Tool independent dust protection apparatus and associated dust protection methods

Abstract

Methods and apparatus are described that provide an alternative to dust protection shrouds that must be clamped or be otherwise affixed to the body of a tool. The shroud captures and facilitates the removal of dust from an area being worked upon by a tool bit while being attached to the bit (not the tool itself). The shroud housing includes an exhaust orifice; a shaft receptive orifice through which the bit shaft may be passed and be coupled to the tool; and means, such as a ball bearing located on the edge of the shaft receptive orifice, for attaching the shroud housing to the shaft upon which it rides as the bit rotates. The tool independent dust protection methods and apparatus taught by the invention provide a one size fits all dust shroud that does not sacrifice build quality or structural integrity in favor of flexibility.

Description

CONTINUITY INFORMATION

This application claims the benefit of Provisional Application Ser. No. 60/758,310, filed Jan. 11, 2006, the complete disclosure of which is hereby incorporated by reference.

BACKGROUND OF THE INVENTION

The invention relates generally to methods and apparatus for controlling exposure to dust during, for example, sanding, grinding and fabricating operations. More particularly, the invention relates to methods and apparatus that limit exposure to dust without requiring the fabrication or use of special purpose, tool specific, dust protection mechanisms commonly attached to the tool itself.

Dust generated during the exemplary sanding, grinding and fabricating operations can be hazardous, often containing chromates, lead and other carcinogenic materials. At a minimum, the dust generated can cause respiratory issues when inhaled in quantity.

For a number of years, different companies have created products to deal with dust collection. Sanders, for example, generally have a shroud which attaches to the body of the sander and covers the “backup pad”, i.e., the softer pad to which an abrasive is normally attached. Dust is typically drawn upwards through holes in, for example, an abrasive disc and then through corresponding holes in the backup pad. The dust may then be captured by, for example, vacuum suction, and be channeled through the shroud to an exhaust.

The above described shroud approach works well on sanders; but becomes complex and less effective when, for example, used with right-angled grinders and other tools. On these types of tools one accepted approach is to create a shroud which is specific to the tool on which it will be used. For example, it is known in the prior art to create an aluminum or plastic mounting fixture which can clamp to the body of a tool in order to support a vacuum shroud hanging below, over, for example, an abrasive disc.

Many different tool clamp on type shrouds have been manufactured; however, it is required that the shroud be designed to fit the tool for which it is intended.

It is also known to manufacture “one size fits all” type shrouds for grinders of various makes and sizes. However, this approach relies on a stepped shroud which can be trimmed or adjusted to fit a given tool. This is a true one size fits all, but sacrifices build quality and structural integrity in favor of flexibility. Moreover, this type of shroud is once again a tool clamp on type shroud, i.e., the shroud is joined to the tool via a mechanism that clamps the shroud to the tool body.

Examination of tools on the market indicates that the characteristics that are universal among all tools are the air input (¼ MNPT) and the size of the shank that is captured by the collet. In order to create a shroud that will truly fit any tool on the market, it is desirable to incorporate these commonalities into the solution.

Finally, non of the known dust protection shrouds is “tool independent”, defined herein to mean a shroud that is not tool design specific and does not have to be attached (for example be clamped) to the tool body in order to provide the desired dust protection.

SUMMARY OF THE INVENTION

It is an object of the invention to provide tool independent methods and apparatus for providing dust protection.

It is a further object of the invention to provide a one size fits all dust shroud that does not sacrifice build quality or structural integrity in favor of flexibility.

It is another object of the invention to provide an alternative to tool specific dust prevention solutions such as special purpose shroud designs and attachment mechanisms per tool.

It is still a further object of the invention to provide methods and apparatus that facilitate the floating attachment and positioning of a dust protection shroud on a tool bit shaft to thereby allow the shroud to maintain its position over a work area by riding on the shaft; rather than by making a physical or mechanical connection to the tool itself.

It is yet another object of the invention to provide methods and apparatus that prevent a dust shroud using the aforementioned floating attachment to a tool bit shaft, from spinning on the bit as the shaft rotates.

Further still, it is an object of the invention to provide methods and apparatus that allow a shroud riding on the shaft of a tool bit to maintain a variable distance between the shroud and the tool work area.

Furthermore, it is an object of the invention to provide methods and apparatus for providing dust protection solutions in which a given shroud used on a tool bit shaft is always fixed in position by its coaxial relationship to the shaft although the shape of the shroud may be varied to meet new and different application.

The dust protection shroud and associated methods for its use, as contemplated by the invention, are clearly distinguishable over the prior art by virtue of the shroud being attached to a tool bit (not the tool itself).

In accord with aforestated object, which will be discussed in detail below, a first aspect of the invention provides a dust protection shroud for capturing and facilitating the removal of dust from an area being worked upon by a tool bit (itself removably coupled via, for example, an integral tool bit shaft to a given tool), where the shroud includes (a) a shroud housing that further includes an exhaust orifice and a shaft receptive orifice through which the tool bit shaft may be passed for coupling to the tool; along with (b) means for attaching the shroud housing to the tool bit shaft.

The means for attaching contemplated by this first aspect of the invention includes, according to an illustrative embodiment of the invention, means for suspending the shroud housing on the shaft.

According to a further illustrative embodiment of this first aspect of the invention, a ball bearing operative to press in toward the center of the shroud housing, with the ball bearing being located on the periphery of the aforementioned shaft receptive orifice, may serve as a means for suspending the shroud housing on the shaft. This would enable the housing to “float” above the area being worked upon by the tool bit as the tool bit shaft spins within the ball bearing.

Further still, in accordance with yet another illustrative embodiment of this first aspect of the invention, the shroud housing is not tool design specific and is operative to maintain its position over the area being worked by the tool bit without being attached to the tool, i.e., is tool independent as defined hereinabove.

Further yet, in accordance other illustrative embodiments of this first aspect of the invention, the shroud housing is operative to maintain its position over the work area by riding on the tool bit shaft; is operative to maintain a variable distance from the work area by sliding up and down the tool bit shaft; and may be varied in shape dependent on application while maintaining a fixed position relative to the tool bit shaft defined by the shroud's coaxial relationship therewith.

According to a second aspect of the invention, apparatus for providing protection from dust produced when using a given tool is described which includes (a) a tool bit having a shaft that is removably coupled to the tool; (b) a shroud; and (c) means for suspending the shroud on the shaft.

According to a third aspect of the invention, a tool independent dust protection shroud is described that includes (a) a shroud housing; (b) means for enabling said shroud housing to float on the shaft of a tool bit; and (c) an exhaust orifice through which dust collected within the shroud housing may be removed.

According to a fourth aspect of the invention, a method for capturing and removing dust from an area being worked upon by a tool bit is provided. The tool bit itself includes a shaft that allows the tool bit to be removably coupled to a tool. The method contemplated by this fourth aspect of the invention includes the steps of (a) attaching a dust protection shroud to the tool bit shaft; and

(b) coupling the tool bit shaft to a tool. According to an illustrative embodiment of this aspect of the invention, the shroud “floats” on the tool bit shaft.

Further steps contemplated by various (but not necessarily all) embodiments of this fourth aspect of the invention include removing dust captured within the shroud via a shroud exhaust orifice; removing the dust under the influence of a vacuum; and using the vacuum to prevent the shroud from spinning on the shaft to which it is attached.

According to a fifth aspect of the invention a method for capturing and removing dust from an area being worked upon by a tool bit having an integral shaft, utilizing a dust protection shroud housing, is described. The method contemplated by this fifth aspect of the invention includes the steps of (a) passing the shaft through the shroud housing; (b) suspending the shroud housing on the shaft; (c) coupling a vacuum source to the shroud housing; and (d) coupling the tool bit to the tool via the shaft.

The invention features methods and apparatus that provide an alternative to dust shrouds that need to be clamped or be otherwise affixed to the body of a tool. Accordingly, an advantage of the invention is that it works well, for example, on right angle grinders and other tools.

Further advantages and features of the invention include, but are not limited to, tool independent methods and apparatus for providing dust protection; the provision of a one size fits all dust shroud that does not sacrifice build quality or structural integrity in favor of flexibility; an alternative to tool specific dust prevention solutions; methods and apparatus that facilitate the floating attachment and positioning of a dust protection shroud on a tool bit; and the provision of methods and apparatus that (a) prevent a dust shroud, having the aforementioned floating attachment to a tool bit shaft, from spinning on the bit; (b) allow a shroud riding on the shaft of a tool bit to maintain a variable distance between the shroud and the tool work area; and (c) allow the shape of a shroud to be varied to meet new and different applications.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects, features and advantages of the invention will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout.

FIGS. 1A-1E depict exploded side views of various tool, tool shaft and shroud combinations contemplated by the various aspects of the invention;

FIG. 2 is an exploded side view of an exemplary embodiment of the invention depicting a shroud housing suitable for attachment to a tool shaft and a vacuum hose, all in combination with an exemplary right angle grinder;

FIG. 3 is a top perspective view of an exemplary shroud housing and ball bearing combination of the type depicted in FIG. 2 and contemplated by the invention;

FIG. 4 is a side view of an exemplary assembled tool, tool bit and shroud combination of the type depicted in FIG. 2 and contemplated by the invention.

FIG. 5 is a perspective view of an exemplary shroud housing, ball bearing and shaft combination of the type depicted in FIG. 2 and contemplated by the invention; and

FIG. 6 is a bottom perspective view of an exemplary shroud housing and ball bearing combination of the type depicted in FIG. 2 and contemplated by the invention.

DETAILED DESCRIPTION OF THE INVENTION

As indicated hereinbefore, the shroud (and associated methods for its use) contemplated by the invention is not mounted on the tool itself. Instead the shroud attaches to the shaft of the tool's bit.

The shroud has, according to an illustrative embodiment of the invention, a ball bearing pressing into its center. The shaft of the bit spins within the ball bearing. The shroud is suspended on the shaft, and as the tool spins the shaft, the ball bearing center allows the shroud to “float” above the abrasive or cutting disc beneath.

According to one embodiment of the invention, a vacuum hose connected to the shroud's exhaust can be utilized to provide enough force to prevent the shroud from spinning on the rotating bit. Again, the shroud, in accordance with this illustrative embodiment of the invention, is not in any way connected to the tool itself. Because it is not dependent on tool design it can be used with any tool.

Turning to the drawing, as indicated hereinabove, FIGS. 1A-1E depict exploded side views of various tools, tool shaft and shroud combinations contemplated by the various aspects of the invention.

In particular, FIG. 1A-1C depict a router 100, grinder 102 and drill 103, respectively, each along with an exemplary dust protection shroud, illustrative of the principals of the invention, suitable for attachment to the depicted tool bits. In FIG. 1A, shroud 104 may be seen as interposed between router 101 and router bit 105. Rather then being mounted onto the tool (router 101), the invention contemplates attaching shroud 104 (to be described in detail hereinafter with reference to FIGS. 2-6), tool shaft bit portion 105a of router bit 105.

In FIG. 1B, shroud 107 may be seen as interposed between grinder 102 and, for example, radial disc 108. Once again, in accordance with the teachings of the invention, shroud 107, rather than being mounted onto the tool (grinder 102), the invention contemplates attaching shroud 107 to shank 108a of the tool bit (in this case, redial disc 108). Also shown in FIG. 1B, for the sake of illustration, is flexible shaft 106, coupled to grinder 102. Flexible shaft 106 may be used in conjunction with shroud 107 and illustrative radial disc 108 in order to be able to more conveniently use the tool and dust protection shroud combination in those applications where extended reach and flexibility are required.

FIG. 1C, like FIGS. 1A and 1B, depicts an exploded side view of a tool, dust protection shroud and tool bit combination of the type contemplated by the invention. As indicated hereinabove, drill 103 is depicted in FIG. 1C. Also shown in FIG. 1C is, in accordance with the teachings of the invention, shroud 109 interposed between drill 103 and drill bit 110. Once again, in accord with the teachings of the invention, shroud 109 is intended to be attached to drill bit 110; and not drill 103.

Attention is directed to FIGS. 1D-1E which each depict an exploded side view of other exemplary tool, shroud and tool bit combinations that incorporate the teachings of the invention.

In particular, FIG. 1D depicts a right angle grinding tool, grinder 111, which will be discussed in greater detail hereinafter with reference to FIGS. 2-6. The combination depicted in FIG. 1D includes grinder 109 and shroud 112 which, in accordance with the teachings of the invention, may be attached to bits like drill bit 113 or grinding disc 114 (with the shroud being attached on shank 114a of grinding disc 114).

FIG. 1E depicts another grinder tool, grinder 115, in combination with collet 116; with a shroud 117 interposed between grinder 115 and one of 3 other illustrative die grinder bits: tool bit 118 having an integrated tool bit shaft 118a; tool bit 119 having an integrated tool bit shaft 119a; and tool bit 120 having an integrated tool bit shaft 120a. In accord with the teachings of the invention, the shaft of a selected tool bit is passed through shroud 117 and is attached (the tool bit shaft) to collet 116. Shroud 117 is not attached to the tool; but rather is attached, for example by the aforementioned ball bearing attachment, to the shaft so as to allow the shroud to float thereon as the bit spins.

The dust protection components and assemblies shown in FIGS. 2-6 are meant to illustrate the principals of the invention in the context of an exemplary 2 inch right angle grinder. The shroud depicted in FIGS. 2-6 may also be used, in accordance with the teachings of the invention, for a straight line tool, like a die grinder or an angled too. The tool is not important, as long as it is designed to rotate.

As indicated hereinbefore, FIG. 2 is an exploded side view of an exemplary embodiment of the invention depicting a shroud housing 205 suitable for attachment to a tool shank 210 and a vacuum hose 209, all in combination with an exemplary right angle grinder 201.

The illustrative right angle grinder 201 is shown having a conventional quick disconnect air intake 202. Further, collet 204 is shown with right angle tool head 203, with collet 204 being designed to receive shank 210 to which shroud housing 205, in accordance with the teachings of the invention, is attached, after passing shank 210 through the open bottom of shroud 208 (shown at 208a and in greater detail in FIG. 6) and through the center of depicted shaft receptive orifice 207 of shroud 208, through ball bearing 206. Once again, as indicated hereinabove, the shroud (and associated methods for it's use) contemplated by the invention is not mounted on the tool itself. Instead the shroud attaches to depicted tool shank 210.

Shroud 208 has, according to this illustrative embodiment of the invention, ball bearing 206 pressing into its center. Tool bit shank 210 is designed to spin within ball bearing 206 and as ball bearing 206 presses inward against shaft 210, shroud 208 is suspended on the shaft. As the tool spins the shaft, the ball bearing center allows the shroud to “float” above the abrasive or cutting disc, like depicted disc 213, beneath. Also shown in FIG. 2 are an exemplary hard back up pad 212, typically included in combination with grinding tools.

As indicated hereinbefore, in accord with the teachings of the invention, vacuum hose 209 connected to a shroud exhaust (shown as exhaust orifice 214 in the shroud housing 208 depicted in FIG. 2), may be utilized to provide enough force to prevent the shroud from spinning on the rotating bit. Once again, the shroud, in accordance with this illustrative embodiment of the invention, is not in any way connected to the tool itself. Because it is not dependent on tool design it can be used with any tool.

Turning attention to FIG. 3, a top perspective view of an exemplary shroud housing and ball bearing combination of the type depicted in FIG. 2 is shown.

In accord with the teachings of the invention, depicted shroud housing 301 is shown to include exhaust orifice 302, shaft receptive orifice 304, through which a tool bit shaft may be passed and be coupled to given tool; and the exemplary ball bearing attachment means 303, which in operation presses in toward the center of orifice 304 depicted in FIG. 3. Again, as a tool bit spins within ball bearing attachment means 303, the ball bearing pressing inward against the shaft allows the shroud housing to be suspended thereon.

Referring to FIG. 4, a side view of an exemplary assembled tool, tool bit and shroud combination of the type depicted in FIG. 2 and contemplated by the invention, is shown.

In particular, the depicted right angle grinder 401 is shown assembled to include air intake 402, tool head 403, collect 405; and shroud 406 which, in accord with the teachings of the invention, is attached to a tool bit shaft passing there through.

Turning to FIG. 5, a perspective view of an exemplary shroud housing 501 is shown in combination with ball bearing attachment means 503 and shaft 504 combination of the type depicted in FIG. 2 and contemplated by the invention. Also depicted in illustrative FIG. 5 is exhaust orifice 504 to which a vacuum hose (not shown) may be connected.

Finally, as indicated hereinbefore, FIG. 6 is a bottom perspective view of an exemplary shroud housing 601 and ball bearing combination of the type depicted in FIG. 2 and contemplated by the invention. In particular, the aforementioned open bottom of a shroud housing, like open bottom 605 of shroud housing 601 (referred to as 208a in FIG. 2), is depicted in FIG. 6; along with ball bearing attachment means 602, shaft receptive orifice 603, and exhaust orifice 604, all serving the purposes hereinbefore described.

It should be noted that the shape and size of a shroud (shroud housing) can be changed to meet the needs of different bits. For example, the same rotary tool might be used for a ¾ inch, 1 inch, 1.5 inch, 2 inch, 3 inch or any other suitable size abrasive dis. The shroud would be sized differently depending on the size of the bit being used. The shroud might be used on a tool with ¼ inch shank, but may also be used on other size shanks, both larger and smaller in diameter. The bearing size is also subject to change based on the application.

Further, it will be appreciated by those skilled in the art that the tools described herein may be powered, for example, by compressed air, electricity, mechanically or other means.

Applications for the invention include, but are not limited to, sanding with a right angle tool or a straight line tool; grinding with a right angle tool or a straight line tool; using the shroud to collect chips and dust from routers of any size or configuration; surface preparation or corrosion removal using radial discs or radial bristle discs or other surface preparation discs.

There have been described and illustrated herein tool independent dust protection apparatus and associated dust protection methods. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. It will therefore be appreciated by those skilled in the art that certain modifications could be made to the provided invention without deviating from its spirit and scope as so claimed.

Claims

1. A dust protection shroud for capturing and facilitating the removal of dust from an area being worked upon by a tool bit removably coupled, via a tool bit shaft, to a given tool, comprising:

(a) a shroud housing further comprising: (1) an exhaust orifice; (2) a shaft receptive orifice through which said tool bit shaft may be passed and be coupled to said tool; and

(b) means for attaching said shroud housing to said tool bit shaft.

2. Apparatus as set forth in claim 1 wherein said means for attaching further comprises means for suspending said shroud housing on said tool bit shaft.

3. Apparatus as set forth in claim 2 wherein said means for suspending further comprises a ball bearing.

4. Apparatus as set forth in claim 3 wherein said ball bearing is operative to press in toward the center of said shroud housing.

5. Apparatus as set forth in claim 4 wherein said ball bearing is located on the periphery of said shaft receptive orifice.

6. Apparatus as set forth in claim 4 wherein said shroud housing is operative to float above the area being worked upon by said tool bit as said tool bit shaft spins within said ball bearing.

7. Apparatus as set forth in claim 6 wherein said shroud housing is operative to maintain its position over said area without being attached to said tool.

8. Apparatus as set forth in claim 6 wherein said shroud housing is operative to maintain its position over said area by riding on said tool bit shaft.

9. Apparatus as set forth in claim 6 wherein said shroud housing is operative to maintain a variable distance from said area by sliding up and down said tool bit shaft.

10. Apparatus as set forth in claim 6 wherein the shape of said shroud may be varied dependent on application while maintaining a fixed position relative to said tool bit shaft defined by its coaxial relationship therewith.

11. Apparatus for providing protection from dust produced when using a given tool, comprising:

(a) a tool bit having a shaft that is removably Coupled to said tool;

(b) a shroud; and

(c) means for suspending said shroud on said shaft.

12. Apparatus as set forth in claim 11 wherein said means for suspending is a ball bearing.

13. Apparatus as set forth in claim 11 wherein said shroud further comprises a shroud housing that includes an exhaust orifice and a shaft receptive orifice through which the shaft of said tool bit may pass and be coupled to said tool.

14. Apparatus as set forth in claim 13 further comprising means for preventing said shroud housing from spinning on the shaft of said tool bit.

15. Apparatus as set forth in claim 14 wherein said means for preventing further comprises a vacuum source and a vacuum hose coupled between said vacuum source and said shroud housing exhaust orifice.

16. Apparatus as set forth in claim 15 wherein said vacuum source and vacuum hose 4 combination is further operative to remove dust captured by said shroud via said shroud housing exhaust orifice.

17. Apparatus as set forth in claim 11 wherein said shroud is operative to maintain its position over an area being worked upon by said tool without being attached thereto.

18. Apparatus as set forth in claim 11 wherein said shroud is operative to maintain its position an area being worked upon by riding on the shaft of said tool bit.

19. Apparatus as set forth in claim 11 wherein said shroud is operative to maintain a variable distance from an area being worked upon by sliding up and down the shaft of said tool bit.

20. Apparatus as set forth in claim 11 wherein the shape of said shroud may be varied dependent on application while maintaining a fixed position relative to the shaft of said tool bit defined by its coaxial relationship therewith.

21. A tool independent dust protection shroud comprising:

(a) a shroud housing;

(b) means for enabling said shroud housing to float on the shaft of a tool bit; and

(c) an exhaust orifice through which dust collected within said shroud housing may be removed.

22. Apparatus as set forth in claim 21 wherein said means for enabling further comprises:

(a) A shaft receptive orifice through which the shaft of a tool bit may pass; and

(b) means for attaching said shroud housing to the shaft of said tool bit.

23. Apparatus as set forth in claim 22 wherein said means for attaching further comprises a ball bearing operative to press in toward the center of said shroud housing.

24. Apparatus as set forth in claim 23 wherein said ball bearing is located on the periphery of said shaft receptive orifice.

25. Apparatus as set forth in claim 21 wherein said shroud housing is operative to maintain its position over an area being worked upon.

26. Apparatus as set forth in claim 21 wherein said shroud housing is operative to maintain its position over an area being worked upon by riding on the shaft of said tool bit.

27. Apparatus as set forth in claim 21 wherein said shroud is operative to maintain a variable distance from an area being worked upon by sliding up and down the shaft of said tool bit.

28. Apparatus as set forth in claim 21 wherein the shape of said shroud housing may be varied dependent on application while maintaining a fixed position relative to the shaft of said tool bit defined by its coaxial relationship therewith.

29. A method for capturing and removing dust from an area being worked upon by a tool bit, wherein said tool bit includes a shaft that allows said tool bit to be coupled to a tool, comprising the steps of:

(a) attaching a dust protection shroud to said tool bit shaft; and

(b) coupling said tool bit shaft to a tool.

30. A method as set forth in claim 29 further comprising the step of floating said shroud on said tool bit shaft.

31. A method as set forth in claim 29 further comprising the step of removing dust captured within said shroud via an exhaust orifice in said shroud.

32. A method as set forth in claim 31 wherein said step of removing is performed under the influence of a vacuum.

33. A method as set forth in claim 32 wherein vacuum prevents said shroud from spinning on said shaft.

34. A method as set forth in claim 29 wherein the step of coupling said tool bit shaft to a tool further comprises the step of passing said shaft to a tool further comprises the step of passing said shaft through a shaft receptive orifice in said shroud.

35. A method as set forth in claim 29 further comprising the step of suspending said shroud on said tool bit shaft utilizing a ball bearing.

36. A method as set forth in claim 30 further comprising the step of rotating said tool bit shaft to enable said shroud to float thereon.

37. A method for capturing and removing dust from an area being worked upon by a tool bit having an integral shaft, utilizing a dust protection shroud housing, comprising the steps of:

(a) passing said shaft through said shroud housing;

(b) suspending said shroud housing on said shaft;

(c) coupling a vacuum source to said shroud housing; and

(d) coupling said tool bit to said tool via said shaft.

38. A method as set forth in claim 37 further comprising the step of rotating said shaft to enable said shroud to float thereon.

39. A method as set forth in claim 38 further comprising the step of utilizing a ball bearing to suspend said shroud housing on said shaft.

40. A method as set forth in claim 39 wherein said shaft spins within said ball bearing.

41. A method as set forth in claim 40 wherein said shroud housing is prevented from spinning on said shaft under the influence of the vacuum source coupled said shroud housing.

42. A method as set forth in claim 37 wherein dust is removed from said shroud housing under the influence of the vacuum source coupled to said housing.