Patent Application
20090191799
The present disclosure is directed to an apparatus and system for conditioning a surface. More particularly, it is directed to an easy to use and low cost surface modifying tool adapter including a plurality of removable surface modifying articles, such as abrasive article inserts, and a surface modifying tool system using such surface modifying tool adapter in a surface modifying method.
A variety of attachment systems have been employed to attach abrasive articles, such as abrasive sheets or discs, to a power surface modifying tool, such as a sanding tool, whereby the former is driven by the latter. Abrasive sheets and discs have relatively flexible constructions and are available in a wide variety of sizes and shapes. Typically, abrasive particles are on one major surface of abrasive discs or sheets. These kinds of abrasive articles are normally held in place on the surface modifying tool by a mechanical bolt and washer and the like that require user manipulations to mount and replace.
Typically, during surface modifying with a rotary abrader, disc shaped abrasive articles tend to wear adjacent their outer periphery more than towards their center. Because of the uneven wear, there may be a considerable amount of wastage of otherwise good abrasive particles near the center of the discs. Moreover, in response to forming abrasive discs, in the first instance, a considerable amount of sheet material from which the discs are cut is wasted, thereby compounding wastage of the single abrasive disc. This amount of wastage, for example, may be in the order of about 16% to about 23% for discs having 16-20 inch diameters. In addition, material in the center of such discs generally does not abrade as well as at the periphery of the disc or at all. It will be appreciated that the total wastage regarding the converting of sheet material to discs and the general loss of material at disc centers lead to wastage loss that may at times be considerable. Moreover, abrasive discs may become damaged during usage, such as in response to striking a protrusion (e.g., nail) from the working surface. Accordingly, the entire abrasive disc must be replaced. Not only is this costly since undamaged portions must be replaced, but in a surface modifying operation, such as sanding operation, the downtime increases due to the relatively tedious process of removing and replacing damaged discs. Furthermore, there is a desire to eliminate waste of materials in products, as well as in the manufacturing process.
Accordingly, needs exist for an improved surface modifying tool adapter including a plurality of abrasive article inserts, and a surface modifying tool system using such surface modifying tool adapter and inserts for enabling easy coupling to a power tool, whereby the former is driven in order to perform surface conditioning operations on a working surface. These needs further include being able to easily and economically replace only those portions of a surface modifying assembly that have been damaged. Moreover, needs exist for reducing wasted materials in products, as well as in their manufacturing processes, as manufacturers strive for zero waste manufacturing.
The present description provides an apparatus comprising: a rotatable carrier; a plurality of surface modifying articles on the carrier, each of the surface modifying articles having a major surface modifying surface and at least a leading edge portion; and a retaining assembly on one of the carrier and the surface modifying article for retaining the leading edge portion of each of the surface modifying articles in spaced apart relationship from a working surface during surface modification by the major surface.
The present description provides a surface modifying system for modifying a working surface. The system comprises: a surface modifying power tool having a driving member rotatable about an axis; and, a surface modifying tool adapter connectable to the driving member, the surface modifying tool adapter including: a rotatable carrier; a plurality of surface modifying articles on the carrier, each of the surface modifying articles having a major surface modifying surface and at least a leading edge portion; and a retaining assembly on one of the carrier and the surface modifying article for retaining the leading edge portion of each of the surface modifying articles in spaced apart relationship from a working surface during surface modification by the major surface.
The present description provides a surface modifying assembly couplable to a surface modifying tool assembly. The surface modifying assembly comprises: a generally elongated body having first and second opposed major surfaces, and at least a leading edge portion; a surface modifying material on at least a portion of one of the first and second major surfaces that is spaced from the leading edge for modifying a working surface in a working plane; a first attachment mechanism portion for releasably attaching the leading edge portion to the surface modifying tool assembly; and a second attachment mechanism portion spaced from the first attachment portion for releasably holding a segment of the body against the surface modifying tool assembly so that the surface modifying material is generally linearly spaced from the leading edge portion and from the working plane.
The present description provides a method of modifying a surface with a surface modifying article. The method comprises: providing a plurality of surface modifying articles on a rotatable carrier, each of the surface modifying articles having a major surface modifying surface and at least a leading edge portion; and retaining the leading edge portion of each of the surface modifying articles in spaced apart relationship from a working surface during surface modification by the major surface.
Aspects of the present description provide a surface modifying tool adapter and surface modifying tool system that utilize replaceable abrasive or surface modifying assemblies.
Aspects of the present description provide a surface modifying tool adapter that is easily mountable to a power surface modifying tool system.
Aspects of the present description include use of surface modifying articles and adapters that substantially reduce the amount of material that is wasted by utilizing same sized segmented pieces for a wide range of disc diameters, thereby minimizing inventoried discs.
Aspects of the present description provide an economical approach that enables a low cost surface modifying tool adapter attachable to a power tool assembly.
Aspects of the present description include use of abrasive assembly inserts for providing low cost and convenient mounting and dismounting of abrasive articles.
Aspects of the present description include use of abrasive assembly inserts that facilitate replacement of only those abrasive pieces or segments that may be worn or damaged.
Aspects of the present description include use of surface modifying articles and adapters that substantially reduce the amount of material that is wasted in their construction.
Aspects of the present description include use of surface modifying articles and adapters that substantially reduce the amount of material that is wasted during manufacturing of disc shaped articles.
Aspects of the present description include use of surface modifying articles and adapters that provide dust relief by increasing efficiency of abrading by reducing build-up of dust accumulation between an abrading surface and the surface being abraded.
Aspects of the present description include use of surface modifying articles and adapters that achieve the foregoing advantages as well as allows for providing higher unit pressure.
Aspects of the present description include use of surface modifying articles and adapters that improve the surface modifying operations by floating over non-planar surfaces while abrading.
The aspects described herein are merely a few of the several that may be achieved by using the present description. The foregoing descriptions thereof do not suggest that the present disclosure must only be utilized in a specific manner to attain the foregoing aspects.
These and other features and aspects of the present description will be more fully understood from the following detailed description of exemplary embodiments.
The words “a”, “an”, and “the” are used interchangeably to mean one or more of the elements being described. By using words of orientation, such as “top”, “bottom”, and “backing” and the like for location of the various elements in the disclosed articles, I refer to the relative position of an element with respect to a horizontally-disposed body portion. It is not intended that the disclosed articles should have any particular orientation in space during or after their manufacture.
The present description is directed to
In the exemplary embodiment, the surface modifying tool adapter 12, that is adapted to be connected to the rotatable driving member 14, may include a carrier assembly 20 that has a plurality of abrasive or surface modifying assemblies 22 that may be removable inserts or elements 22 carried thereby on a major generally planar surface 24 thereof. As will be described, the abrasive or surface modifying assemblies 22 may be releasably secured to the carrier assembly 20 by approaches to be described. Advantageously, because of the fact that there is not a continuous single sheet of an abrasive disc assembly covering the carrier assembly, considerable savings in material costs are realized utilizing such abrasive or surface modifying assemblies particularly those that have straight edges. It will be appreciated that use of abrasive assembly inserts or segments provide for low cost and convenient mounting and dismounting of abrasive articles. Moreover, such spaced abrasive inserts provide dust relief by increasing efficiency of abrading by reducing build-up of dust accumulation between an abrading surface and the surface being abraded since trapping of dust particles is diminished greatly.
In one exemplary embodiment the abrasive or surface modifying assemblies 22 are generally of the same size. Accordingly, one size may be used to fit different diameter or sized driving discs or members 14. It will be understood that the number of abrasive or surface modifying assemblies used may depend primarily on the diameter of the driving member or disk. In general, the larger the diameter of the driving member tool or adapter, the greater the number of abrasive or surface modifying assemblies that will be used. For example, a driving member 14 having a diameter of about 15 inches may have three (3) abrasive or surface modifying assemblies having a rectangular shape (e.g., 4 inches×6 inches). A driving member having a 20 inch diameter may have about six (6) abrasive or surface modifying assemblies of the size noted above.
This substantially reduces the amount of material that is wasted by utilizing same sized abrasive pieces for a wide range of disc diameters. This is also advantageous since it enables distributors to stock replacements having one size instead of a single sheet having a plurality of different disc sizes to match tools having different driving disc diameters. Advantageously, this approach reduces inventory.
While in an exemplary embodiment, the abrasive or surface modifying assemblies 22 appear to be made of the same constructions, shapes and sizes; those are not requirements of the present disclosure. A wide variety of materials, constructions, shapes and sizes may be used for the abrasive or surface modifying assemblies 22. The present description envisions many shapes having straight edges in order to reduce waste. Also, readily available round discs could be used, but with less waste reduction. In an exemplary embodiment, each of the abrasive or surface modifying assemblies 22 may be defined by a single generally elongated rectangular sheet for abrading the working surface 18 (
An exemplary embodiment is illustrated in
As illustrated, the abrasive or surface modifying assemblies 22 may be arranged in a spaced apart and generally circumferential relationship relative to each other about and adjacent the peripheral edge or extent of the major surface 24. By being placed adjacent the periphery, the abrasive or surface modifying assemblies 22 may apply more unit pressure than would be the case with a single abrasive disc encompassing the abrasive or surface modifying assemblies 22 (same total machine pressure over a smaller total contact area). Also, more abrading is performed because the abrasive assemblies at the periphery are rotating at higher speeds as compared to single discs areas (e.g., centers) that do not rotate at optimum speed. Dual-sided abrasive or surface modifying assemblies, although not shown, may be provided. The abrasive or surface modifying assemblies 22 may be made of any suitable materials and sizes. As such, they may be commercially available from 3M Company, St. Paul, Minn.
The present description envisions any suitable number of abrasive or surface modifying assemblies 22 may be used. The number may depend on the type of surface treating to be performed, as well the type of abrasive articles to be used. Their pattern of distribution may also vary depending on factors, such as the type of surface treatment to be performed. As noted, the abrasive or surface modifying assemblies 22 may have the same, similar or different configurations and abrasive qualities or characteristics. Since the abrasive or surface modifying assemblies 22 are to be rotated about an axis, it is important that their respective leading edges be spaced up and away from the surface modifying plane 29 so that they do not catch on or become damaged during abrading. While the leading edge 22c of this embodiment is a linear leading edge of a generally rectangular abrasive sheet 22, the leading edge may take any configuration and assume other orientations. Whatever configurations are selected, however, the leading edges should remain away from the surface modifying plane and otherwise protected to avoid being damaged or destroyed. In this regard, a wide variety of such protective retaining arrangements are envisioned by the present disclosure.
In one exemplary embodiment, the carrier assembly 20 may include a supporting member 32 and a retainer member 34. A two-piece construction made of a planar abrasive supporting member 32, such as a plate 32, and a retaining or retainer member 34, such as a plate 34 is illustrated, but a single member or plate may be used or a; plurality of plate segments may be used. The abrading tool adapter 12 is arranged to be removably secured to the power tool 16. The supporting member 32 and the retainer member 34; respectively, may be made of any suitable material and thickness that are appropriate for the surface(s) to be treated. In the exemplary embodiment, supporting member 32 may be made of fiberglass, and may also include, but not be limited to vulcanized rubber, laminated or pressed wood, metallic plates or the like. The supporting member 32 may have any suitable thickness to provide for reliability and durability. The retainer member 34 may be fixedly attached or removably coupled to the supporting member 32. In the exemplary embodiment, they may be coupled together in a generally coextensive relationship. It will be appreciated that such a relationship is not required since the retainer member 34 may be radially larger or smaller than the supporting member 32. Also, the geometries of the shapes of both the retainer member and the supporting member need not be the same. While the carrier assembly 20 is disclosed as including at least two components, it will be appreciated that other suitable numbers of components may be used including a unitary (i.e., one piece) body. The retainer assembly 34 of the present description encompasses any suitable structure(s) that can removably retain the surface modifying assemblies 22 on the carrier assembly 20 so as to perform abrading, but also protect the leading edges 22c to avoid or minimize their damage or destruction, and yet retain them so that they are easily replaceable.
Continued reference is made to
In the exemplary embodiment illustrated in
The foregoing constructions are simple and yet effective in preventing the leading edge 22c from being damaged. The present description envisions use of a wide variety of suitable constructions to retain and protect the leading edge. Of course, the present disclosure envisions that the retaining assemblies 34 may include any suitable mechanical and/or adhesive joining system to be used for joining the surface modifying assemblies to the carrier assembly in either a permanent or releasable manner. For example, the retaining assemblies 34 may take several forms of construction including but not limited to clamps (not shown), retainers (not shown), or the like. The retaining assembly 34 may include any structure(s) that keeps a leading edge of the surface modifying assemblies away from the surface modifying plane. The present description envisions all kinds of equivalent retaining mechanisms for securing the leading edge portion to the carrier assembly.
The releasable assemblies instead of being carried by the carrier assembly may be included on the surface modifying assembly. The abrasive assemblies 22 may be removed and reused. During abrading, the abrasive assemblies tend to wear more towards their radially outward portions than their radial inward portions. As such, the abrasive assemblies may be rotated by 180 degrees following removal, whereby the less worn radial inward portion may be positioned so that they are the radial outward most portions.
In addition, in the embodiments depicted in
From the foregoing, it will be appreciated that the present disclosure enables the formation of articles, systems, and adapters that substantially reduce the amount of material that is wasted on surface modifying products, per se, and during their manufacture. As noted, the present description substantially reduces the amount of material that is wasted during manufacturing of disc shaped articles. Also, the present description includes use of surface modifying articles, such as abrasive articles, that substantially reduce the amount of material that is wasted since the same sized abrasive pieces may be used for a wide range of disc diameters. Accordingly, distributors, for example, need not stock as many pieces as would otherwise be the case.
The present disclosure enables the formation of articles, systems, and adapters that utilize replaceable abrasive or surface modifying assemblies that are easily mountable and dismountable to a power surface modifying tool system. Moreover, the present disclosure provides an economical approach that enables a low cost surface modifying tool adapter attachable to a power tool assembly.
Furthermore, the present description provides inserts for surface modifying assemblies, such as abrasive or surface modifying assemblies thereby enabling low cost and convenient mounting and dismounting of abrasive articles. The present description includes use of abrasive assembly inserts that facilitate replacement of only those abrasive portions that may be worn or damaged instead of an entire disc.
The present disclosure may take on various modifications and alterations without departing from the spirit and scope. Accordingly, this disclosure is not limited to the above-described embodiments, but may be controlled by limitations set forth in the following claims and any equivalents thereof.
