RANDOM ORBIT SANDER WITH ANGLED BATTERY ORIENTATION

Abstract

An orbital sander includes a housing, a motor within the housing and having a drive shaft defining a motor axis, an eccentric drive unit coupled to the drive shaft and configured to convert rotation of the drive shaft to an orbit motion around the motor axis, a sanding pad defining a horizontal work plane and coupled to the eccentric drive unit for orbital motion about the motor axis, and a battery receptacle extending along the housing. The battery receptacle is operable to receive a removable battery pack for providing electrical current to the motor. The battery receptacle defines a battery axis along which the battery pack is installed and the battery axis forms an acute battery angle relative to the work plane.

Description

FIELD OF THE DISCLOSURE

The present disclosure relates to random orbit sanders, and more particularly to battery powered random orbit sanders.

BACKGROUND OF THE DISCLOSURE

Random orbit sanders are used to smooth workpieces that include wood, metal, etc. Improvements in these tools are always sought after in the industry.

SUMMARY OF THE DISCLOSURE

The present disclosure provides, in one aspect, an orbital sander that includes a housing, a motor within the housing, the motor including a drive shaft defining a motor axis, an eccentric drive unit coupled to the drive shaft and configured to convert rotation of the drive shaft to an orbit motion around the motor axis, a sanding pad defining a horizontal work plane and coupled to the eccentric drive unit for orbital motion about the motor axis, and a battery receptacle extending along the housing, the battery receptacle operable to receive a removable battery pack for providing electrical current to the motor, wherein the battery receptacle defines a battery axis along which the battery pack is installed and the battery axis forms an acute battery angle relative to the work plane.

The present disclosure provides, in another aspect, an orbital sander that includes a motor housing, a motor within the motor housing, the motor including a drive shaft defining a motor axis, a grip portion extending along a top of the motor housing, the grip portion defining a grip axis perpendicular to the motor axis and an end face that is parallel to the motor axis, an eccentric drive unit coupled to the drive shaft and configured to convert rotation of the drive shaft to an orbit motion around the motor axis, a sanding pad defining a horizontal work plane parallel to the grip axis and coupled to the eccentric drive unit for orbital motion about the motor axis, and a battery receptacle extending along the motor housing, the battery receptacle including a battery contact face that is parallel to the motor axis and perpendicular to the grip axis and inset from the end face of the grip portion, the battery receptacle operable to receive a removable battery pack for providing electrical current to the motor, wherein the battery receptacle defines a battery axis along which the battery pack is installed and wherein the battery axis forms an acute battery angle relative to the work plane.

The present disclosure provides, in yet another aspect, an orbital sander that includes a motor housing, a motor within the motor housing, the motor including a drive shaft defining a motor axis, a grip portion extending along a top of the motor housing, the grip portion defining a grip axis perpendicular to the motor axis, an eccentric drive unit coupled to the drive shaft and configured to convert rotation of the drive shaft to an orbit motion around the motor axis, a sanding pad defining a horizontal work plane parallel to the grip axis and coupled to the eccentric drive unit for orbital motion about the motor axis, a battery receptacle extending along the motor housing, and a battery isolator disposed within the battery receptacle, the battery isolator including at least one guide rail operable to receive a portion of a removable battery pack, wherein the at least one guide rail extends within a guide plane that is parallel to the motor axis and perpendicular to the grip axis, and wherein the at least one guide rail forms an acute battery angle relative to the work plane.

Other features and aspects of the disclosure will become apparent by consideration of the following detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a random orbit sander.

FIG. 2 is side view of the random orbit sander of FIG. 1.

FIG. 3 is a rear view of the random orbit sander of FIG. 1.

FIG. 4 is a top view of the random orbit sander of FIG. 1.

FIG. 5 is a cross-section view of the random orbit sander of FIG. 1 taken along Line 5-5 in FIG. 4.

FIG. 6 is a side view of the random orbit sander of FIG. 1 with an edge guard partially disengaged from a dust collection assembly.

FIG. 7 is top view of an edge guard of the random orbit sander of FIG. 1.

Before any embodiments of the present disclosure are explained in detail, it is to be understood that the embodiments described herein are not limited in scope or application to the details of construction and the arrangement of components set forth in the following description or as illustrated in the following drawings. The devices described herein are capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

DETAILED DESCRIPTION

Referring to FIGS. 1-6, a random orbit sander 100 is illustrated. The random orbit sander 100 includes a housing 102 having a first housing shell 104 joined to a second housing shell 106 along a seam 108. Further, the housing 102 includes a motor housing 110 extending along a motor axis 112. A grip portion 114 extends from the motor housing 110 along a top of the motor housing 110 along a grip axis 116. In a particular aspect, the grip axis 116 is perpendicular to the motor axis 112. As shown, the grip portion 114 includes an end face 118 that is parallel to the motor axis 112 perpendicular to the grip axis 116. Further, the end face 118 of the grip portion 114 is offset from, or spaced away from, the motor axis 112 by a first distance D1.

The random orbit sander 100 further includes a battery receptacle 120 formed on housing 102 at least partially the along the length of the motor housing 110 beneath the grip portion 114. The battery receptacle 120 includes a battery contact face 122 that is parallel to the motor axis 112 and perpendicular to the grip axis 116. Further, the battery contact face 122 is offset from, or spaced away from, the motor axis 112 by a second distance D2. In a particular aspect, the second distance D2 is less than the first distance D1 such that the battery contact face 122 is tucked under the grip portion 114 and the battery contact face 122 is inset apart from the end face 118 of the grip portion 114 by an amount equal to the first distance D1 minus the second distance D2. This arrangement is ergonomic and provides a relatively compact tool. Further, by placing the battery contact face 122 closer to the motor axis 112 than the end face 118 of the grip portion 114 of the housing 102, the balance of the random orbit sander 100 is substantially improved.

In particular, the second distance D2 is less than or equal to 0.95 times the first distance D1, such as less than or equal to 0.9 times the first distance D1, less than or equal to 0.85 times the first distance D1, or less than or equal to 0.8 times the first distance D1. In another aspect, the second distance D2 is greater than or equal to 0.6 times the first distance D1, greater than or equal to 0.65 times the first distance D1, greater than or equal to 0.7 times the first distance D1, or greater than or equal to 0.75 times the first distance D1. In another aspect, the second distance D2 is within a range between, and including, any of the maximum and minimum values of the second distance D2 as related to the first distance D1.

As further illustrated in FIGS. 2 and 3, the battery receptacle 120 is formed with an opening 124 and a battery isolator 126 fits into the opening 124. The battery isolator 126 is configured to receive and engage a removable battery pack 128 (shown in dashed lines in FIG. 4). Specifically, the battery isolator 126 includes pair of parallel guide rails 130, 132 that are configured to receive complementary features on the removable battery back 128. As such, the battery isolator 126 within the battery receptacle 120 is sized and shaped to slidably receive the removable battery pack 128 therein. In a particular aspect, the random orbit sander 100 includes a plurality of damping elements between the battery isolator 126 and the battery receptacle 120 and therefore, the housing 102. The damping elements attenuate vibration transmitted from the housing 102 to the battery pack 128. It is to be understood that the battery isolator 126 is a separate component from the housing 102 and not formed therewith.

As indicated in FIGS. 2 and 3, the guide rails 130, 132 are parallel to each other and extend within a guide plane 134 along which the battery pack 128 is installed or removed from the battery isolator 126 within the battery receptacle 120. The guide plane 134 is parallel with the motor axis 112 of the random orbit sander 100. Specifically, as shown in FIGS. 2 and 3, the battery pack is installed on and removed from the sander housing 102 along a battery axis 136 that is parallel to, or extends within, the guide plane 134 and perpendicular to the grip axis 116 of the grip portion 114 of the housing 102.

As best illustrated in FIG. 3, the battery receptacle 120, the battery isolator 126, the parallel guide rails 130, 132, the battery axis 136, and the battery pack 128 (when engaged with the random orbit sander 100) are each angled with respect to a work plane 140 that is parallel to a work surface 142, parallel to the grip axis 116, and perpendicular to the motor axis 112. Specifically, each of the battery receptacle 120, the battery isolator 126, the parallel guide rails 130, 132, the battery axis 136, and the battery pack 128 (when engaged with the random orbit sander 100) extends along, or is parallel with, the battery axis 136 and forms a battery angle A with respect to the work plane 140.

In a particular embodiment, the battery angle A is an acute angle with respect to the work plane 140. Specifically, the battery angle A is greater than or equal to two and one-half degrees (2.5°), such as greater than or equal to five degrees (5°), greater than or equal to seven and one-half degrees (7.5°), or greater than or equal to ten degrees (10°). In another embodiment, the battery angle A is less than or equal to thirty degrees (30°), such as less than or equal to twenty-five degrees (25°), less than or equal to twenty degrees (20°), or less than or equal to fifteen degrees (15°). It is to be understood that the battery angle A may be within a range between, and including, any of the minimum and maximum values for the battery angle A disclosed herein.

In a particular aspect, the battery angle A allows the battery pack 128 to be tilted, or angled, with respect to the housing 102 of the random orbit sander 100 when the battery pack 128 is engaged therewith. Tilting the battery pack 128, as shown in at least FIG. 3, provides additional clearance for a dust outlet 146. Further, tilting the battery pack 128 provides additional clearance for a dust collector 148 that is removably coupled to the dust outlet 146 and extends away from the dust outlet 146 adjacent a portion of the battery pack 128. The battery angle A also facilitates installation of the battery pack 128 with the battery isolator 126 within the battery receptacle 120 since the battery angle A extends in a downward direction along an installation direction of the battery pack 128. The battery angle A also facilitates retention of the battery pack 128 with the battery isolator 126 of the battery receptacle 120.

The removable battery pack 128 is slidable in a direction perpendicular to the grip axis 116 in a first direction (downward) along the battery axis 136 to be engaged with the battery receptacle 120 and in a second direction opposite the first direction (upward) along the battery axis 136 to be disengaged from the battery receptacle 120. In a particular aspect, the removable battery pack 128 provides approximately 324 kilojoules of energy and weighs approximately 0.82 kilograms. Therefore, the removable battery pack 128 includes an energy density of approximately 395 kilojoules per kilogram.

As shown in FIG. 5, the sander 100 includes a motor 150 disposed within the motor housing 110. For example, the motor 150 is a brushless direct current (BLDC) motor that receives power from the removable battery pack 128 that is engaged with the battery receptacle 120. The motor 150 includes a motor shaft 152 that rotates on a first bearing 154 and a second bearing 156. It is to be understood that the motor shaft 152 defines and rotates about the motor axis 112. The motor shaft 152 drives an eccentric drive unit 160 and a sanding pad 162 is removably attached to the eccentric drive unit 160. The eccentric drive unit 160, when the motor 150 is activated, converts rotation of the motor shaft 152 to an orbit motion applied to the sanding pad 162 about the motor axis 112 The sanding pad 162 defines the work plane 140 that is horizontal when the sander 100 is used on a horizontal surface. Further, the work plane 140 is parallel to the grip axis 116 and the work surface 142. FIG. 5 further shows a cooling fan 164 that is disposed on the motor shaft 152 above the second bearing 156. The fan 164 rotates with the motor shaft 152 to pull air, and heat, away from the motor 150 during operation of the random orbit sander 100. An exhaust outlet 166 (FIG. 2) is formed in each of the housing shells 104, 106, opposite each other, to provide air exit channels for the air flow generated by the fan 164.

As further illustrated in FIG. 5, a dust fan 168 is disposed on the motor shaft 152 below the second bearing 156 and above the eccentric drive unit 160 and the sanding pad 162 mounted thereon. A dust collection assembly 170 surrounds the dust fan 168. During operation, the dust fan 168 rotates with the motor shaft 152 to pull air, and dust, away from the sanding pad 162 and blow it into the dust collector 148 attached to the dust outlet 146 of the dust collection assembly 170. FIG. 5 further shows a brake pad 172 removably mounted on a brake pad bracket 174. The brake pad 172 is fixed with respect to the brake pad bracket 174 while the sanding pad 162 rotates relative to the brake pad 172. The brake pad 172 is flexible and is biased into contact with an upper surface 176 of the sanding pad 162. The brake pad 172 slows the sanding pad 162 when the motor 150 is de-energized. The random orbit sander 100 further includes an edge guard 180 that is removably engaged with the random orbit sander 100. The edge guard 180 at least partially surrounds the sanding pad 162 and prevents the random orbit sander 100 and the sanding pad 162 thereof from running into vertical structures extending from a workpiece, e.g., the inner wall of a cabinet.

Referring to FIG. 6, the dust collection assembly 170 further includes an edge guard slot 190 formed partially around the outer periphery of the dust collection assembly 170. The edge guard slot 190 includes an opening 192 formed in the edge guard slot 190 at each end 194 of the edge guard slot 190. FIG. 7 shows that the edge guard 180 includes a first tab 200 and a second tab 202 formed at each end 204, 206 of the edge guard 180 and extending inward from an inner lip 208 of the edge guard 180. When the edge guard 180 is engaged with the dust collection assembly 170, as shown in FIG. 2, the inner lip 208 of the edge guard 180 fits into the edge guard slot 190 on the dust collection assembly 170 and the edge guard 180 may be slid into the edge guard slot 190 until the tabs 200, 202 on the edge guard 180 engage the openings 192 formed at each end 194 of the edge guard slot 190. The rigidity of the edge guard 180 acts as a spring to maintain the tabs 200, 202 in the openings 192. When fully engaged with the dust collection assembly 170, the edge guard 180 at least partially surrounds the sanding pad 162 to prevent the sanding pad 162 from bumping into objects extending upward from a workpiece (e.g., sidewalls inside of a cabinet). The edge guard 180 may be removed from the dust collection assembly 170.

Although the disclosure has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the disclosure as described.

Various features of the invention are set forth in the following claims.

Claims

1. An orbital sander comprising: a housing;a motor within the housing, the motor including a drive shaft defining a motor axis;an eccentric drive unit coupled to the drive shaft and configured to convert rotation of the drive shaft to an orbit motion around the motor axis;a sanding pad defining a horizontal work plane and coupled to the eccentric drive unit for orbital motion about the motor axis; anda battery receptacle extending along the housing, the battery receptacle operable to receive a removable battery pack for providing electrical current to the motor, wherein the battery receptacle defines a battery axis along which the battery pack is installed, and wherein the battery axis forms an acute battery angle relative to the work plane.

2. The orbital sander of claim 1, wherein the work plane is parallel to a work surface on which the orbital sander is used.

3. The orbital sander of claim 1, wherein the battery angle is greater than or equal to two and one-half degrees (2.5°).

4. The orbital sander of claim 3, wherein the battery angle is less than or equal to thirty degrees (30°).

5. The orbital sander of claim 1, wherein the battery axis extends within a guide plane that is parallel to the motor axis.

6. The orbital sander of claim 1, further comprising a battery isolator within the battery receptacle, wherein the battery isolator is configured to receive the removable battery pack, and wherein the battery isolator is aligned along the battery angle.

7. The orbital sander of claim 6, wherein the battery isolator includes at least one guide rail that is parallel to the battery axis.

8. An orbital sander comprising: a motor housing;a motor within the motor housing, the motor including a drive shaft defining a motor axis;a grip portion extending along a top of the motor housing, the grip portion defining a grip axis perpendicular to the motor axis, andan end face that is parallel to the motor axis;an eccentric drive unit coupled to the drive shaft and configured to convert rotation of the drive shaft to an orbit motion around the motor axis;a sanding pad defining a horizontal work plane parallel to the grip axis and coupled to the eccentric drive unit for orbital motion about the motor axis; anda battery receptacle extending along the motor housing, the battery receptacle including a battery contact face that is parallel to the motor axis, perpendicular to the grip axis, and inset from the end face of the grip portion, wherein the battery receptacle is operable to receive a removable battery pack for providing electrical current to the motor, wherein the battery receptacle defines a battery axis along which the battery pack is installed, and wherein the battery axis forms an acute battery angle relative to the work plane.

9. The orbital sander of claim 8, wherein the battery angle is greater than or equal to two and one-half degrees (2.5°).

10. The orbital sander of claim 9, wherein the battery angle is less than or equal to thirty degrees (30°).

11. The orbital sander of claim 8, wherein the end face of the grip portion is spaced a first distance D1 from the motor axis, wherein the battery contact face is spaced a second distance D2 from the motor axis, and wherein the second distance D2 is less than the first distance D1.

12. The orbital sander of claim 11, wherein the battery contact face is inset from the end face of the grip portion by an amount equal to the first distance D1 minus the second distance D2.

13. The orbital sander of claim 11, wherein the second distance D2 is less than or equal to 0.95 times the first distance D1.

14. The orbital sander of claim 13, wherein the second distance D2 is greater than or equal to 0.6 times the first distance D1.

15. An orbital sander comprising: a motor housing;a motor within the motor housing, the motor including a drive shaft defining a motor axis;a grip portion extending along a top of the motor housing, the grip portion defining a grip axis perpendicular to the motor axis;an eccentric drive unit coupled to the drive shaft and configured to convert rotation of the drive shaft to an orbit motion around the motor axis;a sanding pad defining a horizontal work plane parallel to the grip axis and coupled to the eccentric drive unit for orbital motion about the motor axis;a battery receptacle extending along the motor housing; anda battery isolator disposed within the battery receptacle, the battery isolator including at least one guide rail operable to receive a portion of a removable battery pack, wherein the at least one guide rail extends within a guide plane that is parallel to the motor axis and perpendicular to the grip axis, and wherein the at least one guide rail forms an acute battery angle relative to the work plane.

16. The orbital sander of claim 15, wherein the grip portion defines an end face and the battery receptacle includes a battery contact face that is inset from the end face of the grip portion.

17. The orbital sander of claim 16, wherein the end face of the grip portion is spaced a first distance D1 from the motor axis and the battery contact face is spaced a second distance D2 from the motor axis that is less than the first distance D1.

18. The orbital sander of claim 16, wherein the end face of the grip portion and the battery contact face are parallel to the motor axis and perpendicular to the grip axis.

19. The orbital sander of claim 17, wherein the second distance D2 is less than or equal to 0.95 times the first distance D1, and wherein the second distance D2 is greater than or equal to 0.6 times the first distance D1.

20. The orbital sander of claim 15, wherein the acute battery angle is greater than or equal to two and one-half degrees (2.5°), and wherein the acute battery angle is less than or equal to thirty degrees (30°).