FIELD OF THE DISCLOSURE

[0001] The present disclosure generally relates to a vacuum sander.

BACKGROUND OF THE DISCLOSURE

[0002] A motorized vacuum sander may be used to sand drywall and reduce clean up time by collecting dust and debris while sanding drywall compound, for example. A dust collection system may be coupled to the motorized sander whereby a vacuum draws the sanded drywall dust into a dust collecting vessel as the drywall compound is removed.

SUMMARY

[0003] In one aspect, a vacuum sander generally comprises an elongate handle; a forked handle attachment coupled to the elongate handle, wherein the forked handle attachment includes two prongs; and a drive coupled to the forked handle between the two prongs thereof, wherein the drive is configured to couple to a sanding implement and to selectively drive movement of the sanding implement.

[0004] In another aspect, a head assembly for a vacuum sander generally comprises a forked handle attachment configured to couple to an elongate handle, wherein the forked handle attachment includes two prongs; a drive rotatably coupled to the forked handle attachment between the two prongs thereof, wherein the drive is configured to couple to a sanding implement and to selectively drive rotation of the sanding implement about an axis; and a debris shroud coupled to the drive and configured to enclose the sanding implement when coupled to the drive.

[0005] In yet another aspect, a head assembly of a vacuum sander generally comprises a handle attachment configured to couple to an elongate handle; a drive configured to couple to a sanding implement and to selectively drive rotation of the sanding implement about an axis; and a debris shroud configured to enclose the sanding implement when coupled to the drive. The handle attachment is rotatable coupled to the drive to allow selective rotation of the handle attachment relative to the drive and the debris shroud about a first axis. At least a portion of the drive is rotatable relative to the debris shroud to allow selective rotation of said at least a portion of the drive and the handle attachment relative to the debris shroud about a second axis different from the first axis.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIG. l is a perspective of one embodiment of a vacuum sander constructed according to the teachings of the present disclosure.

[0007] FIG. 2 is an enlarged perspective of a sanding head of the vacuum sander;

[0008] FIG. 3 is an exploded view of FIG. 2.

[0009] FIG. 4 is an exploded view of a drive of the sanding head.

[0010] FIG. 5 is a right perspective of a housing body of a belt-drive transmission of the drive.

[0011] FIG. 6 is a left perspective of a housing body of a belt-drive transmission of the drive.

[0012] FIG. 7 is an exploded view of a gearbox transmission of the drive.

[0013] FIG. 8 is a bottom perspective of the gearbox transmission, with a worm and an output shaft of the belt-drive transmission exploded therefrom.

DETAILED DESCRIPTION OF THE DISCLOSURE

[0014] Referring to FIG. 1, one embodiment of a vacuum sander is generally indicated at reference numeral 10. The illustrated vacuum sander 10 is suitable for sanding drywall, as is generally known in the art. In general, the vacuum sander 10 includes a sanding head, generally indicated at 12; an elongate handle or pole 14 coupled to the head and extending distally therefrom; and a control 16 coupled to the handle 14. Referring to FIG. 2, as explained in more detail below, the sanding head 12 includes a drive, generally indicated at 17 (e.g., an electrically-powered drive), configured to drive rotation of a sanding disc (not shown) coupled to the head assembly; a debris shroud 18 coupled to the drive; and a handle attachment, generally indicated at 19, coupling the handle to the drive. The illustrated debris shroud 18 includes ribs on an upper surface thereof to provide rigidity to the shroud to maintain flatness.

[0015] Referring still to FIG. 1, the handle 14 is hollow and defines a vacuum passage 20 extending along its length between its proximal and distal ends in fluid communication with the vacuum passage of the head 12. The exterior of the illustrated handle 14 has a polygonal (e.g., octagonal) cross-sectional shape, although it may have other shapes. The handle 14 may be adjustable in length (e.g., telescoping). The proximal end of the handle 14 is operatively coupled to a vacuum source 21 configured to pull a vacuum or create negative pressure within the handle and the head 12. As an example, a flexible tube 22 fluidly connects the handle 14 to the vacuum source 20. A canister or container 24 is fluidly connected to the vacuum source 21 to collect debris being drawn from the head 12 and through the handle 14.

[0016] As shown in FIG. 1, the control 16 is coupled to the handle 14 between the proximal and distal ends. The control 16 includes one or more actuators (e.g., button, lever, or the like) in electrical communication with the drive 17 of the head assembly 12 and configured to actuate operation of the head assembly (i.e., rotation of the sanding disc) and/or the vacuum source 21. Referring to FIG. 2, the control 16 is electrically connected to the drive 17 via an electrical wire 30 other electrical conductor extending along the handle 14.

As shown in FIG. 1, the control 16 is electrically connectable to a power source via an electrical cord 32 or other electrical conductor extending proximally from the proximal end of the handle 14. The use of the actuator(s) of the control 16 selectively supplies power from the power source to the drive 17. In another embodiment, the vacuum sander 10 may be battery-operated and a battery (e.g., a rechargeable battery) may be coupled (e.g., mounted on) the sander.

[0017] Referring to FIGS. 2 and 3, the handle attachment 19 is forked and includes two prongs (e.g., upper and lower prongs 40a, 40b) converging at a coupling 42 configured to be fastened (such as by screw, bolts, or other fasteners) to the distal end of the handle 14. Each of the prongs 40a, 40b and the coupling 42 defines a portion of a vacuum passage of the head 12 in fluid communication with the vacuum passage 20 of the handle 14. Each of the prongs 40a, 40b is rotatably coupled to the drive 17 at a drive coupling 40 to allow selective rotation of the attachment 19 and the handle 14 about a first axis A1 (FIG. 2) relative to the debris shroud (and the drive). The prongs 40a, 40b are also fluidly connected to a portion of the vacuum passage of the head 12 extending through the drive, as explained in more detail below. The drive 17 is received in the space between the prongs 40a, 40b to provide clearance for the attachment 19 and the handle 14 to rotate about the first axis Al. In one example, the attachment 19 is rotatable about 180 degrees about the axis Al.

[0018] Referring to FIG. 4, the drive 17 includes an electric motor 50 electrically connected to the control 16; a belt-drive transmission, generally indicated at 52, operatively coupled to the electric motor; and a gearbox transmission, generally indicated at 54, operatively coupled to the belt-drive transmission. Mechanical power is transmitted from the electric motor 50 to the sanding disc through the belt-drive and gearbox transmissions 52, 54, respectively. The electric motor 50 includes an output shaft 60 that is rotatably driven about an output axis OA1. A fan 62 is coupled to the output shaft 60 to produce air flow through the belt-drive transmission 52 to cool the motor 50. In one example, the motor 50 is a universal motor, although it may be of other types. In another embodiment, the motor may be another type of motor other than electrical, such a pneumatic.

[0019] Referring to FIGS. 3 and 4, the belt-drive transmission 52 includes a belt- drive housing 70, and a belt assembly 72 in the housing. The belt-drive housing 70 includes a housing body 74, a belt assembly cover 76, and a divider 78 sandwiched between the housing body and the belt assembly cover. The output shaft 60 of the motor 50 extends into the belt-drive housing 70 through the housing body 74. The fan 62 is received within a cavity 80 defined by the housing body 74 and a fan portion of the divider plate 78 overlies the fan to capture the fan within the cavity. A bearing 86 coupled to the output shaft 60 of the motor 50 is received in an opening 88 in the divider plate 78 to allow rotation of the output shaft.

[0020] The belt assembly 72 includes an input shaft 90 coaxially coupled to the output shaft 60 of the motor 50 for rotation about the axis OA1 of the output shaft; an input gear 92 coupled to the input shaft for rotation about the axis OA1 of the output shaft; an output gear 96 coupled to the input gear by a toothed belt 98 and configured to rotate about its center; and an output shaft 100 coaxially coupled to the output gear for rotating about its axis OA2. The input and output gears 92, 96 and the belt 98 are received in the cover 76 and on the side of the divider plate 78 opposite the housing body 74. The output shaft 100 of the belt assembly 72 extends through an opening 102 in the divider plate 78 and is coupled to a bearing 104 received in the opening. The diameter of the first gear 92 is less than the diameter of the second gear 96. For example, the gear ratio may be from about 3 : 1 to about 6: 1, or other suitable ratios.

[0021] Referring to FIG. 7, the gearbox transmission 54 includes a gearbox housing 110 defining a gear compartment into which the output shaft 100 of the belt assembly 72 extends. As shown in Fig. 2, the belt-drive housing 70, and in particular the housing body 74, is rotatably coupled to the gearbox housing 110 such that the belt-drive transmission — along with the motor 50, the attachment 19, and the handle 14 — is rotatable generally about an axis A2 that is coaxial with the output axis OA2 of the output shaft 100, although the axis of rotation A2 may not be coaxial with the output axis OA2 in other embodiments. The gearbox transmission 54 further includes a worm 111 coupled to the output shaft 100 of the belt assembly 72; a worm gear 112 engaging the worm; and an output shaft 114 coaxially coupled to the worm gear for rotation about its axis OA3. The output shaft 114 extends through an opening 118 in an upper surface of the debris shroud 18. The output shaft 114 is configured to couple to a sanding disc within the shroud 18. Bearings 120 are disposed within the gearbox.

[0022] As can be understood from the above description, in operation the output shaft 60 of the motor 50 is rotatably driven to impart coaxial rotation of the input shaft 90 and input gear 92 of the belt assembly 72. Rotation of the input gear 92 drives axial rotation of the output gear 96 and output shaft 100 of the belt assembly 72 via the belt 98. Rotation of the output shaft 100 of the belt assembly 72 drives rotation of the worm 111, which in turn drives rotation of the worm gear 112 and the output shaft of the gearbox transmission to rotate the sanding disc.

[0023] As mentioned above, the drive 17 defines the portion of the vacuum passage that fluidly connects the debris shroud 18 to the handle attachment 19 and the handle 14. In this regard, the vacuum passage is defined the coupling 40, the belt-drive housing body 74, and the gearbox housing 110. The coupling 40 defines upper and lower downstream openings 120a, 120b fluidly connecting the prongs 40a, 40b of the forked attachment 19 and a coupling plenum 124 defined by the coupling. The coupling plenum 124 is fluidly connected to a housing plenum 126 defined by the housing body 74 and the divider plate 78. The divider plate 78 separates the vacuum passage and the belt assembly cover 76. The housing body 74 defines an opening 128 (e.g., an annulus) to fluidly connect the housing plenum 126 to a gearbox plenum 130 in the gearbox housing 110. A boss 140, which may include a bearing, for the output shaft 100 of the belt-drive transmission 52 extends through the opening 128, whereby the vacuum passage extends around the boss. As shown in FIG. 8, the gearbox plenum 130 extends from a lower surface of the gearbox housing 110 and is in fluid communication with one or more openings 134 in the upper surface of the debris shroud 18.

[0024] As can be understood from the above description, in operation the vacuum pulls a vacuum or creates negative pressure within the vacuum passage to draw debris from the sanding disc, through the sanding head 17, the attachment 19, and the handle, into the container 24. The debris flows through the openings 134 in the debris shroud 18 and into the gearbox plenum 130. From the gearbox housing 110, the debris flows through the housing body 74 of the belt-drive transmission 52, into the plenum 124 of the coupling 44. From the coupling plenum 124, the debris is drawn into the handle attachment 19, and then into the vacuum passage of the handle 14 where it exits and enters the container 24. [0025] Modifications and variations of the disclosed embodiments are possible without departing from the scope of the invention defined in the appended claims.

[0026] When introducing elements of the present invention or the embodiment(s) thereof, the articles "a", "an", "the" and "said" are intended to mean that there are one or more of the elements. The terms "comprising", "including" and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements.

[0027] As various changes could be made in the above constructions, products, and methods without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.