WO1997038813A1

WO1997038813A1 - Sanding accessory for an oscillating sander

Info

Publication number: WO1997038813A1
Application number: PCT/US1997/005834
Authority: WO
Inventors: Steven M. Antler
Original assignee: Antler Steven M
Priority date: 1996-04-18
Filing date: 1997-04-18
Publication date: 1997-10-23
Also published as: AU2609897A

Abstract

A sanding accessory (R) for an oscillating sander comprises a rigid substrate (2), such as metal or plastic for securing to a flat surface or profile sanding head of a sander. In one embodiment, the substrate is a flat plate with spring clips (4) around its periphery that are adapted to press against the edge of the sanding head. In another embodiment, the substrate is approximately U-shaped with the same cross-sectional shape of a profile rubberhead to which it is clipped. The U-shaped substrate has spring biased side walls adapted to grip the side walls of the rubberhead. The substrate is made of plastic, brass or other suitable rigid materials directly or indirectly provided with abrasive particles, such as aluminum oxide, silicon carbide, diamond, cubic boron nitride (CBN), or other suitable abrasive materials. In yet another embodiment, the substrate is in the form of a wire-mesh.

Description

SANDING ACCESSORY FOR AN OSCILLATING SANDER

FIELD OF THE INVENTION

The present invention relates generally to a sanding accessory for an oscillating or reciprocating sander that includes a rigid substrate, such as plastic, metal or other suitable materials in the form of a plate or profile surface directly or indirectly provided with abrasive grits, such as aluminum oxide, silicon carbide, diamond, cubic boron nitride (CBN) , or other suitable abrasive materials.

The present invention also relates to a wire-mesh sanding sheet that includes a flat or profile wire-mesh surface coated with diamond and/or cubic boron nitride (CBN) abrasive particles, or other suitable abrasive materials.

BACKGROUND OF THE INVENTION

A prior art oscillating sander typically uses sandpaper that is cut to size and is affixed directly to a flat or profile surface of the working head of a sander tool, using glue or VELCRO. Sandpaper when used as such has several limitations. Sandpaper is susceptible to falling off during use as, for example, when the edge of the sandpaper is engaged. The glue used to affix the grits to the paper has a certain shelf life. Sandpaper wears out relatively quickly and is prone to tearing or breaking apart during use. Further, the sander working head is subject to damage when the sandpaper wears out during use, exposing the underlying working head to the work piece. Additionally, sandpaper clogs up relatively quickly and thereby lose its effectiveness.

There is therefore a need for a sanding accessory for oscillating sanders that obviates the shortcomings of prior art sandpaper.

OBJECTS AND SUMMARY OF THE INVENTION It is an object of the present invention to provide a sanding accessory that could outlast all types of sandpaper.

It is another object of the present invention to provide a sanding accessory that uses a rigid substrate, such as plastic, brass or other suitable materials coated with aluminum oxide, silicon carbide, diamond, CBN, other suitable abrasive materials, thereby preventing the danger of tearing or breaking apart during operation that is typical with sandpaper. It is yet another object of the present invention to provide a sanding accessory that provides protection to the sander working head from inadvertent damage due to the sandpaper wearing out and breaking apart during use. It is still another object of the present invention to provide a sanding accessory with a reusable or disposable substrate.

It is another object of the present invention to provide a sanding accessory that could work on a larger variety of materials, such as glass and ceramics, than sandpaper.

It is still another object of the present invention to provide a sanding accessory that allows closer production tolerances than is possible with sandpaper, thereby allowing the user more precise control over the work being performed.

It is another object of the present invention to provide a sanding accessory that would not easily fall off or be dislodged during use.

It is yet another object of the present invention to provide a sanding accessory where the abrasive particles are secured to a base or substrate with electrolytic deposition, thereby providing an unlimited shelf life. It is another object of the present invention to provide a sanding accessory that is secured to the sanding head of the sander with a positive mechanical lock, thereby minimizing the chance of the accessory falling or separating from the tool during use. It is another object of the present invention to provide a sanding accessory that can be made to the exact configuration of the profile rubberhead used by the sanding tool. It is still another object of the present invention to provide a sanding sheet that uses a metallic wire-mesh coated with diamond, CBN abrasive particles or other abrasive particles, thereby preventing the danger of tearing or breaking apart during operation that is typical with sandpaper.

It is yet another object of the present invention to provide a sanding sheet where the abrasive particles are secured to a wire-mesh sheet without the use of glue, thereby providing greater durability than a sandpaper.

In summary, the present invention is a sanding accessory for an oscillating sander, comprising a rigid substrate, such as plastic or metal for securing to a flat surface or profile sanding head. In one embodiment, the substrate is a flat plate with spring clips disposed around its periphery that are adapted to press against the edge of the sanding head of the tool. In another embodiment, the substrate is approximately U-shaped with resilient side walls and with the same cross-sectional shape as the profile rubberhead to which it is clipped. The U-shaped substrate has spring biased side walls adapted to grip the side walls of the rubberhead. The substrate is made from plastic, brass or other suitable materials with its outside surface affixed directly or indirectly with abrasives such as aluminum oxide, silicon carbide, diamond, cubic boron nitride (CBN) or other suitable abrasive materials. Where the substrate is made of metal, such as brass, the abrasives, such as diamond and/or cubic boron nitride (CBN) abrasive particles, are secured to the substrate by means of an electroplating process using nickel sulfamate.

In another aspect of the present invention, the substrate is in the form of a wire-mesh for securing to the sanding head with glue or VELCRO. Abrasives, such as diamond and/or cubic boron nitride (CBN) abrasive particles, are secured to the wire-mesh by means of an electroplating process using nickel sulfamate.

These and other objects of the present invention will become apparent from the following detailed description.

BRIEF DESCRIPTIONS OF THE DRAWINGS Figure IA is a top perspective view of one embodiment of a sanding accessory made in accordance with the present invention.

Figure IB is a side elevational view of the sanding accessory of Figure IA.

Figure IC is a top plan view of Figure IA. Figure ID is a cross-sectional view through the sanding accessory showing the abrasive particles affixed indirectly to the surface of the substrate.

Figure 2A is a top plan view of another shape of the sanding accessory of Figure IA.

Figure 2B is another embodiment of the sanding accessory of Figure 4, showing vacuum holes for dust control. Figure 3A is a bottom perspective view of a profile sanding accessory, showing one cross-sectional configuration, for attachment to a profile rubberhead.

Figure 3B is a cross-sectional view of Figure 3A, showing the exterior surfaces coated with abrasives, such as aluminum oxide, silicon carbide, diamond, CBN or other suitable abrasive materials.

Figure 4A is a bottom perspective view of another configuration of a profile sanding accessory. Figure 4B is a cross-sectional view of Figure 4A.

Figure 5A is a bottom perspective view of another configuration of a profile sanding accessory.

Figure 5B is a cross-sectional view of Figure 5A.

Figure 6 is a bottom plan view of another embodiment of a sanding sheet using a wire-mesh in accordance with the present invention.

Figure 7 is an enlarged portion of a section of the wire-mesh sanding sheet of Figure 6.

Figure 8A is a cross-sectional view taken along line 8A-8A, showing a layer of glue as one means for securing the sanding sheet to a tool.

Figure 8B is similar to Figure 8A, showing a VELCRO fastener for securing the sanding sheet to the tool.

Figure 9 is a bottom plan view of another shape of the sanding sheet of Figure 6.

Figure 10 is a bottom plan view of another shape for the sanding sheet of Figure 6.

Figure 11 is a bottom perspective view of a concave profile sanding sheet made in accordance with the present invention and attached to a correspondingly shaped profile sanding rubberhead.

Figure 12 is a cross-sectional view taken along Figure 12-12 of Figure 11. Figures 13 and 14 show alternative concave shapes for the profile sanding sheet of Figure 11.

Figures 15, 16 and 17 show still other alternative convex shapes for the profile sanding sheet of Figure 11. Figures 18, 19 and 20 show still other alternative shapes for the profile sanding sheet of Figure 11.

DETAILED DESCRIPTION OF THE INVENTION A sanding accessory R made in accordance with the present invention is disclosed in Figure IA. The sanding accessory R includes a rigid base plate or substrate 2 and a plurality of clips 4 disposed along the edges of the base plate 2. The substrate 2 is preferably made from plastic, brass or other suitable materials. The clips 4 are used to removably secure the sanding accessory R to the sanding head of a sander tool (not shown) , such as a Black & Decker Detail Sander VP510T. Abrasive particles, such as aluminum oxide, silicon carbide, diamond, cubic boron nitride (CBN) , or other suitable abrasive materials are affixed to the bottom outside surface 6 of the base plate 2, as best shown in Figure IB. Direct deposition to a metal substrate, such as brass, is preferably made by electrolytic process, such as that disclosed in U.S. Patent No. 4,047,902, issued to Wiand. Nickel sulfamate is preferably used as the electrolytic solution. Adhesives or other suitable means may also be used for directly affixing the abrasive particles to the substrate. The abrasive particles may also be affixed indirectly onto the substrate 2. Referring to Figure ID, abrasive particles 3 are affixed with adhesive or other means to an intermediate layer, such as a paper backing 5.

The paper backing 5 is then affixed to the substrate 2 with glue 7 or VELCRO fastener. In this manner, the substrate 2 is advantageously made reusable and provides protection to the sander head when the paper backing 5 wears out during use.

The clips 4 are advantageously resilient enough so that the sanding accessory R can be snapped onto the tool through the spring action of the clips 4. When installed, the clips 4 serve to hold the sanding accessory R in place. The clips 4 are advantageously spring biased inwardly when the sanding accessory R is installed, thereby gripping the sides of the sanding head.

The sanding accessory R may also include other attachment means, such as glue or VELCRO (shown in Figures 8A and 8B) , for securing the base plate or substrate 2 to the sanding head, without using the clips 4. The plate 2 of sanding accessory R is substantially triangular in plan view, as best shown in Figure IC. It may also be made as a six sided polygon as best shown in Figure 2A. It may also include holes 8 as best shown in Figure 2B. The holes 8 communicate with a vacuum system of the tool for picking up dust generated during use. Other shapes may be used, depending on the job.

A profile sanding accessory S made in accordance with the present invention is disclosed in Figures 3A and 3B. The profile sanding S is a clip-on substantially U- shaped member that is clipped onto a rubberhead having a similar cross sectional shape, such as that available from PORTER CABLE, Kit No. 14480. The profile sanding accessory S is preferably made from plastic, brass or other suitable materials with sufficient spring action from its side walls 10 to compress the rubberhead (not shown) when installed to keep it secured thereto. The side walls 10 are resiliently biased toward each other when installed on a rubberhead, thereby gripping the sides of the rubberhead.

The outside surfaces 12 of the profile sanding accessory S are provided with abrasive particles 13, such as aluminum oxide, silicon carbide, diamond, cubic boron nitride particles, or other suitable abrasive materials. Direct deposition of the particles onto a metal substrate may be done by means of electrolytic deposition using nickel sulfamate. Adhesives or other suitable means may also be used for affixing the abrasive particles to the substrate. An intermediate layer, such as paper, may be used to affix the abrasive particles indirectly to the substrate, as disclosed for the sanding accessory R. The intermediate layer is then affixed to the substrate with glue or VELCRO fastener. The surfaces 12 are flat and make a V-shape in cross-section as best shown in Figure 3B. Another configuration of a profile sanding accessory T is disclosed in Figures 4A and 4B. The accessory T includes a concave surface 14 provided directly or indirectly with abrasive particles 15, such as aluminum oxide, silicon carbide, diamond, cubic boron nitride, or other suitable abrasive materials. The side walls 16 of the accessory T are resiliently biased toward each other for gripping the sides of the profile rubberhead when installed thereto. Still another configuration of a profile sanding accessory W is disclosed in Figures 5A and 5B. The accessory W includes a convex or cylindrical surface 18 provided directly or indirectly with abrasive particles 19, such as aluminum oxide, silicon carbide, diamond, cubic boron nitride, or other suitable abrasive materials. The side walls 20 are resiliently biased toward each other for gripping the sides of the profile rubberhead when installed thereto.

Other cross-sectional shapes can be made for the profile sanding accessory to conform to the various shapes of profile rubberheads that may be used.

Where the abrasive particles are affixed indirectly to the substrate through an intermediate layer, such as the paper backing 5 to which the abrasive particles are directly affixed with glue or other suitable means, the substrate is advantageously made reusable for replacement abrasive sheets as the paper-backed abrasives wear out during use. Yet another embodiment of the present invention is a sanding sheet 22 as disclosed in Figures 6 and 7. The sanding sheet 22 includes a metallic wire-mesh 24 and a layer of glue 26 with a protective removable cover 28, as best shown in Figure 8A. The cover 28 is removed prior to use to expose the glue 26. The layer of glue 26 is provided on one surface of the wire-mesh 24 for removably securing the sheet 22 to the head of a sanding tool (not shown) , such as a Black & Decker Detail Sander VP510T or other tool. VELCRO fastener 30 may also be used to removably secure the sheet 22 to the tool, as best shown in Figure 8B. The fastener 30 is secured to the wire-mesh 24 by standard means, such as glue.

The wire-mesh 24 is preferably made from metal or other suitable electrically conducting material. Other suitable materials, such as plastic, may also be used. Diamond and/or cubic boron nitride abrasive particles 32 are deposited on the bottom outside surface 34 of the wire- mesh 24, as best shown in Figures 7, 8A and 8B. Deposition is preferably made by electrolytic process, such as that disclosed in U.S. Patent No. 4,047,902, issued to Wiand. Nickel sulfamate is preferably used as the electrolytic solution. Other suitable abrasive particles secured with glue may also be used. The wire-mesh 24 is disposed on a layer of the abrasive particles within the solution tank. As the wire- mesh 24 is electroplated with nickel, the abrasive particles in contact with the wire-mesh 24 become locked in place by the deposited layer of nickel. Thus, the nickel layer secures the abrasive particles to the wire-mesh 24.

The nickel layer also advantageously welds the individual wires together, making the wire-mesh 24 much stronger. The wire-mesh 24 is then cut to the appropriate shape to fit the platen of the sanding tool.

The wire-mesh 24 has a multitude of cavities 36 formed between the individual wires 37. These cavities 36 advantageously serve as storage for the dust created during sanding, thereby minimizing clogging of the spaces between the individual abrasive particles. A coarser mesh size is used for larger grits and smaller mesh size for smaller grits.

The sheet 22 may be made in any shape to fit the planar outline or footprint of the head of the sanding tool. The sheet 22 is disclosed as being substantially triangular in plan view in Figure 6. It may also be made as a six sided polygon as best shown in Figure 9. It may also include holes 38 that communicate with the vacuum system of the tool for picking up dust generated during use. Other shapes may be used, depending on the job, such as a rectangle, as best shown in Figure 10.

A profile sanding sheet 40 is disclosed in Figures 11 and 12. The sanding sheet 40 is made the same way as the sanding sheet 22. The profile sanding sheet 40 has a three-dimensional surface 42 for use in a profile rubberhead 44, which has a congruent or parallel surface 46, as best shown in Figures 11 and 12 The profile rubberhead 44 is available from PORTER CABLE, Kit No. 14480 and is designed for use with an oscillating or reciprocating profile sander to treat curved surfaces or inside corner surfaces.

The profile sanding sheet 40 includes the wire- mesh 24 that is bent to the required profile shape before being electroplated with nickel and diamond and/or CBN abrasive particles 32. The nickel plating effectively welds each individual wires 36 of the wire-mesh to each other, thereby providing strength and rigidity. The sheet 40 is attached to the rubberhead surface 42 with glue 26 or VELCRO fastener 30, as best shown in Figure 12. The profile sanding sheet 40 is used for sanding convex surfaces. The sanding sheet 40 may be made with different radii of curvature, as best shown in Figures 13 and 14.

Another profile sanding sheet 48 is disclosed in Figures 15, 16 and 17. The sanding sheet 48 includes an outside convex surface 49 coated with the abrasive particles 32 for sanding the concave surface of a workpiece. The undersurface 50 of the sanding sheet 48 is coated with glue 26 or provided with VELCRO fastener 30 for securing to the appropriately shaped rubberhead of the profile sander.

Another profile sanding sheet 52 is disclosed in Figures 18 and 19. The sanding sheet 52 includes outside surfaces 54 that are flat and make a V-shape in cross- section. The surfaces 54 are coated with the abrasive particles 32 for sanding the inside corner of a workpiece. The undersurface 56 of the sanding sheet 52 is coated with glue 26 or provided with VELCRO fastener 30 for securing to the appropriately shaped rubberhead of the profile sander. Another profile sanding sheet 58 is disclosed in Figure 20. The sanding sheet 50 includes an outside surface 60 that is flat. The surface 60 is coated with the abrasive particles 32 for sanding a flat surface of the workpiece. The undersurface 62 of the sanding sheet 60 is coated with glue 26 or provided with VELCRO fastener 30 for securing to the appropriately shaped rubberhead of the profile sander.

Other cross-sectional shapes can be made for the profile sanding sheet to conform to the various shapes of profile rubberheads that may be used.

While this invention has been described as having preferred design, it is understood that it is capable of further modification, uses and/or adaptations following in general the principle of the invention and including such departures from the present disclosure as come within known or customary practice in the art to which the invention pertains, and as may be applied to the essential features set forth, and fall within the scope of the invention or the limits of the appended claims.

Claims

I claim:

1. A sanding accessory for an oscillating sander, comprising: a) a rigid substrate for securing to a sanding head of a sander, said substrate including a sanding surface; and b) abrasive particles secured to said sanding surface.

2. The sanding accessory as in claim 1, wherein said substrate includes a flat plate with spring clips around its periphery that are adapted to press against the edge of the sanding head.

3. The sanding accessory as in claim 1, and further comprising adhesive for securing said substrate to the sanding head.

4. The sanding accessory as in claim 1, and further comprising VELCRO fastener for securing said substrate to the sanding head.

5. The sanding accessory as in claim 1, wherein said sanding surface is profiled.

6. The sanding accessory as in claim 1, wherein said substrate is approximately U-shaped for securing to a rubberhead with complementary shape.

7. The sanding accessory as in claim 6, wherein said substrate has spring biased side walls adapted to grip the rubberhead.

8. The sanding accessory as in claim 1, wherein said substrate is made from metal.

9. The sanding accessory as in claim 1, wherein said substrate is made from plastic.

10. The sanding accessory as in claim 1, wherein said abrasive particles include aluminum oxide.

11. The sanding accessory as in claim 1, wherein said abrasive particles include silicon carbide.

12. The sanding accessory as in claim 1, wherein said abrasive particles include diamond.

13. The sanding accessory as in claim 1, wherein said abrasive particles include cubic boron nitride.

14. The sanding accessory as in claim 1, wherein said abrasive particles are deposited onto said substrate by electrolytic deposition.

15. The sanding accessory as in claim 1, wherein said abrasive particles are secured to said substrate by glue.

16. A sanding accessory, comprising: a) a wire-mesh for securing to a sanding head; b) said wire-mesh including a sanding side; and c) abrasive particles secured to said sanding side.

17. The sanding accessory as in claim 16, wherein said wire-mesh is substantially planar.

18. The sanding accessory as in claim 16, wherein said wire-mesh is profiled.

19. The sanding accessory as in claim 16, wherein said abrasive particles are deposited by electrolytic deposition.

20. The sanding accessory as in claim 16, wherein said abrasive particles are secured by adhesive.

21. The sanding accessory as in claim 16, wherein said wire-mesh is secured to the sanding head with glue.

22. The sanding accessory as in claim 16, wherein said wire-mesh is secured to the sanding head with VELCRO fastener.

23. The sanding accessory as in claim 16, wherein said abrasive particles include diamond.

24. The sanding accessory as in claim 16, wherein said abrasive particles include cubic boron nitride.

25. The sanding accessory as in claim 16, wherein said wire-mesh is approximately U-shaped for securing to a rubberhead with complementary shape. 27. The sanding accessory as in claim 16, wherein said wire-mesh is metal.