RANDOM ORBIT SANDER

Abstract

A random orbit sander includes a housing and a motor enclosed within the housing. The motor includes a motor shaft that is rotatable about a first axis. An eccentric carrier coupled to the motor shaft includes a circular internal bore that defines a second axis that is offset from the motor shaft. A bearing is received within the circular internal bore of the eccentric carrier. A sanding pad is supported by the bearing and is rotatable about the first axis in an eccentrically orbiting manner. The motor shaft and the eccentric carrier are integrally formed as a single piece.

Description

FIELD OF THE INVENTION

The present invention relates to power tools, and more particularly to random orbit sanders.

BACKGROUND OF THE INVENTION

A sander includes an abrasive sheet attached to a movable sanding pad. As the sanding pad and attached abrasive sheet are moved in an eccentric manner against a workpiece, dust and debris is generated.

SUMMARY OF THE INVENTION

The present invention provides, in one aspect, a random orbit sander including a housing and a motor enclosed within the housing. The motor includes a motor shaft that is rotatable about a first axis. An eccentric carrier coupled to the motor shaft includes a circular internal bore that defines a second axis that is offset from the motor shaft. A bearing is received within the circular internal bore of the eccentric carrier. A sanding pad is supported by the bearing and is rotatable about the first axis in an eccentrically orbiting manner. The motor shaft and the eccentric carrier are integrally formed as a single piece.

The present invention provides, in another aspect, a random orbit sander including a housing having a motor housing portion defining a first axis, a handle portion defining a second axis extending transversely to the first axis, and a battery receptacle located at an end of the handle portion that is distal to the motor housing portion. A motor is enclosed within the motor housing portion. A sanding pad is driven by the motor in an eccentrically orbiting manner. A dust extraction tube is offset from the handle portion and may extend approximately parallel thereto. A fan is driven by the motor and may be operable to induce an airflow around and/or through the sanding pad and to direct the airflow through the dust extraction tube to transport dust away from the sanding pad.

The present invention provides, in yet another aspect, a sander including a housing, a motor enclosed within the housing, a fan driven by the motor and operable to induce an airflow, and a sanding pad driven by the motor in an eccentrically orbiting manner. The sanding pad includes a bottom surface to which a replaceable abrasive sheet is attachable. For example, the replaceable abrasive sheet may be attached to the bottom surface of the sanding pad by an adhesive, by a hook-and-loop interface, or by another attachment system. The sanding pad further includes a plurality of radial air passageways each having an external radial opening to fluidly communicate the corresponding radial air passageway with an outer periphery of the sanding pad. The sanding pad further includes a plurality of axial air passageways, each being in fluid communication with one of the corresponding radial air passageways and each having an opening in the bottom surface of the sanding pad. The radial air passageways and the axial air passageways are configured to prevent a vacuum from being developed by the airflow between the replaceable abrasive sheet and a workpiece surface upon which the sander is being used.

The present invention provides, in yet another aspect, a random orbit sander comprising a housing and a motor enclosed within the housing, the motor including a motor shaft rotatable about a first axis. The random orbit sander further comprises an eccentric carrier including a circular internal bore defining a second axis that is offset from the first axis. The eccentric carrier includes a first adjustable counterweight on a first side of the eccentric carrier and a second adjustable counterweight on a second side of the eccentric carrier. The random orbit sander further comprises a bearing received within the circular internal bore of the eccentric carrier and a sanding pad supported by the bearing and rotatable about the first axis in an eccentrically orbiting manner.

The present invention provides, in yet another aspect, a sander comprising a housing and a battery pack coupled to the housing. The battery pack includes a positive terminal and a negative terminal. A motor is enclosed within the housing, and the motor includes a motor shaft that is rotatable about a first axis. A radial bearing rotatably supports a first end of the motor shaft. The random orbit sander further comprises a sanding pad driven by a second end of the motor shaft. A grounding strap extends between the radial bearing and the negative terminal of the battery pack to transmit an electrical charge from the radial bearing to the negative terminal of the battery pack.

The present invention provides, in yet another aspect, a random orbit sander comprising a housing and a motor enclosed within a motor housing portion of the housing. The motor includes a motor shaft that is rotatable about a first axis. The random orbit sander further comprises an eccentric carrier coupled to the motor shaft and driven by the motor. The eccentric carrier includes a circular internal bore defining a second axis that is offset from the motor shaft and the first axis. A bearing is received within the circular internal bore of the eccentric carrier. A sanding pad is supported by the bearing and rotatable about the first axis in an eccentrically orbiting manner. A dust extraction tube is configured to transport dust away from the sanding pad. The sanding pad is configured to sand a workpiece. A light is located on an outside of the housing, and the light is oriented to illuminate at least a portion of the workpiece. For example, a first work light may be positioned on a front surface of the motor housing portion to illuminate at least a portion of the workpiece in front of the sanding pad. A second work light may be positioned below the dust extraction tube to illuminate at least a portion of the workpiece behind the sanding pad.

The present invention provides, in yet another aspect, a random orbit sander operable to perform a sanding operation on a workpiece. The random orbit sander comprises a housing and a motor enclosed within the housing. The motor includes a motor shaft rotatable about a motor axis. The random orbit sander further comprises a brake pad coupled to the housing. A sanding pad is configured to eccentrically orbit the motor axis. The sanding pad includes a central axis, a bottom surface configured to face away from the housing, and a top surface configured to face toward the housing. The sanding pad further includes a sloped brake surface configured to engage the brake pad. The sloped brake surface is sloped in a radially inward direction at a slope angle.

The present invention provides, in yet another aspect, a holster for supporting a sander in a storage position. The holster includes a wall having a front surface spanning between two lips. Each lip includes an extension portion and a lateral portion that extends transverse to a respective one of the extension portions. The holster further includes a clip positioned on an opposite side of the front surface from the lips. The clip has an upper end and a lower end, and the clip is coupled to the wall at the upper end. The lower end of the clip is a free end. An aperture is provided in the clip. The aperture is configured to receive the head of a fastener to support the holster in a hanging position.

The present invention provides, in yet another aspect, a sander comprising a housing and a dust extraction tube supported by the housing. A motor is enclosed within the housing, and the motor has an on state and an off state. A sanding pad is driven by the motor. The sanding pad sands a workpiece, thereby generating dust as a byproduct. A fan is driven by the motor to induce an airstream to draw the dust through the dust extraction tube. The sander further includes a dust container with an inlet. The dust container receives the dust from the dust extraction tube and stores the dust therein. The sander further includes a baffle having a first side and an opposite, second side. The baffle is adjustable between an open position in which a movement of dust from the first side of the baffle is permitted, and a closed position in which a movement of dust from the second side of the baffle to the first side of the baffle is prevented.

The present invention provides, in yet another aspect, a sander comprising a housing having a handle portion. The handle includes a base material and at least one of an additive mixed with the base material or a coating on the base material. A motor is enclosed within the housing. The motor includes a rotatable motor shaft. A sanding pad is rotatable by the motor in an eccentrically orbiting manner. A surface resistivity of the base material may be greater than 10¹⁶ ohms. A surface resistivity of the housing may be between 10¹⁰ ohms and 10¹⁴ ohms (i.e., after any coatings or additives are included). In some embodiments, the surface resistivity of the housing may be less than 10¹² ohms (i.e., after any coatings or additives are included).

The present invention provides, in yet another aspect, a method of assembling a sander. The method includes providing an eccentric carrier, a dust extraction fan, a radial bearing, and a shaft having a longitudinal axis. The method further includes sizing an internal bore of the dust extraction fan to be nominally smaller than an external surface of the eccentric carrier, sizing an internal bore of the eccentric carrier to be nominally smaller than an external surface of the radial bearing, and sizing an internal bore of the radial bearing to be nominally smaller than an external surface of the shaft. The method further includes pressing the eccentric carrier, the dust extraction fan, the radial bearing, and the shaft together with an interference fit between the respective external surfaces and the internal bores of the eccentric carrier, the dust extraction fan, the radial bearing, and the shaft in a direction parallel to the longitudinal axis of the shaft.

The present invention provides, in yet another aspect, a random orbit sander comprising a housing and a motor enclosed within the housing. The motor includes a motor shaft that is rotatable about a first axis. An eccentric carrier is coupled to the motor shaft. The eccentric carrier includes a circular internal bore defining a second axis that is offset from the motor shaft. A radial bearing is received within the circular internal bore of the eccentric carrier. A dust extraction fan is rotationally unitized with the eccentric carrier for corotation therewith. The sander further includes an eccentric shaft that has a longitudinal axis, and a sanding pad is supported by the eccentric shaft and is rotatable about the first axis in an eccentrically orbiting manner. The eccentric carrier, the radial bearing, the dust extraction fan, and the eccentric shaft are coupled to each other by press-fit connections.

The present invention provides, in yet another aspect, a random orbit sander comprising a housing including a motor housing portion having a first radius. A motor is enclosed within the motor housing portion. The motor includes a motor shaft that is rotatable about a first axis. An eccentric shaft is coupled to the motor shaft and defines a second axis that is offset from the first axis by an offset distance. The second axis is parallel to the first axis. A sanding pad is supported by the eccentric shaft and is rotatable about the first axis in an eccentrically orbiting manner. The sanding pad has a second radius equal to or greater than a sum of the first radius and the offset distance.

The present invention provides, in yet another aspect, a sander comprising a housing including a motor housing portion. A motor is enclosed within the motor housing portion. The motor includes a motor shaft that is rotatable about a first axis. A sanding pad is coupled to the motor shaft and is rotatable by the motor. A fan is positioned between the motor and the sanding pad, and within a volute that is at least partially defined by the housing. The fan is rotatable by the motor about the first axis. The fan directs a motor-cooling airflow through the volute, downward toward the sanding pad through an interior passageway within the housing, and through an exhaust opening at a lower elevation in the motor housing portion than the fan.

The present invention provides, in yet another aspect, a sander comprising a housing including a motor housing portion. A motor is enclosed within the motor housing portion. The motor includes a motor shaft that is rotatable about a first axis. The sanding pad is coupled to the motor shaft and is rotatable by the motor. A fan is positioned between the motor and the sanding pad, and within a volute defined by a peripheral wall. At least a portion of the peripheral wall is formed by the housing. The fan is rotatable by the motor about the first axis to direct a motor-cooling airflow through the volute. A light holder is supported in the motor housing portion. The light holder includes a curved, upstanding wall that forms another portion of the peripheral wall.

The present invention provides, in yet another aspect, a sander comprising a housing including a motor housing portion. A motor is enclosed within the motor housing portion. The motor includes a motor shaft that is rotatable about a first axis. A sanding pad is coupled to the motor shaft and is rotatable by the motor. A light is supported at a front of the motor housing portion. The light projects light rays in a direction perpendicular to the first axis. A lens is positioned in front of the light. The lens is configured to refract the light rays in a downward direction parallel to the first axis and toward a front side of the sanding pad.

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

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a random orbit sander in accordance with an embodiment of the invention, illustrating an attached battery pack in a first orientation.

FIG. 2 is a side view of the sander of FIG. 1.

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

FIG. 4 is a front view of the sander of FIG. 1.

FIG. 5 is a perspective view of the sander of FIG. 1, but illustrating an attached battery pack in a second orientation.

FIG. 6 is a cross-sectional view of the sander of FIG. 1, but illustrating an attached battery pack in a third orientation.

FIG. 7 is a perspective view of a unified motor output shaft and eccentric carrier for use with a sander such as the sander of FIG. 1.

FIG. 8 is a side view of the unified motor output shaft and eccentric carrier of FIG. 7.

FIG. 9 is another side view of the unified motor output shaft and eccentric carrier of FIG. 7, orthogonal to the view of FIG. 8.

FIG. 10 is an end view of the unified motor output shaft and eccentric carrier of FIG. 7.

FIG. 10A is a perspective view of another embodiment of a unified motor output shaft and eccentric carrier.

FIG. 10B is a side view of the unified motor output shaft and eccentric carrier of FIG. 10A.

FIG. 10C is a cross-sectional view of the unified motor output shaft and eccentric carrier of FIG. 10A.

FIG. 11 is a perspective view of an integrated fan and counterweight unit for use with a sander such as the sander of FIG. 1.

FIG. 12 is a bottom view of the integrated fan and counterweight unit of FIG. 11.

FIG. 13 is a side view of the integrated fan and counterweight unit of FIG. 11.

FIG. 14 is a top view of the integrated fan and counterweight unit of FIG. 11.

FIG. 14A is a lower perspective view of an integrated fan and counterweight unit according to another embodiment.

FIG. 14B is an upper perspective view of the integrated fan and counterweight unit of FIG. 14A.

FIG. 14C is a lower perspective view of an integrated fan and counterweight unit according to another embodiment.

FIG. 15A is a perspective view of a sanding pad for use with either of the random orbit sanders of FIGS. 1 and 16.

FIG. 15B is another perspective view of the sanding pad of FIG. 15A.

FIG. 15C is a perspective view of another embodiment of a sanding pad for use with a sander such as either of the random orbit sanders of FIGS. 1 and 16.

FIG. 16 is a perspective view of a random orbit sander in accordance with another embodiment of the invention, illustrating an onboard dust box.

FIG. 17 is a cross-sectional view of the sander of FIG. 16.

FIG. 18 is a cross-sectional view of a random orbit sander in accordance with an embodiment of the invention.

FIG. 19 is a side view of a random orbit sander in accordance with an embodiment of the invention.

FIG. 20 is a rear view of the sander of FIG. 19.

FIG. 21 is a side view of a random orbit sander in accordance with an embodiment of the invention.

FIG. 22 is a cross-sectional view of the sander of FIG. 21.

FIG. 23 is a partial cutaway view of the sander of FIG. 21 with a portion of a housing removed.

FIG. 24 is a partial cutaway perspective view of the sander of FIG. 21 with a base portion of a dust extraction tube removed.

FIG. 25 is an upper perspective view of a cover portion of the dust extraction tube of the sander of FIG. 21.

FIG. 26 is a lower perspective view of the cover portion of FIG. 25.

FIG. 27 is an upper perspective view of the base portion of the dust extraction tube of the sander of FIG. 21.

FIG. 28 is a lower perspective view of the base portion of FIG. 27.

FIG. 29 is a top view of the base portion of FIG. 27.

FIG. 30 is an enlarged, cutaway view of the sander of FIG. 21 illustrating a grounding strap.

FIG. 31 is an enlarged, cross-sectional view of the sander of FIG. 21 illustrating another embodiment of a grounding strap.

FIG. 32 is a side view of the grounding strap of FIG. 31.

FIG. 33 is a perspective view of the grounding strap of FIG. 31.

FIG. 34 is an enlarged, cutaway view of the sander of FIG. 21 illustrating another embodiment of a grounding strap.

FIG. 35 is a perspective view of the grounding strap of FIG. 34.

FIG. 36 is a bottom perspective view of the sander of FIG. 21 illustrating an adjustable eccentric carrier.

FIG. 37 is cross-sectional view of the sander and adjustable eccentric carrier of FIG. 36.

FIG. 38 is a side view of a random orbit sander according to an embodiment of the invention including dual work lights.

FIG. 39 is a bottom view of the sander of FIG. 38.

FIG. 40 is a bottom view of the sander of FIG. 38, but modified to include an additional work light.

FIG. 41 is a top view of a sanding pad for use with any of the random orbit sanders shown in the previous figures.

FIG. 42 is a perspective view of a shaft for use with any of the random orbit sanders shown in the previous figures for attaching the sanding pad of FIG. 41.

FIG. 43 is a cross-sectional view of a sanding pad for use with any of the random orbit sanders shown in the previous figures.

FIG. 44 is a perspective view of a sanding pad for use with any of the random orbit sanders shown in the previous figures showing a sticker on a top surface of the sanding pad.

FIG. 45 is a perspective view of a random orbit sander supported in a holster.

FIG. 46 is a perspective view of the holster of FIG. 45 mounted to a surface.

FIG. 47 is a perspective view of a clip of the holster of FIG. 45.

FIG. 48 is a perspective view of another embodiment of a holster.

FIG. 49 is a front view of the holster of FIG. 48.

FIG. 50 is a rear view of the holster of FIG. 48.

FIG. 51 is a side view of the holster of FIG. 48.

FIG. 52 is a top view of the holster of FIG. 48.

FIG. 53 is a perspective view of a sander according to an embodiment of the invention.

FIG. 54 is a bottom view of the sander of FIG. 53.

FIG. 55 is a side view of the sander of FIG. 53.

FIG. 56 is a cross-sectional view of a random orbit sander according to an embodiment of the invention showing a dust collection baffle in a closed position.

FIG. 57 is a cross-sectional view of the random orbit sander of FIG. 56 showing the dust collection baffle in an open position.

FIG. 58 is a cross-sectional view of the random orbit sander of FIG. 53 along the section line 58-58.

FIG. 59 is a schematic view of an outline of a sanding pad and an outline of a motor housing portion of the random orbit sander of FIG. 53 showing the sanding pad in a first eccentric position.

FIG. 60 is a schematic view of an outline of the sanding pad and an outline of the motor housing portion of the random orbit sander of FIG. 53 showing the sanding pad in a second eccentric position.

FIG. 61 is a perspective cross-sectional view of the random orbit sander of FIG. 53 along the section line 61-61.

FIG. 62 is a top cross-sectional view of the random orbit sander of FIG. 53 along the section line 61-61.

FIG. 63 is a perspective view of a light holder of the random orbit sander of FIG. 53.

FIG. 64 is a detailed cross-sectional view of the random orbit sander of FIG. 53 along the section line 58-58.

FIG. 65 is a cross-sectional view of a lens of the random orbit sander of FIG. 53 along the section line 65-65 of FIG. 64 showing lights positioned in the lens.

FIG. 66 is a top view of the lens of the random orbit sander of FIG. 53.

FIG. 67 is a perspective view of the lens of the random orbit sander of FIG. 53.

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is 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

With reference to FIGS. 1-4, a random orbit sander 10 includes a housing 14 and a sanding pad 18 that is movable relative to the housing 14 in an eccentrically orbiting manner. The housing 14 includes a motor housing portion 22 in which a motor 26, such as a brushless direct current (“BLDC”) electric motor, is located (see also FIG. 6). The motor 26 may drive a motor fan 29 that is operable to cool the motor 26 (FIG. 6). The housing 14 also includes a handle portion 34 defining a handle axis A1 that is transverse to a motor housing axis A2 defined by the motor housing portion 22. A motor-activation trigger 30 is positioned beneath the handle portion 34 and adjacent the motor housing portion 22 and configured to activate the motor 26 when pressed.

With reference to FIGS. 1 and 2, the sander 10 also includes a dust extraction tube 50 extending from a bottom end of the motor housing portion 22. In the illustrated embodiment, the dust extraction tube 50 is integrally formed as a single piece with the housing 14. The dust extraction tube 50 defines a tube axis A3 (FIG. 2) that extends approximately parallel to the handle portion 34, and more specifically, to the handle axis A1. In some embodiments, “approximately parallel” means within 20 degrees of being parallel. The handle portion 34 and the dust extraction tube 50 may extend perpendicularly or at an oblique angle to the motor housing axis A2. The sander 10 also includes a brace 54 extending between a rear end of the dust extraction tube 50 and a rear end of the handle portion 34. A protective space 58 is collectively defined by a combination of the handle portion 34, motor housing portion 22, dust extraction tube 50, and brace 54 through which a user may insert their fingers for grasping the handle portion 34 and maneuvering the sander 10 during a sanding operation. In the illustrated embodiment, the motor-activation trigger 30 is positioned within the protective space 58 and, when actuated, moves linearly in a direction away from the dust extraction tube 50. The dust extraction tube 50 is configured to transport dust away from the sanding pad 18.

With continued reference to FIGS. 1 and 2, the sander 10 includes a removable dust container 59 in which dust and debris created from a sanding operation is stored. The dust container 59 includes a fitting 66 that is attachable to an outlet port 62 of the dust extraction tube 50 and a collection receptacle 60 (e.g., a flexible bag or rigid bin) secured to the fitting 66. In some embodiments, the fitting 66 includes a latch 70 to secure or lock the fitting 66, and therefore the collection receptacle 60, to the outlet port 62. To remove the dust container, the latch 70 is pressed to release its engagement from the outlet port 62, and the fitting 66 is pulled away from the outlet port 62. In some embodiments, the dust container 59 may be omitted and instead a vacuum hose, which is connected to a remote vacuum source, may be attached to the outlet port 62 to induce an airflow through the dust extraction tube 50 to carry dust and debris away from the sanding pad 18 and into the vacuum hose.

The sander 10 also includes a low-capacity battery pack 74, which is received in a battery receptacle 78 defined in a rear end of the handle portion 34 opposite the motor housing portion 22 and above the outlet port 62 of the dust extraction tube 50. In the illustrated embodiment, the battery pack 74 is slidably coupled to the battery receptacle 78 along an insertion axis A4 that is coaxial with the handle axis A1. Individual battery cells (not shown) within the battery pack 74 are oriented parallel with the insertion axis A4, such that the entirety of the battery pack 74 is located above the outlet port 62 of the dust extraction tube 50.

With continued reference to FIGS. 1, 2, and 4, the sander 10 may include a work light such as an LED (light emitting diode) work light 24 located on the motor housing portion 22 and, in the illustrated embodiment, on a front portion of the motor housing portion 22. A switch may selectively activate the LED work light 24. In some embodiments, a plurality of work lights, some or all of which may be LED work lights, may be positioned in various locations on the sander 10.

With continued reference to FIGS. 1-4, exhaust ports 25 may be provided in the housing 14 of the sander 10 to, for example, vent to an ambient environment exhaust airflow that is generated by a fan such as, for example, the motor fan 29. In some embodiments, the exhaust ports 25 may be configured to allow free convection to occur through the exhaust ports 25. A top portion 27 of the motor housing portion 22 may be referred to as a pommel portion 27 of the motor housing portion 22. The pommel portion 27 may be a grip portion of the housing 14 that is configured for gripping by a user during operation. The exhaust ports 25 may be provided below the pommel portion 27 at a narrower neck portion 28 of the motor housing portion 22. The neck portion 28 may house the motor fan 29, and the motor fan 29 may be driven by the motor 26 to generate a motor-cooling airflow that may be discharged through the exhaust ports 25. The pommel portion 27 may be devoid of an additional exhaust port through which the motor-cooling airflow is discharged. By positioning the exhaust ports 25 at a location other than the pommel portion 27, the exhaust ports 25 may be configured such that gripping of the housing 14 by the user does not inhibit airflow through the exhaust ports 25. In some embodiments, by positioning the exhaust ports 25 at a location below the pommel portion 27, and more specifically, by positioning the exhaust ports 25 at the narrower neck portion 28, the exhaust ports 25 may be configured such that gripping of the housing 14 by the user does not inhibit airflow through the exhaust ports 25. In the illustrated embodiment, four exhaust ports 25 are provided, but in other embodiments, any number of exhaust ports such as one, two, three, five, six, or more may be provided.

With reference to FIGS. 5, 6, and 16, variations of the sander 10 may include a high-capacity battery pack 82, which includes more individual battery cells than the low-capacity battery pack 74. The battery cells are located within a triangular housing portion 86 and a rectangular housing portion 90 of the battery pack 82. The battery pack 82, and specifically the triangular housing portion 86, is received in the battery receptacle 78, which in the embodiments of FIGS. 5, 6, and 16 has been reoriented to provide different mounting orientations for the battery pack 82. The rectangular housing portion 90 is offset from the triangular housing portion 86, with a long side 98 and an opposite, short side 102 on opposite sides of the triangular housing portion 86. In FIG. 5, the battery pack 82 is received within the battery receptacle 78 such that the long side 98 of the battery pack 82 is facing one side of the sander 10. In the sander 10 of FIG. 6, the battery pack 82 is received within the battery receptacle 78 with the long side 98 of the battery pack 82 facing upward and away from the sanding pad 18. In the sander of FIG. 16, the battery pack 82 is received within the battery receptacle 78 with the long side 98 of the battery pack 82 facing downward. In other variations, the battery receptacle 78 may be configured to receive the battery pack 82 in other orientations.

With reference to FIG. 6, the motor housing portion 22 includes an upper cavity 110 in which the motor 26 is located and a lower cavity 128 adjacent the sanding pad 18. The motor housing portion 22 also includes a wall 126 separating the cavities 110, 128. A bearing pocket 130 is defined in the wall 126 in which a radial bearing 134 is positioned that rotatably supports a motor shaft 106 that is driven by the motor 26 and extends between the upper cavity 110 and the lower cavity 128. The motor shaft 106 defines a motor shaft axis A5 (see also FIG. 7) that is offset from the motor housing axis A2 in a rearward direction. As such, the position of the motor 26 within the upper cavity 110 is shifted to the rear of the motor housing portion 22, leaving empty space 138 in front of the motor 26 through which electrical wires may be routed.

With reference to FIGS. 6 and 7, the motor shaft 106 is integrally formed with an eccentric carrier 142 to form a unified or one-piece motor shaft/eccentric carrier unit 146. As mentioned above, a lower end of the motor shaft 106 is rotatably supported within the motor housing portion 22 by the radial bearing 134 (FIG. 6). With reference to FIG. 6, an upper end of the motor shaft 106 is rotatably supported by another radial bearing 156 held within a corresponding pocket 157 defined near the top of the motor housing portion 22. As such, with the eccentric carrier 142 integrally formed with the motor shaft 106 at the lower end thereof, the eccentric carrier 142 is cantilevered within the lower cavity 128.

With reference to FIG. 7, the eccentric carrier 142 includes a circular internal bore 162 that defines a central axis A6, which is parallel to and offset from the motor shaft axis A5. A radial bearing 150 (FIG. 6) is received within the bore 162 and is supported by the eccentric carrier 142. An inner race of the bearing 150, in turn, receives a post 158 upstanding from the sanding pad 18 to support the sanding pad 18. In operation of the sander 10, the bearing 150 permits the sanding pad 18 and post 158 to freely rotate, in either direction, relative to the eccentric carrier 142 about the central axis A6. Because the central axis A6 is offset from the motor shaft axis A5, a rotation of the motor shaft 106 imparts an eccentric orbiting motion to the bearing 150 and thus to the post 158 and sanding pad 18 (FIG. 6). When the sanding pad 18 orbits about the motor shaft axis A5 in an eccentric manner, the sanding pad 18 has a first degree of freedom, namely the eccentric orbiting motion of the sanding pad 18 about the motor shaft axis A5. The sanding pad 18 and post 158 are also freely rotatable about the central axis A6, providing a second degree of freedom for the sanding pad 18.

With reference to FIGS. 7-10, the eccentric carrier 142 also includes a semicircular external surface 166 having both a rounded portion 170 and a flat portion 174. A flange 178 may be positioned between the eccentric carrier 142 and the motor shaft 106, and oriented perpendicular to the motor shaft axis A5 and to the central axis A6.

With reference to FIGS. 10A-10C, another embodiment of a unified motor output shaft and eccentric carrier 144 includes an integrated counterweight 145. In some embodiments, the unified motor output shaft and eccentric carrier 144 does not include a counterweight.

With reference to FIG. 11, the sander 10 includes a fan 182 and a counterweight 184 that are both rotationally unitized to the external surface 166 of the eccentric carrier 142. The fan 182 and the counterweight 184 are coupled for co-rotation. As such, the fan 182 and counterweight 184 define a one-piece, integrated fan and counterweight unit 186. In the illustrated embodiment, the fan 182 and the counterweight 184 are integrally formed as a single piece with the fan 182 provided on an opposite side of the integrated fan and counterweight unit 186 from the counterweight 184. The fan 182 includes a hub 188 and a plurality of fan blades 190 radially outside the hub 188. The fan blades 190 may be relatively long and thin. The hub 188 includes an internal bore (i.e., an internal surface) having a rounded portion 198 and a flat portion 202. The semicircular external surface 166 of the eccentric carrier 142 is received in the internal bore of the hub 188, with the flat portion 174 of the eccentric carrier 142 engaging the flat portion 202 of the internal bore of the hub 188, to rotationally position the one-piece motor shaft/eccentric carrier unit 146 with respect to the integrated fan and counterweight unit 186 and, to a certain extent, to transmit torque from the one-piece motor shaft/eccentric carrier unit 146 to the integrated fan and counterweight unit 186 to ensure both units 146, 186 rotate in unison. Torque is also transmitted between components by a press fit interaction between the components (e.g., by a press fit between the one-piece motor shaft/eccentric carrier unit 146 and the integrated fan and counterweight unit 186).

With reference to FIGS. 11-14, the integrated fan and counterweight unit 186 includes a flange 203 circumscribing the hub 188 from which the blades 190 extend. The counterweight 184 is located on an opposite side of the flange 203 as the blades 190, and the counterweight 184 is located on an opposite side of the hub 188 as the flat portion 202 of the internal bore. A plurality of holes 210, 211 (FIGS. 12 and 14) are provided in the flange 203. In the illustrated embodiment, a first array of five holes 210 is provided in the flange 203 and also through the counterweight 184, and a second array of five holes 211 is provided in the flange 203 on a side opposite the counterweight 184. The holes 210, 211 are provided along a circular arc such that the holes 210 are equidistant from each other and such that the holes 211 are also equidistant from each other. In some embodiments, the holes 210, 211 may be used in conjunction with adjustment screws, nuts, washers, and/or other components to adjust a center of gravity of the integrated fan and counterweight unit 186.

With reference to FIGS. 14A-14B, another embodiment of a dust extraction fan 187 such as an integrated fan and counterweight unit 187 includes fan blades 189 that do not completely encircle the integrated fan and counterweight unit 187. The fan blades 189 extend from a flange 197 that circumscribes a hub 205. The integrated fan and counterweight unit 187 includes a first counterweight 191 on a same side of the integrated fan and counterweight unit 187 as the fan blades 189. The first counterweight 191 is positioned between two fan blades 189 such that the first counterweight 191 may span, for example, between 10 degrees and 180 degrees, between 30 degrees and 120 degrees, 60 degrees and 120 degrees, approximately 90 degrees, or another angle around the integrated fan and counterweight unit 187. The first counterweight 191 is stepped and includes a short portion 191a and a tall portion 191b. The short portion 191a is defined by a distance 199 measured between the flange 197 and an edge of the short portion 191a that is distal from the flange 197 along a direction parallel to a motor axis when the integrated fan and counterweight unit 187 is installed. The tall portion 191b is defined by a distance 201 measured between the flange 197 and an edge of the tall portion 191b that is distal from the flange 197 along a direction parallel to a motor axis when the integrated fan and counterweight unit 187 is installed. A weight of the short portion 191a, a weight of the tall portion 191b, the distance 199, the distance 201, and other features of the integrated fan and counterweight unit 187 may be selected to provide a desired location of a center of gravity of the integrated fan and counterweight unit 187.

The integrated fan and counterweight unit 187 also includes a second counterweight 192 on an opposite side of the integrated fan and counterweight unit 187 from the fan blades 189 and from the first counterweight 191. Further, the second counterweight 192 is also positioned diametrically opposite the first counterweight 191. In the illustrated embodiment, the first counterweight 191 is a larger (i.e., heavier) counterweight than the second counterweight 192. The first counterweight 191 may include one or more holes 193, and in the illustrated embodiment includes three holes 193. The second counterweight 192 may include one or more holes 193, and in the illustrated embodiment includes one hole 193. In the illustrated embodiment, the holes 193 are blind holes, but in other embodiments, the holes 193 may include through holes. The holes 193 may be used in conjunction with adjustment screws, nuts, washers, and/or other components to adjust the center of gravity of the integrated fan and counterweight unit 187.

With reference to FIG. 14C, another embodiment of a dust extraction fan 194 such as an integrated fan and counterweight unit 194 includes fan blades 195 and a plurality of holes 196 (which may be either blind holes 196, through holes 196, or a combination of blind holes and through holes). In the illustrated embodiment, the holes 196 form two rows of holes 196, each row of holes 196 positioned at a different radial distance from a center of the integrated fan and counterweight unit 194. In other embodiments, the holes 196 may be positioned in other patterns. The holes 196 may be used in conjunction with adjustment screws, nuts, washers, and/or other components to adjust a center of gravity of the integrated fan and counterweight unit 194. Using more holes 196 that are relatively smaller in size permits a center of gravity of the integrated fan and counterweight unit 194 to be fine-tuned.

With reference to FIGS. 15A-15B, a replaceable abrasive sheet 324 is attachable to a bottom surface 325 of the sanding pad 18. The sanding pad 18 includes a plurality of radial air passageways 328 and axial air passageways 332 (i.e., first axial air passageways), each of the axial air passageways 332 being in fluid communication with one of the corresponding radial air passageways 328, and each of the axial air passageways 332 having an opening in the bottom surface 325 of the sanding pad 18. More specifically, the radial air passageways 328 and the axial air passageways 332 are provided within the sanding pad 18, and the radial air passageways 328 do not directly communicate with the bottom surface 325 of the sanding pad 18. In other words, the radial air passageways 328 are exposed to the bottom surface 325 of the sanding pad 18 only via the axial air passageways 332. In the illustrated embodiment of FIGS. 15A-15B, the sanding pad 18 includes six radial air passageways 328 and six axial air passageways 332 equally spaced about the sanding pad 18. Each of the radial air passageways 328 includes an internal radial opening 336 and an external radial opening 340 opposite the internal radial opening 336. The abrasive sheet 324 includes a plurality of holes 344, each of which aligns with one of the axial air passageways 332 when the abrasive sheet 324 is installed on the sanding pad 18. As shown in FIG. 15A, each of the axial air passageways 332 intersects a corresponding one of the radial air passageways 328. The sanding pad 18 includes a central bore 348 with which the internal radial openings 336 of the respective radial air passageways 328 are exposed and in fluid communication, thereby allowing fluid communication between the radial air passageways 328 and the central bore 348. Each external radial opening 340 allows fluid communication between the corresponding radial air passageway 328 and an outer periphery 341 of the sanding pad 18. This arrangement of radial air passageways 328 and axial air passageways 332 is configured to prevent a vacuum from being developed by airflow (e.g., airflow generated by the fan 182 or by a remote vacuum source) between the abrasive sheet 324 and a workpiece upon which the sander 10 is being used.

With reference to FIG. 15A, the sanding pad 18 further includes a plurality of axial holes 352 (i.e., second axial air passageways), and the abrasive sheet 324 includes a plurality of corresponding aligned holes 356 cooperating with the axial holes 352. The airflow induced by the fan 182 or by the remote vacuum source moves through the axial holes 352 and the aligned holes 356 to allow dust extraction therethrough. The radial air passageways 328 are fluidly isolated from the axial holes 352. The axial holes 352 are larger in diameter than the radial air passageways 328 and the axial air passageways 332. In other words, the radial air passageways 328 and the axial air passageways 332 may both be smaller in diameter than the axial holes 352. In some embodiments, the axial air passageways 332 may have a diameter of less than 30% of a diameter of the axial holes 352. In various other embodiments, the axial air passageways 332 may have a diameter of less than 28%, 26%, 24%, 22%, 20%, 18%, or 16% of a diameter of the axial holes 352. The radial air passageways 328 may be similar in diameter to the axial air passageways 332. Because of the relatively small diameter of the radial air passageways 328 and the axial air passageways 332, the radial air passageways 328 and the axial air passageways 332 are configured to inhibit dust extraction therethrough.

With reference to FIG. 15C, a variation of the sanding pad 18 may not include the central bore 348 and further may not include the internal radial openings 336. In the embodiment of FIG. 15C, four radial air passageways 328, four axial air passageways 332, and four external radial openings 340 are provided in the sanding pad 18. Two of the external radial openings 340 may be closer to each other than either one of those two external radial openings 340 is to a third one of the external radial openings 340. In other words, the radial air passageways 328 and the axial air passageways 332 may not be equidistantly and/or symmetrically arranged about the sanding pad 18.

In operation, and with reference to FIGS. 1 and 15A-15C, the sander 10 may be equipped with a version of the sanding pad 18. The integrated fan and counterweight unit 186 may rotate with the rotation of the motor 26, thereby pulling air and any associated dust and debris from a vicinity of a workpiece (in other words, from an area near the abrasive sheet 324) through the aligned holes 356 and the axial holes 352 in the abrasive sheet 324 and the sanding pad 18, respectively. To prevent an unintentional accumulation of a vacuum between the abrasive sheet 324 and the workpiece, the connected radial and axial air passageways 328, 332 permit replacement air from the outer periphery 341 of the sanding pad 18 to be drawn through the passageways 328, 332 and into the space between the abrasive sheet 324 and the workpiece.

With reference to FIGS. 16 and 17, another embodiment of a sander 300 is shown that is similar to the sander 10 of FIGS. 1-15C, except for visible and/or noted differences. The sander 300 includes an onboard dust box 304 with a filter 308 provided therein to capture dust and debris. The dust box 304 may be integrally formed with a dust extraction tube 320 as a single piece, and the dust extraction tube 320 may be selectively attachable to the sander 300 via a latch 322. In the illustrated embodiment, the dust box is positioned downstream of the dust extraction tube. In some embodiments, the dust box 304 and the dust extraction tube 320) may be removable and interchangeable with the dust extraction tube 50, and similar to the dust extraction tube 50, the dust extraction tube 320 may be configured to transport dust away from the sanding pad 18. The dust box 304 may include a cover 312 which, in some embodiments, is provided at a bottom of the dust box 304 (FIG. 17). The cover 312 is slidable, pivotable, removable, or otherwise openable to allow a user to remove the filter 308 to clean and/or replace the filter 308. The filter 308 may be a cyclonic filter, or the filter 308 may have a cylindrical or other shape. The filter 308 may have an orientation that is approximately parallel to the motor shaft 106.

With reference to FIG. 17, a dust shroud 316 within the housing 14, and more specifically within the motor housing portion 22, includes a dust shroud outlet 318 and surrounds the integrated fan and counterweight unit 186 (and, accordingly, the fan 182) as well as the eccentric carrier 142. The dust shroud outlet 318 is in fluid communication with the dust extraction tube 320. In some embodiments, the dust shroud 316 may be integrally formed as a single piece with the dust extraction tube 320. The dust shroud 316 extends at least partially into the dust extraction tube 320, which connects the dust box 304 to the motor housing portion 22. The integrated fan and counterweight unit 186 functions as a radial-flow fan to discharge air and associated dust and debris in a direction transverse to the motor shaft 106, and more specifically, in a direction transverse to the motor shaft axis A5 (FIG. 6). As a result, the dust shroud 316 may provide a seal between the upper cavity 110 and an airflow path generated by the rotation of the integrated fan and counterweight unit 186. In other words, the dust shroud 316 may direct the airflow into the dust extraction tube 320 by inhibiting the airflow from entering other internal spaces within the housing 14.

In operation of the sander 300, air and associated dust and debris are drawn through the abrasive sheet 324 and sanding pad 18, through the dust shroud 316, through the dust extraction tube 320, and into the dust box 304 where the dust and debris are filtered from the air by the filter 308.

With reference to FIG. 18, an embodiment of a random orbit sander 400 may be similar to other sanders disclosed herein and may be the same as the sander 10 (FIG. 1). A motor diameter 404 of the sander 400 may be 42.3 mm or may be within a tolerance such as within 10%, 20% etc. of 42.3 mm. An overall battery pack height 408 of the sander 400, which may be measured in a direction parallel to the motor shaft axis A5 (FIG. 6) from a lower side of the sander 400 at the sanding pad 18 to an upper side of the sander 400 at an upper side of a battery pack such as the high-capacity battery pack 82, may be 177.72 mm or may be within a tolerance such as within 10%, 20%, etc. of 177.72 mm. An overall height 412 of the sander 400, which may be measured in a direction parallel to the motor shaft axis A5 (FIG. 6) from a lower side of the sander 400 at the sanding pad 18 to an upper side of the sander 400, disregarding any added height from a battery pack such as the high-capacity battery pack 82, may be less than, for example, 145 mm and may be 139.57 mm or may be within a tolerance such as within 10%, 20%, etc. of 139.57 mm. A motor housing portion height 416 of the sander 400, which may be measured in a direction parallel to the motor shaft axis A5 (FIG. 6) from a lower side of the sander 400 at the sanding pad 18 to an upper side of the motor housing portion 22, may be 123.64 mm or may be within a tolerance such as within 10%, 20%, etc. of 123.64 mm. A sanding pad diameter 420 of the sanding pad 18 may be 76.2 mm or may be within a tolerance such as within 10%, 20%, etc. of 76.2 mm.

With continued reference to FIG. 18, an overall battery pack length 424 of the sander 400, which may be measured in a direction perpendicular or generally perpendicular to the motor shaft axis A5 (FIG. 6) from a front side of the sander 400 at the sanding pad 18 to a rear side of the sander 400 at a rear side of a battery pack such as the high-capacity battery pack 82, may be 272.88 mm or may be within a tolerance such as within 10%, 20%, etc. of 272.88 mm. An overall length 428 of the sander 400, which may be measured in a direction perpendicular or generally perpendicular to the motor shaft axis A5 (FIG. 6) from a front side of the sander 400 at the sanding pad 18 to a rear side of the sander 400, disregarding any added length from a battery pack such as the high-capacity battery pack 82, may be less than 225 mm and may be 218.21 mm or may be within a tolerance such as within 10%, 20%, etc. of 218.21 mm. As a result, the motor housing portion height 416 may be less than 0.6 times the overall length 428. The collection receptacle 60 (e.g., a flexible bag or rigid bin: also shown, for example, in FIGS. 1 and 2) may include a rigid portion 61 that couples to the fitting 66. An overall rigid portion length 432 of the sander 400, which may be measured in a direction perpendicular or generally perpendicular to the motor shaft axis A5 (FIG. 6) from a front side of the sander 400 at the sanding pad 18 to a rear side of the sander 400 at a rear side of the rigid portion 61, may be 356.05 mm or may be within a tolerance such as within 10%, 20%, etc. of 356.05 mm.

With continued reference to FIG. 18, the work light 24 is positioned at a front of the pommel portion 27 (FIG. 1). A sanding pad-work light setback distance 436, which may be measured in a direction perpendicular or generally perpendicular to the motor shaft axis A5 (FIG. 6) from a front side of the sander 400 at the sanding pad 18 to the work light 24, may be 9.85 mm or may be within a tolerance such as within 10%, 20%, etc. of 9.85 mm. A pommel-work light setback distance 440, which may be measured in a direction perpendicular or generally perpendicular to the motor shaft axis A5 (FIG. 6) from a front side of the pommel portion 27 to the work light 24, may be 6.26 mm or may be within a tolerance such as within 10%, 20%, etc. of 6.26 mm.

With reference to FIG. 19, an embodiment of a random orbit sander 500 may be similar to other sanders disclosed herein and, more specifically, may be similar to the sander 400 with certain dimensions being adjusted and/or scaled. For example, an overall height 504 of the sander 500, which may be measured in a direction parallel to the motor shaft axis A5 (FIG. 6) from a lower side of the sander 500 at the sanding pad 18 to an upper side of the sander 500, disregarding any added height from a battery pack such as the low-capacity battery pack 74, may be 5.32 inches or 135.13 mm or may be within a tolerance such as within 10%, 20%, etc. of 5.32 inches or 135.13 mm. In some embodiments, the overall height 504 may be less than 5.32 inches or 135.13 mm. A motor housing portion height 508 of the sander 500, which may be measured in a direction parallel to the motor shaft axis A5 (FIG. 6) from a lower side of the sander 500 at the sanding pad 18 to an upper side of the motor housing portion 22, may be 4.75 inches or 120.65 mm or may be within a tolerance such as within 10%, 20%, etc. of 4.75 inches or 120.65 mm. In some embodiments, the motor housing portion height 508 may be less than 4.75 inches or 120.65 mm.

With reference to FIG. 20, the sander 500 may be able to connect to a dust container 59 (analogously to FIG. 2, for example) at the outlet port 62. The sander 500 may be interchangeably selectively connectable to a variety of battery packs such as the low-capacity battery pack 74, the high-capacity battery pack 82, or other types of battery packs. The sander 500 may receive and in some embodiments interchangeably selectively receive the sanding pad 18, which may be a sanding pad with a diameter of 3 inches or 76.2 mm or within a tolerance such as within 10%, 20%, etc. of 3 inches or 76.2 mm.

With reference to FIGS. 21 and 22, an embodiment of a random orbit sander 600 may be similar to other sanders disclosed herein and may include aspects, features, and dimensions of the other embodiments disclosed herein. The sander 600 includes, similar to other embodiments disclosed herein, the housing 14, the motor housing portion 22 with a pommel portion 27, and one or more LED work lights 24, as well as a dust shroud 652 (FIG. 23) surrounding the fan 182. The dust shroud 652 has a dust shroud outlet 690 (FIG. 29). A dust extraction tube 604 extends from the outlet 690 in a rearward direction, and the dust extraction tube 604 transitions into the outlet port 62, which is couplable to a dust container such as the dust container 59. In some embodiments, the dust shroud 652 and the dust extraction tube 604 may be integrally formed as a single piece. The sander 600 may include a strut portion 608 having a proximal end 612 near the motor housing portion 22 and a distal end 616 that is positioned away from the motor housing portion 22 (e.g., in some embodiments, the distal end 616 is close to the battery receptacle 78). At least a portion of the strut portion 608 may include a tube portion 620 that allows the dust extraction tube 604 to pass through the tube portion 620 and to transport dust and debris therethrough.

With continued reference to FIG. 22, the sander 600 includes the unified motor output shaft and eccentric carrier 144 (FIGS. 10A-10C), which includes a motor shaft 1500 and an eccentric carrier 1504 that are integrally formed as one piece. The eccentric carrier 1504 supports a radial bearing 1508 (which may also be called an eccentric bearing 1508) within the eccentric carrier 1504. An eccentric shaft 1512 is rotatably supported by the radial bearing 1508. The eccentric shaft 1512 may be a post or may be integrated with a mounting interface for affixing the sanding pad 18 to the eccentric shaft 1512. In the illustrated embodiment, the radial bearing 1508 is a double-row ball bearing that includes two rows of ball bearings positioned between the eccentric shaft 1512 and the eccentric carrier 1504. An integrated fan and counterweight unit 187 is mounted on an outside of the eccentric carrier 1504. The integrated fan and counterweight unit 187 is rotationally unitized with the eccentric carrier 1504 for corotation with the motor shaft 1500. The integrated fan and counterweight unit 187 functions as a dust extraction fan 187 that transports dust and air from an area proximal to the sanding pad and through the dust extraction tube 604 to the dust container 59.

With continued reference to FIG. 22, a reference plane S is parallel to a working surface 1516 of the sanding pad 18 and/or perpendicular to the motor housing axis A2. The reference plane S passes through the integrated fan and counterweight unit 187 (and, more specifically in the illustrated embodiment, through at least one fan blade 189 and also through the counterweight 191), through the eccentric carrier 1504, through the radial bearing 1508, and through the eccentric shaft 1512. These features (i.e., the integrated fan and counterweight unit 187, the eccentric carrier 1504, the radial bearing 1508, and the eccentric shaft 1512) are provided within a lower cavity 1520 of a motor housing portion 1524. As a result, the compactness of the sander 600 is increased. The unified motor output shaft and eccentric carrier 144, the radial bearing 1508, the eccentric shaft 1512, and the integrated fan and counterweight unit 187 are press-fit together.

With continued reference to FIG. 22, a method of assembling a sander 600 includes sizing an internal bore 1600 of the dust extraction fan 187 and an external surface 1604 of the eccentric carrier 1504 such that the dust extraction fan 187 and the eccentric carrier 1504 are affixed by a press-fit connection. The method further includes sizing an internal bore 1608 of the eccentric carrier 1504 and an external surface 1612 of the radial bearing 1508 such that the eccentric carrier 1504 and the radial bearing 1508 are affixed by a press-fit connection. The method further includes sizing an internal bore 1616 of the radial bearing 1508 and an external surface 1620 of the shaft 1512 such that the radial bearing 1508 and the shaft 1512 are affixed by a press-fit connection. The method further includes pressing the eccentric carrier 1504, the dust extraction fan 187, the radial bearing 1508, and the shaft 1512 together in a direction parallel to a longitudinal axis A10 of the shaft 1512. The method may further include coupling the eccentric carrier 1504, the dust extraction fan 187, the radial bearing 1508, and the shaft 1512 such that the reference plane S passes through the eccentric carrier 1504, the dust extraction fan 187, the radial bearing 1508, and the shaft 1512. The dust extraction fan 187 may be an integrated fan and counterweight unit 187, and the method may further include coupling the components such that the reference plane S also passes through a counterweight 191 of the integrated fan and counterweight unit 187 and through a fan blade 189 of the integrated fan and counterweight unit 187. The method may include stacking the eccentric carrier 1504, the dust extraction fan 187, the radial bearing 1508, and the shaft 1512 prior to pressing together the eccentric carrier 1504, the dust extraction fan 187, the radial bearing 1508, and the shaft 1512. The method may include press-fitting the eccentric carrier 1504, the dust extraction fan 187, the radial bearing 1508, and the shaft 1512 together as a stack.

With reference to FIG. 23, the dust extraction tube 604 may comprise a base portion 632 and a cover portion 636. The cover portion 636 may define a cover for the dust shroud 652. In some embodiments, a unitized dust shroud 652 and dust extraction tube 604 may be formed by the base portion 632 and the cover portion 636. The base portion 632 may be selectively connectable to and detachable from the cover portion 636 by means of, for example, screws or one or more quick-connect fasteners such as a plurality of snap-fit connectors 624, 628. In some embodiments, the base portion 632 may be detachable from the cover portion 636 by first detaching two clamshell halves of the housing 14 from each other. The base portion 632 may include a lower partial tube portion 633, and the cover portion 636 may include an upper partial tube portion 637. The lower partial tube portion 633 may interface with the upper partial tube portion 637 to form at least a portion of the dust extraction tube 604 and to sufficiently seal the dust extraction tube 604 to inhibit a loss of air pressure and/or dust and debris from an airstream prior to reaching the dust container 59. The base portion 632 and the cover portion 636 may seal against each other with a tongue-and-groove connection along the entire interface, or along portions thereof, where the base portion 632 contacts the cover portion 636 to improve a seal between the base portion 632 and the cover portion 636. In some embodiments, one or both of the base portion 632 or the cover portion 636 may be integrally formed as a single piece. The dust extraction tube 604 is configured to transport dust away from the sanding pad 18.

With reference to FIG. 24, the tube portion 620 may surround and house one or both of the base portion 632 or the cover portion 636. In some embodiments, an airstream configured to deliver dust and/or debris to the dust container 59 may be contained within the base portion 632 and the cover portion 636.

With reference to FIGS. 25 and 26, the cover portion 636 may include a shroud cover 644 with a bore 648 therethrough. In some embodiments, the bore 648 may be circular. The bore 648 may be configured to accommodate components that are contained within the motor housing portion 22 such as an eccentric carrier 772 (FIG. 36), which may, in some respects, be similar to the eccentric carrier 142 and which may be an integrated motor shaft/eccentric carrier unit 772. The shroud cover 644 may seal against one or more components including, for example, the eccentric carrier 772 or the integrated fan and counterweight unit 186 to inhibit the airstream contained within the cover portion 636 and the base portion 632 (i.e., the airstream that is generated by the rotation of a fan such as the fan 182 included in the integrated fan and counterweight unit 186) from reaching other portions of the motor housing portion 22. For example, the cover portion 636 and the base portion 632 may cooperate to inhibit dust and/or debris from entering the motor 26.

With reference to FIGS. 27 and 28, the base portion 632 may include the dust shroud 652 and a bore 656 therethrough (FIG. 28). In some embodiments, when the base portion 632 and the cover portion 636 are assembled in the sander 600, the bores 648, 656 may form concentric circles when projected onto a plane perpendicular to the motor shaft axis A5 (FIG. 6). In some embodiments, the bores 648, 656 may be the same size or may be similar sizes. The dust shroud 652 may seal against one or more components including, for example, the eccentric carrier 772, to inhibit the airstream contained within the cover portion 636 and the base portion 632 (i.e., the airstream that is generated by the rotation of a fan such as the fan 182 included in the integrated fan and counterweight unit 186) from reaching other portions of the motor housing portion 22 (i.e., from escaping from within the cover portion 636 and the base portion 632). The base portion 632 may include a tube portion 660 into which the lower partial tube portion 633 transitions in a direction away from the dust shroud 652. In other words, the dust extraction tube 604 may include the tube portion 660. The base portion 632 includes a sealing ridge 664 that interfaces with a sealing ridge 668 (FIG. 26) of the cover portion 636. The sealing ridges 664, 668 interface in a manner that acts to extend the dust extraction tube 604 between the outlet port 62 and the dust shroud 652. The sealing ridges 664, 668 may cooperate to form a tongue-and-groove connection.

With reference to FIG. 29, the base portion 632 may have an overall length 672 of 207 mm or within a tolerance such as within 10%, 20%, etc. of 207 mm. The outlet port 62 of the base portion 632 may include an outlet diameter 676 of 30.2 mm or within a tolerance such as within 10%, 20%, etc. of 30.2 mm. The bore 656 may include a diameter 680, which may be referred to as an inlet diameter 680 and/or an air inlet diameter 680. The dust shroud 652 may have an outer diameter 684 of 67.5 mm or within a tolerance such as within 10%, 20%, etc. of 67.5 mm. In some embodiments, an outer perimeter 688 of the dust shroud 652 may be a circle and may be concentric with the bore 656. However, in other embodiments, the bore 656 may not be concentric with the outer perimeter 688. In some embodiments, the outer perimeter 688 of the dust shroud 652 may have a center at a different location from a center of the bore 656. In some embodiments, various components of the dust shroud 652, which may include the outer perimeter 688, may be defined by an expanding radius about a center 692. The dust shroud 652 may define a volute 696 configured to direct an airstream produced by a fan such as the fan 182 of the integrated fan and counterweight unit 186 (or, for example, the integrated fan and counterweight unit 187 or the integrated fan and counterweight unit 194), which may carry dust and debris away from, for example, the sanding pad 18. The volute 696 may include an expanding radius about, for example, the center 692 that leads to the outlet 690, which may serve as an outlet of the volute 696. For example, a first volute radius R1 may be different from, and in the illustrated embodiment shorter than, a second volute radius R2, which is measured at a different rotational angle about the center 692 from the first volute radius R1.

As a result of the geometry of the volute 696, there is a relatively small amount of clearance between a fan (e.g., the fan 182, the integrated fan and counterweight unit 187, or the integrated fan and counterweight unit 194) and the outer perimeter 688 at a first location (e.g., at a side of the volute 696 nearest the outlet port 62), and there is a relatively large amount of clearance at another location (e.g., at a side of volute 696 at or near where the radius R2 is measured in FIG. 29, which is approximately 140 degrees in a counterclockwise direction from a line extending from the center 692 towards the outlet port 62 such as the line along which the overall length 672 is measured in FIG. 29). The outlet 690 of the dust shroud 652 may be in fluid communication with the dust extraction tube 604. Further, the base portion 632 includes a ledge 635 surrounding the center 692. The ledge 635 is positioned below the fan (e.g., the fan 182, the integrated fan and counterweight unit 187, or the integrated fan and counterweight unit 194) to inhibit dust from escaping before being transported toward the outlet port 62.

With reference to FIGS. 21-29, one or both of the base portion 632 or the cover portion 636 may be wholly or partially made of a different material from other components of the sander 600. For example, one or both of the base portion 632, cover portion 636, and/or the dust extraction tube 604 may be made at least partially of a material different from a material that comprises the housing 14 (and in some embodiments, for example, the handle portion 34 and/or the strut portion 608). The base portion 632, the cover portion 636, and/or the dust extraction tube 604 may have a lower electrical resistivity than the housing 14. The base portion 632, the cover portion 636, and/or the dust extraction tube 604 may be wholly or partially made of a relatively low-resistance plastic with respect to, for example, a material such as a plastic that wholly or partially makes up the housing 14. The low resistance and/or resistivity (i.e., relatively high conductivity) of the plastic or other material that makes up the base portion 632, the cover portion 636, and/or the dust extraction tube 604 allows for a dissipation of static charge. The low-resistance material of the base portion 632, the cover portion 636, and/or the dust extraction tube 604 may have a surface resistivity or sheet resistance below 1,000,000,000 ohms (less than 10⁹ ohms) and, in some embodiments, may have a surface resistivity below 100,000 ohms (less than 10⁵ ohms). The low-resistance material of the base portion 632, the cover portion 636, and/or the dust extraction tube 604 may be wholly or partially made of carbon fiber, which is a relatively low-resistivity material. The base portion 632, the cover portion 636, and/or the dust extraction tube 604 may be wholly or partially made of stainless-steel fibers, water-absorbent plastic, and/or another material. Further, other components such as parts of the dust container 59 and/or the outlet port 62 may include carbon fiber. In some embodiments, an adapter for attaching the dust container 59 to the dust extraction tube 604 includes carbon fiber. The material of the low-resistance material of the base portion 632, the cover portion 636, the dust extraction tube 604, and/or other components may dissipate electric charge to the air during a sanding process.

Surface resistivity is a measurement of current resistance of a material in a direction along a plane formed by a sheet of the material. Surface conductivity is a measurement of current flow of a material in a direction along a plane forming a sheet of the material. Volume resistivity is a measurement of current resistance of a material in a direction perpendicular to a plane formed by a sheet of material. Volume conductivity is a measurement of current flow of a material in a direction perpendicular to a plane formed by a sheet of material. Generally, many plastics, such as for example, a material that may make up some or all of the housing 14 may have a surface resistivity of 10¹² ohms or higher. Generally, certain materials that may be classified as, for example, “anti-static” may have a surface resistivity of between 10¹⁰ and 10¹² ohms. Generally, certain materials that may be classified as, for example, “static dissipative” may have a surface resistivity of between 10⁶ to 10¹² ohms. Generally, certain materials that may be classified as, for example, “conductive” may have a surface resistivity of between 10¹ to 10⁶ ohms. Generally, certain materials that may be classified as, for example, “EMI/RFI Shielding” may have a surface resistivity of between 10¹ to 10⁴ ohms. “EMI” may refer to “electromagnetic interference.” and “RFI” may refer to “radio frequency interference.” Generally, certain materials that may be classified as, for example, “metals” may have a surface resistivity of between 10⁻¹ to 10⁻⁵ ohms. In this disclosure, the unit of “ohms” may be used interchangeably with the unit of “ohms/sq” in the context of surface resistivity (sheet resistance).

Further, the clamshell halves defining the housing 14 may include a coating or additive to disperse static charge accumulated in the housing 14 or other components of the sander 600 into the environment. For example, the coating may be applied onto a surface of the housing 14, and the additive may be mixed with a base material of the housing 14. Purposefully, a coating 44 or additive 43 allows the induced static charge within the sander 600 a less resistive path to discharge so that it does not accumulate in any one location on or within the sander 600. In some embodiments, the additive 43 may be carbon fiber that is mixed with the housing 14 or that fills (e.g., wholly or partially) certain cavities in the housing 14. For example, with reference to FIG. 21, the housing 14 may include an additive 43 that, compared to the base material of the housing 14, changes the electrical conductivity properties of the housing 14 to provide a lower surface resistivity or volume resistivity to the housing 14. Thus, a less resistive path is formed to discharge any static electric charge accumulated on the housing 14 or any of the internal components of the sander 600 (e.g., the motor 26, the printed circuit board 700 (FIG. 30), the controller 1384 (FIG. 57), etc.). The static charge may be conducted away from the internal components of the sander 600 through the housing 14, provided that the housing 14 allows for a less resistive path to ground than a ground path conducted through the sander components. In some embodiments of the sander 600, the additive 43 is spread throughout the entirety of the housing 14. However, in other embodiments, the additive 43 may be confined to the handle portion 34 to provide a ground path through the handle portion 34 and the user of the sander 600.

The housing 14 forming the handle portion 34 may be formed in a plastic injection molding process, which may include the additive 43. Alternatively, the housing 14 may be formed in any one of a variety of different manufacturing process. The additive 43 may change the electrical resistivity properties of the housing 14 and/or the handle portion 34. Specifically, the additive 43 may have a surface resistivity and volume resistivity that are different from the surface resistivity and volume resistivity of the base material used in forming the housing 14. In one embodiment of the sander 600, the additive 43 is dispersed throughout the housing 14 such that the injection molded handle portion 34 has a relatively constant surface resistivity and volume resistivity throughout the handle portion 34. In some embodiments, the additive 43 may be dispersed only within certain regions of the handle portion 34 such that certain regions of the handle portion 34 have different electrical resistivity properties than other regions of the handle portion 34.

In the embodiment of the sander 600 illustrated in FIG. 21, the surface resistivity and volume resistivity of the additive 43 used to form the housing 14 are lower than the surface resistivity and volume resistivity of commonly used base injection molded plastics. As the surface resistivity and volume resistivity of the handle portion 34 (with the additive 43) are lower than those of the base material of the handle portion 34 without the additive 43, static charge more freely flows through the handle portion 34 with the additive 43. In the absence of the additive 43, static charge is more likely to accumulate on and/or in the housing 14 and/or the handle portion 34. In contrast, the housing 14 and/or the handle portion 34 with the dispersed additive 43 allows charge to more freely flow through the housing 14 and/or the handle portion 34 and, typically, through the user and to the ground and/or to dissipate into nearby air. Thus, by dispersing the additive 43 through at least part of the housing 14 and/or the handle portion 34, during a cutting operation with the sander 600, it is less likely that static charge will accumulate in or on the sander 600 and discharge through the user as an electrical shock or through the electronic components of the sander 600.

With continued reference to FIG. 21, an embodiment of the sander 600 may include a coating 44 applied to the handle portion 34. In some embodiments, the coating 44 may be applied to a portion of the housing 14 or the entire housing 14. The coating 44 may be applied to a portion of the handle portion 34, or the entire handle portion 34. Alternatively or additionally, the coating 44 may be applied to a portion of the interior surface of the housing 14 (e.g., an interior surface of clamshell halves of the housing 14, which is located on an opposite side of the housing 14 vis-à-vis an exterior surface of the clamshell halves of the housing 14). The coating 44 is made of a material different than the remainder of the handle portion 34 and the housing 14. The material of the coating 44 may have a surface resistivity that is different from the surface resistivity of the handle portion 34. Specifically, the coating 44 may have a surface resistivity that is less than the surface resistivity than the base material of the handle portion 34 and/or the housing 14. The coating 44 distributes static charge away from the surface of the sander 600. In some embodiments of the sander 600, the coating 44 may be less than 0.1 mm thick. And, in some embodiments, the coating 44 may comprise a conductive paint or the like having a surface resistivity of between, for example, 10⁷ and 10⁹ ohms and, more specifically, having a surface resistivity of approximately 10⁸ ohms (Ω).

In some embodiments, the coating 44 may include a conductive liquid paint, such as Techspray Licron Crystal, an ESD (“electrostatic discharge”) safe coating (also referred to as an electrostatic discharge coating), which is commercially available from Techspray, with a principal place of business of 8125 Cobb Center Drive, Kennesaw, GA 30152, which is a related entity of Illinois Tool Works, with a principal place of business of 155 Harlem Avenue. Glenview. IL 60025. In some embodiments, the coating 44 may include a conductive coating such as graphite. The coating 44 may be applied to a base such as the housing 14 and/or the handle portion 34 of the sander 600. The ESD coating 44 may have an applied thickness on the base of 0.004 mm (4 microns) or an applied thickness of, for example, 1 micron, 10 microns or any thickness therebetween (or in some embodiments, a thinner application than 1 micron or a thicker application of greater than 10 microns may be used). The graphite coating 44 may have an applied thickness on the base of 0.033 mm (33 microns) or an applied thickness of, for example, 10 microns, 100 microns or any thickness therebetween (or in some embodiments, a thinner application than 10 microns or a thicker application of greater than 100 microns may be used). In some embodiments, a relatively light ESD coating 44 may be about 1 micron or between about 1 micron and about 4 microns, and a relatively heavy ESD coating 44 may be about 10 microns or between about 4 microns and about 10 microns. In some embodiments, a relatively light graphite coating 44 may be about 10 microns or between about 10 microns and about 33 microns, and a relatively heavy graphite coating 44 may be about 100 microns or between about 33 microns and about 100 microns. In some embodiments, the coating 44 may be applied to an interior surface (i.e., a surface that faces the interior components within the sander 600) of the base such as the housing 14 and/or the handle portion 34. When applied to a base (e.g., the housing 14 and/or the handle portion 34) in a relatively light coating, the coating 44 may dry relatively clearly without significantly changing the color of the base. In some embodiments, without an ESD or graphite coating 44, a base such as the housing 14 and/or the handle portion 34 may have a measured surface resistivity of approximately 5×10¹¹ ohms. In some embodiments, with a relatively light application of an ESD or graphite coating 44, the measured surface resistivity may be approximately 6×10⁸ ohms. In some embodiments, with a relatively heavy application of an ESD or graphite coating 44, the measured surface resistivity may be approximately 1×10⁸ ohms.

As described above and illustrated in FIG. 21, the volume resistance and surface resistivity of the handle portion 34 may be influenced by the addition of one or more additives 43 to commonly used injection molding plastics. Additionally, as described above and illustrated in FIG. 21, surface resistivity of the handle portion 34 may be influenced by a coating 44 on the handle portion 34. Any number of additives 43 with any number of volume and surface resistivities may be added to the handle plastic or provided in a handle coating. However, Table 1 provides a list of materials that may be relevant and useful in the design of tools, and specifically power tools, for the mitigation of static discharge. The columns of the table below provide the trade name of the additive 43 and/or coating 44, surface resistivity, volume resistivity, and manufacturer of each relevant material. Other low-resistivity materials include “PA6+G30 ASNC001” (which may be used, for example, for the handle portion 34) and “PA6+CF” (which may be used, for example, for certain dust collection components such as the dust extraction tube 604 and/or the dust shroud 652.

TABLE 1
List of Certain Relevant Materials
		Surface	Volume
		resistivity	Resistivity
Additive/Trade Name	Manufacturer	[Ω]	[Ω · cm]
MAC-601 ASBKG002	Kingfa	1E6-1E9	Unknown
HP-126	Kingfa	Unknown	1E16
MAC-851	Kingfa	1E16	1E16
PERMASTAT PLUS	RTP Co.	1E7-9.9E8	1E7-9.9E8
2500 A
PERMASTAT 2500	RTP Co.	1E9-9.9E10	1E9-9.9E10
ESD C 2500	RTP Co.	<1E5	<1E3

For reference, the surface resistivity of the base material of the handle portion 34 (i.e., without the additive 43 or coating 44) may be approximately or greater than 10¹⁶ ohms. In some embodiments, the surface resistivity of the base material of the handle portion 34 with at least one additive 43 is less than 10¹⁵ ohms. In other embodiments, the surface resistivity of the base material of the handle 34 with at least one additive 43 may be between 10¹⁰ and 10¹⁴ ohms. In yet other embodiments, the surface resistivity of the base material of the handle 34 with at least one additive 43 may be less than 10¹² ohms.

In operation of the sander 600, a user depresses the trigger 30 to activate the motor, which rotates the sanding pad 18. The sanding pad 18 contacts a work piece, creating debris that contacts the sander 600 and the air surrounding the sander 600. Thus, a static charge is generated in the sander 600 as a result of the repeated contact between the sanding pad 18 and the workpiece, and the contact between the workpiece debris with the sander 600. In some embodiments of the sander 600, a low surface resistivity coating 44 on the housing 14 and/or on the handle portion 34 prevents accumulation of static charge on the housing 14 and/or on the handle portion 34 and other portions of the sander 600 by creating a low-resistance path to ground through the housing 14 and/or on the handle portion 34 and the user holding the sander 600. In other embodiments of the sander 600, a low surface resistivity and volume resistivity housing 14 and/or handle portion 34 with a dispersed additive 43 prevents accumulation of static charge on the housing 14 and/or on the handle portion 34 and other portions of the sander 600 by creating a low-resistance path to ground through the housing 14 and/or on the handle portion 34 and the user holding the sander 600 and/or into nearby air. The additive 43 gives the housing 14 and/or on the handle portion 34 a surface resistivity and a volume resistivity that is less than the surface resistivity and volume resistivity of the base material from which the housing 14 and/or on the handle portion 34 is made. Gradually, static charge created during a cutting operation is directed away from the sander 600, through the housing 14 and/or on the handle portion 34 and user to the surroundings, rather than accumulating over a period of time until the static charge is high enough to potentially shock the user or the electronics of the sander 600.

In some embodiments, the housing 14 and/or on the handle portion 34 (with the additive 43 and/or the coating 44 included) may have a surface resistivity that is greater than the surface resistivity of the dust extraction tube 604 and/or the dust shroud 652 but less than the surface resistivity that the housing 14 and/or on the handle portion 34 would have in the absence of the additive 43 and/or the coating 44.

With returning reference to FIG. 23, in the illustrated embodiment, the base portion 632 and the cover portion 636 are located below the handle portion 34. In other words, in the illustrated embodiment, dust extraction occurs below the handle portion 34. In other embodiments, dust extraction may occur in and/or through the handle portion 34. In some embodiments, one or both of the base portion 632 and the cover portion 636 may be at least partially received within the housing 14. In some embodiments, the dust extraction tube 604 may be at least partially received within the housing 14.

In operation, and with continued reference to FIG. 23, an airstream may be generated by a fan such as the fan 182, which is a component of the integrated fan and counterweight unit 186 (FIG. 11). The airstream may collect dust and debris in a vicinity of the sanding pad 18 that is generated by a sanding operation. The airstream may enter the bore 656 that is provided in the base portion 632 and pass through the dust shroud 652 in a direction toward the outlet 690 and ultimately through the dust extraction tube 604 defined by the base portion 632 and the cover portion 636 in a direction toward the outlet port 62 to deposit the dust and debris into the dust container 59.

Electrical bonding is the practice of intentionally electrically connecting all exposed metal items not designed to carry electrical current to each other and also electrically connecting those items to an electrical ground in order to provide protection from electric shock. The metal components of a sander such as the sander 600 that are not intended to carry electrical current (i.e., any metal structural components of the sander 600 such as screws, the unified motor output shaft and eccentric carrier 144, the integrated fan and counterweight unit 187, any bearings such as the radial bearing 1508, and/or any other metal components of the sander 600) are electrically connected (e.g., by wires, grounding straps, direct contact, and/or other electrical connections) to each other and to a negative terminal 713 of the battery pack 74. Bonding metal components of a sander such as the sander 600 to the negative terminal 713 of the battery pack 74 may assist in dissipating an electrical charge (e.g., a static charge) generated during sanding operations.

With reference to FIG. 30, a sander such as the sanders 10, 300, 400, 500, 600, 800 described herein may include a radial bearing 156 (FIG. 6) supporting a motor shaft such as the motor shaft 106. A printed circuit board 700 such as, for example, a Hall effect board that acts as a speed sensor may be positioned between the radial bearing 156 and a motor such as the motor 26. A grounding strap 704 may extend between the radial bearing 156 and a negative terminal 713 (FIG. 22) of a battery (e.g., a low-capacity battery pack 74 or a high-capacity battery pack 82) that powers the sander 10, 300, 400, 500, 600, 800. The grounding strap 704 may be positioned adjacent to the bearing 156 and in axial contact with the bearing 156. The grounding strap 704 may be shaped as a washer with a hole (e.g., a central hole) configured to accommodate a portion of the motor shaft 106. The grounding strap 704 may be in electrical contact with the bearing 156 so that electrical charge, which may include static charge, may be dissipated from the bearing 156. The grounding strap 704 may include one or more wave spring portions 708, and in the illustrated embodiment, the grounding strap 704 includes two wave spring portions 708 that may be compressed during installation of the bearing 156. In other words, the wave spring portions 708 may be compressed between the bearing 156 and a portion of the housing 14. One or more of the wave spring portions 708 may be in direct contact with the bearing 156, and in some embodiments may be in direct contact with an axial end of the bearing 156. The grounding strap 704 may include a terminal portion 712 that electrically connects the bearing 156 to other components of the sander 10, 300, 400, 500, 600, 800 such as the negative terminal 713 by a wire or other means to, among other things, dissipate an electrical (e.g., static) charge from the bearing 156. The terminal portion 712 may extend transversely from the wave spring portions 708. The electrical charge may be transmitted to the negative terminal 713 (FIG. 22) of a battery (e.g., a low-capacity battery pack 74 or a high-capacity battery pack 82) that powers the sander 10, 300, 400, 500, 600, 800. A battery pack, such as either of the low-capacity battery pack 74 or the high-capacity battery pack 82, may also include a positive terminal 714 (FIG. 22).

In some embodiments, various components including the base portion 632, the cover portion 636, and/or the bearings 150, 156 may be partially or wholly coated (i.e., “doped”) with a material having a desired resistivity (e.g., for example, in some embodiments, a resistivity of less than 10⁹ ohms and/or a sheet resistance of less than 10⁹ ohms, or some embodiments, a resistivity of less than 10⁵ ohms and/or a sheet resistance of less than 10⁵ ohms) to facilitate a dissipation of static charge.

With reference to FIG. 31, another embodiment of a grounding strap 716 may be configured to dissipate electrical charge from the bearing 156 by contacting the bearing 156. The grounding strap 716 may extend between the bearing 156 and the negative terminal 713 (FIG. 22) of a battery (e.g., a low-capacity battery pack 74 or a high-capacity battery pack 82) that powers the sander 10, 300, 400, 500, 600, 800. The grounding strap 716, when assembled in a sander such as one of the sanders 10, 300, 400, 500, 600, 800, may at least partially encircle the motor shaft 106. The grounding strap 716 may be provided between the bearing 156 and a bearing support wall 720 such that the bearing 156 is pressed into contact with the grounding strap 716 so that electrical charges may be able to pass from the bearing 156, through the grounding strap 716, and to a negative terminal of a battery (e.g., a low-capacity battery pack 74 or a high-capacity battery pack 82) that powers the sander 10, 300, 400, 500, 600, 800. In some embodiments, the grounding strap 716 may be positioned between the pocket 130 and a circumferential outer periphery of the bearing 134. In some embodiments, the grounding strap 716 may be positioned between the pocket 157 and a circumferential outer periphery of the bearing 156. The grounding strap 716 may include a clip portion 732 and a terminal portion 724 extending from the clip portion 732 that assists with grounding the grounding strap 716 (i.e., electrically connecting the grounding strap 716 to the negative terminal of the battery pack 74, 82).

With reference to FIG. 32, the grounding strap 716 may include one or more legs 728, and in the illustrated embodiment two legs 728, that partly define the clip portion 732 of the grounding strap 716. The legs 728 may extend downwardly in a direction generally parallel to the motor shaft 106. The legs 728 may directly contact the bearing 156 to ground the bearing 156. The clip portion 732 may surround, and in some embodiments at least partially surround, the bearing 156. The clip portion 732 may surround, and in some embodiments may at least partially surround, the circumferential outer periphery of the bearing 156.

With reference to FIG. 33, each leg 728 of the grounding strap 716 may include an energy storing mechanism 734, which may be configured as a leaf spring portion including at least one bend 736. In the illustrated embodiment, each leg 728 includes extension portions 740) that alternate with the bends 736. In the illustrated embodiment, the bends 736 and extension portions 740 cooperate to form the energy storing mechanisms 734, which act as springs to store energy and maintain a contact pressure between the grounding strap 716 and the bearing 156 that is larger than the contact pressure would be in the absence of the energy storing mechanisms 734.

With reference to FIG. 34, another embodiment of a grounding strap 744 may be configured to dissipate electrical charge from the bearing 156 by contacting the bearing 156. The grounding strap 744 may extend between the bearing 156 and the negative terminal 713 (FIG. 22) of a battery (e.g., a low-capacity battery pack 74 or a high-capacity battery pack 82) that powers the sander 10, 300, 400, 500, 600, 800. The grounding strap 744, when assembled in a sander such as one of the sanders 10, 300, 400, 500, 600, 800, may at least partially encircle the motor shaft 106 and may encircle the motor shaft 106 and/or the bearing 156 by, in some embodiments, at least 10%, at least 25%, at least 50%, and/or at least 75%. The grounding strap 744 may be provided between the bearing 156 and the bearing support wall 720 such that the bearing 156 is pressed into contact with the grounding strap 744 so that electrical charges may be able to pass from the bearing 156, through the grounding strap 744, and to a negative terminal of a battery (e.g., a low-capacity battery pack 74 or a high-capacity battery pack 82) that powers the sander 10, 300, 400, 500, 600, 800. In some embodiments, the grounding strap 744 may be positioned between the pocket 130 and a circumferential outer periphery of the bearing 134. In some embodiments, the grounding strap 744 may be positioned between the pocket 157 and a circumferential outer periphery of the bearing 156. The grounding strap 744 may include a terminal portion 748 that assists with grounding the grounding strap 744 (i.e., electrically connecting the grounding strap 744 to the negative terminal 713 of the battery pack 74, 82).

With reference to FIG. 35, the grounding strap 744 includes a clip portion 750 that defines a bearing-receiving recess 752 that is configured to receive a bearing such as the bearing 156. The clip portion 750 may surround, and in some embodiments at least partially surround, the bearing 156. The clip portion 750) may surround, and in some embodiments may at least partially surround, the circumferential outer periphery of the bearing 156. The terminal portion 748 may include a bore 756 for connecting the grounding strap 744 to another component such as a conductive portion of a frame of the sander 10, 300, 400, 500, 600, 800 to cooperate in grounding the grounding strap 744. The grounding strap 744 may include an energy storing mechanism 760 that may be formed, for example, as a leaf spring portion and that, in the illustrated embodiment, includes a plurality of (and more specifically, seven) bends 764 that alternate with a plurality of (and more specifically, eight) extension portions 768. In other embodiments, different numbers of bends 764 and extension portions 768 may be provided. When assembled, the energy storing mechanism 760 may act as a spring to store energy and maintain a contact pressure between the grounding strap 744 and the bearing 156 that is greater than the contact pressure would be in the absence of the energy storing mechanism 760.

The grounding straps 704, 716, 744 may be connected to a wire, and more particularly to a ground wire, to electrically connect the grounding straps 704, 716, 744 to the negative terminal of a battery (i.e., to ground the grounding straps 704, 716, 744), whether directly to the negative terminal of the battery or indirectly through a frame or other grounded component of the sander 10, 300, 400, 500, 600, 800. The ground wire may be connected to an outside diameter of one or more bearings such as the bearings 150, 156.

With reference to FIGS. 36 and 37, a sander such as one of the sanders 10, 300, 400, 500, 600 may include an adjustable eccentric carrier 772 that may function, in certain respects, similarly to the eccentric carrier 142. The adjustable eccentric carrier 772 may include dual adjustable counterweights 776, 780 (i.e., a first adjustable counterweight 776 and a second adjustable counterweight 780). The first adjustable counterweight 776 may be provided on a first side of the adjustable eccentric carrier 772, and the second adjustable counterweight 780 may be provided on a second side of the adjustable eccentric carrier 772. In the illustrated embodiment, the first side of the adjustable eccentric carrier 772, on which the first adjustable counterweight 776 is provided, is opposite the second side of the adjustable eccentric carrier 772, on which the second adjustable counterweight 780 is provided. In some embodiments, the first adjustable counterweight 776 may be a lower counterweight (i.e., a counterweight that is relatively closer to the sanding pad 18), and the second adjustable counterweight 780 may be an upper counterweight (i.e., a counterweight that is relatively farther away from the sanding pad 18 and, in some embodiments, relatively closer to the motor 26).

With continued reference to FIG. 36, each adjustable counterweight 776, 780 may include one or more bores provided therein. More specifically, in the illustrated embodiment, the first adjustable counterweight 776 may include a first bore 784a, a second bore 784b, and a third bore 784c. The first bore 784a, the second bore 784b, and the third bore 784c may together be a first plurality of bores 784a-c. The second adjustable counterweight 780 may include a fourth bore 788a, a fifth bore 788b, and a sixth bore (present in an analogous location on the second adjustable counterweight 780 to the location of the third bore 784c on the first adjustable counterweight 776). The fourth bore 788a, the fifth bore 788b, and the sixth bore may together be a second plurality of bores 788a-c. Each bore 784a-c. 788a-c may be threaded to threadably receive a threaded fastener such as a bolt or screw 792, 796. In some embodiments, nuts may be attached to the screws 792, 796. In some embodiments, the bores 784a-c may not be threaded, and the screws 792, 796 may be mounted to the adjustable counterweights 776, 780 by the nuts. Washers and other objects may be mounted to the adjustable counterweights 776, 780 by the screws 792, 796. Different quantities (i.e., different weights) of added objects (e.g., screws 792, 796, nuts, washers, etc.) and different locations of those added objects on the adjustable counterweights 776, 780 produce a variety of obtainable centers of gravity of the adjustable eccentric carrier 772.

With continued reference to FIG. 36, a user (e.g., an operator of the sander 10, 300, 400, 500, 600, 800, a manufacturer, etc.) may choose to place, in some embodiments, no screws 792, 796 in any of the bores 784a-c, 788a-c. In other embodiments, a user may place one screw 792, 796 in the bore 784a, and/or one screw 792, 796 in the bore 784b, and/or one screw: 792, 796 in the bore 784c, and/or one screw 792, 796 in the bore 788a, and/or one screw 792, 796 in the bore 788b, and/or one screw 792, 796 in another bore. In other words, any combination of screws 792, 796 may be positioned in any combination of the bores 784a-c. 788a-c. Similarly, one or more nuts and/or washers may be placed on any combination of the screws 792, 796. In other words, the adjustable counterweights 776, 780 may be adjustable (i.e., tunable) to a plurality of weighting configurations based on a number and location of the screws 792, 796 and a number and location of other objects such as washers and nuts. For example, a number of washers such as zero, one, two, three, four, or more may be placed on one or more of the screws 792, 796. Further, a number of nuts such as zero, one, two, three, four, or more may be placed on one or more of the screws 792, 796. In some embodiments, the first adjustable counterweight 776 and/or the second adjustable counterweight 780 may be adjustable by a user by first at least partially disassembling the tool. In some embodiments, the first adjustable counterweight 776 and/or the second adjustable counterweight 780 may be adjustable by a user without disassembling the tool. The user and/or the manufacturer may adjust the adjustable counterweights 776, 780 to a particular weighting configuration based on a particular abrasive and/or accessory that is attached to the sander 10, 300, 400, 500, 600, 800. The user and/or the manufacturer may adjust the adjustable counterweights 776, 780 to a particular weighting configuration to reduce vibration in the sander 10, 300, 400, 500, 600, 800.

With reference to FIG. 38, a sander 800, which may be one of the sanders 10, 300, 400, 500, 600 or which may be similar to one of the sanders 10, 300, 400, 500, 600, may include a housing 14 that is generally similar to the housing 14 described herein with respect to the sanders 10, 300, 400, 500, 600. The sander 800 may define a handle axis A1, a tube axis A3, and a battery insertion axis A4 (FIGS. 1 and 2). The sander 800 may include a first work light 808 and may include a second work light 812. The work lights, such as the work lights 808, 812, may illuminate a workpiece upon which a sanding operation is performed. The first work light 808 may be a front work light that is positioned on a motor housing portion 22 and may be positioned, more specifically, on a front surface of the motor housing portion 22 on a neck portion 28 below a pommel portion 27.

With reference to FIG. 39, the sander 800 includes a sanding pad 18. When projected into a plane that is parallel to a workpiece and/or to the sanding pad 18, the handle axis A1, the tube axis A3, and the battery insertion axis A4 may be generally parallel, parallel, and/or collinear. In other words, the projection of the axes A1, A3, A4 may pass through a center of the sander 800 along a direction between an outlet port 62 and the sanding pad 18. One or more of the axes A1, A3, A4 may be defined within a vertical plane P that bisects the housing 14 and that is perpendicular to the bottom surface of the sanding pad 18. The work light 812 may be positioned on an underside of the sander 800 and below the dust extraction tube 604 and oriented towards the sanding pad 18. The work light 812 may project light in an illumination direction 817. The work light 812 may project light in a direction that is tangential to an adjacent point on the dust extraction tube 604. The work light 812 (i.e., the illumination direction 817) may be oriented at a lateral illumination angle 818 transverse to the handle axis A1, the tube axis A3, the battery insertion axis A4, and/or the plane P. The work light 812 may be disposed transversely to one or more of the handle axis A1, the tube axis A3, the battery insertion axis A4, or the plane P by the lateral illumination angle 818, and the lateral illumination angle 818 (e.g., an absolute value of the lateral illumination angle 818) may be less than about 10 degrees, between about 10 degrees and about 20 degrees, between about 20 degrees and about 30 degrees, between about 30 degrees and about 40) degrees, about 30 degrees, between 40 degrees and about 50 degrees, about 45 degrees, between about 50 degrees and about 60 degrees, about 60 degrees, or more than about 60) degrees. The work light 812 may also be oriented downwardly toward the workpiece and/or downwardly towards the sanding pad 18. In some embodiments, a further work light may be provided on an opposite side of the handle axis A1, the tube axis A3, the battery insertion axis A4, and/or the plane P from the work light 812. The further work light may be positioned in a mirrored location with respect to the work light 812 across one or more of the axes A1, A3, A4 and/or across the plane P. One or more of the work lights 808, 812 may be positioned below the dust extraction tube 604. One or more of the work lights 808, 812 may be positioned on a dust extraction portion of the housing 14. One or more of the work lights 808, 812 such as the work light 808 may be positioned in front of or at a front side of the sanding pad 18, and one or more of the work lights 808, 812 such as the work light 812 may be positioned behind or at a rear side of the sanding pad 18 and/or directed toward the sanding pad 18.

With reference to FIG. 40, the sander 800 may include a work light 812 that is oriented at a shallower illumination angle 832 relative to the illumination angle 818 of the embodiment of FIG. 39 and a work light 824 that may also be positioned at an underside of the sander 800 and oriented at the illumination angle 832 or at a different illumination angle. The work light 812 and the work light 824 may be oriented such that the work light 812 and the work light 824 are generally parallel to each other and/or are parallel to one or more of the handle axis A1, the tube axis A3, the battery insertion axis A4, or the plane P. In other embodiments, the work light 812 and the work light 824 may be oriented at the lateral illumination angle 832 transverse to each other and/or at the lateral illumination angle 832 transverse to one or more of the handle axis A1, the tube axis A3, the battery insertion axis A4, or the plane P. For example, in the illustrated embodiment, the work light 824 may have an illumination direction 828 that may be oriented at the lateral illumination angle 832 with respect to one or more of the axes A1, A3, A4 and/or the plane P. For example, the illumination direction 828 may be toward or away from the axes A1, A3, A4 and/or the plane P when moving from the work light 824 toward the sanding pad 18. The angle 832 (e.g., an absolute value of a lateral illumination angle 832) may be about 0) degrees, less than about 5 degrees, between about 5 degrees and about 10 degrees, between about 10 degrees and about 20 degrees, between about 20 degrees and about 30 degrees, between about 30 degrees and about 40 degrees, about 30 degrees, between about 40 degrees and about 50 degrees, about 45 degrees, between about 50 degrees and about 60 degrees, about 60 degrees, or more than about 60 degrees. The work light 812 may be oriented similarly to the work light 824 or may be oriented in a mirrored fashion relative to the work light 824 about an axis such as about one or more of the axes A1, A3, A4 and/or about a plane such as the plane P. The work light 812 may be located on one side of the plane P, and the work light 824 may be located on an opposite side of the plane P. One or both of the work lights 812, 824 may be oriented downwardly toward a workpiece and/or toward the sanding pad 18. One or more of the work lights 808, 812, 824 may be LED work lights, and the work lights 808, 812, 824 may be used in combination with other features disclosed herein, such as in a cordless sander and/or a cordless sander with dust extraction capabilities and/or a cordless sander with dust extraction capabilities with a sanding pad diameter of, for example, about 2, 3, or 4 inches.

With reference to FIG. 41, a sanding pad 900, which may be coupled to a sander such as one or more of the sanders 10, 300, 400, 500, 600, 800, includes a diameter 904 that may be less than about 2 inches, between about 2 inches and about 3 inches, about 3 inches, between about 3 inches and about 4 inches, about 4 inches, and/or greater than about 4 inches. In inset area 906 on a top side of the sanding pad 900 may define an attachment area 906 on the sanding pad 900. The attachment area 906 is inset with respect to a raised area 907 that surrounds the attachment area 906. The sanding pad 900 may include bores 908 that are spaced and are so dimensioned to receive fasteners such as screws to attach the sanding pad 900 to one or more of the sanders 10, 300, 400, 500, 600, 800. The bores 908 may include metal inserts 909 to inhibit deformation of a material (e.g., plastic) of the sanding pad 900 during installation of the sanding pad 900 to a sander (e.g., during installation of the sanding pad 900 to an eccentric shaft 928 as shown in FIG. 42). In some embodiments, the bores 908 are threaded, and in some embodiments, the bores 908 are not threaded. In some embodiments, the inserts 909 are threaded. Notches 912 may be provided on the sanding pad 900. The bores 908 and the notches 912 may both be spaced about the attachment area 906. In some embodiments, the same number of bores 908 and notches 912 may be provided. In the illustrated embodiment, one bore 908 is provided in each notch 912. Each notch 912 is inset into a top of the sanding pad 900. Transition areas 914 may be provided between the notches 912 and may be spaced circumferentially about the attachment area 906. The transition areas 914 may be tapered or sloped to provide a non-stepwise transition between the attachment area 906 and the raised area 907. In the illustrated embodiment, the transition areas 914 include a uniform slope, but in other embodiments, the transition areas 914 may include a non-uniform slope.

With continued reference to FIG. 41, the sanding pad 900 may include first dust extraction holes 916, and in the illustrated embodiment may include six first dust extraction holes 916, that may be circumferentially spaced about the sanding pad 900 and may be positioned radially outside of the attachment area 906. The sanding pad 900 may include second dust extraction holes 920, and in the illustrated embodiment may include six second dust extraction holes 920, that may be circumferentially spaced about the sanding pad 900 and may be positioned radially outside of the attachment area 906. The first dust extraction holes 916 may circumferentially alternate with the second dust extraction holes 920. The sanding pad 900 may include third dust extraction holes 924. The third dust extraction holes 924 may be positioned within the attachment area 906. The sanding pad 900 may include a plurality of third dust extraction holes 924 and, in the illustrated embodiment, may include four third dust extraction holes 924. The sanding pad 900 may include the same number of third dust extraction holes as the bores 908 and/or the notches 912. In the illustrated embodiment, the dust extraction holes 916, 920, 924 are circular, but in other embodiments, the dust extraction holes 916, 920, 924 may be other sizes and/or shapes.

With reference to FIGS. 17 and 42, a shaft 928, which may be referred to as an eccentric shaft 928, includes a post 932 or shaft portion 932 extending from a base 936. The shaft 928 may connect the sanding pad 900 and/or the sanding pad 18 to a sander such as the one or more of the sanders 10, 300, 400, 500, 600, 800. For example, FIG. 17 shows the shaft 928 assembled in the sander 300. The shaft 928 couples the sanding pad 18 to an eccentric carrier such as the eccentric carrier 142 or, in some embodiments, the eccentric carrier 772. The shaft portion 932 may be surrounded and rotatably supported by the radial bearing 150. A plurality of flanges 944 may extend from the base 936 circumferentially and/or axially. The flanges 944 may be configured to transmit rotational torque to the sanding pad 18, 900. In the illustrated embodiment, four flanges 944 are circumferentially and equidistantly positioned around the base 936. In other embodiments, more or fewer flanges 944 may be provided. Further, in other embodiments, torque may be transmitted between the sanding pad 18, 900 and the eccentric carrier 142, 772 ways other than the flanges 944. Bores 948 may be provided in the base and/or the flanges 944. In the illustrated embodiment, one bore 948 is provided in each of the flanges 944.

With reference to FIGS. 41 and 42, the base 936 of the shaft 928 is configured to be positioned over the attachment area 906 of the sanding pad 900 for mounting to the sanding pad 900. The flanges 944 of the shaft 928 may be positioned within the notches 912 of the sanding pad such that torque may be transmitted between the raised walls defining the notches 912 and the flanges 944. When assembled, one or more of the transition areas 914, and in the illustrated embodiment each of the four transition areas 914, may be located between the notches 912 and/or the flanges 944. In certain embodiments, such as in embodiments in which the flanges 944 extend axially from the base 936 as illustrated in FIG. 42, a space may be provided between the base 936 and one or more of the transition areas 914 to allow airflow from an area immediately above the attachment area 906 to an area immediately above the raised area 907 and/or vice versa to facilitate dust extraction therethrough.

With returning reference to FIG. 41, the sanding pad may include a total top side area, which in the illustrated embodiment is a sum of a top side area of the attachment area 906, a top side area of the raised area 907, and top side areas of the transition areas 914. A particular percentage of the total top side area may be used for dust extraction (i.e., a total top side dust extraction area percentage), which in other words may be the summation of the areas of the first dust extraction holes 916, the second dust extraction holes 920, the third dust extraction holes 924, and/or any additional dust extraction holes divided by the total top side area. In the illustrated embodiment, the total top side dust extraction area percentage is 8% or about 8%. In other embodiments, the total top side dust extraction area percentage may be about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 9%, about 10%, about 11%, about 12%, between about 12% and about 15%, between about 15% and about 20%, between about 20% and about 25%, greater than about 25%, and/or greater than or less than the figures disclosed herein. A particular percentage of the top side area of the attachment area 906 may be used for dust extraction (i.e., an attachment dust extraction area percentage), which in other words may be the summation of the areas of the third dust extraction holes 924 and/or any additional dust extraction holes divided by the attachment area. In the illustrated embodiment, the attachment dust extraction area percentage is 5% or about 5%. In other embodiments, the attachment dust extraction area percentage may be about 1%, about 2%, about 3%, about 4%, about 6%, about 7%, about 8%, about 9%, about 10%, about 11%, about 12%, between about 12% and about 15%, between about 15% and about 20%, between about 20% and about 25%, greater than about 25%, and/or greater than or less than the figures disclosed herein.

In some embodiments, a sander 10, 300, 400, 500, 600, 800 with dust extraction capabilities may include a fan, and in other embodiments, the fan may be external to the sander 10, 300, 400, 500, 600, 800.

The sander 10, 300, 400, 500, 600, 800 may be an inline tool (i.e., a tool in which an axis of rotation of a motor is parallel to an output axis that is driven by the motor).

With reference to FIG. 43, a sanding pad 1000 for use with a sander such as the sanders 10, 300, 400, 500, 600, 800 includes an annular (i.e., ring shaped) sloped surface 1004, which may also be referred to as a sloped brake surface 1004, for engaging a brake pad such as a brake pad 1008, as illustrated in FIGS. 21 and 22. The sanding pad 1000 includes certain features of other sanding pads disclosed herein, such as, for example, the attachment area 906. The sloped surface 1004 is downwardly (i.e., in a direction toward a bottom surface 1016 of the sanding pad 1000, which attaches to an abrasive) sloped in a radially inward direction (e.g., in the illustrated embodiment, in a direction toward the attachment area 906). The sloped surface 1004 at least partially defines a cavity 1010 that is concave with respect to a top surface 1012 of the sanding pad 1000. The cavity 1010 is also partially defined by a sidewall 1020 that, in the illustrated embodiment, is a vertical sidewall 1020 that is approximately perpendicular to both the top surface 1012 and the bottom surface 1016. In some embodiments, the sidewall 1020 is approximately perpendicular to at least one of the top surface 1012 or the bottom surface 1016. In other embodiments, the sidewall 1020 is perpendicular to neither the top surface 1012 nor the bottom surface 1016 (e.g., in embodiments in which the sidewall 1020 is sloped). In other embodiments, the sidewall 1020 is shaped and/or angled differently.

With continued reference to FIG. 43, the sloped surface 1004 includes a normal vector N that is directed toward a central axis A7 of the sanding pad 1000. In the illustrated embodiment, the sloped surface 1004 is centered about the central axis A7 of the sanding pad 1000. A reference line L is defined to be parallel to the central axis A7 of the sanding pad 1000, and a slope angle α of the surface 1004 is defined between the normal vector N and the reference line L. In the illustrated embodiment, the slope angle α is also defined between the surface 1004 and the top surface 1012. The slope angle α is, in some embodiments, between 0 degrees and 30 degrees, in some embodiments between 0 degrees and 15 degrees, in some embodiments between 0 degrees and 10 degrees, in some embodiments between 1 degree and 8 degrees, and in some embodiments between 2 degrees and 7 degrees. In some embodiments, for example, the slope angle α may be approximately 3 degrees, approximately 4 degrees, approximately 5 degrees, or approximately 6 degrees. In other embodiments, the slope angle α is selected to be another value as desired, such as greater than 30 degrees.

With reference to FIG. 44, a sanding pad 1100 for use with a sander such as the sanders 10, 300, 400, 500, 600, 800 includes a top plate 1104 having a peripheral lip 1108. The sanding pad 1100 may include features of any of the sanding pads disclosed herein, such as, for example, the sloped surface 1004 illustrated in FIG. 43. The top plate 1104 is made of rigid plastic, but in other embodiments, the top plate 1104 may be made of metal or another material. A damping layer 1112 is attached (e.g., by molding) to a bottom of the top plate 1104. In the illustrated embodiment, the damping layer 1112 is rubber foam, but in other embodiments, the damping layer 1112 may be made of another material. The damping layer 1112 may be resilient. A bottom 1116 of the damping layer 1112 may include an attachment interface (e.g., a hook-and-loop interface) for attaching an abrasive (e.g., an abrasive sheet) to the sanding pad 1100. The peripheral lip 1108 abuts an upper edge 1120 of the damping layer 1112.

With continued reference to FIG. 44, the sanding pad 1100, and more specifically in the illustrated embodiment with the top plate 1104, includes a top surface 1124 for engaging a brake pad such as the brake pad 1008, as illustrated in FIGS. 21 and 22. A sticker 1128 is applied over at least a portion of the top surface 1124. More specifically, the sticker 1128 covers at least a portion, and in the illustrated embodiment all, of a braking portion 1132 of the top surface 1124. The braking portion 1132 is configured to be engaged by the brake pad 1008. In the illustrated embodiment, the braking portion 1132 is annular and defined between an inner boundary 1136 and an outer boundary 1140. A sticker such as the sticker 1128 may be applied to top surfaces of any of the sanding pads disclosed herein.

With continued reference to FIG. 44, the sticker 1128 includes an attachment surface that, in the illustrated embodiment, includes an adhesive layer that sticks to the top surface 1124 of the sanding pad 1100. The sticker 1128 includes, opposite the attachment surface, a low-friction surface 1144. In the illustrated embodiment, the low-friction surface 1144 includes a thin layer of low-friction material such as Teflon (polytetrafluoroethylene). The low-friction surface 1144 may extend over the entirety of the sticker 1128, and in the illustrated embodiment, extends over at least the braking portion 1132 of the sanding pad 1100. In the illustrated embodiment, the sticker 1128 includes apertures 1148 that align with apertures 1152 (e.g., dust extraction holes 1152) in the sanding pad 1100. In the illustrated embodiment, the sticker 1128 includes a central aperture 1156 to provide access to the attachment area 906 of the sanding pad 1100 (see also the attachment area 906 of the sanding pad 1000 illustrated in FIG. 43).

With continued reference to FIG. 44, in operation, the low-friction surface 1144 is configured to contact the brake pad 1008 (FIGS. 21 and 22). During rotation of the sanding pad 1100, the friction generated between the brake pad 1008 and the sanding pad 1100, and more specifically between the brake pad 1008 and the low-friction surface 1144, acts to, for example, stabilize the random orbit motion of the sanding pad 1100 to provide a relatively smooth transition when the sanding pad 1100 is applied to a workpiece surface and when the sanding pad 1100 is removed from contact with a workpiece surface. The low-friction surface 1144 reduces friction and, accordingly, wear on the brake pad 1008 and on the sticker 1128. In some embodiments, the sticker 1128 is removable and replaceable, and in other embodiments, a new sticker 1128 may be applied over the existing sticker 1128 to extend the life of the sanding pad 1100. In some embodiments, the sticker 1128 is annular.

With reference to FIG. 45, a sander 1200, which includes features of some of the sanders 10, 300, 400, 500, 600, 800, is supported by a holster 1204. The holster 1204 may be made of a resilient material such as a type of resilient plastic in whole or in part. The holster 1204 is mountable to a surface 1208, which may be a flat surface such as a side of a wood board (e.g., a two-by-four, two-by-six, etc.) or a post. The holster 1204 includes two lips 1212a. 1212b that attach to (e.g., by clipping) onto a strut portion 1217 of the sander 1200. In the illustrated embodiment, the strut portion 1217 includes a dust extraction tube 1216. In other words, the strut portion 1217 is clipped to the holster 1204. The strut portion 1217 interconnects distal ends of a handle portion 1227 and a motor housing portion 1229 of the housing 1220. In the illustrated embodiment, the strut portion 1217 includes opposing side portions 1218a, 1218b (only one of which is shown in FIG. 45) and a top portion 1219. Angled portions 1221 extend between one of the side portions 1218a, 1218b and the top portion 1219 (see FIG. 53). The dust extraction tube 1216 may include certain features of other dust extraction tubes disclosed herein. In some embodiments, the holster 1204 may attach to a portion of a housing 1220 of the sander 1200 that does not include a dust extraction tube.

With reference to FIG. 46, the holster 1204 includes a front wall 1223 having an abutment surface 1224 (which also may be called a front surface) spanning between two lips 1212a. 1212b. The abutment surface 1224 abuts or, in some embodiments, approximately abuts, or in other embodiments approaches, a portion of the sander 1200 when the sander 1200 is supported by the holster 1204. Each lip 1212a. 1212b of the holster 1204 includes an extension portion 1228a. 1228b and a lateral portion 1232a. 1232b that extends transverse to a respective extension portion 1228a. 1228b. The lips 1212a. 1212b are each configured to engage (e.g., to grip) the angled portions 1221, and more specifically in the illustrated embodiment, the lateral portions 1232a. 1232b each grip a respective angled portion 1221. An upper support 1236 extends from a top side of the abutment surface 1224 in a direction away from the lips 1212a. 1212b. In the illustrated embodiment, a rear wall 1240 extends downwardly from the upper support 1236 in a direction generally parallel to the abutment surface 1224. An intermediate wall 1244 also extends downwardly from the upper support 1236. In the illustrated embodiment, the intermediate wall 1244 also extends downward in a direction parallel to the abutment surface 1224 and is positioned between the rear wall 1240) and the abutment surface 1224. A first space 1248 is defined between the intermediate wall 1244 and the abutment surface 1224, and a second space 1252 is defined between the rear wall 1240) and the intermediate wall 1244.

With reference to FIG. 47, the rear wall 1240 includes an aperture 1256 defined therethrough. In other embodiments, the aperture 1256 does not pass through the rear wall 1240 but rather is a recess in the rear wall 1240. The aperture 1256 is configured to receive a head 1260 of a screw, nail, or other fastener or object. In the illustrated embodiment, the head 1260 protrudes from the surface 1208 such that, when the head 1260 is received within the aperture 1256, the holster 1204 is mounted to the surface 1208 (i.e., by hanging from the surface 1208 in the illustrated embodiment). The aperture 1256 includes a larger (first) end 1264 and a smaller (second) end 1268. When head 1260 is placed through the aperture 1256 such that the holster 1204 hangs on the head 1260 under the influence of gravity, the smaller end 1268 of the aperture 1256 is above the larger end 1264 of the aperture 1256. In other words, the head 1260) may be inserted through the larger end 1264, and the holster 1204 is moved downward such that the head is supported in the smaller end 1268 of the aperture 1256. In some embodiments, the head 1260 is not removable through the smaller end 1268. To remove the holster 1204 from the head 1260, the holster 1204 is moved upward such that the head 1260 can exit the aperture 1256 through the larger end 1264. When the holster 1204 hangs on the head 1260 under the influence of gravity, a gravitational force vector G1 generally points in the direction from the smaller end 1268 toward the larger end 1264 of the aperture 1256. In some embodiments, other structural arrangements in addition to or instead of the aperture 1256 such as, for example, hooks used to hang pictures, mirrors, or other objects on walls, may be provided on the rear wall 1240 or on another part of the holster 1204 for selectively hanging the holster 1204 on the surface 1208.

With continued reference to FIG. 47, the rear wall 1240 includes a first (upper) end 1272 and a second (lower) end 1276 opposite the first end 1272. The first end 1272 is connected to and adjacent the upper support 1236. However, the lower end 1276 is only connected to the upper support 1236 by means of the first end 1272 such that the lower end 1276 at least partially defines an opening 1280 between the lower end 1276 and the intermediate wall 1244 that leads to the second space 1252. In other words, the lower end 1276 of the rear wall 1240 is a free end 1276. The rear wall 1240 is formed as a clip 1240 such that a first distance D1 between the lower end 1276 and the intermediate wall 1244 is less than a second distance D2 between the upper end 1272 and the intermediate wall 1244. The lower end 1276 is biased toward, and in some embodiments into contact with, the intermediate wall 1244. Further, the lower end 1276 is biased toward the abutment surface 1224. The rear wall 1240, functioning as the clip 1240, stores mechanical energy in the manner of a spring when an object (e.g., a belt or waistband of an operator) is inserted through the opening 1280 into the second space 1252 between the lower end 1276 and the intermediate wall 1244. In the illustrated embodiment, the holster 1204 is integrally formed as one piece.

In operation, and with continued reference to FIG. 47, the holster 1204 may be selectively mounted on the surface 1208 by attachment means such as the aperture 1256. Alternatively, the holster 1204 may be removed from the surface 1208 and clipped onto a waistband, belt, or other object. The holster 1204 receives the sander 1200 between the lips 1212a, 1212b (e.g., by clipping the sander 1200 into the holster 1204). In this manner, the holster 1204 is a dual-function holster 1204 that may alternatively support the sander 1200 on a surface 1208 or on a belt of an operator.

In some embodiments of the holster 1204, the intermediate wall 1244 may be omitted such that only a single space is defined between the abutment surface 1224 and the rear wall 1240. In such an embodiment, the second end 1276 is biased toward the abutment surface 1224, and the rear wall 1240 acts as a clip 1240 to clip the holster 1204 onto a belt of an operator or onto another object.

With reference to FIG. 48, in another embodiment of a holster 1400, a pair of lips 1404a, 1404b are supported between a first support 1406 that spans between the lips 1404a, 1404b. The first support 1406 includes a front surface 1408 facing toward the lips 1404a, 1404b. When a sander such as the sander 1200 is supported in the holster 1400 in a storage position, the sander 1200 (and more specifically, in some embodiments, the strut portion 1217 of the sander 1200) may bear against the front surface 1408. In the illustrated embodiment, a second support 1412 is integrally formed with the first support 1406. The second support 1412 may be shaped to accommodate a sanding pad (e.g., shaped as a circle with a diameter similar to a diameter of a sanding pad, such as, for example, three inches). In the illustrated embodiment, the first support 1406 forms a shape with a curved outer periphery 1420 such as a circle. In the illustrated embodiment, an upper support web 1416 supports the second support 1412 relative to the first support 1406 by interconnecting the first support 1406 and the second support 1412. The first support 1406 may be a lower support 1406, and the second support 1412 may be an upper support 1412. In some embodiments, one of the supports 1406, 1412, and in the illustrated embodiment the second support 1412, includes an aperture 1424 (i.e., a support aperture 1424). In the illustrated embodiment, the second support 1412 includes a central aperture 1424 that provides access through the second support 1412. A lower support web 1444 spans between the lips 1404a, 1404b and may include a notch or aperture 1448 to accommodate a portion of the sander 1200 such as a dust extraction tube or a support.

With reference to FIG. 49, the holster 1400 includes a flange or clip 1428 having an aperture 1432 (i.e., a clip aperture 1432) with a larger portion 1436 and, in the illustrated embodiment, two smaller portions 1440a. 1440b. In some embodiments, the aperture 1432 may be shaped differently. For example, the aperture 1432 may include a single smaller portion 1440a that is located above the larger portion 1436 such that the aperture 1432 is configured to selectively receive and retain a head of a fastener (e.g., a screw; a nail, etc.). In the illustrated embodiment, the aperture 1432 is accessible from a front of the holster 1400 through the aperture 1424 in the second support 1412. In addition, with continued reference to FIG. 49, the lips 1404a. 1404b are positioned at an angle to each other relative to a longitudinal axis A8 of the holster 1400 such that the lips 1404a, 1404b approach each other at a lower end of the holster 1400 at which a distance between the lips 1404a, 1404b is defined by a first lip distance 1476 and such that the lips 1404a, 1404b diverge from each other at an upper end of the holster 1400 at which a distance between the lips 1404a, 1404b is defined by a second lip distance 1480. The second distance 1480 is greater than the first lip distance 1476.

With reference to FIG. 50, the aperture 1432 in the clip 1428 is oriented such that the holster 1400 can hang from the head of a fastener under the influence of a gravitational force vector G2. The clip 1428 includes an upper end 1452 which is connected to the second support 1412 and a lower end 1456. The second support 1412 includes a rear surface 1460, and the lower end 1456 of the clip 1428 approaches the rear surface 1460 such that a strap or belt of an operator can be passed between the rear surface 1460 and the clip 1428 to support the holster 1400 on the strap or belt of the operator.

With reference to FIG. 51, a space 1464 may be defined between the lower end 1456 of the clip 1428 and the rear surface 1460 that allows a strap or belt of an operator to be inserted between the clip 1428 and the rear surface 1460.

With reference to FIG. 52, each lip 1404a, 1404b includes a respective extension portion 1468a, 1468b and a respective lateral portion 1472a, 1472b that extends transverse to the respective extension portion 1468a, 1468b. In some embodiments, the lateral portions 1472a, 1472b may be perpendicular to a respective extension portion 1468a, 1468b.

With reference to FIGS. 53-55, strut portion 1217 of the sander 1200 includes a bottom side 1222 and the side portions 1218a, 1218b disposed on either side of a sander housing axis A9 (FIG. 54). The strut portion 1217 includes a first location 1488 at which a distance measured transverse to, and in the illustrated embodiment perpendicular to, the axis A9 and between the side portions 1218a, 1218b is equal to the first lip distance 1476. The strut portion 1217 also includes a second location 1492 at which a distance measured transverse to, and in the illustrated embodiment perpendicular to, the axis A9 and between the side portions 1218a, 1218b is equal to the second lip distance 1480. In this manner, the strut portion 1217 may be configured to fit between the lips 1404a, 1404b such that the holster 1400 selectively grips the strut portion 1217 to support the sander 1200 in a storage position (e.g., in a hanging position from a fastener, from a belt of an operator, etc.). For example, the extension portions 1468a, 1468b each grip a respective side portion 1218a, 1218b, and the lateral portions 1472a, 1472b each grip a respective angled portion 1221.

With continued reference to FIG. 53, a motor axis A11 is defined by a rotational axis of the motor 26. The motor axis A11 passes through a user control panel 1284, which is located at a top of the motor housing portion 1229. In the illustrated embodiment, the user control panel 1284 is shaped as a plus sign. In operation, a user can change a rotational speed of the motor 26 and/or a mode of operation of the sander 1200 by activating a button, dial, or other actuator on the user control panel 1284.

With reference to FIGS. 56 and 57, in the illustrated embodiment, a sander 1300 is a random orbit sander 1300, but in other embodiments may be a rotary sander or another type of sander. The sander 1300 also includes a dust container 1308, which may include certain features of other dust containers, such as the dust container 59. The sander 1300 includes a housing 1312, a dust extraction tube 1316 supported by the housing 1312, and a motor 1320 enclosed within the housing 1312. A fan 1328 is also enclosed within the housing 1312 and is rotatable by the motor 1320. The motor 1320 includes an on state and an off state. In the on state, the motor 1320 drives a sanding pad 1324 such that the sanding pad 1324 is operable to sand a workpiece. During sanding of a workpiece, the sanding pad 1324 generates dust as a byproduct. In the on state, the motor 1320 drives the fan 1328, which induces (e.g., draws) an airflow through the dust extraction tube 1316 to transport the dust toward the dust container 1308. In some embodiments, the fan 1328 that induces an airflow to transport dust toward the dust container 1308 may be driven by a motor that is different from the motor 1320, and in some embodiments, the fan 1328 may not be enclosed within the housing 1312. For example, the fan 1328 may be a part of a separate dust extraction system.

With continued reference to FIGS. 56 and 57, the dust extraction tube 1316 includes an outlet 1332. The dust container 1308 includes an inlet 1336 that attaches to the outlet 1332 of the dust extraction tube 1316 to form a substantially airtight seal. The dust container 1308 further includes a flexible housing 1340 that is structurally supported by a stiffening member 1344. In the illustrated embodiment, the flexible housing 1340 is made of cloth, and the stiffening member 1344 is a spring. In other embodiments, the housing 1340 may be self-stiffening (i.e., the housing 1340 may be made of a material such as plastic that does not require a separate stiffening member 1344).

With continued reference to FIG. 56, the sander 1300 includes a baffle 1348 having a first side 1349 facing toward the fan 1328 and a second side 1350 facing away from the fan 1328 (i.e., facing toward the housing 1340 of the dust container 1308). In other words, the first side 1349 is a high-pressure side of the baffle 1348, and the second side 1350) is a low-pressure side of the baffle 1348. In the illustrated embodiment, the baffle 1348 is provided in the inlet 1336 of the dust container 1308. In other embodiments, the baffle 1348 is provided in another location within the dust container 1308. In vet other embodiments, the baffle 1348 is provided in the outlet 1332 of the dust extraction tube 1316 or in another location in the dust extraction tube 1316. The baffle 1348 includes a first end 1352 and a second end 1356, and the baffle is hinged at the first end 1352. In the illustrated embodiment, the first end 1352 is positioned proximal the housing 1312 of the sander 1300, and the second end 1356 is positioned distal from the housing 1312 of the sander 1300. In other embodiments, the first end 1352 and the second end 1356 are positioned in other orientations such that, for example, the baffle 1348 is hinged at a location distal from the housing 1312 or in another location.

With reference to FIGS. 56 and 57, the baffle 1348 is positionable in a first, closed position (shown in FIG. 56) and in a second, open position (shown in FIG. 57). The baffle 1348 is sized and shaped to cover the inlet 1336 when in the closed position to inhibit dust that is contained within the dust container 1308 from passing through the inlet 1336 and thereby exiting the dust container 1308 (i.e., to inhibit a movement of dust). In the open position, the baffle 1348 allows the movement of dust. In the illustrated embodiment, the baffle 1348 is biased into the closed position by a spring 1360 (e.g., a torsion spring) and/or by an inherent stiffness of the material of the baffle 1348 (e.g., by energy stored by a deformable material such as a deformable plastic). In other words, the baffle 1348 may be made entirely of a resilient material such as a type of plastic and/or may include a portion of resilient material (e.g., a living hinge) that flexes or deforms as the baffle 1348 is moved between the closed position and the open position. When the baffle 1348 is in the open position (FIG. 57), a gap 1364 is formed between the second end 1356 of the baffle 1348 and wall 1368 of the inlet 1336. The gap 1364 allows an airstream 1372a, 1372b, 1372c (which may be more specifically described as including a first portion of the airstream 1372a, a second portion of the airstream 1372b, and a third portion of the airstream 1372c), which is generated by the fan 1328 and which may include dust, to pass through the inlet 1336, through the gap 1364, and into the housing 1340 of the dust container 1308. More specifically, the fan 1328 generates the first portion of the airstream 1372a through the dust extraction tube 1316 and through the outlet 1332 of the dust extraction tube 1316, the second portion of the airstream 1372b through the inlet 1336 of the dust container 1308 and through the gap 1364 between the baffle 1348 and the wall 1368 of the inlet 1336, and the third portion of the airstream 1372c into the housing 1340 of the dust container 1308. The baffle is positioned to selectively intercept the airstream 1372a, 1372b, 1372c (e.g., to intercept one of the first portion of the airstream 1372a, the second portion of the airstream 1372b, or the third portion of the airstream 1372c).

With reference to FIGS. 56 and 57, a dust extraction tube pressure is defined within the dust extraction tube 1316 such as, for example, at a dust extraction tube pressure location 1376. A dust container pressure is defined within the housing 1340 of the dust container 1308 such as, for example, at a dust container pressure location 1380. When the fan 1328 is not being rotated by the motor 1320, a pressure differential between the dust container pressure and the dust extraction tube pressure may be approximately zero. When the fan 1328 is being rotated by the motor 1320, a pressure differential between the dust extraction tube pressure and the dust container pressure (i.e., the dust extraction tube pressure minus the dust container pressure) may be greater than zero. In some embodiments, when the pressure differential exceeds a pressure threshold, the air pressure causes the baffle 1348 to move from the closed position to the open position. A sensor 1382 (e.g., a pressure sensor) may be positioned within the dust extraction tube 1316 and/or on the first side 1349 of the baffle 1348 to sense the dust extraction tube pressure. The sander 1300 may include a controller 1384 that receives information from, for example, the sensor 1382 (i.e., the sensor 1382 sends a signal such as a pressure signal to the controller 1384). The controller 1384 may operate an actuator 1362 (FIG. 56) that selectively moves the baffle 1348 between the open position and the closed position. The baffle 1348 may move between the open position and the closed position solely under the influence of the pressure differential between the dust extraction tube pressure and the dust container pressure without an actuator 1362, a sensor 1382, or a controller 1384 (i.e., by utilizing a pressure force applied by the airstream 1372a. 1372b, 1372c to move the baffle 1348 toward the open position).

With reference to FIG. 58, the sander 1200 includes the unified motor output shaft and eccentric carrier 144, which itself includes the motor shaft 1500 and the eccentric carrier 1504. The eccentric carrier 1504 supports the radial bearing 1508 that, in turn, rotatably supports the eccentric shaft 1512. The motor shaft 1500 defines the motor shaft axis A5. The eccentric shaft 1512 defines the axis A10 of the eccentric shaft 1512, which also serves as the axis A10 of the sanding pad 18. The motor shaft axis A5 is offset from the axis A10 of the eccentric shaft 1512 by an offset distance 1700. In FIG. 58, the offset distance 1700 is 1.25 mm, but in other embodiments, the offset distance 1700 may be selected as desired. The offset distance 1700 defines a radial eccentricity 1700 of the sanding pad 18 with respect to the motor shaft axis A5.

With reference to FIG. 59, top view of the sander 1200 is provided showing a schematic outline of an outer perimeter of the round sanding pad 18 and a schematic outline of an outer perimeter of the motor housing portion 1524. The sanding pad 18 has a sanding pad radius 1704 that may be selected as desired, but in the illustrated embodiment of FIG. 59 is 38.1 mm (i.e., the sanding pad 18 has a diameter of 76.2 mm, which is larger than a diameter of the motor housing portion 1524). The motor housing portion 1524 has a motor housing portion radius 1708 that may be selected as desired, but in the illustrated embodiment of FIG. 59 is 36.85 mm, such that a difference between the sanding pad radius 1704 and the motor housing portion radius 1708 is 1.25 mm. In some embodiments, including in the illustrated embodiment, the motor housing portion 1524 does not have a perfectly circular outer projection. Nevertheless, the term “motor housing portion radius” may still be understood as meaning a maximal outer distance from the axis A5. Therefore, the difference between the sanding pad radius 1704 and the motor housing portion radius 1708 may be equal to or approximately equal to the radial eccentricity 1700 of the sanding pad 18 with respect to the motor shaft axis A5. If the difference between the sanding pad radius 1704 and the motor housing portion radius 1708 is equal or approximately equal to the radial eccentricity 1700 of the sanding pad 18 with respect to the motor shaft axis A5, then at all degrees of rotation of the sanding pad 18 about the motor shaft axis A5, the sanding pad 18 extends outward from all points on the outer perimeter of the motor housing portion 1524 except at one point where the outer perimeter of the motor housing portion 1524 and the outer perimeter of the sanding pad 18 are tangent (i.e., the point 1712 in FIG. 59). In other embodiments, the difference between the sanding pad radius 1704 and the motor housing portion radius 1708 may be greater than the radial eccentricity 1700 such that, at all degrees of rotation of the sanding pad 18 about the motor shaft axis A5, the sanding pad 18 extends outward from all points on the outer perimeter of the motor housing portion 1524. At a point 1716 on the motor housing portion 1524 opposite the point 1712, the sanding pad 18 extends maximally from the outer perimeter of the motor housing portion 1524 by a maximal offset 1720 that is twice the radial eccentricity 1700 (i.e., the maximal offset 1720 is 2.5 mm in FIG. 59).

With reference to FIG. 60, as the sanding pad 18 rotates about a stationary motor housing portion 1524, the sanding pad 18 reaches a position (shown in FIG. 60) that is 180 degrees from the position shown in FIG. 59. In FIG. 60, the point 1712 (i.e., the point at which the sanding pad 18 extends outwardly from the motor housing portion 1524 a minimal amount and, in the illustrated embodiment, extends 0 mm or approximately 0 mm beyond the motor housing portion 1524) and the point 1716 (i.e., the point at which the sanding pad 18 extends outwardly from the motor housing portion 1524 a maximal amount and, in the illustrated embodiment, extends outwardly by the maximal offset 1720, which is twice the radial eccentricity 1700) have switched positions. As the sanding pad 18 rotates about the motor shaft axis A5, the sanding pad axis A10 orbits about the motor shaft axis A5, leading to a continued orbit of the points 1712, 1716 about the motor shaft axis A5.

In operation, and with continued reference to FIGS. 58-60, as the sanding pad 18 rotates, the sanding pad 18 extends beyond the motor housing portion 1524 at all points on the outer perimeter of the motor housing portion 1524 except for at a single point or, in some embodiments, except for no points. This configuration facilitates sanding against vertical surfaces (e.g., walls) by allowing the sanding pad 18 to fully access edges and corners of a working surface, even when positioned against a vertical surface, without being inhibited by the physical size of the motor housing portion 1524 or by other components of the sander 1200. In cases in which the motor housing portion 1524 and/or the sanding pad 18 do not have a round projection into a plane (such as the round projections shown in FIGS. 59 and 60), the radial eccentricity 1700 and the respective largest diameters of the motor housing portion 1524 and the sanding pad 18 may be sized such that at all rotational positions of the sanding pad 18, a point on the sanding pad 18 extends at least up to or beyond a farthest point on a periphery of the motor housing portion 1524 from the motor shaft axis A5. As a result, the sanding pad 18, the motor housing portion 1524, and the radial eccentricity 1700 may be sized to allow the sander 1200 to work against a vertical surface without interference otherwise caused by the motor housing portion 1524 or other components of the sander 1200.

With reference to FIG. 61, the sander 1200 includes a housing 1220 having a first clamshell half 1800 and a second clamshell half 1804. The motor fan 29 is rotatable by the motor 26 (FIG. 58) within an upper cavity 1808 of the motor housing portion 1524 (FIG. 6). The motor fan 29 rotates in a clockwise direction from a direction facing toward the sanding pad 18.

With reference to FIGS. 61 and 62, the motor fan 29 rotates within a volute 1812 bounded by a peripheral wall 1814 that defines an expanding radius when moving from an inlet 1816 of the volute 1812 toward an outlet 1820 of the volute 1812. At the volute inlet 1816, an inlet clearance 1824 between the motor fan 29 and the peripheral wall 1814 is less than an outlet clearance 1828 between the motor fan 29 and the peripheral wall 1814. The outlet clearance 1828 may be approximately 2, approximately 3, approximately 4, approximately 5, or approximately 6 times the inlet clearance 1824. In other embodiments, the outlet clearance 1828 may be another multiple (and not necessarily an integer multiple) of the inlet clearance 1824. The motor fan 29 generates a motor-cooling airflow 1832 that flows through the volute 1812, into an interior passageway 1836 that directs the motor-cooling airflow: 1832 downwardly toward the sanding pad 18, and out at least one exhaust opening 1840 provided in the second clamshell half 1804. In some embodiments, additional exhaust openings 1840 are symmetrically provided in the first clamshell half 1800.

With reference to FIGS. 61-63, the sander 1200 includes a light holder 1844 that supports three circuit boards 1848 (e.g., printed circuit board assemblies). Each circuit board 1848 supports at least one light 1852 (FIG. 64), which may include one or more light emitting diodes (“LEDs”). In some embodiments, each light 1852 may be of the same or similar brightness as the other lights 1852. The light holder 1844 includes a curved, upstanding wall 1856 that partially defines a portion of the peripheral wall 1814 and thereby defines a portion of the volute 1812. In the illustrated embodiment, the first clamshell half 1800 forms a portion of the peripheral wall 1814, the second clamshell half 1804 forms another portion of the peripheral wall 1814, and the light holder 1844 (and more particularly, the curved, upstanding wall 1856 of the light holder 1844) forms yet another portion of the peripheral wall 1814. The upstanding wall 1856 guides the motor-cooling airflow 1832 around the volute 1812 and toward the outlet 1820 of the volute 1812.

In operation, and with reference to FIGS. 61-63, the exhaust openings 1840, which are positioned below the motor fan 29, cooperate with the interior passageway 1836 to allow the pommel portion 27 of the motor housing portion 1524 to be used as a grip by a user and to discharge the motor-cooling airflow: 1832 away from (i.e., below) the pommel portion 27 so that the motor-cooling airflow: 1832 does not interfere with the user's grip. In other words, by locating the exhaust openings 1840 at a lower elevation in the motor housing portion 1524 than where the motor fan 29 is located, the heated airflow discharged from the exhaust openings 1840 does not flow over or around a user's hand if placed atop the motor housing portion 1524 for increased leverage over the sanding pad 18 during a sanding operation. Accordingly, the exhaust openings 1840 and the interior passageway 1836 cooperate to allow the motor 26 to be positioned higher in the motor housing portion 1524 of the sander 1200. This design, for example, may more efficiently use the space within the motor housing portion 1524.

With reference to FIG. 64, the sander 1200 includes a lens 1860 through which the lights 1852 project light rays. The lens 1860 includes a top rounded edge 1864, a bottom rounded edge 1868, and a front surface 1900 that protrudes forwardly from a front surface 1876 of the motor housing portion 1524. In some embodiments, the front surface 1900 of the lens 1860 may be flush with or substantially flush with the front surface 1876 of the motor housing portion 1524. The lights 1852 project light rays in a forward direction 1880, and the light rays are reflected and/or refracted to project the light rays in a plurality of directions including, for example, a first direction 1884a, a second direction 1884b, a third direction 1884c, and a fourth direction 1884d to illuminate, among other things, a region at a front of the sanding pad 18. Light rays can also project through the lens 1860 in the forward direction 1880 without internal reflection within the lens 1860 or refraction caused by the lens 1860.

FIG. 65 is a cross-sectional view of the lens 1860 taken along the section line 65-65 of FIG. 64. The lens 1860 includes pockets 1888a, 1888b, 1888c that house the lights 1852. In the illustrated embodiment, each light 1852 is positioned within a respective pocket 1888a, 1888b, 1888c (e.g., a right pocket 1888a houses a right light 1852, a central pocket 1888b houses a central light 1852, and a left pocket 1888c houses a left light 1852). The lens 1860 includes curved internal features to disperse the light rays generated by the lights 1852 as desired. For example, each pocket 1888a, 1888b, 1888c includes a respective curved front face 1892a. 1892b, 1892c. Each light 1852 projects light rays in a forward direction 1880 parallel to a workpiece surface and perpendicular to the motor shaft axis A5 and to the axis A10. The curved front faces 1892a, 1892b, 1892c then refract or disperse the light rays in all directions through the lens 1860 to illuminate, among other things, a front side 1896 of the sanding pad 18, with light rays projecting from the bottom rounded edge 1868 in the fourth direction 1884d in FIG. 64, or with light rays projecting vertically downward from a bottom surface 1862 of the lens 1860 adjacent the rounded edge 1868.

With reference to FIG. 66, the lens 1860, including the curved front surface 1900, may be wholly or partially made of semi-clear or partially translucent or transparent polycarbonate plastic. The lens 1860 may include a textured exterior. For example, the curved front surface 1900 may be wholly or partially textured (i.e., rough rather than completely smooth). The curved front surface 1900 may include a radius of curvature of 37.45 mm, approximately 37.45 mm, between 35 mm and 40 mm, between 30 mm and 50 mm, or another size as desired. The curved front surface 1900 may include a surface area of 203.95 square millimeters, approximately 203.95 square millimeters, between 200 square millimeters and 205 square millimeters, between 180 square millimeters and 220 square millimeters, between 150 square millimeters and 250 square millimeters, or another size as desired. The curved front surface 1900 may extend between a first side 1904 and a second side 1908 by spanning an angle of 118.69 degrees, by spanning an angle of approximately 120 degrees, by spanning an angle of between 100 degrees and 140 degrees, by spanning an angle of between 80 and 160 degrees, or by spanning another angular amount as desired. A length of the curved front surface 1900 measured along the curvature between the first side 1904 and the second side 1908 may be 77.58 mm, approximately 80 mm, between approximately 70 mm and approximately 90 mm, between approximately 50 mm and approximately 110 mm, or another size as desired.

With reference to FIG. 67, the lens 1860 includes a pair of positioning nubs 1912 that protrude upwardly and engage the light holder 1844 and to position the light holder 1844 with respect to the lens 1860. The lens 1860 also includes a generally semicircular flange 1916 at least partially bounded by a wall 1920. The wall 1920 may align with the upstanding wall 1856 when the lens 1860 and the light holder 1844 are installed within the sander 1200.

Although the invention 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 invention as described.

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

Claims

1.-103. (canceled)

104. A method of assembling a sander, the method comprising: providing: an eccentric carrier,a dust extraction fan,a radial bearing, anda shaft having a longitudinal axis;sizing an internal bore of the dust extraction fan to be nominally smaller than an external surface of the eccentric carrier;sizing an internal bore of the eccentric carrier to be nominally smaller than an external surface of the radial bearing;sizing an internal bore of the radial bearing to be nominally smaller than an external surface of the shaft; andpressing the eccentric carrier, the dust extraction fan, the radial bearing, and the shaft together with an interference fit between the respective external surfaces and the internal bores of the eccentric carrier, the dust extraction fan, the radial bearing, and the shaft in a direction parallel to the longitudinal axis of the shaft.

105. The method of claim 104, further comprising pressing together the eccentric carrier, the dust extraction fan, the radial bearing, and the shaft such that a plane defined perpendicular to the longitudinal axis of the shaft passes through the eccentric carrier, the dust extraction fan, the radial bearing, and the shaft.

106. The method of claim 105, further comprising pressing together the eccentric carrier, the dust extraction fan, the radial bearing, and the shaft such that the plane passes through a counterweight of the dust extraction fan and through a fan blade of the dust extraction fan.

107. The method of claim 104, further comprising stacking the eccentric carrier, the dust extraction fan, the radial bearing, and the shaft prior to pressing together the eccentric carrier, the dust extraction fan, the radial bearing, and the shaft.

108. The method of claim 107, wherein pressing the eccentric carrier, the dust extraction fan, the radial bearing, and the shaft includes pressing the eccentric carrier, the dust extraction fan, the radial bearing, and the shaft together as a stack.

109. The method of claim 104, further comprising affixing a sanding pad to the shaft.

110. A random orbit sander comprising: a housing;a motor enclosed within the housing, the motor including a motor shaft rotatable about a first axis;an eccentric carrier coupled to the motor shaft, the eccentric carrier including a circular internal bore defining a second axis that is offset from the motor shaft;a radial bearing received within the circular internal bore of the eccentric carrier;a dust extraction fan rotationally unitized with the eccentric carrier for corotation therewith;an eccentric shaft having a longitudinal axis; anda sanding pad supported by the eccentric shaft and rotatable about the first axis in an eccentrically orbiting manner;wherein the eccentric carrier, the radial bearing, the dust extraction fan, and the eccentric shaft are coupled to each other by press-fit connections.

111. The random orbit sander of claim 110, wherein a plane is defined perpendicular to a longitudinal axis of the eccentric shaft such that the plane passes through the eccentric carrier, the dust extraction fan, the radial bearing, and the eccentric shaft.

112. The random orbit sander of claim 111, wherein the plane passes through a counterweight of the dust extraction fan and through a fan blade of the dust extraction fan.

113. The random orbit sander of claim 110, wherein the dust extraction fan is integrally formed as a single piece with a counterweight to form an integrated fan and counterweight unit.

114. The random orbit sander of claim 110, wherein the eccentric carrier is integrally formed as a single piece with the motor shaft.

115. The random orbit sander of claim 110, wherein a diameter of the sanding pad is less than four inches.

116. The random orbit sander of claim 115, wherein a diameter of the sanding pad is three inches.

117. The random orbit sander of claim 110, wherein a motor housing portion height of the random orbit sander is less than 0.6 times an overall length of the random orbit sander.

118. The random orbit sander of claim 110, wherein the eccentric carrier, the dust extraction fan, the radial bearing, and the eccentric shaft are positioned within a lower cavity of a motor housing portion of the random orbit sander.

119. The random orbit sander of claim 110, wherein the radial bearing and the eccentric shaft are provided within the eccentric carrier, and wherein the dust extraction fan is provided outside the eccentric carrier.

120. The random orbit sander of claim 110, wherein the radial bearing includes two rows of ball bearings positioned between the eccentric shaft and the eccentric carrier.

121. The random orbit sander of claim 110, wherein: the housing includes a motor housing portion defining a motor housing axis and a handle portion defining a handle axis transverse to the motor housing axis,the motor is enclosed within the motor housing portion and oriented vertically within the motor housing portion, anda battery pack is removably connectable to a rear end of the handle portion.

122. The random orbit sander of claim 110, further comprising a user control panel positioned at a top of a motor housing portion of the housing, wherein the first axis passes through the user control panel.

123. The random orbit sander of claim 110, wherein: the housing includes a motor housing portion having a neck portion and a pommel portion, anda front work light is positioned on a front surface of the neck portion and is positioned below the pommel portion.

124.-164. (canceled)