CA2186422A1 - Power tool - Google Patents

Abstract

A power tool is provided which includes a main housing containing a motor for driving a working element and a hollow handle connected to the housing. An actuator paddle is mounted for pivotable movement relative to the handle and is pivotable between (1) an open position where-in the motor is disabled and (2) a closed position wherein the motor is activated to drive the working element. With the paddle in the closed position, release of the paddle causes the paddle to return to the open position to disable the motor. A locking member is mounted to the paddle to be movable therewith whereby with the paddle in the closed position the member is capable of maintaining the paddle in the closed position when the paddle is released.

Description

2i86422 p~w~ TQO~I ~
Field Q~E l h~ lnVf'ntiOIl The present invention relates to actuators f or power tools and, more particularly, to paddle actuators 5 having a lock-on mechanism.
Back~rQlmd o~ the Tnv~ntio~
Trigger-type menh~n;c~ for activating a power tool where the trigger must be cnntlnll~l ly depressed closing the switch circuit to provide power to the power 10 tool motor are known. It is also known to provide these power tnols with lock-on meeh~n~cmc so as not to require an operator to ~nntlnll~l ly depress the trigger mechanism to operate the tool. Such lock-on meeh~n~mf~ avoid operator fatigue and thereby enhance an operator' s control of the 15 tool.
While these locking m~h~nl ~mR are known, they are typically removed from the triggering mechanism such that they of ten require an operator to move: their hand to adjust their grip on the trigger, or use their other hand, 20 so as to move the locking mechanism into its operative locked state. Utilizing both hands to activate the tool and employ the lock-on mechanism is undesirable in t~at it complicates the use of the lock-on mechanism and prevents the other hand from being used for other functions during 25 tool operation.
In addition, where~the lock-on me~h~n~mq can be simultaneously engaged by the same hand operating the trigger, the locking meeh~ni cmR still generally require a movement distinct from the movement of the trigger as in 30 opposite or transverse directions, again complicating application of the lock-on mechanism. Where the hand on the trigger can be used, the distinct IV~ -ntq required and the relative position of the triggering and lock- on mechanisms which usually entails an adjustment to the 35 operator' s grip on the trigger to allow the operator to -properly engage and employ the lock-on mechanism as men-tioned above both enhance the potential for the operator to decrease the pressure being applied to the trigger with their hand upon engagement and employment of the lock-on 5 mechanism w~th the same hand. Such decrease in pressure applied to the trigger can correspondingly allow the triggering mechanism to move from its depressed position 80 as to disable the motor and re~uires the operator to re-depress the triggering mechanism and once more attempt to 10 engage and move the lock-on mechanism without deactivating the motor. This is especially undesirable where the tool already has its working element in engagement with the working surface as abrupt cut-offs of power to the tool and the accompanying rapid deceleration in speed of the working 15 element can cause damage to the working surface and/or the tool .
Where the power tool drives its working element in an orbital path, such as with orbital polishers and their associated pads, the operator experiences a signifi-20 cant increase in the vibratory response from the tool overother tools which do not drive their working element in orbital paths. Such vibratory response sharpens the need for an easy-to-use actuator and lock-on me~n1cmF~, partic-ularly as the operator moves the polisher away from their 25 body to reach remote areas, such as on a car's exterior surfaces, from a relatively stationary position. As the operator extends their arms, the weight of the polisher is accordingly cantilevered further outwardly making control over the polisher and, therefore, continued application of 30 the actuator, more difficult. In such an extended posi-tion, it is especially desirable that the lock-on mechanism for the actuator be ergonomically located and usable 80 as to easily and readlly allow for~ its- employment.

Summa~ of the Inventlon In accordance with the present invention, a power tool having an actuator and lock-on mechanism i9 provided which overcomes the aforementioned problems of the prior art. =-In one form of the invention, the power tool includes a main housing containing a motor for driving a w~rking element and a hollow handle connected to the housing. An actuator paddle is mounted for pivotable movement relative to the handle and is pivotable between (1) an open position wherein the motor i9 disabled and (2) a closed position wherein the motor is activated to drive the working element. With the paddle in the closed position, release o~ the paddle~ causes the paddle to return to the open ~osition to disable the motor. A locking member is mounted to the paddle to be movable therewith whereby with the paddle in the closed position the member is capable of maintaining the paddle in the closed position when the paddle is released. With the locking member mounted to the paddle so as to move with the paddle-as the paddle is pivoted, the power tool herein makes it signifi-cantly easier for an operator to engage the locking member over :prior lock-on mechanisms which were not mounted for movement with the triggering mechanism.
In one form, the handle has an elongate, arcuate shape and extends away from the housing and the padd~e has an elongate, arcuate shape substantially conforming to the handle shape The handle can include a paddle recéiving slot along the length thereof with the paddle being mounted to the handle to project from the slot and allowing the paddle to be depressed in the slot as it is moved from the op~en position to the closed ~ position The elongate, arcuate matching or confor~Ling shape of the actuator to the handle provides for an ergonomic actuating mechanism in that an operator can readily activate the tool while 2~ 86422 gripping the arcuate handle at a variety of positions along its reach.
The paddle can include an aperture with the lock-ing member including a button portion pro~ ecting through the paddle aperture and a cam portion in the hollow handle.
A flange can be mounted in the hollow handle such that with the paddle moved to the closed position, the button member can be depressed in the paddle aperture to cause the cam portion to latch onto the flange and maintain the paddle in the closed position when the paddle is released.
The handle can include switching structure mounted therein for activating the motor and the paddle can in:clude an actuating member with the paddle mounted to the handle so that in the open position the~actuating member is spaced from the switching structure~ an~d the motor is dis-abled and in the closed position, the actuating member engages the switching structure to activate the motor.
In one form, cam structure is provided cooper-ating between the handle and the locking member for moving the locking member between ~1 ) an unlocked position where the paddle is freely movable between its open and closed positions and (2) a lock position wherein the paddle is mi:l;nti:l;n~fl in the closed position. The handle can include a flange mounted therein and the locking member can include a portion l~srt~nrl;ng into the handle. The cam structure can include a cam surface on at least one of the flange and the locking member: portion which allows the portion to latch onto the flange as the locking member is moved from the un-locked to the locked position.
In one form, the paddle has a length and spaced ends and the locking member is pivotably mounted to one end of the paddle and the paddle is pivotably mounted to the housing at the_other end of the paddle.
In another: form of the invention, the power tool has an actuator paddle mounted for pivotable movement relative to the handle where movement of the handle to an _ _ _ .. , . _ _ . . _ . _ . . ... . . . _ _ operative po-sition in a f irst direction causes the motor to drive the working element. A locking member is mounted for pivotable movement relative to the paddle, wherein movement of the locking member in the first direction 18 capable of locking the paddle in the operative position. With the locking member mounted to the paddle and the paddle to the handle such that movement of elther in the same direction, i.e., depressed towards the interior o~ the handle, can activate the power too~ motor, an operator is no longer faced with two aistinct movements which must be performed with the hard gripping the power tool handle 80 as to lock the tool in its operative state. This significantly simplifies the employment of the lock-on mechanism of the pre8ent invention.
Preferably, the handle has a hollow interior and includes a slot. The paddle can be mounted in the slot with the paddle being depressible in the slot in the f ir8t direction towards the interior of the handle to thereby be moved to its operative position.
In one form, both the paddle and the locking member can be depressed in the first direction towards the interior of the handle to thereby maintain the paddle in its operative position and readily allow one-handed opera-tion of the tool.
~ In yet another form of the_invention, a switch in the handle is electrically connected to the motor and has on and off states ~such that with the switch in the on 8tate, the motor is energized to drive the working element and in the of:f 8tate, the motor is de-energized A paddle aotuator is mounted for movement relatlve to the handle between ~1) an extended position wherein the actuator extends a first distance from the handle and the switch is in the off state and (2) a first depressed position wherein the actuator extends a second distance ~rom the handle less than the first distance and the switch is in the on state A locking member is ca~ried by the paddle actuator and is ... . . , _ . _ , , .. ,, _ _ _ _ _ 2 ~ 86422 capable of being depressea with the paddie ln the depressed po-sition to lock the paddle in the depressed position.
With the paddle in the first locked, depressed po~ition, the paddle can be depres8ed further to a second aepressed 5 position whereln the paddle actuator extends a third dis-tance from the handle le8s than the ~econd distance. In the second deprèssed poeition, 'che locking member and paddle are released from the first, locking position to allow the paddle to move. to lts P~tPnfl~rl ~sition upon lO release o~ the paddle by the operator to turn the switching mechanism and, therefore, the power tool, to its off state.
In this manner, the power tool can be activated, locked in the activated state and then released from its locked state all by movement of the paddle and=associated locking member 15 in a single direction, thu~ providing a power tool which is ~ignificantly 8impler to use-o~er tho8e rer~uiring different m~v~ -nts to apply and to release their lock-on merh~n1cm~
from the movement of their trigger.
In one form, a lock flange is mounted in the 20 hollow handle and the locking member include a cam member in the hollow handle arranged that 80 with the paddle in its first depre~38ed position, the button member can be depressed in the paddle aperture to cause the cam member to cam over and latch onto the :elange and mA1nt~1n the paddle 25 in: the ~irst depressed position when the paddle i~
rel cased. ~ - -Brlef ~oAcri~ Qf f-hC- Praw$Il~s FIG. l is a perspective view of an apparatus for waxing, buffing, polishing or the like according to the 30 present inventioni FIG. 2 is a left side elevational view of the apparatu~ shown in FIG . l, including a f ront handle and a rear handle and a paddle actuator on the rear handle;
FIG. 3 i~ a top plan view of the apparatus 8hown 35 in 7IG. l showing details of the engagement of a first and ~ 2~86422 a ~econd rl ;Imq~c~1 1 housing member which def ine a cord lock and a collar for a male receptacle;
FIG. 4 is a right side elevational view of the apparatus shown in FIG. l;
~ FIG. 5 i8 a rear elevational view of the apparatus shown in FIG. l;
FIG. 6 is a bottom plan view of the apparatus shown in ~IG. 1 showing the counterweight assembly including a sIuick-change post for mounting a buffer pad thereDn;-FIG. 7 is an enlarged top plan view of the cord lock and the cDllar and male receptacle assembly of the apparatus shown in FIG 1, as seen i~n- FIG. 3;
FIG. 8A is a side sectional view taken along lines 8A- 8A of FIG . 7;
FIG. 8B is a side sectional view taken along lines 8B-8~ of FIG. 7;
FIG. 9 is a rear sectionaI view taken along line 9-9 of FIG. i;
: FIG. lO is an exploded~perspective view of the apparatus shown in FIG. l showing details of the arrange-ment of a DC ~otor havlng a support plate and rectifier assembly, the paddle actuator with a lock-on button, and the counterweight and pad assembly;
: FIG. 11 is a~ enlarged perspective view of the motor and support p:Late asse-mbly and the paddle actuator and its lock- on button mounted in the ~irst rl ~m housing memb~r shown in FIG. lO;
FIG 12 is an exploded perspective view of the 3 o paddle actuator and lock- on button: assembly shown in FIG .
16;
FIG. 13 is a side elevational view, partially in section, of the assembled paddle actuator and lock-on button assembly shown in FIG. 10;
FIG. 14 is a perspective view of the assembled support plate and rectlfier assembly shown in FIG. lO;

FIG. 15 is an exploded vlew of the support plate and rectif ier assembly shown in EIG . 14;
FIG. 16 is a ~lde sectional view of the counter-weight and buf f er pad assembly showing a mounting plate of 5 the pad and a mounting post and detent ball inserted through an axial lining of the buffer pad mounting plate;
FIG. 17 is an enlarged sectional view of the support post and the axial lining shown in FIG. 16 showing a circumf erential groove in the axial lining with the 10 detent ball in the gr~ove;
FIG. 13 i8 an~ enlarge¢ sectional view of a portion of the apparatus shown in FIG. 17, showing the post inserted through the axial lining with the detent ball abutting the bottom of the lining to removably secure the 15 pad to the post;
FIG. 19 is a ~qide sectional Yiew of the post showing the detent ball attached to a pla~qtic backing which is :attached in a recess of the post;
FIG. 20 is an e~larged perspective view of the 20 first ~7~mqhl~1l housing member;
FIG. 21 is an e~larged perspective view of the seconl-d clamshell housing member; and FIG. 22 is an electrical qchematic diagram of the DC motor assembly according to the present invention.
: I)etailed De~cri~tinn Q~ ~h~ pre~f~rred ~ ~nfl~ t FIG. l illustrates an ergonomic apparatus 10 for waxing, polishing, buffing or the like, according to the present invention. ~he inventive . apparatus 10 has a symmetrical design about a vertical re~erence plane, not shown, ,=~t~nfl~ng centrally from a forward end 12 to a rearward end ~14 The apparatus 10 includes a housing 16 preferably having a c~mqh~ design with a first cl~mqhf~ll housing member 13 and a second ~ l ~mqhl~l 1 housing member 20 which, when connected to 4~ach other, define a part line 21 which extends in~ the vertical re~erence plane about which 21 8642~
the houslny 1~ ls symmetrical, as shown in FIG. 3. Prefer-ably, the first and second ~l~mRh~ll housing members 18 and 20 are molded plastic parts with their~various portions described herein being formed integrally with each other.
5 Corresponding portions on each of the symmetrical housing members 18 and 20 are identified by the same reference numeral with the portion~ on the first housing member 18 additionally provided with letter ~'a" and portions on the second housing member provided with the letter "b".
The housing 16 includes a main central housing 22 in~ which the motor assembly 24 is mounted, as best seen in FIGS 10 and 11. The main housing 22 includes a front handle 26 and a rear handle 28 Pl~t~n~11ng therefrom. As illustrated in FIGS. 1-6, ~he main housing 22 includes a 15 substantially ~lat top 30 and a bottom 32 and the front and rear handles 26 and 28 extend transversely to each other with the front handle 26 extending horizontally outwardly towards the forward end 12 from the main housing 22 between and substantially parallel to the top 3 0 and bottom 32 20 thereof while the rear handle 28 extends outwardly towards the rear~ end 14 from the main housing- 22 and extend~
vertically and arcuately between the top 30 and bottom 32 of ~ the main housing 22 The rear handle 28 has a hollow interior 34 in 25 which a box-shaped switch housing 36, for a switching mechanism 37 illustrated schematically in FIG. 22, and an actuator paddle- 38 are mounted. The actuator paddle 38 extends from the interior 34 through a bottom slot 35 formed in handle 28 to a predetermined distance outside the 30 rear handle interior 34 in a rear gripping aperture 39 bounded by the rear handle 28. The paddle 38 has an arcuate shape substantially matching the contour of the rear handle 28 so as to be easily and readily operable when the user grips the rear handle 28 along its arcuate portion 35 as more fully described hereafter.

2 ~ 864~2 At the top 30 of the housing 16, a raised wedge-shaped collar reglon 40 is defined into which a male recep-tacle or plug plate 42 can be mounted for receiving a female socket head of an electrical cord (not shown) for 5 electrically connecting an alternating current power source, for 110 volts at 60 Hz, to the motor assembly 24.
Adjacent the collar region 40 towards the rearward end 14 of the housing 16, a cord locking mechanism 44 is def ined in the housing top 30, as shown in FIGS. 7-9. The cord 10 locking mechanism 44 erevents ~ nt~1 disconnection of the female socket head connected in the collar reg-ion 40 to the male receptacle 42. Thus, with the motor 24 activated to~ drive a working element, such as a buffer pad 46, and with the buffer pad 46 driven in an orbital path as will be 5 described more fully herein, the above-described design of the housing 16 allows an operator to easily manipulate the apparatus 10 of the present invention with two hands to exert bi-planar control over the apparatus 10 while the buffer pad 46 is moved along the working surface in lts 20 orbital path without having to grab the main housing 22 to effectively and accurately guide and control the pad 46 along the working surface. Also, the placement of the electrical connection between the apparatus 10 and the electrical cord supplying AC=~ power thereto in a recessed 25 location on the housing top 30 and with the cord-locking mechaniam 44 adjacent thereto m~int~1n~ the cord in place remotely from the interface between the pad 46 and the surface being worked upon, such as a car finish, while at the same -time limiting disconnections interrupting the 30 waxing, buffing or polishing process for which the apparatus 10 can be used.
Referring now more specifically to the configura-tion of the housing 16, it will be noted that the symmetrical ~ m~hPl 1 housing members 18 and 20 cooperate 35 to: form the front and rear handles 26 and 28, the collar region 40 and the cord-locking mechanism 44 described , ~ _ , . , , , , . , _ _ _ _ _ . . _ _ _ _ _ _ _ above More specifically and referencing FIG. 3, the ~1 ~mqh~7 1 housing member 18 includes main housing portion half 22a, front handle half 26a, rear handle half 28a, collar region half 40a and cord locking mechanism half 44a.
5 I,ikewise, second rl ~mqh~l 1 housing member 20 includes main housing portion half 22b, front handle half 26b, rear handle half 28b, collar region Aalf 40b and cord locking mechanism half 44b. TAe first rl~mqhi~ll housing member 18 i5 provided with threaded bosses 48 and the second clam-10 shell housing member 20 has countersunk recesses 50 formedtherein with each of the recesses 50 leading to a threaded boss 52, as seen in FIGS. 10, 20 ana 21.
To assemble the apparatus 10, the internal com-ponents including the motor assembly 24, the switch housing 15 36, the actuator paddle 38 and the male receptacle 42 are mounted to the first t~l ~mqh~l 1 housing member 18, ae Yeen in FIG 11, wlth the second ~ l ~mqh~l 1 housing member 20 then being arranged against the first rl~rnqhf~ll housing member 18 90 as to align the tAreaded bosses 52 of the 20 housing member 20 with the corresponding threaded bosses 48 of the first clamshell housing member 18. With the housing members 18 and 20 80 aligned, screws 54 received in threaded bosses 52 can be, in turn, received in corre-sponding bosses 48 to clamp the ~ l ~mqhGl 1 housing members 25 18 and 20 to each other with the heads of the screws 54 seated within the countersunk recesses 50 of the second housing member 20 80 as not to protrude therefrom.
With the first and second clamshell housing members 18 and 20 attached to each other, the main housing 30 portions 22a and 22b cooperate to define an' interior space 56 in which the motor assembly 24 is mounted. As best seen in FIG. 3, the main housing portion 22 so formed has a pear-shaped cross-sectional configuration. The raised collar region 40 has a triangular shape in cross-section 35 and, as previously mentioned, proiects from the substan-tially flat top 30 of the housing 16. The wedge-shaped .. _ _ .. .. _ . _ _ _ _ . _ .

collar region 40 has an oblong central recessed area 58 into which the male receptacle 42 is placed.
Turning to the configuration of the front handle 26, each of the main housing portions 22a and 22b includes 5 a triangular attached portion 60a and 60b, respectively, which extends horizontally outward and forward ~rom the respective main housing portions 22a and 22b between and substantially parallel to the top 30 and the bottom 32 of the housing. From the outermost forward corner of the lO triangular portions 60a and 60b extend respective outer channel - shaped straight sections 62a and 62b such that with the el ~ Pl 1 housing members 18 and 20 attached to each other, the outer straight sections 62a and 62b extend substantially parallel to one another and the channels open 15 towards each other. The straight sections 62a and 62b extend forwardly to angled channel-shaped gripping portions 64a and 64b, raspectively, which extend at an angle from their respective straight sections 62a and 62b ~orwardly towards each other to distal ends 66a and 66b which abut 20 on-e ànother along the part line 21 and define a bent section sf the front handle 26 where the ~h;lnn~l ~ open rearwardly towards the main housing 22 with the clamshell housing members 18 and 20 attached.
Intermediate horizontal supporting members 67a 25 and 67b extend within the channels of the respective straight sections 62a and 62b and angled gripping portions 64a and 64b, as best seen in FIGS. 20 and 21. Correspond-ing bosses -48 and 52 are formed on the intermediate supporting members 67a and 67b at the distal ends 66a and 30 66b and can be aligned with each other when the housing members 18 and 20 are brought together such that one of the screws 54 received in the aligned front handle threaded bosses will provide an attachment between the housing members 18 and 20 at the front handle distal ends 66a and 35 66b. In t~lis manner, the front handle 26 is formed defining a forward gripping aperture 69 by the above-.. , . . , _ _ _ _ _ _ _ _ _ . _ described connection between the angled portions 64a and 64b .
The rl ~m~h~l 1 housing members 18 and 20 also include rear handle arcuate gripping portions 68a and 68b which extend integrally from near the rear end oE the top 30 of the main housing 22 and, more specifically, from the rear o~ the cord locking mechanism 44. The arcuate gripping portions 68a and 68b .-,)ntinll,~ rearward and vertically downward to a point aligned with the bottom 32 of the main housing portion 22 80 ag to extend substan-tially through a quarter- circle arc . At this point, the rear handle 28 includes straight joining sections 70a and 70b, respectively, which extend from their respective arcuate gripping portions 68a and 68b back to the main housing portions 22a and 22b at the bottDm 32 thereo~. To join the rear handle portions 28a and 28b, one of the threaded bosses 48 is formed in the arcuate gripping portions 68a and one is formed in the straight ioining section 70a along with corresponding ~hr~ i bosses 52 in the arcuate gr~pping portion 68b and straight joining section 70b such that with screws 54 received in the rear handle aligned bosses 48 and 52, the rear handle portions 2 8a and 2 8b are secured to each other to f orm the rear handle 28 and define the rearward gripping aperture 39.
~s shown in PIGS. 20 and 21, the rear handle portions 28a and 28b are formed as channel-like members having opposing sidewalls with each including a smaller inner sidewall 72a and 72b and a larger outer sidewall 74a and 74b and a connecting web wall 76a and 76b spanning their respective irner and outer side~alls 72 and 74 such that when the rear handle portions 28a and 28b are connected, they define a hollow rear handle 28 with the rear handle interior space 34 in which the switch housing 36 is mounted. Further, the inner sidewalls 72a and 72b each include respective cut-out sections aOa and 80b along the arcuate gripping portions 68a and 68b such that, with = ~ . _ _ _ _ _ _ _ _ _ .. . . .... .

2 ~ 86422 the rear handle portions 28a and 28b co~nected, the cut-out sections 80a and 80b cooperate to define the bottom slot 35 for the actuator paddle 38. With the actuator paddle 38 mounted in the rear handle interior space 34, the actuator 5 paddle 38 includes a portion which extends through the bottom slot 35 into the rearward gripplng aperture 39 spring bia~ed to a predetermined dlstance beyond the inner sidewall 72 The conf iguration of the cord locking mechanism 10 44~ adjacent the collar region 40 will next be described with reference to FIGS. 7-9, 20 and 21. A~ previously mentioned, the cord locking mechanism 44 is disposed rear-wardly of the raised wedge-s~iaped collar region 40 and includes a trough or well surface 82 defined by recessed 15= U-shape~ ~surfaces ~82a and 82b in the respective main housing top portions 30a and 30b, as best ~een= in FIGS. 8A
and 8B. An upstanding flange 8g extends from the bottom of the trough portion 82b to the top - of the proj ecting wedge collar region 40 with a tab 86 formed thereat at right 20 angles to the flange 84 and pro ~ ecting over the trough 82 80 that the top of the tab 86 is flush with the top of the wedge collar 40. Trough portion 82a has upstanding parallel side ~langes 38 and 90 spaced from each other along either ~ide of the ~rough portion 82a and having 25 re~pective overhung lip portions 92 and 94 which project towards each other over the trough portion 82a.
Thus, when the housing members 18 and 20 are aligned and clamped together, the cord locking mechanism 44 is formed. With the female socket head on an electrical 30 cord attached in the collar region 40 to the prongs 43 of the plug plate 42, the portion of the~ cord adjacent the female head can be inserted through the zig- zag entry slot 96 defined between the overhung lip portions 92 and 94 and the tab 86. The section of the cord ad~acent the female 35 head lnserted through the entry slot 96 can be positioned 80~ that it is clamped between the trough surface 82 and the ~ 2~ 86422 overhung tab 86 positioned thereabove with the ends of the cord section extending around the upstanding flange 84 and through access openings 98 and 100 formed in the sidewall portion 102 of ~the trough surface 82b on either ~ide of the 5 flange 84. In practice, when the apparatus 10 is being used=and the slack in the cord i~ taken up, a~ when the apparatus 10 is moved further away from the electrical outlet, tension created by tightening of the ~lack in the cord~ will be ~ubstantially taken up by the frictional 10 engagement of the cord between the well surface 82 and the overhung tab 86 and lip portions 92 and 94 such that the interface of the female head with the male prongs 43 will experience little or no tension during normal usage of the appliancè, thereby significantly reducing the potential 15 occurrences of ac- l.lPl~t~l disconnection at the interface.
Turning to FIGS. 12 and 13, the co~struction and operation of the actuator paddle 38 including a lock-on mechanism 104 which is mounted in nested relation therewith is illuctrated. The actuator paddle 38 has an arcuate 20 elongate channel-shape with a bottom cur~ace 106 having an arcuate portion 107 provided with a radius of curvature substantially the same as the rear handle arcuate gripping portion 68 and=being adapted to be gripped by an operator.
Two upstanding parallel sidewalls 108 and 110 extend along 25 either side of the bottom wall 106 such that the channel of the elongate arcuate-shaped actuator paddle 38 openE3 towards the rear handle interior space 34.
The elongate actuator paddle 38 has a- forward end 112 and a rearward end 114 and includes a pair of trunnion 30 pivots 116 and 118 extending laterally each from one of the sidewalls 108 and 110 at the forward end 112 of the paddle 38. The paddle 38 is mounted ln the rear handle interior space 34 by a pair of corresponding trunnion mounts 120 and 122 in respective housing members 18 and 20. The trunnion 35 mounts 120 and 122 are disposed adjacent the well 82 rear-wardly thereof such that with the housing members 18 and 20 .. .. .. .. . , . . . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . .. . ...

2 ~ g6422 connected, the actuator paddle 38 will extend from the base of the well 82 along the curve. of the arcuate rear handle grlpping portion 68 to the rear end of the cut-out 80 therein. At the rearward end 114 Qf the pàddle 38, a 5 suppQrt 124 for the lock-on mechani8m 104 is formed. With the trunnions 116 ana 118 mounted in their respective trunnion mounts 120 and 122, the support 124 extends sub-stantially horizontally and is normally biased into engagement with a transverse portion,126 o:E the inner 10 sidewall 172 at the rear of the cut-out 80. A pair of spring pedestal~ 128 and 130 are formed on~the bottom wall 106 with the forward pedestal 128 located on the arcuate portion 107 of the bottom wall 106 and the rear pedestal 130 located on the horizontal support portion 124 of the 15 bottom wall 106.
The paddle 38 is further provided with an aperture 132 formed along its arcuate portion 107 in the bottom wall 106 and sidewalls 108 and 110 for receipt of the lock-on mPrh~nl~m 104 therethrough. More speclfically, 20 the lock-on mPrh~nl~m 104 ;nrl~ P~~ a button 134 and a substantially flat base member 136 extending rearwardly therefrom. With the lock-on mPrh~n~ ~m 104 assem,bled in nested relation tD the actuator paddle 3 8 and the button 134 projectirg through the paddle aperture 132, the base 25 13'6 exter,ds from a support portion 137 formed on the backside of the arcuate portion 107 adjacent the rear of the button aperture 132 in the channel of the actuator paddle 3a and into the channel of the support portion 124 where the base 136 has a curved end 138 whlch i8 adapted to 30 engage a pivot rod 140 fixed to the paddle 38 extending across the sidewalls 108 and 110 in the support portion 124. Partition wall 141 extends along the back of the button 134 and the flat portion of the base 136 and upward-' ly beyond the, channel formed by the paddle 38 where it ends 35 at a transverse wall 142 upstanding ~rom the base 136 with the transverse wall 142 similarly extending upwardly beyond _ _ _ _ _ . . , _ ,, _ _ . ... , .. . , , _ _ _ 2 ~ 86422 the channel of the paddle 3 8 . At the top of the transverse wall 132, a curved cam surface 144 is formed for locking the paddIe 138 in a closed position, as will be more fully described hereafter.
Above the curved end 138 and below the curved cam surface 14g, an ~ntPrmP~l~te sprlng engaging member 146 extends rearwardly from the~ tran8verse wall 142 . A small spring 148 is mounted in compression between the inter-mediate spring engaging member 146 and the bottom wall 106 in the support 124 encircling the spring pedestal 13 0 . In this manner, the lock- on mechanism 104 is normally biased about pivot rod 140 80 that the button member 134 extends through the paddle aperture 132~ The rear handle portion 28a includes a spring-engaging flange 150 formed in the rear handle interior space 34 disposed along the cut-out 80 of the rear handle 28. A large spring 152 is mounted in compression between the spring-engaging flange 150 and the base 136 and encircling the spring pedestal 128 to normally bias the actuator paddle 38 to an open position where the paddle 38 pro~ects from the slot 80 in the rear handle inner sidewall 82 into the rear gripping aperture 39.
The rear handle portion 28 has switch supporting bracket r~bs 154 and 156 fDrmed in the rear handle interior space 34 along the cut-out slot 80 with the ribs 154 and 156 framing and supporting either side of the box switch housing 36. The switch housing 36 includes an activation plunger 158 (see FIG. 11) P~tPnfl;ng there~rom and the actuator paddle 3 8 includes an upstanding trapezoidal flange or actuating member 160 forwardly of the aperture 132 and the pedestal 128 adapted to engage the activation plunger 158 when the paddle 38 is depressed.
In practice, an operator can readily use one hand wrapped about the rear handle 28 to properly orient the buffer pad 46 over :the surface on which work, e.g., buff-ing, polishing or the like, is to be performed. As the rear handle 28 extends back from the main housing 22, below _ _ _ . . , , , ,, . , , , , _ _ _ _ _ _ _ _ _ _ _ , _ 2 ~ ~6422 which is mounted the pad 46, the operator can use the rear handle 28 to reach a large region OI a work surface from a reiatively stationary position. Once the pad 46 is proper-ly oriented above the work surface, the actuator paddle 38 can be depressed against the spring bias to a closed position with the paddle 38 pivoting about its forward trunnions 116 and 118 and carrying the lock-on m~rh~n; nm 104 therewith as by engagement of the support portion 137 with the base 136 of the lock-on mechanism 104. With the paddle 38 so depressed, the flange 160 engages and likewise depresses the activation plunger ~58 closing the switch circuit (see FIG. 22) to activate the motor assembly 24 and drive the pad 46 in its orbital path.
By providing an elongate, arcuate paddle 38 which follows the contour of the arcuate rear handle gripping portion 68 an operator can grab the rear handle 28 at various positions along the gripping portion 68, while still being able to depress the paddle 38 to lts operative position without requiring an independent operation with their other: hand and/or before the operator is ready to support and maneuver the apparatus ~0 by the rear handle 28 during operation thereof. To deactivate the motor assembly 24, and therefore the apparatus 10, an operator need merely release the actuator paddle 38 which, by virtue of being sprlng Ioaded to its extended open position, will deacti-vate the motor assembly 24 by disengagement of the flange 160 from the activation plunger 158 to ope~ the switch circuit .
In addition, if an operator does not wish to Aont;nll~lly depress the paddle 38 during operation of the apparatus 10, the lock- on mechanism 104 can be readily accessed and utilized in an easy manner without interrupt-ing operation of the apparatus 10 and/or requiring use of the operator~ s other hand. As previously mentioned, the lock-on mechanism 104 includes the =transverse wall 142 extending into the rear handle interior space 34. In the ~ 1 86422 interior space 34, a locking flange 162 is connected to the outer sidewall 74a disposed over the inner sidewall trans-verse portion 126 and ;n~ Pc a horizontal portion 164 and a connected vertical portio~ 166 Cooperating with the lock flange 162 is a guide flange 168 connected to the outer sidewall 74a and spaced ~orwardly f rom the vertical portion 166. =
The paddle 38 and lock-on mechanism 104 are arranged so that with the paddle 3 8 depressed to its opera-tiYe position, the cam end 144 will be positioned near the top of the vertical portion 166 between it and the guide 3~lange 168. To continuously use the apparatus 10 without having to correspondingly cnn~; nllm1~1y depress the paddle 38 to its operative position, the button member 134 can be depressed towards the rear handle interior space 34, i.e., in the same direction in which the actuator paddle 38 is being depressed, against the bias of spring 148, causing the outside of the curved cam surface 144 to cammingly engage the guide flange 168 and be directed over the top of the vertical portion 166 of the lock flange 162 and latch onto the lock flange vertical portion 166 under the in~luence of large :spring 152 with the actuator 38 being maintained in its closed operative position by the lif ting force applied by the curved end 138 on the~ pivot rod 140.
To effect =release of the actuator paddle 38 ~rom the locked position, t~e operator merely depresses the paddle 38 slightly further to reduce the influence of large spring 152 suf ~iciently so as to allow the spring 148 to urge the curved cam end 144 over the top of the lock flange vertical pc~rtion 166 and against the guide ~lange 168 as by the pivoting action o~ the curved end 138 about the pivot rod 140. Thereafter, the paddle 38 is released with the spring 150 bia~ing the paddle 38 to the open position to deactivate the motor assembly 24.
= To provide electrical power from the plug plate 42 to the motor assembly 24, the switching mechanism 37 includes an input terminal 170 and an output tPrm;n~l 172 extending through sides of the switch housing 36. As best seen in FIG . 10 ~ a lead 174 is electrically connected to the plug plate 42 and extends to the switehing mechanism 5 input tPrmln~l 170 while another lead 176 extends from the output tPrm;n~l 172 to a fullwave reetifier 178 for the DC
motor as~3embly 24. A lead 181 is eleetrieally eonneeted to the plug plate 42 and extends direetly to the reetifier 178 . As is conventional, the rectif ier 178 eonverts AC
10 power reeeived at the plug plate 42 to DC power for appli-eation to the DC motor assembly 24. Thus, with the switeh-ing circuit closed as cau~ed by depres~ing the paddle 38 to its operative posltion, DC electrical power will be provided to the armature coils, a~ more ~ully discussed 15 herein.
The variou~ motor assembly components are supported and oriented directly by the rl ~mqhPl 1 housing members 18 and 20 which, when connected, cooperate to clamp the motor in place in the main housing 22 without employing 20 an!extended yoke as a rrnt~;nPr to support and position the variou~ motor components and/or a separate base or frame member to~support the yoke in the housing. Referring to FIGS. 10 and 11, the motor assembly 24 consists of an armature 180 which can be of standard construction, 25 including a core and windings 182 aligned around a shaft 134 on which is also mounted the rrlmmllt~trr 186. A steel stator yoke 18a of open cylindrical shape is provided and can have a pair of large semi-cireular pPrm~nPnt magnets 190 and 192 pressed therein with the magnets 190 and 192 30 having a half-ineh gap between eaeh other in the yoke 188 at their ends.
A support plate 194 mounts the brushes 196 and 198 in respeetive brush housings 200 and 202 thereon and the rectifier 178 in a rectifier well 204 formed therein, 35 as illustrated in FIGS. 14 and 15. Referring to FIGS. 10 and 11; the armature shaft 184 includes top and bottom ends .. . , . . , . .. . . . . , . . . . _ _ _ ~ 6422 206 and 208 with a spherical bushing 210 being mounted about the top end 206 of the shaft 184 and a ring ball bearing 212 being mounted about the shaft 184 nea~ its bottom end 208.
The ~irst and second housing members 18 and 20 each include a plurality of alignment and support members generally designated 214 which are symmetrically arranged about a longitudinal axis 216 P~tPn~ng centrally through the main housing~ 22. The alignment and support members 214 clampingly engage the outer sur:~ace 218 o~ the yoke 188 and tightly capture the top and bottom bearings 210 and 212 when the housing members 18 and 20 are secured to each other so that the yoke 188 and the armature 180 are in alignment along the longitudinal axis 216 with the armature shaft 184 extending therealong and the cylindrical yoke 188 enGircling the armature 180. In this manner, the motor assembly 24 and the housing 16 are as~embled together in one manuLacturing operation without requiring a separate assembly operation ~or the motor before it is mounted in the: housing. In= addition, the:motor circuitry including the~ switch housing 3-6, the pIug plate 42 and the support plate 194, including the brushes 196 and 198 and the recti-fier 178 can be asse~bled as a sub-assembly before the they are mounted to the housing 16.
More speci~ically and ref rring to FIGS. 14 and 15,~ the support plate 194 preferably has a U-shape-having opposed leg portions 220 and 222 and a transverse foot portion 224 which extends between an-d cooperates with the leg~ portions 220 and 222 to de~ine a central -commutator space 226. The support plate 194 is mounted in the housing 16 such that the leg portions 220 and 222 are spaced on either side of the commutator 186 with the commutator 186 positioned.in the central space 226. The brush housing 200 i9 mounted on leg portion 220 -and the brush housing 202 is mounted on leg porti~n 222 spaced 180~ from each other around the commutator 1~6. The brush hous1ngs 200 and 202 .. .. . .. ..

2 ~ 86422 each include a main body 228 and 230, respectively, having respective brush-receiving bores 232 and 234 ~ Pntl;nr therethrough. Central guide slots 236 and 238 are formed in the top of the main :bodies 228 and 230, respectively, with the guide slots 236 and 238 communicating with respec-tive bores 232 and 234. The brushes 196 and 198 are received in' their respective brush-receiving bores 232 and 234 and include attached leads 240 and 242, respectively, each having respective flag trrm;n~ 244 and 246 for:
10 electrically connecting the brushes 196 and 198 to the rectif ier 178 .
With the brushes 196 and 198 placed in their bores 232 and 234, and the. support plate 194 mounted ln the housing 16 about the commutator 186, the brushes 196 and 15 198 are biased so that at least a portion thereof extend into the central space 226 into contact with the outer surface 218 of the commutator 186. In this manner, the brushes 196 and 198 slidingly ride along the commutator outer surface Z18 as it rotates on the armature shaft 184 20 to .thereby electrically connect the power source to the armature coils. To urge the brushes 196 and 198 into contact with the commutator 186, each of the houslngs 200 and 202 inGlude respective caps 248 and 250 and springs 252 and 254 The main body 228 and the main body 230 include 25 enlarged outer ends 256 and 258,- respectively. The enlarged outer end 256 includes oppositely- facing ramp surfaces 260 and :262 extending inwardly to respective straight shoulder surfaces 264 and 266. Likewise, enlarged end 258 includes oppositely- facing ramp surfaces 268 and 30 270 extendlng inwardly to re8pective straight shoulder surfaces 272 ana 274.
For capturing and locking the cap 248 on the main body 228, the cap 24a ;nrll]~l~Y a pair of ramp surfaces 276 and 278 extenaing from either side thereof to respective 35 inner shoulder surfaces 280 and 282. Likewise, cap 250 is provided with ramp surfaces 284 and 236 extending from , , ,, , , _ . _ _ . ,, , _ ,, _ _ _ _ _ ~ 2 ~ 86422 either side thereof to re8pective shoulder surfaces 288 and 29~0 The inne~ rear surfaces of each of the caps 248 and 250 is provided with a slightly raised spring locating boss 292 and 294, respectively.
To assemble the brushes 196 ana 198 in their respective housings 200 and 202, the brushes 196 and 198 are inserted into their respective bores 232 and 234 with their lead wires 240 and 242 extending from the bores 232 and 234 through the slots 236 and 238 thereof with the flag lQ terminals 244 and 246 then being connected to appropriate output tprmln~l~ on the rectifier 17~8, as will be described herein. To urge the b~ush 196 through the bore 232 of the housing 228 and into the central space 226, the spring 252 is placed in the bQre 232 with one end in contact with the brush 196 and its other end located on the boss 292 with the cap 248 then being press fit onto the enlarged end 256 of the main body 228 of the housing 200. The cap 248 is press fit onto the main body 228 by moving the ramp surfaces 276 and 278 against and along the ramp surfaces 260 and 262 so- as to urge t~e cap sides o~twardly as the cap 248 is pushed onto the main body 228. Once the ramp surfaces are pushed past each other, the sides of the cap 248 will rebound to their original, straight configuration with the cap shoulder surfaces 280 and 282 confronting respective shoulder surfaces 264 and 266 on the main body so as to lock the cap 248 thereon. With the cap 248 locked in place, the spring 252 will act to bias the brush 196 so that it e~tends out from the central bore 232 into the central space 226, limited by the engagement of the lead 240 with the inner end of the guide slot 236, as best seen in FIG. 13. The cap 250 is slmilarly press-fit and locked onto the main body 230 so as to bias the brush 198 through the bore 234 into the central space 226.
In the foot portion 224 of the support plate 194, the recessed rèctifier well 204 is formed. The rectifier well 204 inrll~P~ a pair of= resilient upstanding locking .. _ . , . , . .. , , _ _ _ _ _ . . . . .

1 21 86~22 members 296 and 298 therein, with the locking members 296 and 298 each having an enlarged locking portion 300 and 302 at their respective upper ends . The rectifier 178 l nr~ r~R
a body portion 304 with a pair of input t~rmln~l~ 306 and 5 308 and a pair of output tF~rm;n~1~ 310 and 312 extending from the body portion 304. The rectifier 178 i~ assembled in the rectifier well 204 by pushing the rectifier body portion 304 against the enlarged ends 300 and 302 of the resilient locking members 296 and 298. This causes the 10 locking members 296 and 298 to be urged outwardly thereby a~lowing the rectifier body portion 304 to be pushed past the enlarged ends 300 and 302 to seat in the well 204 with the resilient locking members 296 ~ and 298 then snapping back to a locking po~3ition with the enlarged ends 300 and 15 302 abutting against the upper face of the body portion 304 to tightly capture the rectifier 178 in the recesE3ed well 204 .
A pair of lead guiding stakes 314 and 316 extend from the support plate 194 substantially at the juncture~
20 of the ~upport=plate foot portion 224 with the leg portion~
220 and 222 The sub-a~sembly of the plug plate 42, the switch housing 36, and the rectifier 178 and brushes 196 and 19 8 on the support plate 194 includes lead electrical connection~ as described below. As one skilled in the art 25 will appreciate, various arrangements of lead wires can be utilized with the motor assembly 24 to tran~mit electrical power thereto. ~ Preferably, the lead 174 is electrically connected at one end to the plug plate 42 and at itE3 other end it has a flag terminal 174a which is electrically 30 connected to the input terminal 170 of the switching mechanism 37. The lead 176 has a flag terminal 176a attached to the output terminal 172 of the switching m~rh~n~ cm 27 with itg other ~lag terminal 176b at the other end of the lead 17 attached to one of the input terminals 35 30-~ and 308 of' the rectifier 178. The lead 181 is elec-trically connected at one end to the plug plate 42 and at .. , . .. .... . , . _ _ _ _ _ _ _ _ _ _ _ _ _ . _ _ its other end lt has a flag terminal 181a which is attached to the other one of the rectifier input term;n~l ~ 306 and 308. The brush leads 240 and 242 are each electrically connected to Qne of the output t~rm;n~ 310 and 312 5 pre~erably with f lag terminal 244 connected to output tPrm;n~l 310 and flag terminal 246 connected to output termirlal 312, as seen in FIG. 14. To ensure that the non-insulated braided lead wire 242 is isolated from the other similarly non- insulated braided wires, the lead wire 242 10 extends from the guide slot 238 around the lead guiding stake 316 and to the output tPrm~n~i 312. As is apparent, the lead guiding stakes 314 and 316 can be used to guide the lead wires connecting to the rectifier t~rmln~31 s in various arrange~nents 80 a~r to prevent the non- lnsulated 15 lead wires from contacting each other.
For mounting of the rectif ier and brush support plate 194 in: the housing interior space 56, cut-outs defining shoulders 318 and 320 are formed along the outer edges of the support plate leg portions 220 and 222, 20 respectively. Referring to FIGS. 11 and 20, the alignment and support members 214 of the houslng memaer 18 include a pair of notched vertical ribs 322a and 324a with each of the vertical ribs including a horizontal abutment member 326a and 328a extending laterally from the notched area to 25 the housing member 18. The vertical ribs 322a and 324a are laterally spaced from each other in the housing internal space portion 56a with the spacing carre6ponding to the distance between the support plate s~ Prs 318 and 320 so as to snugly receive the support plate shoulders 318 and 30 ~3Z0 in the vertical rib notches against the abutments 326a and 328a when the plate 194 is raounted to the housing member 18. With the support plate 194 60 mounted, the longitudinal axis 216 extends through the support plate central space 226. - ~ ~
35 . == To clamp the supFort plate 194 in the housing interior space 56, corresponding notched vertical ribs 322b ~ ~64~

and 324b are formed in housing member 20 (see FIG. 21) with their notches being vertically aligned with the notches in the vertical ribs 322a and 324a when the housing members 18 and 20 are connectea. The notched vertical ribs 322b and 5 324b engage the ends 334 and 336 of the support plate leg portions 220 and 222 projecting beyond the respective brush housing 228 and 230 -90 as to clamp the support plate 194 against movement in the 4Ousing interior space 56.
To mount the armature 180 in the housing interior 10 space 56 with ~the armature = sha~t 184 aligned along the longitudinal axis 216, the alignment and support members 214 include upper and lower bearing engaging members 338a and 340a in housing member 18 and corresponding upper and lower bearing engaglng members 338b and 340b in housing 15 member 20 which cooperate to form top and bottom pockets in the housing interior space 56 with the longitudinal axis 216 extending through these pockets. The pockets formed by the bearing engaging members 338 and 340 are configured 90 as to securely capture the respective top and bottom bear-20 ings 210 and 212 against movement in the housing interiorspace 5 6 .
More specifically, since the top bearing 210 is preferably a spherical bearing, the top bearing engaging member 338 is formed with a pair of curved sidewalls 342 25 -and 344 with the radius of curvature of the sidewalls 3g2 and 344 substantially matching that of the spherical bear-ing 210.~ -In this manner, the spherical bearing 210 is prevented from moving axially along the longitudinal axis 216 when captured by the upper bearing engaging member 338 30 in the housing interior space 56. In addition, the curved sidewalls 342 and 344 are connected by horizontal top and bottom members 346 and 348 with the top and bottom members 346 and 348 being curved at their ends adjacent the longi-tudinal axis 216. Extending between the curved sidewalls 35 342 and 344 intermediate the top and bottom members 346 and 348 is a horizontal support rib 349 having a curved end - 27 - 2 'I 8 6 4 2 2 which does not extend as far toward3 the axis 216 as the ends of the top and bottom members 346 and 348 to accommo-date and match the shape of the spherical bearing 210.
Thus, the diameter across the curved ends of the inter-5 mediate support ribs 349a and 349b in each of the housingmembers 18 and 20 when attached is substantially the same as the largest ~l; Am~t~r extending across the middle o~ the spherical bearing 210. Similarly, the diameter across the curved ends of the horizontal top and bottom members 346 10 and 348 subst~nt;~ly matches the smaller diameter across the top and bottom of the spherical bearing 210 so as to prevent the same f rom moving in a -lateral direction when clamped and captured in the housing interior~ space- 56 .
The lower bearing engaging member 340 is con-15 ~tructed similarly to the top bearing engaging member 338except that it is conf igured so as to capture the lower bearing 212 which is preferably in the form of a ring ball bearing. Thus, the lower bearing engaging member 340 has a pair o~ spaced etraight sidewalls 350~and 352. The side-20 walls 350 and 352 are interconnected by horizontal top andbottom members~354 and 356 with the top and bottom members 354 and 356 having curved ends which terminate in straight end portions extending to the respective tops and bottoms of sidewalls 350 and 352. With the housing members 18 and 25 20 attached, the curved ends of the top and bottom members 354a and 354b and 356a and 356b define a diameter slightly smaller than the outer diameter of the ring bearing 212.
Thus, with the ring bearing 212 secured and mounted in the lower bearing engaging member 340, the top and bottom 30 members 354 :and 356 prevent the bottom ring bearing 212 from moving axially along the longitudinal axis 216.
~ 7ct~nr~;n~ between the sidewalls 350 and 352 intermediate the top and bottom members 354 and 356 is a horizontal support rib 353 having a curved end terminating 35 at~ the sidewalls 350 and 352 cuch that with the housing members 18 and 20 connected together, the intermediate 2~ 86422 horizontal support rib portions 358a and 358b of each of the housing members define a diameter across their curved ends substantially corresponding to the outer diameter of the ring bearing 212 so as to capture the same against 5 movement in a lateral direction in the housing interior space 56. Thus, with the armature 8haft 184 mounted for rotation in upper spherical bearing 210 and the lower ring bearing 212 and with the bearings 210 and 212 clamped in the housing interior space 56 in the pockets formed by the 10 bearing engaging members 33~8 and 3~0, the armature 180 along with it8 commutator 186 will be aligned for rotation on the shaft 184 extending along the longitudinal axis 216.
The cylindrical stator yoke 188 is mounted in the housing interior space 56 so that it encircles the armature 15 core and winding8 182 in alignment_about the longitudinal axis 216. To mount the cylindrical yoke 188 in alignment about the axis 216, the alignment and support men~bers 214 include horizontal arcuate ledges 360, vertically spaced in the housing members 18 and 20, as best seen in FIGS. 20 and 20 21~. Interconnecting pairs of vertically-spaced arcuate ledges 360 are vertical reinforcing rib~s 362. The ledges 360 incluae uppermost arcuate ledges 364 and lowermost arcuate horizontal ledges 366 which extend hor1 ~nti:ll ly slightly further towards the axis 216 than do the other 25 arcuate ledges 360 therebetween so that when the housing members 18 and 20 are attached, aligned uppermost ledges 364a and 364b in respective housing mer~bers 18 and 20 and aligned lowermost ledges 366a and 366b in respective housing members 18 and 20 cooperate to define a diameter 30 which is slightly less than the diameter acro=ss the yoke outer surface~ 218. In this manner, the uppermost ledges 364 extend over the top end surface 368 of the yoke 188 and the bottom ledges 366~extend below the bottom end surface 370 of the yoke 188 so that the yoke 188 is tightly 35 captured between the upper and lower ledges 364 and 366 against axial movement along the longitudinal axis 216 .. ,, . . .. , , . ,, _ . . . , _ _ , .

21 86~22 To capture the yoke 188 against lateral movement in the interior space 56, the intPrmPfl;~te arcuate ledges 360 have a radius of curvature subst~ntli~lly matching the radius of curvature of the cylindrical yoke 188 80 that 5 together the arcuate ledges 360 define a diameter~substan-tially the same as the yoke outer surface diameter. As previously mentioned, the housing members 18 and 20 are preferably molded plastic parts and the alignment and support members 214 including the horizontal ledges 360 are lO preferabIy integrally formed therewith In this manner, the arcuate ends of the plastic ledges 360 can resiliently engage the outer surface 218 of the yoke 188 when the housing members 18 and 20 are connected to each other so as to clamp the yoke 188 wlthin the interior space 56 in 15 alignment about the longitudinal axis 216 and in encircling relation to the armature core and windings 182 with the clamping force~being transmitted from the force applied in inserting the screws 254 in aligned=bosses 48 and 52.
The mounting of the DC motor components directly 20 to the housing members 18 and 20 by the clamping action therebetween provides significant= cost savings in the manufacture of the apparatus 10 as the motor assembly 24 no longer needs to be assernbled in a separate assembly opera-tion and, instead, can be incorporated into the same 25 assembly operation for the apparatus 10. In addition, the motor assembly 24 does not require the "can" form for the yoke 188 which required an P~tPnflPfl yoke having cap and bearing plates to close the cylindrical yoke ends nor does the motor assembly 24 require an independent base or frame 30 for mounting the "can" motor thereto. Typically the rectifier is mounted adjacent to the "can" motor, as on the motor frame, with provision being made to allow the leads from the motor brushes to extend through the motor housing to be electrically connected to the rectif ier exterior of 35 the motor housing Thus, cost savings are obtained by minimizlng the time required for assembly as well as by 30 2 l 86422 el;m;n~t;ng parts associated with a "can" type motor and allowing for uninterrupted paths for the leads between the brushes and rectif ier .
As previously mentioned, preferably the apparatu8 5 10~ mounts a pad 46 for buffing, waxing, polishing or the like. In this form, the housing 16 can be provided with a sheath 372 formed at the bottom thereof with the sheath 372 having an annular portion 374 extending outwardly from the bottom 32 of the main housing portion 22 aligned about the 10 longitudinal axis 216. Depending from the annular portion 374 is a circumferential skirt 376 ~rom which the buffer pad 46 can proj-ect.
To allow the buffer pad 46 to stably move in an orbital path as it is driven, a countérweight assembly 378 15 i8; provided.= The counterweight assembly 378 includes a pad mounting post 380 mounted thereto for allowing the pad 46 to be quickly mounted to the apparatus lO and removed theref rom .
I!lore specifically and referring to FIGS. 16-19, 20 the counterweight assembly 378 includes a flat, elevated mounting portion 382 and a lower counterweight portion 384 off8et from the elevated mounting 332. The elevated mount-ing portion 382 includes a threaded aperture 386 there-through for receiving the threaded end 208 of the armature 25 shaft 184 proiecting through the ring ball bearing 212.
Thus, with the armature shaft end 208 threaded in the aperture 386, the counterweight assembly 378 is mounted to the apparatus 10 for rotation with the shaft 184.
The quick-change pad mounting post 380 i8 30 con~ected to elevated mounting portion 382 adjacent the threaded aperture 386 and mounts the buffer pad 46 suc~
that rotation of the counterweight a8sembly 378 by virtue of the attachment of the armàture shaft 134 in the apertur~
386 produces a substantially circular orbital path in which 35 the pad 46 ie moved about the shaft 184 and thu8, the longitudinal axis 216. Since the mounting post 380 will be _ _ _ . , . ,, . . _ , _ . . _ . . _ _ .. . ..

2~ 86422 aligned with the center oi the pad 46 as described herein and the shaft 184 is between the post 380 and the counter-weight portion 384, as the counterweight assembly 378 is rotated, the counterweight portion 384 will always be 5 disposed over the smaller~portion of the pad as defined by a chord line drawn so as to extend across the circular pad 46 through the shaft 184 and acrDss the width of the counterweight assembly 378. In this manner, the counter-weight portion 384 acts to counter forces generated during 10 rotation of the pad 46 in its orbital path which otherwise would tend to de-stabilize the apparatus 10.
The pad 46 can be of conventional construction and, in a preferred form has a 9-inch diameter. The pad 46 includes a plastic pad mounting plate 388 attached to its 15 top surface. Pro~ecting upwardly from the center of the pad mounting plate 388 is an annular post receiving member 390 having a central bore 392 extending therethrough in alignment with the central axial bore Df the pad 46. The central bore 392 can have an axial sleeve 394 fixed therein 20 with an axial lining 396 rotatably mountçd in the axial sleeve 394 as by bearings (not shown).
The post 380 has a recess 398 machined near the lower end 400 of the post 380. For removably mounting mount the pad 46 to the quick-change pa~ mounting post 380, 25 a detent ball 402 attached to a plastic backing 404, such as polyurethane, is secured in the recess 398. The recess 398 has a diameter across its opening slightly larger than the diameter o~ :the detent ball 402 such that the ball 402 is snugly received in the recess 398 when attached thereln.
30 With the ball 4Q2 attached in the recess 398 by way of the plastic backing 404, the ball 402 protrudes at a predeter-mined distance beyond the surface Df the post 380 to an extended position. As the ball 402 is mounted on the plastic backing 404, the ball 402 can be depressed by 35 exerting a force on the ball 402 which compresses the plastic backing 404 80 that the ball 402 is flush with the surf ace of the pos t 3 8 0 .
To move the detent ball 402 to itg depressed position, the axial lining 396 has a diameter substantially 5 t~e same ag the diameter of the~pad mounting post 380 so that insertion of the post 380 in the lining 396 cauges the lower curved surface portion 406 of the ball 402 to initially engage the upper annular end 405 of the sleeve 394. Continued downward force applied to the counterweight 10 assembly 398, and thus to the post 380, causes the axial lining 396 to cam over the curved surface portion 406 by application af a predetermined inwardly directed force to move the ball 402 radially inwardly to a position flush with the post surface against the bias provided by the 15 plastic backing 404.
With the ball 402 in its depressed, flush position relative to the post 380, the post 380 can be readily pushed through the axial sleeve 394 until the bottom 408 of the elevated mounting portion 382 rests 20 against the top 410 of the raised annular member 390 with the counterweight portio~. 384 adjacent thereto. Thus, with the post 380 ingerted through the axial lining 394, the pad 4Ç is in its releasably gecured state to the post 380. In the releasably secured state, the lower end 400 extends 25 beyond the axial lining 396 such that the ball 402 no longer is~ engaged by the axial lining 396. Accordingly, the predetermined force applied to the curved surface portion 406 is removed therefrom go as to allow the detent ball 402 to rebound under the influence of the plastic 30 backing 404 to its extended position beyond the radius of the post 380. The ball 402 is mounted on the post 380 at a predetermined distance from the bottom 408 of the elevated mounting partion 382 and the length of the axial sleeve 394 is also predetermined so that with the pad 46 is 35 releasably secured to the post 408 and the ball 402 in its extended position, the upper curved surface portion 412 . . =,, . . _ _ _ _ _ .

2~ 86422 will abut against the lower annular end or shoulder 414 of the axial sleeve 80 that there ie no loose space or play between the ralsed post-recelvlng member 390 and the counterwelght aseembly 308.
5 ~ Wlth the pad 46 mounted to the qulck-change pad mounting post 380 having the detent ball 402 thereon and when: an operator wants to change pads to go to a dlfferent type of pad or because the pad 46 needs replaclng due to wear: or damage or the like, the pad 46 can qulckly and 10 eaeily be removed from its mounting to the apparatus 10 without requiring substantial time or disaseembly which would otherwise compllcate the pad changlng process. To remove the pad 46, an operator need merely exert a downward force away from= the pad mounting post 380 on the pad mount-15 lng plate 388 sufflcient to cause the lining annular bottomehoulder 414 to cam over the upper curved surface portion 412 so as to urge the ball 402 to its depreesed position flush with the post surfa~e againet the normal bias of the plastic backing 404. Wlth the ball 402 ln lts depressed 20 position~ continued downward force on~ the pad mounting plate 388 causes the linlng 396 to slide off of the post 380 until the pad mountlng plate 388 and the attached pad 46 are dlsengaged from the post 380, Although the ball 402 and pad mountlng post 380 25 provide a secura mo'unting of the, pad 46 to the apparatus 10, it is possible that during use of the apparatus 10, a force sufficient to cause the detent ball 402 to move to its depressed position could be applied to the pad 46 and/or pad mounting plate 388. In the event of such an 30 occurrence, the a~ial lining 396 ls provlded wlth an inter-medlate circumf erential groove 416 spaced above the detent ball 402 to prevent the post 380 from sliding completely through the a-xial sleeve -394 to the disengaged posltion.
The circumferential groove 416 has a predeter-35 mined radius sized so as to be capable of capturing thedetent ball 402 in an F~ nflc~(l poeition where it protrudes 2~6422 beyond the sur~ace of the post 380 as it passes thereover.
Thus, with the pad 46 mounted to the post 380 and with an unexpected force applied to the pad mounting plate 388 or the attached pad 46 cau~ing the ball 402 to move to it6 5 depressed posltion within the axlal lining 396, cont1n movement of the post 380 through the axial lining 396 will eventually cause the ball 402 to encounter the groove 416.
The urging of the plastic backing 404 will push the ball 402 into an P~tPn~lPf9 position ir the clrcumferential groove 10 416 and thus arrest ~ ntln~lP~l movement of the post 380 through the sleeve 394 80 a~ to provide subst~nt~ y fail-safe operation of the apparatus 10 when the pad 46 is secured on the pa~ mounting post 380.
While there have been illustrated and described 15 various featur~s for use with an electrically-powered waxer or~buffer, it will be appreclated that these features can be utilized with other tools. In addition, it will be apparent that numerous changes and modifications will occur to those skilled in the art, and it is intended in the 20 appended =claims to cover all those changes and modifi-cations which fall within the true spirit and scope of the present invention.

Claims (14)

I CLAIM:

1. A power tool comprising:
a main housing containing a motor for driving a working element;
a hollow handle connected to the housing;
an actuator paddle mounted for pivotable movement relative to the handle and being pivotable between (1) an open position wherein the motor is disabled, and (2) a closed position wherein the motor is activated to drive the working element and with the paddle in the closed position release of the paddle causes the paddle to return to the open position to disable the motor; and a locking member mounted to the paddle to be movable therewith whereby with the paddle in the closed position the member is capable of maintaining the paddle in the closed position when the paddle is released.

2. The power tool of claim 1 wherein the handle has an elongate, arcuate shape and extends away from the housing and the paddle has an elongate, arcuate shape sub-stantially conforming to the handle shape with the handle including a paddle receiving slot along the length thereof, the paddle being mounted to the handle to project from the slot and allowing the paddle to be depressed in the slot as it is moved from the open position to the closed position.

3. The power tool of claim 1 wherein the paddle includes an aperture with the locking member including a button portion projecting through the paddle aperture and a cam portion in the hollow handle.

4. The power tool of claim 3 wherein a flange is mounted in the hollow handle and with the paddle moved to the closed position the button member can be depressed in the paddle aperture to cause the cam portion to latch onto the flange and maintain the paddle in the closed posi-tion when the paddle is released.

5. The power tool of claim 1 wherein the handle includes switch means mounted therein for activating the motor and the paddle includes an actuating member with the paddle mounted to the handle so that in the open position the actuating member is spaced from the switch means and the motor is disabled and in the closed position the actuating member engages the switch means to activate the motor.

6. The power tool of claim 1 further including cam means cooperating between the handle and the locking member for moving the locking member between (1) an un-locked position wherein the paddle is freely movable between its open and closed positions, and (2) a locked position wherein the paddle is maintained in the closed position.

7. The power tool of claim 6 wherein the handle includes a flange mounted therein and the locking member includes a portion extending into the handle, and the cam means includes a cam surface on at least one of the flange and the locking member portion which allows the portion to latch onto the flange as the locking member is moved from the unlocked to the locked position.

8. The power tool of claim 1 wherein paddle has a length and spaced ends and the locking member is pivot-ably mounted to one end of the paddle and the paddle is pivotably mounted to the housing at the other end of the paddle.

9. A power tool comprising:

a housing containing a motor for driving a working element;
a handle connected to the housing;
an actuator paddle mounted for pivotable movement relative to the handle wherein movement of the handle to an operative position in a first direction causes the motor to drive the working element; and a locking member mounted for pivotable movement relative to the paddle wherein movement of the locking member in the first direction is capable of locking the paddle in the operative position.

10. The power tool of claim 9 wherein the handle has a hollow interior and includes a slot and the paddle is mounted in the slot with the paddle being depressible in the slot in the first direction towards the interior of the handle to thereby be moved to its operative position.

11. The power tool of claim 9 wherein the handle has a hollow interior and both the paddle and the locking member can be depressed in the first direction towards the interior of the handle to thereby maintain the paddle in its operative position and readily allow one-handed opera-tion of the tool.

12. A power tool having a working element driven by an electric motor, the power tool comprising:
a housing;
a hollow handle connected to the housing;
switch means in the handle electrically connected to the motor and having on and off states such that with the switch means in the on state the motor is energized to drive the working element and in the off state the motor is de-energized;
a paddle actuator mounted for movement relative to the handle between (1) an extended position wherein the actuator extends a first distance from the handle and the switch means is in the off state, and (2) a first depressed position wherein the actuator extends a second distance from the handle less than the first distance and the switch means is in the on state; and a locking member carried by the paddle actuator capable of being depressed with the paddle in the first depressed position to lock the paddle in the first depressed position such that with the paddle in the first locked, depressed position, the paddle can be depressed to a second depressed position wherein the actuator extends a third distance from the handle less than the second dis-tance to release the locking member and the paddle from the paddle locked position and allow the paddle to move to its extended position when the paddle is released.

13. The power tool of claim 12 wherein the actuator includes an aperture and the locking member includes a button member extending through the aperture.

14. The power tool of claim 13 wherein a lock flange is mounted in the hollow handle and the locking member includes a cam member in the hollow handle arranged so that with the paddle in its first depressed position the button member can be depressed in the paddle aperture to cause the cam member to cam over and latch onto the flange and maintain the paddle in the first depressed position when the paddle is released.