REFERENCE TO RELATED APPLICATIONS

[0001] Reference is made to PCT application serial number PCT/US22/17105 filed Feb. 18, 2022, which claims priority from U.S. provisional application No.

63/127,209 filed Dec. 18, 2020, the entire contents of both of which are hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

[0002] This invention relates generally to a handle for a hand-operated power tool, more particularly to a handle that can be bolted onto a tool and used with a common extension pole, and specifically to a handle for use with an orbital palm sander having a mating dust shroud attachment.

SUMMARY OF THE INVENTION

[0003] The present invention is directed to systems and methods which provide a handle for a power tool to permit use of a standard extension pole to extend the reach of the tool, and to a shroud that accommodates a square palm sander with a quick release which permits rapid replacement of sanding pads. This handle allows the user to operate a palm sander in a handheld, horizontal application or in an extended, pole application for overhead operations.

[0004] The invention is directed to a tool handle having a grip portion with two parallel attachment legs projecting from the two ends of the grip portion and perpendicular to the grip portion; the grip portion having a threaded hole for mounting a threaded extension pole; the threaded hole located on the grip portion and facing the opposite direction from the two legs. The threaded hole may be compatible with any one of the many standard broom-handle threads used throughout the world. [0005] In one example, the threaded hole comprises threads that correspond to an internal Acme thread of %-inch nominal diameter and 5 threads per inch, which would be compatible with a pole having external Acme threads that are ³ /4-inch nominal diameter and five threads per inch.

[0006] The two legs may each have a mounting hole and a mounting bolt for mounting to a specific tool or for mounting to a palm sander shroud. Knobs may be used for mounting. The handle’s angle may be adjusted.

[0007] The invention is also directed to systems including a dust shroud for a palm sander having two attachment projections adapted for attaching to the two attachment legs of the tool handle. The system may include a palm sander. The system may include a compatibly threaded, extension pole.

[0008] A sander shroud allows a palm sander to be used with the legs of the tool handle. The sander shroud includes: a generally circular shroud body comprising two semicircular half bodies with an opening in the middle when assembled; lead-screw tab structures that pull the two semicircular half bodies together to form the assembled shroud body snuggly around a sander housing; and two handle attachment sites projecting upward from the top of the body. A vacuum hose bib may be included. Additional tabs and set screw may be included to more firmly attach the shroud to the sander.

[0009] The invention is also directed to a generally square shroud body for square sanders. The square shroud may be used with the tool handle system described herein. Alternately, the square shroud may be used with the extension handle system described in PCT application serial number PCT/US22/17105 which is incorporated herein by reference.

[0010] The invention is also directed to a variable speed motor controller which can be used with a sander to control the speed of the sander. The variable speed controller includes a clip for attaching to the tool handle.

[0011] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The accompanying drawings, which are incorporated in and form part of the specification in which like numerals designate like parts, illustrate embodiments of the present invention and together with the description, serve to explain the principles of the invention. In the drawings:

[0013] FIG. 1 is a perspective view of an embodiment of the invention;

[0014] FIG. 2 is perspective view of an assembly embodiment of the invention;

[0015] FIG. 3 is an exploded perspective view of an embodiment of the invention;

[0016] FIG. 4 is perspective view of another embodiment of the invention;

[0017] FIG. 5 is an exploded perspective view of another embodiment of the invention;

[0018] FIG. 6 is an exploded perspective view of a round sander shroud embodiment;

[0019] FIG. 7 is another exploded perspective view of the sander shroud of FIG. 6;

[0020] FIG. 8 is a perspective view of a tool handle system embodiment of the invention. [0021] FIG. 9 is a top exploded perspective view of a square sander shroud embodiment;

[0022] FIG. 10 is a bottom exploded perspective view of the embodiment of FIG. 9;

[0023] FIG. 11 is a perspective view of the assembled embodiment of FIG. 9;

[0024] FIG. 12 is a perspective view of an assembly of the embodiments of FIG. 9 and

FIG. 4;

[0025] FIG. 13 is perspective view of a reducer fitting for use with the invention;

[0026] FIG. 14 is a perspective view of a Y fitting for use with the invention;

[0027] FIG. 15 is a rear perspective view of a variable speed controller embodiment; and

[0028] FIG. 16 is a front elevation view of the variable speed controller of FIG. 15.

DETAILED DESCRIPTION

[0029] An embodiment of the invention is shown in FIG. 1. The embodiment of FIG. 1 is tool handle 100 having a grip portion 102 with two parallel attachment legs 104, 105 projecting from the two ends of the grip portion and perpendicular to the grip portion; the grip portion 102 having a threaded hole 120 for mounting a threaded extension pole; the threaded hole 120 located centrally on the grip portion 102 and facing the opposite direction from the two legs 104, 105. The threaded hole may be threaded to be compatible with any one of the many standard broom-handle or extension-handle threads used throughout the world.

[0030] In one example, the threaded hole comprises threads that correspond to an internal Acme thread of %-inch nominal diameter and 5 threads per inch, which would be compatible with a pole having external Acme threads that are Yi-inch nominal diameter and five threads per inch. This thread is commonly found on paint roller extension handles, broom handles, mop handles, and the like, in the U.S.A. See e.g., American National Standard ASME/ ANSI Bl.5(1997) for further details on Acme threads. [0031] Any other common, suitable thread system may be used, depending on the need and the market served. Other exemplary systems include stub Acme threads, European threads, Italian threads, German threads, French threads, Greek threads, and Universal thread systems.

[0032] The two legs 104, 105 may each have an attachment site 106, 107 at the end thereof. The attachment sites may have a mounting hole 108, 109 and a mounting bolt 110, 111 may be used for mounting to a specific tool or for mounting to a palm sander shroud (described in more detail below). This handle allows the user to operate the tool by hand or by extension pole. The handle is highly adjustable and can be locked onto the tool at any desired angle. The tool can then be operated with a fixed extension pole or a telescopic pole to easily reach overhead projects or to reach low projects in a standing position.

[0033] Adjustment knobs 112, 113 may be included to attach the tool handle 100 to a tool or shroud and allow for adjusting the angle of the shroud to accommodate various pitches and angles. The knobs 112, 113 may be quick-adjust knobs, selflocking knobs, or the like. The knobs may facilitate hand adjustment and tightening without need for wrenches or other tools. Threaded holes may be used for attachment bolts or knobs and may be tapered in, open ended, or inserts in any of the embodiments presented herein. Attachment bolts 110, 1 1 shown are carriage bolts with means to prevent rotation of the bolt in the square holes 108, 109, for easy tightening with knobs 112, 113.

[0034] The handle has particular usefulness with tools having a mounting bolt hole on both sides of the tool body or head. Right angle grinders are an example of a hand power tool with mounting bolt holes on both sides of the grinder body. The handle may be bolted directly to such a power tool and used directly, or attached to an extension pole by threading the end of the extension pole into the threaded hole located on the top of the handle.

[0035] The inventive system may be particularly useful for palm sanders. However, palm sanders typically do not have the requisite bolt hole pattern needed. However, a sander shroud for palm sanders can adapt most orbital palm sanders with circular sanding disks so that the tool handle can be used. FIG. 2 illustrates tool handle 100 mounted onto sander shroud 400 at attachment posts 414, 415. FIG. 3 shows in an exploded view handle 100 with optional extension pole 200 and sanding shroud 400.

[0036] Another embodiment of the invention is shown in FIG. 4. As in the first embodiment of FIG. 1, the embodiment of FIG. 4 is tool handle 150 having a grip portion 102 with two parallel attachment legs 104, 105 projecting from the two ends of the grip portion and perpendicular to the grip portion; the grip portion 102 having a threaded hole 120 for mounting a threaded extension pole; the threaded hole 120 located centrally on the grip portion 102 and facing the opposite direction from the two legs 104, 105. The threaded hole may be threaded to be compatible with any one of the many standard broom-handle or extension-handle threads used throughout the world. Note that in either embodiment, the threaded hole 120 need not be exactly centered on the handle, but could be off center, or anywhere desired on the top of the handle.

[0037] In this second embodiment, the two legs 104, 105 may each have an attachment site 156, 157 at the end thereof. The attachment sites may have a mounting slot 158, 159. A mounting system like that of the first embodiment may be used, for example, carriage bolts and knobs. The slots permit adjustment of the handle on the tool, for example to accommodate taller tools. This handle also allows the user to operate the tool by hand or by extension pole. The handle is highly adjustable and can be locked onto the tool at any desired angle. The tool can then be operated with a fixed extension pole or a telescopic pole to easily reach overhead projects or to reach low projects in a standing position.

[0038] FIG. 5 shows in an exploded view of handle 150 with optional extension pole 200 and round sanding shroud 400.

[0039] An inventive palm sander shroud accessory enables use of the tool handle with an optional extension pole for sanding with a palm sander. FIG’s 6 - 8 show round Palm Sander Shroud 400 exploded, assembled, and mounted on the extension handle system, respectively. [0040] In FIG. 6 and FIG. 7, sanding shroud or dust shroud 400 has a main body 402 that is like an inverted cup or a cap with a circular hole 406 in the top surface 403 large enough to accommodate a typical palm sander housing, and a downward projecting perimeter wall or rim 405. The main body 402 is formed in two semicircular sections 404 and 408 which combined form the cap shape. The main body can thus be mounted around a sander housing without removing the sander’s backing disc. The ends of the arcs of the two semi-circular sections 404, 408 are adapted to join up by telescoping together, i.e., one half (408) overlaps the other half (404) to form a closed housing. At each end of the arcs of section 408 is an upward- projecting, lead-screw, tab structure 421. At each end of the arcs of section 404 are similar tab structures 422 set back from the telescoping portion 407. These tabs thus match up in pairs at each of the two joints. Tabs 421 on section 408 have through holes 424, and tabs 422 on section 404 have threaded holes 425, and the holes are all directed circumferentially. Bolts or lead screws 423 inserted through holes 424 and threaded into holes 425 can then draw the tab pairs 421, 422 closer together, telescoping the two shroud halves together and tightening or snugging up the shroud around a palm sander housing. Once snugly on the sander (see sander 420 in FIG. 8), a plurality of radially inward directed set screws 426 in other vertical tabs 409 can be tightened up against the sander housing. The otherwise round top 403 of the shroud 400 includes a non-circular enlarged section 413 where a vacuum hose bib 412 may be located. Two handle attachment sites 414 and 415 project upward from the top surface 403 of the main body 402. Each handle attachment site has a hole which may be threaded or otherwise adapted to fixedly or pivotally attach to the corresponding legs of the tool handle.

[0041] Other features for compatibility or strength may be added as needed. For example, indentation 416 may be included to accommodate the usual dust port on the back side of most palm sanders. Vertical support walls 417 are an example of useful stiffening or strengthening structures that could be added. Threaded holes may be through holes, or tapped in, or threaded inserts in this and all other embodiments presented herein. [0042] The sanding or dust shroud can also be adapted for use in tandem or more in a way analogous to the horizontal shroud described earlier. Adjustable, swivel connector brackets can be added to the shroud to join two or more together. Also, a rubber skirt can be added.

[0043] FIG. 8 shows the round sanding shroud 400 snugged up and secured around sander 420 in a sanding extension system. An embodiment of the tool handle 150 is bolted to the shroud joining the legs to the handle attachment projections 414, 415 at pivots 418. The sander may be mounted fixed or pivotably at the pivots. The mounting angle may be set as desired for the application. Optional extension pole 200 may be screwed into the threaded hole of the handle for extended reach.

[0044] Palm sanders typically have a debris bag attached to the tool that provides little benefit of accumulating dust and debris during operation. Vacuum hose bib 412 provides a better way to collect dust generated by sanding. Conventional drywall sanding is performed using metal screens on a pad and pole which is very messy with no collection capability. The inventive shroud with or without the extension handle system makes finishing drywall quick and relatively mess free with an attached vacuum, dust-collection system.

[0045] FIG’s 9-12 show another embodiment of a square sanding shroud that is adapted for use with sanders have square sanding pads. Square, palm-sander shroud 600 has a two-part housing. Front housing part 602 and rear housing part 603 slide together, telescoping into each other to complete the encapsulation of the shroud around a typical square palm sander. Portions 607a and 607b of the rear housing 603 slide under portions 613a and 613b of the front housing 602 of the shroud. Portions 607 have channel tracks 614 and 615 that a carriage bolt can sit in, and then the bolt can be pushed out a hole 623 in portions 613a and 613b. Then a knob, like knobs 112 and 113 in FIG. 12 can be threaded onto the carriage bolt. The carriage bolt may have a square base on the lower end on the head of the bolt which slides along inside the channel. The channel has no end to the slide so as the carriage bolt in front housing 602 slides to the end of the channels 614 and 615 in rear housing 603, the two parts can slip apart completely, allowing the user quick access to separate the two housing halves for changing the sandpaper and to easily reassemble to resume sanding. Vacuum port 612 is shown facing rearward on the rear housing 603. Indentation 616 may be included to accommodate the usual dust port on the back side of most palm sanders.

[0046] Square sanding shroud or dust shroud 600 has a main body that is like an inverted cup or a cap with a circular hole in the top surface large enough to accommodate a typical palm sander housing, and a downward projecting perimeter wall or rim 605. The main body is formed in two semi-rectangular sections 602 and 603 which combined form the square housing shape. The main body can thus be mounted around a sander housing without removing the sander’s square backing disc. The ends of the two semi -rectangular sections 602, 603 are adapted to join up by telescoping together, i.e., one half (613) overlaps the other half (607) to form a closed housing, telescoping the two shroud halves together and tightening or snugging up the shroud around a palm sander housing. Once snugly on the sander (see sander 420 in FIG. 8), a plurality of radially inward directed set screws 626 in vertical tabs 609 can be tightened up against the sander housing. Vacuum hose bib 612 may be located in the rear housing part 603. Knobs and the carriage bolts may also serve as handle attachment sites, as shown in FIG. 13. Other features for compatibility or strength may be added as needed. For example, tabs 609 may be extended around the round opening for stiffening or strengthening the structure. Threaded holes may be through holes, or tapped in, or threaded inserts in this and all other embodiments presented herein.

[0047] This bolting system exists on both sides of the shroud. When the user wants to add or change a sanding pad, they simply turn the knobs to the left slightly and the two-side slide apart off from the palm sander. The user can then change the sandpaper and return it to service by slipping the two halves back together. These channels also permit the necessary adjustments in length of the shroud to accommodate various sanders made in the world. There can also be multiple set screws at locations 626 (for example, three locations for set screws are shown in FIG. 9) on the side of the palm sander shroud which can snug the palm sander to the shroud and also help to accommodate the many sanders made in the world. [0048] The square palm sander shroud thus allows the user to quickly turn two knobs to remove the shroud from the square palm sander. Square palm sanders use small sheets of sandpaper and is the most commonly used sander in the world. The sandpaper application requires the user to frequently remove and replace the sandpaper from the wire and sometimes plastic clips located on the bottom of the sander. This requires unobstructed access to the replacement of the sandpaper.

[0049] Thus, the shroud has a quick release to separate the two halves of the shroud by slightly turning two knobs on each side of the shroud for quick removal and replacement of sandpaper. This shroud is also highly adjustable to fit on many makes and models of palm sanders with adjustable channel knobs that allows the user to adjust the shroud very specifically to the palm sander model being used. Threaded holes may be tapered in, open ended or inserts to attach a handle to a shroud or palm sander in this and in all other embodiments presented herein.

[0050] There is also a vacuum system built into this shroud that can help remove dust and debris to maintain a clean work environment instead of the mess commonly found in conventional sanding, which can’t be good for your health. Readily available, or custom vacuum hoses may be used on any of our shrouds including vertical and horizontal shrouds and wet or dry applications. The new vacuum system may generate greater suction than the convention 2” vacuum hose which are typically heavy and cumbersome and not suitable for the relatively lightweight design of the present tool accessories. The new system is a dual suction application dividing the suction into two 1” vacuum lines for greater suction capability. One line may attach to the dust port on the sanding shroud, the other fits onto the sander’ s built in dust port. The Y-fitting 720 shown in FIG. 15 may be connected to the two hoses and then attached to the vacuum source. If necessary, the reducer fitting 710 shown in FIG. 14 may be used to transition from a larger vacuum source (e.g., a 2-inch source) to the smaller (e.g., 1-inch) lines or the Y. Alternately, the Y fitting 720 shown in FIG. 15 may be connected to the housing so that two one-inch lines may be used to increase the suction. Then the reducer shown in FIG. 14 may be used with another Y- fitting to transition the vacuum line to a standard two-inch shop vac. We have also developed a new universal reducer to accommodate our 1” vacuum system with a 2” male adapter to fit standard intake ports available on many shop vacs sold in the industry today.

[0051] The shrouds thus accommodate various types of vacuum lines. Preferably the vacuum line uses light weight but heavy duty 1” (one-inch) hose and adapts the 1” hose to accommodate the conventional shop vac connector bibb of 2” commonly found on most shop vacs. A single one-inch line may be used with a single reducer, or a dual line system with a Y-fitting and a reducer may be used. A lightweight hose line may be easier to move around than the conventional 2” hose which is heavier and more cumbersome. A dual, 1” system may have greater suction than a single 2” line and may allow the user to get more done more quickly

[0052] FIG. 13 shows the vacuum reducer fitting 710 for the sander shrouds to take any shop vac from a 2" vacuum intake typical size on all shop vacs to our 1" hose ID to all of our shrouds. The industry standard is 2" ID which is heavy and cumbersome. Our lightweight lines provide more suction than the standard 2" and are quicker and more maneuverable on the fly.

[0053] FIG. 14 shows the “Y” fitting 720 used to accommodate our shrouds having one or two 1" vacuum hose bibs for ultimately connecting to a 2” vacuum. This again replaces the standard 2" lines with lightweight 1" vacuum lines that allows the user to move swiftly on the fly as opposed to the heavy and cumbersome industry standard 2" vacuum lines.

[0054] Drywall sanding involves a mild sanding motion, and most orbital palm sanders rotate at a higher rate than is ideal for drywall sanding. Conventional sanding is performed using a pole, a sanding pad, and a screen. To equate the rpm’s of this hand sanding process you would need to have an rpm equivalent speed of about 2,000 rpm’s. A typical palm sander produces about 12,000 rpm’s. Therefore, it may be advantageous to reduce the rpm’s of the typical 12,000-rpm palm sander to around 2,000 rpm’s with a suitable variable speed controller (“VSC”).

[0055] A variable speed controller should therefore allow the user to reduce the common output of a 12,000 rpm palm sander down to about 2,000 rpm. This would be the equivalent to using a hand sanding screen on a pad that is the conventional method used today. This approach is less taxing on the user and seriously reduces dust and debris commonly associated with drywall and wood sanding. The VSC described in PCT/US2022/17105 may be used advantageously with the inventive sanding system. That Variable Speed Controller has also been re-designed to be used on a paint pole or extension pole and features a mounting capability to attach the variable speed controller to a paint or extension pole.

[0056] . FIG. 15 and FIG. 16 show both sides of variable speed controller (“VSC”) 750. VSC 750 was developed specifically for use with the extension handle system, but is generally applicable to any power tool needing variable speed control. VSC 750 includes housing 752, which has a convenient rectangular solid shape.

Each end of the housing 752 has an opening in which electrical receptacles or plugs are mounted. At one end is female receptacle 758 which may be used as a tool outlet for plugging in the power cord of a tool. At the opposing end of the housing 752 is male electrical outlet 759 which may be used as an extension cord receptacle to provide power the VSC and the attached tool. On the top side of housing 752 is speed control thumb wheel 756. Inside the housing is an AC motor speed control circuit board on which thumb wheel 756 is mounted. Also inside the housing are wires connecting the male outlet 759 to the control circuit board and the female receptable 758 to the control circuit board. Elongated clip 760 is adapted for attachment to a paint pole or extension pole. Locking screw 754 may be used to secure the attachment to a paint pole or extension pole. Other styles of screws, bolts, clips or attachments may be substituted.

[0057] This new handle grip, vacuum system and highly adjustable square sander shroud is useful and is believed to be the first of its kind for operating a square palm sander for sanding dry wall, wood and all other similar sanding projects. The addition of the VSC to the system turns a common palm sander into a versatile dry wall sanding machine. All together the new handle, square shroud along with the round shroud from our previous patent application, the new vacuum line system and the variable speed controller converts a common everyday palm sander into a complete system of dust and debris containment system not currently available in the marketplace today. [0058] Although the present invention and its advantages have been described in detail, various changes, substitutions, and alterations can be made herein without departing from the scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods, and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps. The invention disclosed herein may suitably be practiced in the absence of any element that is not specifically disclosed herein.