centered upon the second face  18 . The collar  24  joins to the gearbox  32 . The disk  14  has a diameter substantially in excess of seven inches. Near the first end of the spine  42 , the bowl sander  10  has a foot switch  30 , shown in FIG. 1. The foot switch  30  controls delivery of power to the motor  26 . Typically, the bowl sander  10  operates in a shop environment where the base  36  and the spine  42  attach to a floor. The rear  54  of the base  36  and the header  40  further attach to a wall.  
         [0043]    Turning to FIGS. 4 a ,  4   b , &amp;  4   c , the fingers  68  of the holder  48  support the rim of the sink bowl  12  and orient the flange F parallel to the sanding disk  14 , see FIG. 1. The fingers  68  join together at a stem  66 . In FIGS. 4 a  &amp;  4   b , the fingers  68  have an L shaped member  72  of two branches  74  and a cross member  76  where the cross member  76  attaches perpendicular to one branch  74  of the L shaped member  72  and the second branch  74  of the L shaped member  72  attaches to the stem  66 . The fingers  68  with L shaped members  72  support either a square or double bowl sink. In FIG. 4 c , the finger  68  has a T shaped member  78  where the vertical web  80  of the T shaped member  78  joins to the stem  66  and extends perpendicular from the stem  66  and the horizontal member  82  of the T shaped member  78  deflects. The fingers  68  with T shaped members  78  support an oval sink bowl  12 .  
         [0044]    In FIG. 5, the present invention has the disk  14  omitted to reveal brackets E for a dust collector. The brackets E extend generally perpendicular to the legs  38  with one bracket E per leg  38 . The brackets E extend parallel to the spine  42 . A bin (not shown) rests upon the brackets E to collect dust from the disk  14  during operation. The bin covers at least the lower six inches of the disk  14 . A vacuum system  66  (not shown) connects to the bin to evacuate the collected dust.  
         [0045]    To utilize the present art, a worker assembles the invention upon a shop floor. The worker constructs the frame  34  by attaching the legs  38  to the header  40  and the front  50  of the base  36 . The worker then installs the first brace  56  and second brace  58 . The motor  26  connects to the gearbox  32 . With the attached motor  26 , the gearbox  32  bolts in front  50  of the first brace  56  and the second brace  58 . With the gearbox  32  and motor  26  connected to the frame  34 , the worker raises the frame  34  and secures it to a wall and the floor as shown in FIGS. 1 &amp; 3. The worker completes the assembly of the base  36  and attaches the spine  42 . Then, the worker connects the second end of the arm  44  to the spine  42  and installs one of a plurality of holders  48  into the socket  46 . The bowl sander  10  takes the form shown in FIG. 2. The worker then connects the switch and power supply for the motor  26 .  
         [0046]    In operation, the worker places a sink bowl  12  upon the stubs  70  and within the fingers  68  of a holder  48 , in the first position A a few degrees from perpendicular and away from the frame  34 , as shown in FIG. 1. Pressing the foot switch  30 , the worker activates the motor  26  and rotates the disk  14 . Once the disk  14  rotates steadily, the worker pushes the arm  44  toward the disk  14  so that the flanges F of the sink bowl  12  contact the abrasive  20 , in the second position B a few degrees from perpendicular and towards the frame  34 , as shown in FIG. 1. Once the flanges F become smooth, the worker pulls the arm  44  back to the first position A. The worker then stops the motor  26  and removes the sink bowl  12  from the holder  48 . The sink bowl  12  is now ready for the next step of production.  
         [0047]    The preferred embodiment uses solid surface material for the sink bowl; tubular steel for the holder, the socket, and the arm; a steel pin for the hinge between the second end of the arm and the spine; a steel channel for the spine; steel angles of L shaped cross section for the base components, legs, header, first brace, second brace, first stiffener and second stiffener; an electrically powered motor; an electrical foot switch; a disk round in shape made of solid surface material bolted to the flange extending from a keyed collar; and sand paper clamped C to the disk as an abrasive. In the preferred embodiment, the steel parts are welded to form the frame. In an alternate embodiment, the motor is pneumatically powered. In a further alternate embodiment, the motor is hydraulically powered. In an alternate embodiment, the disk is plastic. In a further alternate embodiment, the disk is rubber. In a still further alternate embodiment, the disk is wood. In an alternate embodiment, the abrasive is sand adhered to the disk. In an alternate embodiment, the spine is a steel angle of L shaped cross section.  
         [0048]    While a preferred embodiment of the bowl sander has been described in detail, it should be apparent that modifications and variations thereto are possible, all of which fall within the true spirit and scope of the invention. The bowl sander is uniquely capable of sanding the flanges of a sink bowl. With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention. The bowl sander and its various components may be manufactured from many materials including but not limited to ferrous and non-ferrous metals and their alloys, plastics, and composites. Although sanding by a substantially vertical rotating disk has been described, it should be appreciated that the bowl sander herein described is also suitable for buffing surfaces of large objects. Furthermore, a wide variety of abrasives may be used instead of the sandpaper described.  
         [0049]    Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.