The present invention relates to a constant angular grinding tool preferably used for grinding the edge of stone or the like at a constant angle and more particularly to a constant angular grinding tool having a guide function capable of grinding the edges of sheet materials accurately at a proper angle, specifically, at an angle of 45° in order to apply the sheet materials to a wall face at right angle with an accurate butting surface, when carrying out exterior construction work on an existing wall with those sheet materials such as tiles, natural stones represented by granite or marble or engineered stones.
Conventionally, as the exterior construction material used for covering an existing wall surface, various kinds of fired tiles, various kinds of natural stones, engineered stones and the like (hereinafter, referred to as “material” or “module tile” depending on a situation) have been generally used. As the tile material as construction material, as shown in
Although the exterior construction material represented by the tile material has attracted public popularity in terms of its finished luxurious appearance and excellent heat insulation effect, it has been widely prevalent as an exterior construction material for the wall surface. However, because its base material is a specific hard brittle material, originally, its processibility is very poor and various cares have been paid to even straight cutting work. As a disc like diamond cutter for cutting, for example, a porcelain tile, a so-called rim type diamond saw blade in which diamond abrasive portions 3 mm in thickness are provided continuously on the outer peripheral face of a relatively large substrate has been proposed, the diamond saw blade being capable of cutting without scattering of tile glaze or chipping by providing right and left edge side face portions of the grinding stone portion alternately with a cut-out groove having a width ½ the thickness of the grinding stone portion in proportion to the thickness of the grinding stone portion (see, for example, Japanese Patent Application Laid-Open No. 2001-300855). Further, as the disc like diamond cutter for cutting the porcelain tile, there has been proposed a cutter in which the stiffness of its substrate is intensified by forming the substrate on an outer portion slightly thinner than the diamond abrasive chip layer formed on the outer peripheral face of the substrate while forming a substrate portion in the center of the substrate thicker than the outer portion of the substrate, so as to prevent deformation of the substrate, thereby blocking hand movement originating therefrom to realize precision cutting of the porcelain tile (see for example, Japanese Patent Application Laid-Open No. 2002-205274). A number of proposals have been made and realized for practical application.
Although the processing of the tile material require the above-described care for even cutting along a simple straight line, the side face processing of executing exterior construction by butting two tile materials on a right angle corner of the existing wall from both sides requires an extremely high skill. Thus, conventionally, this work depends upon the skilled engineer specialized in such a edge processing or a tile material in which an inclination angle of 45° is formed on the edge of a tile material is manufactured by means of a special machine for the edge processing developed by a edge processing manufacturer (tile bonding processing manufacturer) or the corner piece material 91 shown in
However, it cannot be denied that such a construction work in this industry includes makeshift factors and it is more difficult than expected to purchase the tile materials whose edges are processed to 45° or the corner piece materials 91 in a sufficient quantity in order to apply them to actual construction. Further, because it is necessary to depend on the processing of subcontractor by, for example, booking him for the processing, a large burden is induced in a serious price competition and there are unstable factors from viewpoints of due date. Thus, although a method of carrying out exterior construction by the means shown in
Although any grinding tool having a function for blocking hand movement has been proposed and a tile material and corner piece material 91 whose edge is preliminarily processed to 45° have been manufactured and marketed and further, it has been confirmed that specialized processing subcontractors exist, it is more difficult than expected to estimate the tile materials and corner piece materials 91 for use accurately and purchase, and complete a construction using them without any insufficiency. Often those components are purchased more than a necessary amount thereby leading to increase in cost or the necessity of making additional order occurs during construction leading to a cause for delay of the due date. Further, making order to such specialized subcontractor itself becomes an excessive burden, and therefore, this is an important problem which is desired to be solved soon.
Accordingly, in views of the current situation of exterior wall construction with such tile materials and the like, an object of the present invention is to provide a grinding tool which is capable of starting processing work immediately on construction site and requires no special skill, thereby enabling grinding of the edge processing easily and accurately with a specified angle, more specifically, an angle of 45° just by simple manual work by average-skilled workers.
That is, the present invention (1) provides a constant angular grinding tool comprising: a profile wheel whose grinding face is formed with a predetermined inclination angle X with respect to the axis of a spindle of a rotary electric tool; a first guide plate which is a disc member attached rotatably to a spindle between the profile wheel and the rotary electric tool so as to guide for a grinding direction by bringing the side face of the disc member into a contact with the reference level of a material to control the inclination angle X; and a second guide plate which is a disc member attached rotatably to a spindle between the first guide plate and the profile wheel and whose outer peripheral end face makes contact with the edge of the material to control a grinding distance Y from the side face, wherein the profile wheel, the first guide plate and the second guide plate are fixed to the spindle of the rotary electric tool with a lock nut such that they are perpendicular thereto.
Further, the present invention (2) provides the constant angular grinding tool in which the first guide plate is a disc member having a bearing fitting hole in the center thereof and larger than the maximum diameter of the grinding face of the profile wheel and mounting thereof to the spindle of the rotary electric tool is carried out through a first bearing fitted to the bearing fitting hole.
Still further, the present invention (3) provides the constant angular grinding tool in which the second guide plate is a disc member having a bearing fitting hole in the center thereof and having an outside diameter substantially equal to the minimum diameter of the profile wheel and mounting thereof to the spindle of the rotary electric tool is carried out through a second bearing fitted to the bearing fitting hole.
Further, the present invention (4) provides the constant angular grinding tool in which the grinding face of the profile wheel is formed at an inclination angle of 45° with respect to the axis of the spindle of the rotary electric tool and super abrasive portion composed of CBN abrasive brazing or diamond abrasive brazing is formed on the grinding face.
Still further, the present invention (5) provides the constant angular grinding tool in which a planarity of cut-out portions are formed radiantly in the abrasive brazing portion of the profile wheel from the axis to the outer periphery.
Still further, the present invention (6) provides the constant angular grinding tool in which the first guide plate and second guide plate are manufactured of metal, resin or composite material thereof.
Yet still further, the present invention (7) provides the constant angular grinding tool in which the material is a square sheet material, such as a tile, natural stone or engineered stone.
Yet still further, the present invention (8) provides the constant angular grinding tool in which flow paths for grinding fluid supplied to the grinding face of the profile wheel are provided in a contact face of the profile wheel to the second guide plate.
By using the constant angular grinding tool of the present invention, for example, the edges of materials composed of two tiles or the like are ground at a predetermined inclination angle X from the end face of the surface of the material to the rear face and at a predetermined distance Y from the edge of the material inwardly, so that when butting the ground faces, a right angle corner can be formed with the two tile materials. When the material side face is ground at 45° using the constant angular grinding tool, the edge of a first guide plate is brought into a contact with the reference level (surface) of the material at the start of the grinding or in a process of the grinding for a guide in order to maintain a horizontality with respect to the reference level of the material. Thus, even a unskilled and relatively inexperienced worker can handle an electric tool rotating at high speeds easily and continue a grinding work to the edge with safety. On the other hand, because the outer peripheral end face of the second guide plate makes a contact with the edge of the material as the grinding progresses and the progress of the grinding is stopped so that a grinding distance (grinding depth) Y with reference to the edge of the material is controlled. As a consequence, the inclination angle of 45° and the inclined area (slope face) on the edge of the material are always controlled from the beginning to the end. The edges of the materials ground in this way form an accurate right angle by butting both, so that the exterior construction at the right angle corner on an existing wall face can be implemented easily, accurately and effectively with manual work of an ordinary worker on construction site. Therefore, increase of cost due to excessive purchase of construction materials and delay of the due date originating from supplementary purchase of the materials are eliminated preliminarily, and burden of relying on making orders to any specialized subcontractor can be removed. Further, accurate construction by adjustment just on site can be implemented effectively with resource saving and at low cost. Further, by changing the inclination angle X of the grinding surface of the profile wheel to a desired angle X1, the side face processing can be executed not only at right angle but at a different angle, so that this is expected to be applied to wide applications.
Next, the constant angular grinding tool 10 of the embodiment of the present invention will be described with reference to FIGS. 1 to 9. In the meantime, description of the rotary electric tool is omitted in the same Figures.
In the constant angular grinding tool of this embodiment a profile wheel 18 having a substantially trapezoidal section is fixed to a spindle 11 of a rotary electric tool (not shown) by tightening a lock nut 20. The grinding face 181 of the profile wheel 18 is formed with an inclination angle X of 45° with respect to the axis of the spindle 11 of the aforementioned rotary electric tool. Grinding stone sections 184 composed of mainly diamond abrasive brazing or CBN abrasive brazing is formed on the grinding face 181 of the profile wheel 18 and it is preferable to provide a planarity of cut-out grooves 185 radiantly in the direction to the outer periphery from the center of axes. As a consequence, discharge of cutting chips and cooling of the grinding stone section can be carried out effectively and biting of a blade into material is accelerated smoothly. As the rotary electric tool, hand-held rotary electric tools such as a disc grinder, sander and polisher can be mentioned.
A first guide plate 13 composed of a disc member in which a first bearing 12 is fitted freely and rotatably to an inside diameter portion thereof is mounted to the first spindle main body 102 of the rotary electric tool. As shown in
As for the first guide plate 13, when grinding the material edge, by bringing the flat outer peripheral edge 131 of the first guide plate 13 as shown in
A second guide plate 16 composed of a disc member having a smaller diameter than the first guide plate 13 is mounted freely and rotatably on the first spindle main body 102 between the first guide plate 13 and the profile wheel 18. The second guide plate 16 has an fitting hole 163 in which the second bearing 15 is fitted to its inside diameter section in the same manner as the first guide plate 13 and when it is installed to the first spindle main body 102 through the second bearing 15 fitted to the fitting hole 163, a free state to the rotation of the spindle 11, so-called freely rotatable state is maintained.
The second guide plate 16 has a circular shape and is located between the first guide plate 13 and the profile wheel 18 and mounted on the first spindle main body 102 through the second bearing 15 so as to determine a grinding distance (grinding depth) from the edge (reference level) of the material 70 (see
Cut-out portions 187, which are connected to the cut-out grooves 185 formed in the grinding face, are formed radiantly in the diameter direction in a contact surface of the profile wheel 18 to the second guide plate 16. At the time of wet grinding, the cut-out portions 187 serve as a supply path of grinding water supplied from the front end of the spindle of the electric tool to the grinding face 181 of the profile wheel 18 through the interior of the spindle 11 and water supply ports 105 of the spindle 11 and are arbitrary components.
In the constant angular tool 10 of this embodiment, to the spindle 11 of each hand held electric tool are attached the disc-like first guide plate 13 in which the first bearing 12 is fitted to the fitting hole 132 of the inside diameter thereof, the spacer 14, the disc-like second guide plate 16 in which the second bearing 15 is fitted to the fitting hole 163 of the inside diameter thereof and the profile wheel 18 whose grinding face 181 is formed at a predetermined inclination angle X to the center of axis, that is, 45° in this example, in this order, such that they are perpendicular to the axis of the spindle 11. After that, they are fixed to the spindle located outside with the lock nut 20 via a washer 19.
An example of a method for grinding the edge 72 of the material 70 at a specified angle using the constant angular grinding tool is shown here. As the material 70, various kinds of burnt tile, various kinds of natural stones, engineered stone and the like can be mentioned. More specifically, as shown in
A marketed hand-held disc grinder was prepared and as shown in FIGS. 1 to 4, the respective members were mounted on and fixed to a multi-stage spindle 11 of the grinder so as to construct a constant angular grinding tool 10. More specifically, to a first spindle main body 102 having an outside diameter of 20.0 mm were attached a first guide plate 13 made of resin and having an outside diameter of 96.2 mm and a thickness of 7.5 mm, in which a first bearing 12 was fitted to a bearing fitting hole 132, and a second guide plate 16 having an outside diameter of 51.0 mm and an outside disc thickness of 3.5 mm, in which a second bearing 15 was fitted to a bearing fitting hole 163. At this time, a ring-like spacer 14 having an outside diameter of 25.4 mm and a thickness of 1.0 mm was attached to the first spindle main body 102 between the both in order to maintain a specified distance. Then, a profile wheel 18 whose grinding face was formed at 45° with respect to the axis was attached to the second spindle main body 103 having an outside diameter of 17.0 mm and fixed to the spindle 11 with a state perpendicular to its axis by tightening a lock nut 20 fitted to a male screw portion 20 through a washer 19. At this time, the inner wheel 123 of the first bearing 12 mounted on the first spindle main body 102 made contact with the base portion 101 of the spindle 11 and the spacer 14, the inner wheel 153 of the second bearing 15, the profile wheel 18 mounted on the second spindle main body 103 and the washer 19 were attached such that they keep contact with each other in this order and fixed firmly by tightening the lock nut 20 fitted to the male screw portion 104 and then, a constant angular grinding tool 10 whose specified inclined angle X was formed to 45° was completed. In the meantime, the grinding face of the profile wheel 18 had a maximum outside diameter of 72.5 mm, a minimum outside diameter of 50.0 mm and a width of 13.25 mm and a grinding stone section 184 composed of diamond abrasive layer was formed on the grinding face 181 and six cut-out grooves 185 having a width of 4.0 mm were formed in the grinding stone portion 184 radiantly toward the outer periphery from the axis.
A plurality of JIS standard tile materials 70 of 10 mm in thickness and 300 mm square as shown in
Because the constant angular grinding tool 10 was capable of grinding a joint edge of tile material used for exterior construction on a right corner of the existing wall accurately and at a good balance with an inclination angle of 45° and a specified grinding distance of Y regardless of such a simple structure in which the first guide plate 13 and the second guide plate 16 are added to a conventional grinding tool, it was confirmed that it functioned extremely effectively. Further, no skilled worker having any special high level capability was necessary for grinding work on construction site and a worker trained in a specified course could implement the side face processing stably and effectively in a relatively easy way. Further, because the constant angular grinding tool 10 allows the processing to be carried out with the first guide plate placed on the reference level of material, even an unskilled worker could handle an electric tool rotating at high speeds and continue the work with safety.
Because when an existing wall surface formed with various kinds of panels is covered with sheet materials such as tiles, natural stones, for example, granite, marble, engineered stone and the like, the constant angular grinding tool of the present invention processes these exterior construction material such as said tiles along a right angle corner of the existing wall surface, this is useful as a tool for grinding the edge of the exterior construction material such as the tiles accurately with an angle of 45°. Further, because the inclination angle X of the constant angular grinding tool of the present invention can be changed freely depending on the angle of the grinding face of the profile wheel for use, it is expected to be used for wider applications, for example, wall surfaces having various corner angles.
Number | Date | Country | Kind |
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2004-130662 | Apr 2004 | JP | national |