Surface treatment disks for rotary tools

[0002] Not applicable.

[0003] 1. Field of the Invention

[0004] This invention relates to surface treatment disks, especially to such surface treatment disks which are attachable to rotary tools.

[0005] 2. Description of Prior Art

[0006] Different types of surface treatment disks are available in the market; including abrasive disks, buffing disks, polishing disks, etc. that are attachable to a rotary tool, such as a drill, a saw, a buffing machine, etc., and these machines may be portable or stationary. (Note: The terms “treatment”, “treating”, “finishing” and their variations, or equivalents are alternatively used in this application, and indicate the action of a disk applied to a surface.)

[0007] In general, the purpose of these disks is to aid in the treatment of surfaces that do not have any high or low relieves or any other intricate shapes. In other words, the surfaces or portions of surfaces to be treated are either flat or if they are not flat, they have a continuous and even shape.

[0008] These prior art disks, and the system to treat surfaces therewith were first introduced into the marketplace by the industry in an attempt to maximize the utility and as a result, the demand for power drills, since they would obviate the need to purchase a dedicated sanding machine, which would represent substantial savings to the consumer.

[0009] A notable variation of this system consists of a rubber padded disk in conjunction with circular sandpaper adhered or otherwise fastened to said rubber padded disk.

[0010] This prior art system fails to provide an adequate alternative to dedicated sanding machines. The reason is precisely that the principles of dedicated sanding machines have been extrapolated to drills and other rotary machines, and thus they have a flat shape. And there is where the problem resides.

[0011] Dedicated sanding machines can function with this type of flat disks because their movement is either of an orbital nature or of an oscillatory nature.

[0012] When using a dedicated sanding machine, the force is uniformly distributed throughout the surface of the disk and then applied to the surfaces being treated, and the disk may be in a controlled motion when flatly in contact with the surface being treated.

[0013] But that is not at all the case with rotary tools, where the movement is of a rotary-centrifugal nature.

[0014] When the prior art disks are attached to rotary tools, the results are very far from satisfactory. The method is not practical or functional, as it is demonstrated by the following specific problems:

[0015] 1) The centrifugal force directs all the action to the periphery of the disk. This constitutes a critical flaw of the system, since the periphery is only a nominal area, while the entire surface area of the disk is virtually inert. Hence, these other problems are derived from this critical defect:

[0016] 2) If the rotary disk is applied flatly parallel to the surface being treated, a tendency to inertia occurs. (See FIGS. 1 and 3.) A “brake” effect is produced and any abrasive or polishing or otherwise finishing effect is voided.

[0017] 3) If the rotary disk is applied in an angle to the surface, all the finishing effect will be applied by the periphery of the disk, treating a minimal area, as indicated before. (See FIGS. 2 and 3.) But this is further aggravated by the concentrated strong effect, particularly if the disk has abrasive properties, that will have a carving effect on the surfaces being treated, which is additionally very difficult to control.

[0018] 4) Due to the high resistance offered by the surface being treated to the disk, a vibration is provoked. This vibration causes the disk to detach from the rotary tool very frequently.

[0019] 5) Likewise, when using sand paper attached to a padded disk, this vibration causes the sand paper to be constantly detached. This has an even more damaging effect if the sand paper is adhered to the padded disk. After two or three detachments and re-attachments, the fastening strength of the adhesive is substantially reduced. This is further aggravated by all the dust that contaminates the adhesive coating of the sand paper, rendering it useless, As a result of the preceding, other significant problems are generated:

[0020] 6) Excessive fatigue and low productivity are imposed on the operator.

[0021] 7) Surfaces are unevenly treated.

[0022] 8) Uneven wear of finishing disks and accessory materials occurs.

[0023] 9) High risk of slipping of the rotary tool, due to the uneven contact of the surfaces, which entails a risk of harm to operator, his/her clothes, and/or surrounding objects.

[0024] The preceding problems relate to the use of the disks when flatly applied to the surface being treated, or when applied in an angle. But there is another scenario. Probably the most common scenario, with some of the preceding disadvantages, plus some others, as follows:

[0025] 10) In an effort to equilibrate the two extreme modes of operation mentioned before (a. Applying the disk flatly against the surface being treated, and b. Applying the disk in an angle to the surface being treated,) the operator may instinctively force the disk into a more natural shape for the task, if the disk offers some flexibility. While the effort is substantial (most probably operator will use both hands) the flexibility is minimal. (See FIG. 4.) Thus, what is achieved is an increased fatigue to operator in exchange for an insignificant improvement in performance, plus a highly enhanced risk of disengagement of the disk from the rotary tool, and/or sand paper or any other surface treatment accessory from the disk. This effort to force the disk into a more co-operative shape, may cause the fracture of the disk, as it commonly happens with wire disks for abrasive purposes, as described by FIGS. 5, 6 and 7.

[0026] Accordingly, several objects and advantages of my invention are:

[0027] 1. Permits an easier treatment of surfaces, and consequently reduces fatigue.

[0028] 2. Permits a faster treatment of surfaces, and consequently increases productivity.

[0029] 3. Permits more control of the treatment of surfaces.

[0030] 4. As a result of #3., permits a uniform and even treatment of surfaces for a better quality job.

[0031] 5. Prevents the uneven wear of the finishing materials.

[0032] 6. Prevents the rupture of abrasive metallic disks, that occurs in the concentric surrounding area where connected to the tool.

[0033] 7. Prevents the slipping of the disks due to an uneven contact with surfaces being treated.

[0034] 8. As a result of #7., prevents any accident against operator of rotary tool, operators clothes and/or any surrounding objects.

[0035] 9. Minimizes incidence of disengagement from the tool, which requires a constant re-attachment of the disk to the machine or tool as vibration is reduced or eliminated.

[0036] 10. When using sand paper disks, permits a stronger adhesion, as vibration is reduced or eliminated, preventing the need to constantly re-attach the sand paper disks

[0037] 11. As a result of #10., extends durability of paper disks, as repeated attachments wear their adhesive strength.

[0038] 12. The good bonding quality of the paper disks and the usefulness of the disks is also extended as contamination of the adhesive substance that occurs when the disks are detached and exposed to the dust is prevented.

[0039] 13. Manufacturing of the disk appears highly compatible with the established systems. Implementation should be facilitated by this.

[0040] 14. As a result of #13., costs to produce should be very similar. Price to consumer could be very similar, while there is a significantly higher value.

[0041] 15. As this system actually uses and exploits the centrifugal force to treat surfaces, disks could be of a larger diameter for a yet better performance.

[0042] Further objects and advantages of my invention will become apparent from a consideration of the drawings and ensuing description.

[0043] In accordance with the present invention an improved surface treatment disk for rotary tools comprises a conical shape, said conical shape having an obtuse angle.

[0044] FIG. 1 is a side view of a drill as an example of a rotary tool, having a prior art finishing disk, flatly applied to a surface.

[0045] FIG. 2 is a side view of a drill as an example of a rotary tool, having a prior art finishing disk, diagonally applied to a surface.

[0046] FIG. 3 is a plan frontal view of a prior art finishing disk, showing the direction of the centrifugal force.

[0047] FIG. 4 is a side view of a drill as an example of a rotary tool having a prior art finishing disk, and both hands of operator applying pressure of rotary tool against surface.

[0048] FIG. 5 is a partial side view of a drill showing in cross section the concentric rupture in progress of an abrasive disk of the prior art.

[0049] FIG. 6 is a plan frontal view of disk of the prior art that suffered a concentric rupture.

[0050] FIG. 7 is a perspective view of an abrasive disk of the prior art that has been fractured into two pieces.

[0051] FIG. 8 is a side view of a drill as an example of a rotary tool, having a disk of the present invention applied against a surface.

[0052] FIG. 9 is a side view of a wire disk of the present invention.

[0053] FIG. 10 is a side view of a padded disk and mating sand paper of the present invention.

[0054] FIG. 11 is a plan frontal view of a disk of the present invention showing me direction of the centrifugal force.

[0055] FIG. 12 is an isometric view of a disk of the present invention with ghost lines and showing alternative means to fasten to a rotary tool.

[0056] 20 disk of the prior art.

[0057] 22 surface being treated or to be treated.

[0058] 24 disk of the present invention.

[0059] 26 side of disk having treating properties.

[0060] 28 base disk with no surface treating properties.

[0061] 30 removable layer attachable to base disk 28 having surface treating properties.

[0062] 32 means to attach disk to rotary tool.

[0063] Since an analysis of the prior art disks lead to the conception of the present invention, FIGS. 1-7 inclusive show the different problems of this prior art and the root of its problems.

[0064] FIG. 1 shows a side view of a rotary tool (drill in this case) having a prior art finishing disk 20 applied flatly parallel to a surface 22. The treating action of the disk is insignificant, as the friction against the surface creates a “braking” effect, due to the centrifugal force generated by the rotary tool, as opposed to the orbital or oscillatory motion of dedicated sanding machines that can function properly when flatly applied against the surface being treated.

[0065] Additionally, the rotary tool is very difficult to control when used in this fashion. Slipping of the tool is very likely to occur, which may cause harm to the operator, the operator's clothes and/or surrounding objects.

[0066] The efforts to control the tool and the unavoidable slipping cause a vibration that provokes the recurrent disengagement of the disk and/or the sanding disks or other finishing accessories.

[0067] FIG. 2 shows a side view of a rotary tool (drill in this case) having a prior art finishing disk 20 applied in an angle to a surface 22. The treating action of the disk is of questionable quality. The disk and the system it embodies; specially if the function performed is of an eroding nature; may actually have counterproductive effects.

[0068] Since all the force is directed to the periphery of the disk, and only the periphery of the disk is in contact with the surface, there is actually a minimal area being treated, and the magnitude of this treatment is excessive; to the point that it actually has a carving effect. Additionally, control of the tool is very difficult, as slipping is very likely to occur, with the inherent risks against operator, operators clothes and/or surrounding objects.

[0069] The difficulty to control the rotary tool, and the likely to occur slipping produce vibrations that eventually cause the constant detachment of the disk and any other accessories like sandpaper fastened thereto.

[0070] FIG. 3 shows a plan frontal view of a disk 20 of the prior art, where dotted arrows indicate the direction of the centrifugal force, pointing to the periphery of the disk.

[0071] FIG. 4 shows a side view of a rotary tool with a disk 20 of the prior art, being applied against surface 22, with both hands of operator, to increase the force of operation, in an effort to overcome the problems explained with FIGS. 1 and 2.

[0072] Since this force results excessive and unnatural, new problems are created in the process, while some of the problems illustrated with FIGS. 1 and 2 still persist.

[0073] a) An excessive wear and tear is imposed to the materials used. Materials may actually collapse and brake. Wire disks used for abrasive purposes will eventually brake, as later illustrated by FIGS. 5, 6 and 7.

[0074] b) An uneven treatment of the surface is obtained.

[0075] c) Fatigue to operator is increased due to the extra effort.

[0076] FIG. 5 shows a partial side view of a wire disk 20 and in cross section 21 point 23 where disk is being ruptured in a concentric fashion, due to the forced operation of the rotary tool as explained with FIG. 4.

[0077] Point 23 appears duplicated because of the side cross section view, but it is one single circular line, as can be seen in FIG. 6.

[0078] FIG. 6 shows in front plan view the wire disk of FIG. 5, showing said point of rupture 23, as a continuous circular line.

[0079] FIG. 7 shows in perspective view the wire disk of FIGS. 5 and 6 after the concentric rupture into two pieces has fully taken place. Pieces 25 and 27 are the resultant of such rupture. Wire disk is rendered useless.

[0080] FIG. 8 shows in side view a rotary tool (a drill, in this case) having a disk 24 of the present invention, with a conical shape applied to a surface 22. The disk enters in contact with the surface to be treated in a fashion that maximizes the effect of the centrifugal force, which is radially distributed throughout the entire surface of the disk by virtue of its conical shape, and then transferred to the surface being treated.

[0081] An optimized treatment of the surface is achieved while all the problems of the prior art are avoided. The tool is easily controlled, disengagement of the disk and/or other accessories is prevented. Slipping and accidental harm to operator, operator's clothes and any surrounding objects is prevented. As a result of all the preceding advantages, substantial savings are achieved. This is further enhanced by the increased durability of the disks and materials, and the fact that disks can now be of a larger diameter, due to the optimized control of operation.

[0082] FIG. 9 shows a side/isometric view of a disk attachment 24 of the present invention. The disk attachment has a treating side 26 with surface treatment properties. Attachment means 32 represented in this case by a shank.

[0083] FIG. 10 shows a side/isometric view of a disk attachment 24 having a disk area 28 serving as a padded base for layer 30, represented in this case by self adhesive sand paper having a mating shape, with respect to the disk 24. Dotted arrows indicate positioning of layer over padded disk. And attachment means 32, represented in this case by a shank.

[0084] FIG. 11 shows in a plan frontal view a disk of the present invention, with dotted arrows indicating the direction of the centrifugal force. By virtue of its conical shape, the effect of this force is uniformly distributed throughout the entire disk, with all the advantages that this entails.

[0085] FIG. 12 shows an isometric view of a disk of the present invention 24 having attachment means 32, represented in this case by a bolt, and further having a recessed area, and a hole, to host said bolt and connect it to the rotary tool.

[0086] The reader will see that the surface treatment disk of the present invention represents a substantial improvement over the prior art.

[0087] It eliminates all the disadvantages of the prior art disks, while making possible disks of a larger diameter. All of which is further enhanced by its simplicity of construction and use.

[0088] The preceding description includes certain specificities, given for illustrative purposes. They are not in any way to be restrictive, and natural equivalents will have the same effect within the scope of this invention. For example, the paper of the sand paper may be replaced by any other suitable sheet material, like for instance a product known in the market as “Tyvek™”. Other means to attach the disk to the rotary tool may include clamps, hooks, or any other suitable mechanism.