Patent Application
20240383101
The present invention relates to dustless sanding attachments for abrasive tools, and more particularly to a dustless sanding attachment for a pole sander tool of the type for sanding drywall.
Dustless sanding devices provide a cleaner and safer alternative to traditional sanding methods for containing the dust generated from the sanding of drywall surfaces. These manual tools typically consist of a pole and a perforated sanding block element, to which a sanding material (e.g., a sanding screen) attaches. The apertures in the sanding material allow for the extraction of drywall dust created through abrasion via a vacuum source.
In a manual dust-free sanding tool affixed with a sanding screen, the suction line or hose runs from the vacuum source, connects to the pole, and then to the sanding block member. In certain configurations, the handle features a hollowed-out architecture to accommodate the connection of a vacuum hose, with one or more vacuum tubes extending from the handle to the sanding block member.
The sanding tool is susceptible to a high coefficient of friction and the suction force exerted by the vacuum, which can impede its rasping action against the surface to be smoothed, leading to the accumulation of abraded material within the screen and the apertures of the sander block; this can diminish its ability to collect dust and reduce the overall efficacy of the dust collection process. The use of dual hose connections to the sanding block, connected in a “Y” configuration on the pole, can lead to kinking or tangling due to angular rotational movements, hindering the efficiency of the suction airflow, and thus lowering the dust collection capability.
Therefore, there is a need for an improved dustless sanding attachment.
The present invention relates to an attachment for a pole sander tool to capture and remove the dust generated by the abrasion of drywall surfaces, thereby reducing the risk of airborne particulates created through the sanding process. The dustless sanding attachment includes a dust shroud with integrated standoff posts affixed with magnets for simple and convenient connection and detachment of the shroud to the pole sander tool. The dust shroud has a planar top wall with an opening to allow the sander tool shaft to protrude and rotate at various angles and four downward extending peripheral planar side walls, forming a low-profile, rectangular box-like configuration.
The dust shroud creates an enclosed space, providing an air intake extending along the perimeter of the pole sander tool, and slightly elevated relative to the sanding surface, which allows for the capture and collection of sanding dust abraded during the sanding process and its removal via a port tube.
The port tube for connecting a vacuum source to the sander tool includes a first end integrally fitted with a coupling nut having internal threads for attachment to the shaft of the pole sander tool and a second end for connecting to a vacuum conduit.
The port tube further features channels at one end equipped with four segmented, circumferential circular arcs, augmenting the efficacy of air and dust flow. Additionally, the arc-shaped cross-sectional apertures in the port tube enable the unimpeded passage of airborne dust particles from the sander and its shroud into the vacuum conduit, providing efficient removal of the dust by the vacuum source.
A flexible bellows connects to the shroud and the port tube to create a vacuum-tight seal, and the shaft of the pole sander tool is operably and securely attached to the port tube. The flexible bellows provides an axis of rotation, enabling the shaft and the port tube to rotate while simultaneously limiting their radial displacement, thus allowing for precise control of the sander tool.
The structure, features, and advantages of the present invention will become apparent upon consideration of the following detailed description and accompanying drawings, wherein:
The following detailed description refers to the accompanying drawings, which are incorporated herein by reference, and in which are shown, by way of illustration, the exemplary embodiments that may be practiced. It is to be understood that various changes may be made to the embodiments, including logical, mechanical, and other changes, without departing from the scope of the embodiments, and that the embodiments have been described in sufficient detail to enable those skilled in the art to practice the embodiments. The following detailed description is therefore not to be taken in a limiting sense.
Referring now to the drawings,
In
The shroud 12 includes fixed-length standoff posts 20 integral to the inner surface of the top wall 14, configured in two parallel pairs at opposite ends of the shroud 12 and extending perpendicularly from the inner surface of the top wall 14, providing for alignment and positioning with respect to the ancillary sander implement (not shown) and sanding substrate (not shown), creating a space that facilitates free air flow.
The two parallel pairs of standoff posts 20 are equipped with neodymium-iron-boron (NdFeB) disc magnets 22 embedded into each post, providing a secure magnetic attachment of the shroud 12 to the ferromagnetic clamp assemblies of the ancillary sander implement.
The preferred material for the shroud 12 is transparent polycarbonate (PC) for impact resistance, optical clarity, and durability to enable direct visual inspection of dust entrainment and assessment of dust accumulation inside the shroud 12.
As depicted in
The open first end 26 of the port tube 24 is configured to provide a clearance fit that allows it to slide along the longitudinal extents of a tubular member (e.g., a vacuum wand or extension, not shown) and be securely connected to a standard vacuum, while the outer diameter of the port tube 24 is suitable for the coupling of a standard vacuum hose adapter.
The port tube 24 is fabricated from polypropylene (PP) due to its high flexural modulus and fatigue resistance, providing an exceptional strength-to-weight ratio, durability, and high resistance to abrasion and pressure. Additionally, port tube 24 is equipped with channels 34, which optimize the efficient flow of dust particles through the tube.
As depicted in
The coupling nut 30 has inner threads 30a to provide fastening between the port tube 24 and the thread shaft of the ancillary sander implement (not depicted), facilitating the alignment and secure fastening of the port tube 24 to the threaded shaft of the ancillary element.
Radially extending from the coupling nut 30, an array of flat, straight fin members 32 are positioned and bonded along their longitudinal edges to the respective adjacent walls of the port tube 24.
The fin members 32 intersect at right angles at the midpoint of the port tube 24, extend longitudinally along the inner wall of the port tube 24 and the wall of the coupling nut 30, and end at the annular base at the second end 28 of the port tube 24, forming circular arc channels 38 between the coupling nut 30 and the inner wall of the port tube 24.
The fin members 32, arranged in a radial formation, create a circumferentially segmented pattern of channels along the inner wall of the port tube 24 and the wall of the coupling nut 30, thereby optimizing air flow through the cross-sectional area while generating a turbulent atmosphere to increase friction and the suspension of dust particles.
The high aspect ratio of arc-shaped curves within the annular space in port tube 24 enables dust particles to move through the arcuate channel surface area with minimal back pressure.
The design ensures a smooth, efficient flow of air through the circumferential circular arc channels 34, and the increased turbulence acts as a booster effect for the vacuum airflow, enabling more effective capture and suspension of particulate matter in the air.
A flexible bellows 36 creates a vacuum-tight seal between the port tube 24 and the shroud 12.
The flexible bellows 36 include a bellows having a U-shaped cross section that allows angular movement about its longitudinal axis, allowing angular rotation of the shaft and the port tube 24.
The flexible bellows 36 attaches to the opening 14a of the top wall 14 of the shroud 12, with its bottom convolute secured to the inner surface of the shroud 12 along the outer perimeter of the opening 14a and its sidewall of the adjacent convolution attached to the exterior surface along the outer perimeter of the opening 14a, and a collar 38 attaches to the outer diameter of the port tube 24.
The flexible bellows 36, constructed from a resilient and flexible material such as rubber, provides a reliable and robust connection which enables efficient operation during significant angular motion.
The present invention 10 is suitable for dust-capture applications, providing an efficient and effective means of transferring airborne dust.
It will be apparent to one with skill in the art that the dust collection system of the invention may be provided using some or all of the mentioned features and components without departing from the spirit and scope of the present invention. It will also be apparent to the skilled artisan that the embodiments described above are specific examples of a single, broader invention, which may have a greater scope than any of the singular descriptions taught. There may be alterations made to the descriptions without departing from the spirit and scope of the present invention.
