IMPROVEMENTS IN SANDING DISKS

The present invention relates generally to disks used for sanding

in conjunction with a power tool, such as an electric drill or vibrating pad.

BACKGROUND OF THE INVENTION

Field of the Invention

The sand disk of the present invention is intended for use in

finishing wood products, or the like, in conjunction with a power tool such as

an electric drill. This represents an improvement in the sand disk shown

and described in the above referenced co-pending application.

As stated in the co-pending application, there is a plethora of

sanding devices, all of which have one or more deficiencies ranging from

quickly loading up with removed material to accelerated wear. It is the

intent and purpose of this device to alleviate, if not eliminate, the

deficiencies of existing devices.

Overview of the Prior Art

While the intrinsic value of sandpaper products is almost

universally recognized, so too are the deficiencies. Among early patented

efforts to eliminate the paper backing used in conventional sandpapers is

Lambert patent number 1,729,881, issued in 1929. Lambert teaches a

rotary disk having a series of uniformly spaced punched cutting teeth.

Lambert was primarily concerned with the positioning and rigidity of the

disk, which was intended for use. with a hand power tool, to avoid imbalance

and the dangers of flying debris. Schwartz, in his patent number 4,685,181

offers a slightly different shaped disk with teeth formed by drilling holes and

then upsetting an edge of the opening.

While Lambert focused on a sanding device for a rotary tool,

Benis et al. applied his thinking to a vibratory device in his patent number

3,583,107 for a flexible sheet metai speed file. A uniform pattern of

punched teeth were formed on a rectangular piece of malleable metal. The

thrust of the patent was, however, directed to the flaps 29, 31 which were

used to hold the device to the hand tool. Konrad patent number 4,028,781

is a similar type device, and Young patent number 5,683,292 is yet another

abrading device with rows of upstanding, similarly oriented, teeth having

angles of 45 to 135 degrees.

Having found devices for use with rotary, orbital and vibratory

power tools, Konrad patent number 4,377,081 addresses the use of a metal

belt surfacing tool which has been perforated to form teeth.

The shape of the teeth is a function of the punching device used

to form them, as evidenced by the several patents discussed, together with

Amsen patent number 2,820,28I ₇ which teaches an abrasive device in which

the teeth are formed by a punch which causes the upward tearing of the

material so as to have five upstanding points. Kaufman, on the other hand,

in his patent number 3,468,079, creates a star-like tooth. Kaufman

envisions his device as a callous remover.

It will be appreciated that when a punch, or stamping device, is

used, the punch penetrated the metal material at a center point, and the

material is literally torn, as the punch advances; from that central point to

the root, or perimeter, of the tooth, which is determined by the depth of the

punch. Each segment of torn material will define a sharp point which is

intended to contact the material, e.g., wood, plastic or metal, and remove

particles thereof.

Yet another inventor, Rickey Newmayer, has yet another device

in the form of a rotary disk (patent number 4,137,617) having square

and/or circular teeth for the cutting of plastics. The formation of the

Newmayer teeth is attributable, in the Newmayer specification, to two other

patents, and both of those patents talk of punch and die methods.

There are several other patents found in the abrading art, all of

which have one or more variations on essentially the same theme.

SUMMARY OF THE INVENTION

The present invention comprises an improved multi-faceted

abrading device, the basic design of which makes it compatible with both

rotary, orbital and vibratory power hand tools to effect a finish of desired

smoothness on a work piece of wooden material.

With the foregoing in mind, it is a primary objective to provide

such a device that is capable of performing like sandpaper, while having

none of the deficiencies of sandpaper as chronicled above.

Another objective of the present invention is to create an

improved metallic abrading device that has the efficacy of sandpaper, in that

it is capable of removing controlled amounts of material, irrespective of the

direction in which it is moved, while having excellent durability and useful

life.

It is yet another objective of the present invention to provide an

abrading device which is usable either with a rotary hand tool or a vibratory

hand tool, and which starts exceptionally sharp and stays sharp for extended

periods of use. An objective related to the foregoing is that the device of the

present invention will not clog or load up in a way which adversely effects its

performance.

More specifically, it is an objective of the present invention to

overcome occasional problems experienced in the use of the abrasive device

of the above referenced co-pending PCT application.

The foregoing, as well as other objects and advantages of the

abrading device of the present invention, will become more evident from a

reading of the following Detailed Description of a Preferred Embodiment,

taken in concert with the drawings, wherein:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1, is a side elevation of the face of an abrading device in

the nature of a sanding disk constructed in accordance with the present

invention; and

FIG. 2, is a side elevation of the rear of the disk of Fig. 1.

DESCRIPTION OF A PREFERRED EMBODIMENT

With reference now to the drawings, and coincidently to the

above referenced application which is incorporated herein by reference, the

improved omnidirectional abrading device in the nature of a disk of the

present invention is illustrated at 10.

The several disk configurations described and claimed in the

above referenced PCT application have been shown in most commercial and

home projects to be exceptionally effective. In some applications, however,

there have been times, and under some conditions, when the disk clogs and

toads up with removed material, causing unacceptable erratic surfaces on a

work piece and work delays while the disk is cleaned off or replaced.

In other situations, e.g., where the moisture content is higher

than usual, the saw dust, or other debris removed from the work piece, will

accumulate behind the disk between the disk and the power tool driving the

disk. When this occurs, the disk tends to deform and may pull away from

the tool, and the surface being worked may be damaged, or even worse, the

disk may separate from the tool. The disk 10 has been specifically created

in order to minimize, if not totally eliminate,, the problems enumerated

above. Further, while the disk 10 is metallic and, as illustrated, is circular,

other shapes may be constructed without departure from the operative

principles taught herein.

Finally, heat generated at the disk under normal operating

conditions is heightened by accumulated debris as it clogs teeth, and

adhesives holding the loop and hook material in place may be adversely

effected, as well as the hook and loop material itself, which is susceptible to

distortion due to excessive heat.

Returning to the drawings, it will be seen in FIG. 1 that there are

a plurality of discrete segments 12 , each having a pattern of cutting teeth.

The segments are positioned about the periphery of the disk. The segments

12 are preferably spaced equidistant from each other, although it may not

be necessary. Each of the peripheral segments is preferably of a geometric

shape to take optimum advantage of the space available on the disk. A

central segment is also provided at 16. In an attempt to alleviate heat

problems, a series of vents 17 are strategically located in spaces between

tooth segments 12 and center segment 16.

As pointed out, each tooth segment is formed with an array of

abrading elements, or teeth, 14, which teeth are preferably formed by a

photo chemical etching process in the nature of that set forth in Sturtevant

et al. patent 5,100,506. Each segment may have a tooth pattern which is

omnidirectional, or where appropriate, the array of teeth in each segment

may be unidirectional and all of the segments combined are able to cut in

an omnidirectional pattern when the disk is rotated.

Several omnidirectional tooth configurations are taught in the

above referenced Sand Disk application, any one of which may be used with

the present disk without departure from the invention. In keeping with the

objective of the present invention to substantially alleviate, if not eliminate,

clogging and loading problems, the positioning of teeth segments 12 on the

disk becomes important.

The disk of the present invention is preferably formed of a flat

disk, and as finished, is a planer piece of relatively rigid material having

front and rear faces 18 and 19, respectively. In order to affix the disk to a

platen mounted on its companion power tool (not shown as it is of well

known configuration), it is fitted with a hook and loop type attachment

arrangement which will adhere the disk to the tool used to power it.

Referring to FIG. 2, it will be seen that the back 19 of the disk is affixed with

a series of attachment devices 20. The attachment devices are in spaced

relation about the disk and, as shown, are located in the spaces 22 between

the tooth segments 12. With this intermittent spacing, none of the teeth are

covered by an attachment device, or any portion thereof. Further, there is a

series of channels created between the disk and the power tool equal to the

thickness of the attachment fabric which has the dual advantage of allowing

air flow beneath the clusters or segments 12.

Each attachment device is formed with one half of a hook and

loop type fabric, and all of the attachment devices 20 are of the same fabric.

The companion fabric, whether hook or loop, is mounted to the tool used to

drive the disk, whether it is rotated, oscillated or vibrated, and the disk is,

thus, secured to the tool, by mating segments of the hook and loop fabric,

and able to function in concert with the power tool as it was designed to do.

Having now described the improved sand disk in considerable

detail it will be seen that by spacing the hook and loop attachment material,

channels are created which permit the discharge of debris otherwise

accumulated behind the teeth and, further, provides air flow which would

tend to cool the disk, thereby decreasing heat build up which would harm

performance. It will be apparent to those skilled in the art that some

variation in the shape, size and nature of the various elements of the disk

would be possible, and such variations are within the contemplation of the

invention as described in the accompanying claims, wherein: