Patent Application
20230020826
The present invention generally relates to a debris collecting system, and more specifically to a drywall dust and debris collection system for use with a hole saw. Accordingly, the present specification makes specific reference thereto. However, it is to be appreciated that aspects of the present invention are also equally amenable to other like applications, devices, and methods of manufacture.
Contractors, builders, and do it yourselfers who work with drywall are often exposed to high concentrations of dusts. Drywall dust is made of a combination of drywall and joint compound that enters the air when cutting or sanding the drywall. Drywall joint compounds are made from many ingredients, such as talc, calcite, mica, gypsum, silica, which have been associated with throat, and respiratory tract irritation. Dust that is dangerous is smaller in size than a human hair and is not visible to the human eye. Breathing this dust may cause persistent throat and airway irritation, coughing, phlegm production, and breathing difficulties similar to asthma or reactive airway disease.
Drywall joint compound manufacturers recognize that workers might be exposed to too much dust during drywall sanding. The National Institute for Occupational Safety and Health warns people to avoid generating dust and to use respiratory protection when cutting drywall. One way to cut dust exposures is by using proper ventilation. However, this is not always followed in actual work practice. When respiratory protection is worn, it is often used incorrectly with no or limited training, proper selection, or fit.
Portable vacuums have been used to capture and remove the dust before the worker is exposed to it when sanding or cutting. In addition to lower exposures, vacuum systems can dramatically reduce dust exposures. This working environment is more comfortable, less irritating to eyes, nose, and throat, and less likely to require respiratory protection. Additionally, this can result in a cleaner environment that reduces dirt, cleanup time, and cleaning floors and carpets.
While a vacuum system is desirable, it is not practical for many applications. For example, cutting holes in a drywall ceiling requires both hands of the worker just to cut the hole. Using a portable vacuum would require a second worker to hold the vacuum in the area of the cutting. There are existing debris shields that surround the hole saw and collect the dust and debris by gravity. Unfortunately, they can obscure the vision of the operator and add to the weight of the tool. Any additional weight creates complications when working overhead.
Accordingly, there is a great need for a way to limit exposure of a worker to drywall dust. There is also a need for a way for a way to cut or drill holes in drywall overhead without dust expanding out of the immediate hole sawing area contaminating the entire room. Similarly, there is a need for a way to visualize the work area while cutting a hole that creates dust. Further, there is a need for a way to permanently contain and remove the dust from cutting or drilling overhead holes in drywall, plaster, or wood.
In this manner, the improved commemorative system of the present invention accomplishes all of the forgoing objectives, thereby providing an easy solution for containing dust generated from sawing holes in drywall. A primary feature of the present invention is a dust collection system that immediately contains dust created from a hole sawing operation. The present invention allows the user to cut holes in drywall overhead without becoming contaminated by the dust or debris created by sawing operations. Finally, the improvement of the present invention is capable of allowing the user to visualize the work area throughout and collect and safely remove and contain the dust and debris for later disposal.
The following presents a simplified summary in order to provide a basic understanding of some aspects of the disclosed innovation. This summary is not an extensive overview, and it is not intended to identify key/critical elements or to delineate the scope thereof. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.
The subject matter disclosed and claimed herein, in one embodiment thereof, comprises a debris collecting system. The debris collecting system is configured to retain and collect dust and debris that is created when using a hole saw or drill to create holes in a surface, particularly an overhead surface, such as a ceiling. The debris collecting system comprises a debris shield, a vacuum port, and a plurality of mounting brackets.
The debris shield is generally transparent and rigid in construction. The debris shield comprises a cylindrical sidewall, a rim, and a circular top. The cylindrical sidewall comprises an interior surface and an exterior surface. The cylindrical sidewall terminates at one end in a rim which defines a base opening in the debris shield. The rim may be configured to fit a flat surface. Alternatively, the rim may comprise a compressible element for conforming to an irregular surface. The circular top is attached to the cylindrical sidewall opposite the rim to define a debris collecting chamber within. The circular top comprises a center aperture sized to accept a hole saw arbor or a hole saw driver. A ring located on either side of the surface at the hole is slightly smaller in size than the hole itself. This ring prevents the spinning arbor and/or chuck of the hole saw driver from impinging on the shell of the dust collector shield and cracking it. This ring is replaceable.
The vacuum port penetrates the cylindrical sidewall. The vacuum port is sized to accept a vacuum hose and may comprise a vacuum hose connector. A. securing component is used to connect the vacuum hose to the vacuum port or the vacuum hose connector.
The plurality of mounting brackets are configured to secure the debris shield to the surface. Each mounting bracket is attached to the exterior surface of the cylindrical sidewall via a sidewall attachment portion. A surface attachment portion extends perpendicularly from the sidewall attachment portion at the rim of the debris shield. Each surface portion is temporarily attachable to the surface with a mechanical fastener to secure the debris shield against the surface and to a secure structural component of a building system. Each surface attachment portion may be adjustable in length.
The debris collection system may further comprise a lighting element. The lighting element is attachable to the interior surface of the debris shield for improving visibility. The debris collection system may further comprise a distance determining component. The distance determining component is positional on the exterior surface of the debris shield for properly locating it on a ceiling.
The debris collection system may further comprise a hose support component or hanger, a vacuum hose, and a vacuum. The hose support component comprises a ceiling strap and a hose engaging element. The ceiling strap is attachable to the surface with a mechanical fastener to secure the hose support component to the surface. The vacuum hose is attachable at one end to the vacuum port and at the opposite end to the vacuum. The vacuum hose is supportable by the hose support component at some point along its length. A debris separator may be positioned in-line between the debris shield and the vacuum.
To the accomplishment of the foregoing and related ends, certain illustrative aspects of the disclosed innovation are described herein in connection with the following description and the annexed drawings. These aspects are indicative, however, of but a few of the various ways in which the principles disclosed herein can be employed and is intended to include all such aspects and their equivalents. Other advantages and novel features will become apparent from the following detailed description when considered in conjunction with the drawings.
The description refers to provided drawings in which similar reference characters refer to similar parts throughout the different views, and in which:
The innovation is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding thereof. It may be evident, however, that the innovation can be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate a description thereof. Various embodiments are discussed hereinafter. It should be noted that the figures are described only to facilitate the description of the embodiments. They do not intend as an exhaustive description of the invention or do not limit the scope of the invention. Additionally, an illustrated embodiment need not have all the aspects or advantages shown. Thus, in other embodiments, any of the features described herein from different embodiments may be combined.
The present invention, in one exemplary embodiment, is a dust catcher or dust control tool that helps to protect people and property from the health-affecting and dispersive dust of drywall and wood hole sawing. It can be used with four to six inch diameter, and possibly smaller size, electric drill-driven hole saws in conjunction with a portable shop vac for dust capture. With a 99% efficient filter down to one micron particles in the shop-vac, the system would help to safeguard people and property. An optional auxiliary centrifugal air separator can be used upstream of the shop vac filter to protect the 99% filter. The shop vac used must have sufficient air pressure in order to be able to draw exhaust air into the dust catcher, down the air hose, dust air separator, final filter in the shop vac, and shop vac discharge.
The dust catcher helps to contain dust from expanding out into the space from the hole sawing operations. The dust catcher catches many more particles of fine dust than would be capable with a non-exhausting dust bowl or other containment around a hole saw that has no dynamic exhaust. The present invention is advantageous in that it is effective in dust capture and containment especially in the small size particles in drywall dust, than other existing nondynamic exhausting systems.
Referring initially to the drawings,
As illustrated in
The cylindrical sidewall 112 terminates at one end in the rim 124. The rim 124 defines a base opening 128 in the debris shield 110. The rim 124 may be configured to fit snugly against a flat surface, such as a smooth drywall ceiling. Alternatively, the rim 124 may comprise a compressible element 126, such as a gasket, ring, liner, or similar sealing ring, for conforming to an irregular surface as illustrated in
The circular top 118 is attached to the cylindrical sidewall 112 disposed opposite the rim 124. The circular top 118 and the cylindrical sidewall 112 define a debris collecting chamber 129 within the debris shield 110. The circular top 118 comprises a center aperture 120 sized to accept a hole saw arbor 20 or a hole saw 10. The center aperture 120 typically ranges between approximately one and six inches in diameter. Arbors, also called mandrels, are designed to connect the hole saw with a thread in the cap of the hole saw to a drill chuck as well as hold the pilot bit. As such, the hole saw 10 can rotate freely within the debris shield 110 while the dust is contained within while the drill remains outside. The center aperture 120 also permits some airflow into the debris collection chamber 129 when a vacuum is applied.
Alternatively, a diameter reducing element 122 can be positioned over a portion of the center aperture 120 and attached to the circular top 118 as illustrated in
The vacuum port 130 penetrates the cylindrical sidewall 112. The vacuum port 130 is sized to accept a vacuum hose 160 and may comprise a vacuum hose connector 132. The vacuum hose connector 132 is may be a tube with a collar extending out of the cylindrical sidewall 112 substantially perpendicularly. A securing component 134, such as a ring clamp, tubing clamp, or similar adjustable clamp, is used to attach to this tube and fastened to allow the connector 132 to spin freely in the sidewall 112. The tube is constrained longitudinally between the raised tube collar and the securing component 134, such as a pipe clamp, on the other side of the sidewall 112. This tube connector may have internal threads that screw on to and engage the vacuum hose 160 allowing it to spin.
The plurality of mounting brackets 136 are configured to secure the debris shield 110 to the surface. Each mounting bracket 136 comprises a sidewall attachment portion 138 and a surface attachment portion 140. Each mounting bracket 136 is attached to the exterior surface 116 of the cylindrical sidewall 112 via the sidewall attachment portion 138 using mechanical fasteners or adhesive. The surface attachment portion 140 is used as a debris shield support and extends substantially perpendicularly from the sidewall attachment portion 138 at approximately the level of the rim 124 of the debris shield 110. Each surface attachment portion 140 is temporarily attachable to the ceiling surface with a mechanical fastener to secure the debris shield 110 against the surface and connected to the structure above.
Drywall, plaster, plasterboard, or similar non-structural elements would be incapable of holding up the weight of the dust catcher hole saw and drill driver and are not to be employed in this manner. Each surface attachment portion 140 may be adjustable in length. Each surface attachment portion 140 may comprise an extension element 142 for increasing a length of each surface attachment portion 140. The user can simply screw the surface attachment portions 140 onto the ceiling so that the debris shield 110 does not need to be supported by the user. When complete, the user then unscrews the surface attachment portions 140, exposes the cut hole and can then patch the screw holes. Each surface attachment portion 140 is intended to be held against the surface of the ceiling by secure mechanical fastener. The unit is typically not intended to have fasteners only into gypsum board, plaster, or plasterboard.
As illustrated in
As illustrated in
The vacuum hose 160 may be a shop vacuum type hose. The vacuum hose 160 is connectable or attachable at one end 162 to the vacuum connector 134 in the debris shield 110 and at the opposite end 164 to the vacuum 180. The vacuum hose 160 is supportable by the hose support component 150 at some point along its length. The vacuum 180 is typically a portable vacuum, such as a shop vacuum or wall vacuum. The vacuum 180 may employ a dust filter and may exhaust to the workspace, or to an outside environment. The vacuum 180 may be used to provide some “suction” to hold the debris shield 110 to the ceiling to initially assist with installation of the mounting brackets 136 for a single user installation.
The debris collecting system 100 may further comprise a debris separator 170. The debris separator 170 may be positioned in-line between the debris shield 110 and the vacuum 180. The debris separator 170 may be a centrifugal air separator configured to trap larger particulates that settle via gravity in the separator. The debris separator 170 connects to the vacuum hose 160 attached to the vacuum port 130 then to the vacuum 180 via an additional vacuum hose. An optional discharge hose may be installed at the outlet of the shop vac 180 and discharge through a termination plate at an exterior wall opening to the outside to discharge fine particles that the high efficiency filter cannot extract from the airstream. A sliding exhaust flange (not shown) configured to adjustably fit a window and the shop vac discharge will further control dust inside an enclosed space. A particulate counter may be added to the system to show efficiency of the dust collection.
The debris collection system 100 may further comprise a control and safety component. The system 100 must be controlled in a manner that maintains space cleanliness as well as operator safety. A master disconnect switch in the form of a portable electric outlet box with a master on-off switch (preferably with a light indicator) may be used to control the operation of the debris shield 110 and the hole saw driver. This will help assure hole sawing and dust extraction will not commence until the switch is turned on by the operator. This will confirm that exhaust is taking place before the drilling and cutting starts, and that the hole saw driver will most likely be attached to the arbor 20 of the hole saw 10 after the dust shield with the hole saw 10 inside has been secured at the ceiling. To help assure safety of the operator from inadvertently turning on the drill while fastening the driver to the arbor 20, the switch will be in the off position. After the driver is attached to the arbor 20 and the worker has the driver firmly in hand with both hands, the switch can be engaged and visually confirmed that power is on to both the exhaust and the driver. After the hole is cut, the switch can be turned off. The exhaust will then stop, and the worker can safely remove the driver from the arbor 20 of the drill if he so chooses.
Notwithstanding the forgoing, the debris collecting system 100 can be any suitable size, shape, and configuration as is known in the art without affecting the overall concept of the invention, provided that it accomplishes the above stated objectives. One of ordinary skill in the art will appreciate that the shape and size of the debris collecting system 100 and its various components, as show in the FIGS. are for illustrative purposes only, and that many other shapes and sizes of the debris collecting system 100 are well within the scope of the present disclosure. Although dimensions of the debris collecting system 100 and its components (i.e., length, width, and height) are important design parameters for good performance, the debris collecting system 100 and its various components may be any shape or size that ensures optimal performance during use and/or that suits user need and/or preference. As such, the debris collecting system 100 may be comprised of sizing/shaping that is appropriate and specific in regard to whatever the debris collecting system 100 is designed to be applied.
What has been described above includes examples of the claimed subject matter. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the claimed subject matter, but one of ordinary skill in the art may recognize that many further combinations and permutations of the claimed subject matter are possible. Accordingly, the claimed subject matter is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.
