SYSTEM AND METHOD FOR CAPTURING DUST CREATED BY ROTARY TOOL ATTACHMENTS

TECHNICAL FIELD

Embodiments of the subject matter described herein relate generally to power tool accessories. More particularly, embodiments of the subject matter described herein relate to a system and method for capturing dust created by rotary tool attachments.

BACKGROUND OF THE INVENTION

The removal of flooring tile is a dirty and time-consuming process. Power rotary tools are often employed to speed the removal of the backing material that remains on the floor after the tile has been removed. However, this process usually results in a large amount of dust and debris that is ejected into the ambient air. In turn, this requires a substantial amount of preparation time to protect surrounding areas from being contaminated with dust. Additionally, the health of individuals in those areas may be negatively affected by the dust. Furthermore, environmental regulations may prohibit the escape of the removed dust into the atmosphere.

In order to combat the dust, various tool attachments utilizing housings have been employed. However, there are significant drawbacks with these designs. First, the location of the vacuum attachment may not be positioned to maximize the capture of the dust. Second, the tube that couples the vacuum to the housing does not allow the tool to reach certain places, such as in corners and underneath cabinets. Third, the durability of many products on the market is suspect. Fourth, the cylindrical shape of the housing does not allow for the rotary tool attachment to reach against walls. Fifth, the products may clog with pieces of debris or may strain the vacuum motors, which reduces the useable life of the vacuum.

In view of the forgoing, it would be desirable to provide a dust collection system that can be attached to a rotary tool, which would allow the rotary tool attachment to reach under cabinets and against walls, while efficiently capture the dust created by the rotary tool attachment. This would reduce the amount of preparation time required to protect surrounding areas, help reduce dust related health risks, and assist in complying with environmental regulations that prohibit dust escaping into the atmosphere.

To reduce the complexity and length of the Detailed Specification, and to fully establish the state of the art in certain areas of technology, Applicant(s) herein expressly incorporate(s) by reference all of the following materials identified in each numbered paragraph below.

U.S. Pat. No. 6,540,598 discloses an above floor vacuum shroud for a floor grinding machine. The vacuum shroud has a rigid cover with a cylindrical skirt and a vacuum port. A flexible cylindrical guard has a plurality of vertical ribs protruding inward to contact the cylindrical skirt to create a plurality of vertical air inlets. The guard bottom is elevated above the floor, such that an annular air passage is created around the periphery of the grinding wheel to communicate dust from outside the guard to the vacuum port.

U.S. Pat. No. 8,133,094 discloses a vacuum shroud for use with an angle grinder with access hatch retention mechanism. The vacuum shroud is comprised of a body, skirt and removable hatch, which generally enclose a grinding disk that is attached to the angle grinder. The removable hatch is configured to either create a part of the skirt to enclose the grinding disk or can be mounted on top of the body for storage.

U.S. Pat. No. 6,027,399 discloses a grinding tool accessory for containing and removing dust formed by a grinding disk. The grinding tool accessory is comprised of a flexible housing, a brush extending from the edge of the housing, and at least one sealable hole to adjust the vacuum suction. The brush that extends from the edge of the housing has bristles with different lengths, which are dimensionally related to the gap between the edge of the housing and a work surface.

Applicant believes that the material incorporated above is “non-essential” in accordance with 37 CFR 1.57, because it is referred to for purposes of indicating the background of the invention or illustrating the state of the art. However, if the Examiner believes that any of the above-incorporated material constitutes “essential material” within the meaning of 37 CFR 1.57(c) (1)-(3), applicant will amend the specification to expressly recite the essential material that is incorporated by reference as allowed by the applicable rules.

BRIEF SUMMARY OF THE INVENTION

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the appended claims.

A shield is provided for capturing dust created from a work surface by a rotary tool attachment. The shield is comprised of a shroud, and a flexible skirt. The shroud has a top surface configured to be couple to a rotary tool and a plurality of air inlets therethrough. The flexible skirt is coupled to a perimeter of the shroud and extends downward from above the top surface of the shroud and is configured to contact the work surface.

Also provided is a shield for capturing dust created from a work surface by a rotary tool attachment. The shield is comprised of a shroud and a flexible skirt. The shroud is configured to be coupled to a rotary tool and to partially expose the rotary tool attachment. The shroud has a plurality of air inlets, a first opening, and a second opening through the top surface of the shroud. The first opening receives a mechanical driveshaft of the rotary tool and the second opening is coupled to an external vacuum source. The flexible skirt is coupled to a perimeter of the shroud and extends downward from above the top surface of the shroud and is configured to contact the work surface.

Furthermore, a method for making a shield for capturing dust created from a work surface by a rotary tool attachment is provided. The method comprises forming a shroud from a rigid material having a top surface, creating a plurality of air inlets, a first opening and a second opening through the top surface of the shroud. A flexible skirt is then coupled to the perimeter of the shroud with a strap around the outside perimeter of the skirt.

Further, the inventors are fully informed of the standards and application of the special provisions of 35 U.S.C. §112, ¶ 6. Thus, the use of the words “function,” “means” or “step” in the Detailed Description or Description of the Drawings or claims is not intended to somehow indicate a desire to invoke the special provisions of 35 U.S.C. §112, ¶ 6, to define the invention. To the contrary, if the provisions of 35 U.S.C. §112, ¶ 6 are sought to be invoked to define the inventions, the claims will specifically and expressly state the exact phrases “means for” or “step for, and will also recite the word “function” (i.e., will state “means for performing the function of [insert function]”), without also reciting in such phrases any structure, material or act in support of the function. Thus, even when the claims recite a “means for performing the function of . . . ” or “step for performing the function of . . . ,” if the claims also recite any structure, material or acts in support of that means or step, or that perform the recited function, then it is the clear intention of the inventors not to invoke the provisions of 35 U.S.C. §112, ¶ 6. Moreover, even if the provisions of 35 U.S.C. §112, ¶ 6 are invoked to define the claimed inventions, it is intended that the inventions not be limited only to the specific structure, material or acts that are described in the preferred embodiments, but in addition, include any and all structures, materials or acts that perform the claimed function as described in alternative embodiments or forms of the invention, or that are well known present or later-developed, equivalent structures, material or acts for performing the claimed function.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention may be derived by referring to the detailed description when considered in connection with the following illustrative figures. In the figures, like reference numbers refer to like elements or acts throughout the figures.

FIGS. 1, 2 and 3 illustrate an exemplary embodiment of a system for capturing dust created by a rotary tool attachment.

FIGS. 4 and 5 are illustrations of perspective views of a shield, rotary tool, and rotary tool attachment in accordance with an embodiment.

FIGS. 6, 7 and 8 illustrate various perspective views of a shroud in accordance with an embodiment.

FIGS. 9, 10, and 11 illustrate perspective views of a shroud in accordance with an embodiment.

FIG. 12 illustrates a perspective view of a spacer fan in accordance with an embodiment.

FIGS. 13 and 14 are illustrations of perspective views of a shield, rotary tool, and rotary tool attachment in accordance with an embodiment.

FIGS. 15 and 16 are illustrations of various perspective views of a shield, rotary tool, and rotary tool attachment in accordance with another embodiment.

FIGS. 17 and 18 illustrate perspective views of a shield and rotary tool in accordance with an embodiment.

FIG. 19 is a flow chart of a process of producing a system for capturing dust created by rotary tool attachments.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is merely illustrative in nature and is not intended to limit the embodiments of the subject matter or the application and uses of such embodiments. Any implementation described herein as exemplary is not necessarily to be construed as preferred or advantageous over other implementations. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary, or the following detailed description.

The following description may refer to elements or features being “coupled” together. Although the drawings may depict one exemplary arrangement of elements, additional intervening elements, devices, features, or components may be present in an embodiment of the depicted subject matter. In addition, certain terminology may also be used in the following description for the purpose of reference only, and thus are not intended to be limiting. Furthermore, it should be noted that many alternative or additional functional relationships or physical connections may be present in an embodiment of the subject matter.

Disclosed herein is a novel system and method for capturing dust created by rotary tool attachments. This is accomplished through the use of a vacuum coupled to a shield which encloses the rotary tool attachment. Presented herein for purposes of explication are certain exemplary embodiments of how a dust shield may be employed on a particular device. For example, multiple embodiments will be discussed in connection with handheld grinders and floor grinders. However, it should be appreciated that this explicated example embodiment is merely an example and a guide for implementing the novel systems and methods herein on any rotary tool that may be used in any industrial, commercial, or consumer application. As such, the examples presented herein are intended as non-limiting.

FIGS. 1, 2 and 3 illustrate an exemplary embodiment of a system for capturing dust created by a rotary tool attachment. In an exemplary embodiment, the system 100 includes, without limitation, a rotary tool 102, a rotary tool spacer 104, a rotary tool attachment 106, and a dust shield 108. The dust shield 108 is comprised of a shroud 110, spacing material 112, a skirt 114, a skirt attachment strap 116, and a vacuum coupler 118. It should be understood that FIG. 1 is a simplified representation of a system 100 for purposes of explanation and ease of description and is not intended to limit the application or scope of the subject matter in any way. In practice, the system 100 may include numerous other devices and components for providing additional functions and features, as will be appreciated in the art. For example, the system 100 may include one or more rotary tool attachments, vacuum, vacuum hoses, leveling systems, and/or tool guiding systems.

In an exemplary embodiment, the rotary tool 102 is coupled to the rotary tool spacer 104, a rotary tool attachment 106, and a dust shield 108. The rotary tool 102 may be any tool that rotates an object (e.g. a rotary tool attachment) substantially parallel to a work surface to remove material from the work surface. One embodiment of a rotary tool 102 is a handheld angle grinder. Such rotary tools are available from various manufactures (e.g. DeWalt, Craftsman Hitachi, and etc.) and are generally referred to by the size of the rotator tool attachment they utilize. For example, a rotary tool that utilizes a four inch disc is generally referred to as a four inch angle grinder. These angle grinders usually operate between 2,000 and 12,000 revolutions per minute (rpm), depending on the work surface and the rotary tool attachment. Rpms less than 2,000 may be considered low speed and are frequently used with concrete polishing, sanding and surface finishing. Whereas, rpms of 12,000 and higher are generally considered to be high speed and are used for more specific industrial uses.

The rotary tool attachment 106 is coupled to the driveshaft 120 of the rotary tool 102, which enables the rotary tool attachment 106 to spin radially in comparison to the rotary tool 102. While the rotary tool attachment 106 is spinning, the user places it on the work surface in order to remove unwanted material from the work surface. For example, the user may desire to remove thin-set mortar from a concrete floor after removing ceramic or porcelain tile from the floor. To do this, the user would place the rotary tool attachment 106 in substantial contact with the thin-set mortar on the concrete floor while spinning; this in turn would remove the thin-set mortar from the floor. In removing the thin-set material, particles and/or dust will be generated. The dust shield 108 may help contain particles and/or dust as discussed in greater detail below. The amount of material that will be removed from the work surface will depend on the speed and design of the rotary tool attachment 106. For example, the rougher the bottom surface of rotary tool attachment 106, the more material will be removed from a work surface.

The dust shield 108 is comprised of a shroud 110, spacing material 112, a skirt 114, a skirt attachment strap 116 and a vacuum coupler 118 in an exemplary embodiment. The shroud 110 is made of a rigid material (e.g. steel, aluminum, or rigid plastic) and is a substantially cylindrical hollow body to enclose the rotary tool attachment 106. The rigidity of the shroud 110 helps protect the user from the rotary tool attachment 106 while in operation. The shroud 110 is coupled to the rotary tool spacer 104 and extends towards the work surface, but stops substantially above the rotary tool attachment 106. This ensures that the shroud 110 does not interfere with the rotary tool attachment 106 contacting the work surface.

The inside diameter of the shroud 110 may be any diameter that is greater than the diameter of the rotary tool attachment 106. For example, FIGS. 1, 2, and 3 depict a seven inch angle grinder with a rotary tool attachment 106 with a diameter of six inches and a shroud with a diameter of approximately seven inches. In addition, in other embodiments discussed in greater detail below, the inside diameter of the shroud is no less then substantially forty percent greater than the diameter of the rotary tool attachment 106. This would make the area of the shroud approximately three hundred percent larger than the rotary tool attachment 106. A shroud 110 with a diameter larger than the rotary tool attachment 106 will help improve the stability of the rotary tool 102. However, the diameter of the shroud must be balanced against the maneuverability of the rotary tool 102 and the suction force of the vacuum.

The shroud 110 has a top surface 122 and a bottom surface 124. The shroud 110 has a first opening 126 through the top surface 122 of the shroud 110 for receiving the driveshaft 120 from the rotary tool 102. In addition, the shroud 110 has a second opening 128 through the top surface 122 of the shroud 110 for receiving the vacuum coupler 118. The vacuum coupler 118 is substantially parallel to the body of the rotary tool 102 when the shroud 110 is coupled to the rotary tool 102. The vacuum coupler 118 allows for particles and/or dust removed by the rotary tool attachment 106 to be contained by the vacuum. In addition, the ability of the rotary tool 102 to reach under overhangs is only limited by the design of the rotary tool 102 and not the vacuum coupler 118.

The spacing material 112 is coupled to the outside perimeter of the shroud 110 in an embodiment. The spacing material 112 permits air to flow from outside the shroud 110 through the second opening 128 in the shroud 110 to the vacuum. The spacing material may be located and shaped in any manner to create air inlets around the perimeter of the shroud 110. For example, circular rods are evenly placed (i.e. the width of a spacing material 130 is equal to the gaps 132 between the spacing material) around the perimeter of shroud 110, as shown in FIGS. 1, 2, and 3. It should be appreciated that the placement of the spacing material 112 may be altered to change the air flow if desired.

The skirt 114 is coupled to the spacing material 112 by the skirt attachment strap 116 and extends downward from above the top surface 122 of the shroud 110 and is configured to contact the work surface. The skirt 114 is in substantial contact with the work surface during use of the rotary tool 102, which prevents particles and/or dust from escaping the dust shield 108. In addition, the dust shield 108 and the rotary tool attachment 108 is not forced into the work surface during operation like other dust shields in the prior art due to the air inlets created by the gaps 132 between the spacing material 112. This allows for sufficient air to flow from outside of the dust shield 108 through the vacuum coupler 118.

The skirt 114 may be made from a flexible material, such as, urethane or a similar substitute. This permits the skirt 114 to stay in substantial contact with the work surface, while traversing uneven work surfaces. This helps to reduce dust or particles from escaping the dust shield 108. However, the skirt 114 does not extend past the shroud 110 to allow the skirt 114 to contact the rotary tool attachment 106, even if the skirt is fully collapsed underneath the shroud 110. This helps extend the useable life of the skirt 114.

FIGS. 4 and 5 are illustrations of perspective views of a shield, rotary tool, and rotary tool attachment in accordance with an embodiment. In an exemplary embodiment, the system 400 includes, without limitation, a rotary tool 102, a rotary tool spacer 104, a rotary tool attachment 106, a dust shield 108, and a spacer fan 1200. The dust shield 108 is comprised of a shroud 402, a skirt 114, a skirt attachment strap 116, and a vacuum coupler 118. In this exemplary embodiment, the shroud 110 (FIGS. 1, 2, and 3) is replaced with another exemplary embodiment of a shroud 402. It should be understood that neither embodiment is preferred, and both embodiments are only example illustrations of shrouds that may be used in a system for capturing dust created by a rotary tool attachment.

The shroud 402 is coupled to the skirt 114 by the skirt attachment strap 116 and to the vacuum coupler 118 by the vacuum coupler collar 412. The shroud 402 is machined out of a rigid material (e.g. steel, aluminum, rigid plastic, etc.) and is a substantially cylindrical hollow body that encloses the rotary tool attachment 106. The rigidity of the shroud 402 helps protect the user from the rotary tool attachment 106 while in operation. The shroud 402 extends from the bottom of the rotary tool spacer 104 towards the work surface, but stop substantially above the rotary tool attachment 106. This ensures that the shroud 402 does not interfere with the rotary tool attachment 106 contact the work surface. The skirt 114 that is coupled to the shroud 402 may be made from a flexible material, such as, urethane or a similar substitute. This permits the skirt 114 to stay in substantial contact with the work surface while traversing uneven work surfaces. This helps to reduce dust or particles from escaping the dust shield 108.

The inside diameter of the shroud 402 may be any diameter that is greater than the diameter of the rotary tool attachment 106. For example, FIGS. 4 and 5 depict a seven inch angle grinder with a rotary tool attachment 106 with a diameter of six inches and a shroud with a diameter of approximately seven inches. In addition, in other embodiments discussed in greater detail below, the inside diameter of the shroud is no less then substantially forty percent greater than the diameter of the rotary tool attachment. This would make the area of the shroud approximately three hundred percent larger than the rotary tool attachment 106. A shroud 402 with a diameter larger than the rotary tool attachment 106 will help improve stability of the rotary tool 102. However, the diameter of the shroud must be balanced against the maneuverability of the rotary tool 102 and the suction force from the vacuum.

The dust shield 108 is coupled to the rotary tool 102, and the rotary tool spacer 104. In addition, the spacer fan 1200 couples the rotary tool driveshaft 120 to the rotary tool attachment 106. This increases the height of the interior of the dust shield 108, which increases air flow through the dust shield 108 to the vacuum. In turn, this helps collect particles and/or dust removed from the work surface. Furthermore, additional features of the spacer fan will be discussed in connection with FIG. 12.

FIGS. 6, 7 and 8 illustrate various perspective views of a shroud 402 in accordance with an embodiment. The shroud 402 has a top surface 404 and a bottom 406. The shroud 402 has a first opening 408 through the top surface 404 of the shroud 402 for receiving the driveshaft 120 (FIG. 4) from the rotary tool 102 (FIG. 4). In addition, the shroud 402 has a second opening 410 through the top surface 404 of the shroud 402 for receiving the vacuum coupler 118 (FIG. 4). A vacuum coupler collar 412 surrounds the second opening to permit the removal of the vacuum coupler 118 (FIG. 4). This allows the user to clear debris that may have collected inside of the vacuum coupler or to replace the vacuum coupler incase of damage.

The shroud 402 has a groove 414 cut around the perimeter of the shroud 402 and has holes 416 periodically drilled from the bottom of the groove 418 through the bottom 406 of the shroud 402. The groove 414 helps prevent dust or other particles escaping from the dust shroud 108, while allowing air to easily flow from outside the dust shroud 108 to the vacuum. The groove may be cut to any depth as long as it supports the outer wall of the shroud 402. In addition, the holes 416 may be located and shaped in any manner to create air inlets through the shroud 402. For example, FIG. 8 depicts circular holes are evenly placed around the perimeter of shroud 402. It should be appreciated that the spacing of the holes 416 may be altered to change the air flow if desired.

In one embodiment the spacing and hole diameter may be calculated by setting eighty to ninety percent of the cross-sectional area of the vacuum coupler 118 (FIG. 4) equal to the area of the holes 416 minus the area taken up but the rotary tool attachment 106 (FIG. 4). When the area of the holes 416 minus the area taken up but the rotary tool attachment 106 (FIG. 4) falls below eighty percent of the cross-sectional area of the vacuum coupler 118 (FIG. 4), the vacuum motor may be strained without a significant increase in dust collection. However, if the area of the holes 416 minus the area taken up but the rotary tool attachment 106 (FIG. 4) goes above one hundred percent of the cross-sectional area of the vacuum coupler 118 (FIG. 4), the dust collection efficiently may be decreased. In performing the above calculation, the spacing between the middle of the holes 416 should not be further than one inch and not closer than 1/16 of an inch. For example, this would require additional smaller holes 416 for larger shrouds 402. The vacuum CFM's are restricted in this embodiment to create high velocity air flow through the holes to help ensure dust collection. It should be appreciated that this is an exemplary method for calculating the hole spacing; however, the spacing and hole diameter may be calculated in any suitable manner.

FIGS. 9, 10, and 11 illustrate various perspective views of a shroud 402 in accordance with an embodiment. The top surface 404 of shroud 402 is depicted in FIG. 9, with first 408 and second 410 openings therethrough. FIGS. 10 and 11 are a cross sectional view of shroud 402 taken along the A to A′ line and the D to D′ line, respectively, as shown in FIG. 9. The cross sections illustrate a clockwise sloping protrusion 420 inside the interior of the shroud 402. In addition, the sloping protrusion 420 increases from the first opening 408 to the perimeter of the shroud 402, creating a conical interior of the shroud. Furthermore, at the second opening 410 a curved protrusion 422 extends from the wall. All three of these protrusions help direct airflow through the second opening 410 and into the vacuum.

FIG. 12 illustrates a perspective view of a spacer fan 1200 in accordance with an embodiment. The spacer fan 1200 has four fan blades 1202, which are designed to force air and debris from the floor through the second opening 410 (FIG. 4) in the shroud 402 (FIG. 4). It should be appreciated that the spacer fan may have any number of blades desired by the designer. This will cause a reverse flow of air and should effectively force the dust through the vacuum coupler 118 (FIG. 4), to minimize the amount of particles and/or dust that escape the dust shield 108 (FIG. 4). The vacuum may operate under less strain and/or a longer vacuum hose may now be used without loss of suction. The spacer fan 1200 may also acts as a type of heat sink, removing heat from the rotary tool attachment 106 (FIG. 4). It should also be appreciated that the spacer fan may be used in connection with other rotary tools, such as, floor grinders, angle grinders, and etc.

FIGS. 13 and 14 are illustrations of various perspective views of a shield 108, rotary tool 102, and rotary tool attachment 106 in accordance with an embodiment. In an exemplary embodiment, the system 1300 includes, without limitation, a rotary tool 102, a rotary tool spacer 104 (not shown), a rotary tool attachment 106, and a dust shield 108. The dust shield 108 is comprised of a shroud 1302, a skirt 1304, a spacing material 112, a skirt attachment strap 116, and a vacuum coupler 118. The dust shield 108 is coupled to the rotary tool spacer 104 (not shown) and the rotary tool 102. In addition, the driveshaft 120 of the rotary tool 102 is coupled to the rotary tool attachment 106. In this exemplary embodiment, the shroud 110 and skirt 114 (FIGS. 1, 2, and 3) are replaced with another exemplary embodiment of a shroud 1302 and skirt 1304, respectively. It should be understood that neither embodiment is preferred, and both embodiments are only example illustrations of shrouds that may be used in a system for capturing dust created by a rotary tool attachment.

The shroud 1302 is coupled to a spacing material 112, rotary tool spacer 104 (not shown) and the vacuum coupler 118. The shroud 1302 is made out of a rigid material (e.g. steel, aluminum, rigid plastic, etc.) and is configured to partially expose the rotary tool attachment 106. The rigidity of the shroud 1302 helps protect the user from the rotary tool attachment 106 while in operation. By partially exposing the rotary tool attachment 106, the user can remove material from the work surface against a wall that is perpendicular to the work surface. For example, the user would be able to remove thin-set that is located against a baseboard wall. Saving the user time and energy usually expended on chipping the thin-set around the baseboards by hand.

The inside diameter of the shroud 1302 is no less than the diameter of the rotary tool attachment 106. In addition, as shown in FIG. 14 the shroud diameter is approximately forty percent greater than the diameter of the rotary tool attachment. This would make the area of the shroud approximately three hundred percent larger than the rotary tool attachment 106. A shroud 1302 with a diameter larger than the rotary tool attachment 106 will help improve stability of the rotary tool 102. However, the diameter of the shroud must be balanced against the maneuverability of the rotary tool 102 and the suction force from the vacuum.

The skirt 1304 is coupled to the spacing material 112 and the shroud 1302 by the skirt attachment strap 116. As depicted in this embodiment the skirt does not go around the entire circumference of the shroud 1302. This permits the rotary tool attachment 106 to be partially exposed. However, the skirt attachment strap 116 does go around the entire circumference of the shroud 1302 to hold the skirt 1304 in place. As described above, the skirt 1304 is made of a flexible material (e.g. urethane, rubber, etc.), to help ensure the particles and/or dust does not escape the dust shield 108.

FIGS. 15 and 16 are illustrations of various perspective views of a shield, rotary tool, and rotary tool attachment in accordance with another embodiment. In an exemplary embodiment, the system 1500 includes, without limitation, a rotary tool 102, a rotary tool spacer 104 (not shown), a rotary tool attachment 106, and a dust shield 108. The dust shield 108 is comprised of a shroud 1502, a skirt 1504, a skirt attachment strap 116, and a vacuum coupler 118. The dust shield 108 is coupled to the rotary tool spacer 104 (not shown) and the rotary tool 102. In addition, the driveshaft 120 of the rotary tool 102 is coupled to the rotary tool attachment 106. In this exemplary embodiment, the shroud 110 and skirt 114 (FIGS. 1, 2, and 3) are replaced with another exemplary embodiment of a shroud 1502 and skirt 1504, respectively. It should be understood that neither embodiment is preferred, and both embodiments are only example illustrations of shrouds that may be used in a system for capturing dust created by a rotary tool attachment.

The shroud 1502 is coupled to the rotary tool spacer 104 (not shown) and the vacuum coupler 118. The shroud 1502 is made out of a rigid material (e.g. steel, aluminum, rigid plastic, etc.) and is configured to partially expose the rotary tool attachment 106. The rigidity of the shroud 1502 helps protect the user from the rotary tool attachment 106 while in operation. By partially exposing the rotary tool attachment 106, the user can remove material from the work surface against a wall that is perpendicular to the work surface. For example, the user would be able to remove thin-set that is located against a baseboard wall. Saving the user time and energy usually expended on chipping the thin-set around the baseboards by hand.

The shroud 1502 is comprised of similar features as discussed above in FIGS. 6-11. As described above, a groove is cut around the perimeter of the shroud and holes 1506 are periodically drilled from the bottom of the groove through the bottom of the shroud. The holes 1506 may be located and shaped in any manner to create air inlets through the shroud 1502. For example, FIG. 15 depicts circular holes are evenly placed around the perimeter of shroud 1502. It should be appreciated that the spacing of the holes 1506 may be altered to change the air flow if desired. In addition, the shroud 1502 has a similar cross-section as that illustrated in FIGS. 10 and 11. The shroud 1502 has a clockwise sloping protrusion inside the interior of the shroud 1502 that increases from the first opening to the perimeter of the shroud 1502, creating a conical interior of the shroud. In addition, at the second opening, a curved protrusion extends from the wall. All three of these protrusions help direct airflow through the second opening and into the vacuum.

The inside diameter of the shroud 1502 is no less than the diameter of the rotary tool attachment 106. In addition, as shown in FIG. 16 the shroud diameter is approximately forty percent greater than the diameter of the rotary tool attachment 106. This would make the area of the shroud approximately three hundred percent larger than the rotary tool attachment 106. A shroud 1502 with a diameter larger than the rotary tool attachment 106 will help improve stability of the rotary tool 102. However, the diameter of the shroud must be balanced against the maneuverability of the rotary tool 102 and the suction force from the vacuum.

The skirt 1504 is coupled to the shroud 1302 by the by the skirt attachment strap 116. As depicted in this embodiment the skirt does not go around the entire circumference of the shroud 1502. This permits the rotary tool attachment 106 to be partially exposed. However, the skirt attachment strap 116 does go around the entire circumference of the shroud 1502 to hold the skirt 1504 in place. In addition, it should be appreciated that multiple attachment straps 116 may be used to attach the skirt 1504 to the shroud as shown in FIG. 15. As described above, the skirt 1504 is made of a flexible material (e.g. urethane, rubber, etc.), to help ensure the particles and/or dust does not escape the dust shield 108.

FIGS. 17 and 18 illustrate perspective views of a shield 1706 and rotary tool 1702 in accordance with an embodiment. In an exemplary embodiment, the system 1700 includes, without limitation, a rotary tool 1702, a rotary tool attachment 1704, and a dust shield 1706. The dust shield 1706 is comprised of a shroud 1708, a skirt 1710, a spacing material 1712, a skirt attachment strap 1714, and a vacuum coupler 1716. It should be understood that this embodiment is not preferred and is only an example illustration of a system for capturing dust created by a rotary tool attachment.

The rotary tool 1702 is coupled to the rotary tool attachment 1704 by a driveshaft 1718. In another embodiment of the rotary tool 1702 is a stand-up floor grinder, as depicted in FIG. 17. Such rotary tools are available form various manufactures (e.g. EDCO) and are generally used in industrial applications. These rotary tools usually operate at a lower rpm then the handheld grinders described above. For example, the TG10 model from EDCO generally operates around 3500 rpm. However, in this embodiment the rotary tool attachments may be much larger (e.g. ten inches in diameter) than the angle grinder described above. In addition, the rotary tool may have a single or multiple rotary tool attachments.

The shroud 1708 is coupled to the spacing material 1712 and the vacuum coupler 1716. The shroud 1708 is machined out of a rigid material (e.g. steel, aluminum, or rigid plastic) and is substantially cylindrical hollow body to enclose the rotary tool attachment 1704. The rigidity of the shroud 1708 helps protect the user from the rotary tool attachment 1704 while in operation. The spacing material 1712 permits air to flow from the outside of the shroud 1704 though the vacuum coupler 1716 to the vacuum. The spacing material may be located and shaped in any manner to create air inlets around the perimeter of the shroud 1708. For example, circular rods are irregularly placed (i.e. the width of a spacing material is not equal to the gaps between the spacing material) around the perimeter of shroud 1708, as shown in FIG. 18. This is done to alter the air flow through the shroud 1708 to help ensure the all particles and/or dust is collect and to help cool off the rotary tool attachment 1704.

The skirt 1710 is coupled to the spacing material by the skirt attachment strap 1714 and is configured to contact the work surface. The skirt 1710 is in substantial contact with the work surface during use which prevents particles and/or dust from escaping the dust shield 108. The skirt 1710 may be made from a flexible material, such as, urethane or a similar substitute. This permits the skirt 1710 to stay in substantial contact with the work surface while traversing uneven work surfaces. The skirt 1710 does not extend past the shroud 1708 to allow the skirt 1710 to contact the rotary tool attachment 1704, even if the skirt is fully collapsed underneath the shroud 1708. This helps extend the useable life of the skirt 1710.

FIG. 19 is a flow chart 1900 of the process of producing a system for capturing dust created by rotary tool attachments. In STEP 1902, a shroud is formed from a rigid material (e.g. steel, aluminum, rigid plastic, etc.), by a process, such as, computer numerical control (CNC), machine stamping and/or welding. A plurality of air inlets, a first opening, and a second opening are created through the shroud utilizing various cutting, drilling or boring methods in STEP 1904. In STEP 1906, the skirt is cut from a flexible material sheet and is coupled to the shroud by a skirt attachment strap in STEP 1908.

Thus, there has been provided a novel system and method for capturing dust created by a rotary tool attachment. This practical solution provides a dust collection system that can be attached to a rotary tool, which would allow the rotary tool attachment to reach under cabinets and against walls, while efficiently capture the dust created by the rotary tool attachment. This reduces the amount of preparation time required to protect surrounding areas, helps reduce dust related health risks, and assist in complying with environmental regulations that prohibit dust escaping into the atmosphere.

While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims.

	Number	Date	Country
Parent	13086334	Apr 2011	US
Child	13836275		US
Parent	13309037	Dec 2011	US
Child	13086334		US
Parent	13691408	Nov 2012	US
Child	13309037		US
Parent	13691461	Nov 2012	US
Child	13691408		US

SYSTEM AND METHOD FOR CAPTURING DUST CREATED BY ROTARY TOOL ATTACHMENTS

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Abstract

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Claims

CROSS-REFERENCE TO RELATED APPLICATIONS

Continuation in Parts (4)