Scratch removal device and method

Abstract

A polishing wheel including a lower polishing surface and defining a different color from a secondary portion of the polishing wheel, so as to indicate wear of the polishing surface. The polishing surface includes a plurality of main radial flutes extending from a central passage to an outer edge. A reduced profile for the main radial flutes is provided adjacent to the outer edge. A plurality of secondary radial flutes is provided extending from the outer edge, but not in communication with either the central passage or the main radial flutes. The reduced profile for the main radial flute is defined by a variable depth portion. The secondary radial flutes defined by a variable depth portion. Each of the main radial flutes and the secondary radial flutes formed by a circular saw. An indexing machine is used to move the polishing wheel during the forming process.

Description

CROSS-REFERENCE TO RELATED APPLICATION

The present application is related to application Ser. No. 11/240,129, filed Sep. 30, 2005, entitled, “Scratch Removal Device and Method”, now issued as U.S. Pat. No. 7,137,872, on Nov. 21, 2006.

FIELD OF THE INVENTION

The present invention relates to apparatus and methods for removing scratches from smooth surfaces such as glass. More specifically, the present invention relates to a polishing wheel and methods for manufacture and for use in removing the scratches.

BACKGROUND OF THE INVENTION

Rotary tools are used to grind and polish glass to remove scratches and other damage from the surface of the glass. After processing the glass, such as windshields, it is desirable to leave the glass so the scratch or other damage is less visible and/or less likely to affect viewing through the glass. U.S. Pat. Nos. 4,709,513 and 4,622,780 show various tools for use in polishing glass.

Further improvements are desired for the rotary tools and methods used to polish glass.

SUMMARY OF THE INVENTION

The present invention relates to a polishing wheel including a body defining a central longitudinal axis and a central passage coaxial with the longitudinal axis. The body is mountable to a rotating polishing device. The body of the polishing wheel has a lower polishing surface including a planar portion. The lower polishing surface includes a plurality of main flutes extending from the central passage to an outer edge of the lower polishing surface. Further flutes extend from the outer edge of the lower polishing surface and terminate without communicating with the central passage or the main flutes.

In one embodiment, the main flutes have a different depth between the central passage and the outer edge. As the lower portion of the body of the polishing is worn away during use, the different depth portion allows for the main flutes to be reformed or recut so as to again be in fluid communication from the outer edge to the central passage if a portion of the main flute becomes worn away to a zero depth or an otherwise insufficient depth. In one preferred embodiment, the different depth portion is a varying depth portion located adjacent to the outer edge.

In one preferred method in accordance with the present invention, a polishing wheel is formed by providing a generally cylindrical disk of polishing material. The disk is formed, such as being cut with a tool, to include a plurality of main flutes located on a lower surface of the disk. The main flutes extend from a central passage to an outer edge. The main flutes preferably include a varying depth portion, adjacent to the outer edge. In one preferred method, the tool for cutting the main flutes is a circular saw. Preferably, secondary flutes separate from the main flutes are cut with the same circular saw. One preferred method uses an indexing machine to equally space the main flutes and the secondary flutes around a central axis of the disk during formation.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a polishing wheel in accordance with the present invention.

FIG. 2 is a bottom view of the polishing wheel of FIG. 1.

FIG. 3 is a side view of the polishing wheel of FIG. 1.

FIG. 4 is a cross-sectional side view of the polishing wheel of FIG. 1, taken along lines 4-4 of FIG. 2.

FIG. 5 is a bottom view of an alternative embodiment of a polishing wheel.

FIG. 6 is a cross-sectional side view of the polishing wheel of FIG. 5, taken along lines 6-6 of FIG. 5.

FIG. 7 is a top view of the polishing wheel of FIG. 5.

FIG. 8 is a bottom view of a further alternative embodiment of a polishing wheel.

FIG. 9 is a cross-sectional side view of the polishing view of FIG. 8, taken along lines 9-9.

FIG. 10 is a top view of the polishing view of FIG. 8.

FIG. 11 is a perspective view of another alternative embodiment of a polishing wheel.

FIG. 12 is a bottom view of the polishing wheel of FIG. 11.

FIG. 13 is a top view of the polishing wheel of FIG. 11.

FIG. 14 is a first side view of the polishing wheel of FIG. 11.

FIG. 15 is another side view of the polishing wheel of FIG. 11.

FIG. 16 is a first cross-sectional view of the polishing wheel of FIG. 11, taken along lines 16-16 of FIG. 12.

FIG. 17 is a second cross-sectional view of the polishing wheel of FIG. 11, taken along lines 17-17 of FIG. 12.

FIG. 18 is a perspective view of one system for forming the polishing wheel of FIG. 11.

FIG. 19 is a side view as shown in FIG. 14, showing a wearing of the polishing wheel and the reformed reduced profile exit passages.

FIG. 20 is a cross-section as shown in FIG. 17, showing the worn polishing wheel and the reformed reduced profile exit passages as shown in FIG. 19.

FIG. 21 is a cross-section like FIG. 16, showing an example T-nut.

FIG. 22 is a cross-section like FIG. 17, showing the T-nut of FIG. 21.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIGS. 1-4, one embodiment of a polishing wheel 10 is shown. Polishing wheel 10 is usable in the apparatus and methods described in U.S. Pat. Nos. 4,622,780 and 4,709,513, the disclosures of which are incorporated by reference.

Polishing wheel 10 includes a body 12 defining a central longitudinal axis 14. During use, body 12 is rotated about longitudinal axis 14. Polishing wheel 10 is designed for use with a center slurry feed tool like that described in the above noted patents.

Body 12 includes a central passage 16 which is coaxial with longitudinal axis 14. Central passage 16 is in fluid communication with the slurry source provided by the rotating tool as described in the above noted patents.

Body 12 further includes a lower portion or layer 18, and an upper portion or layer 20. Lower portion 18 defines a lower polishing surface 26. Upper portion 20 is located on an opposite side of lower portion 18 from polishing surface 26. An upper surface 28 is defined by upper portion 20 and faces in an opposite direction to polishing surface 26. Body 12 further defines a side surface extending between polishing surface 26 and upper surface 28. Polishing surface 26 extends from an inner edge 36 adjacent to central passage 16 to an outer edge 38.

Lower portion 18 includes main flutes 40 extending from central passage 16 at inner edge 36 to outer edge 38. In the preferred embodiment, main flutes 40 extend radially. In one preferred embodiment, main flutes 40 include reduced profile exit passages 42 for providing control of slurry outflow. Generally, a main portion 41 of main flutes 40 extends completely through lower portion 18. Exit passages 42 are shown in the illustrated embodiment as small v-grooves formed in lower portion 18. Main flutes 40 are arranged radially relative to longitudinal axis 14. Main flutes 40 are further arranged to be equally spaced from each other.

Secondary flutes 44 are also provided in lower portion 18. Secondary flutes 44 extend from outer edge 38 toward central passage 16. However, secondary flutes 44 terminate before communicating with central passage 16 or main flutes 40. In the illustrated embodiment, secondary flutes 44 extend all the way through lower portion 18. Secondary flutes 44 are radially arranged, and are equally spaced about polishing surface 26.

Central passage 16 includes a T-nut 46 which permits mounting of polishing wheel 10 to the rotating tool. Preferably, an inner surface of T-nut 46 is threaded. Spikes or other projections on T-nut 46 can be added to assist with holding T-nut 46 in position.

Preferably, body 12 is made from a moldable material. In the preferred embodiment, lower portion 18 and upper portion 20 are made from a common material, such as a moldable elastomeric material. Lower portion 18 is further provided with an impregnated material to facilitate polishing. Preferably, the impregnated material is a particulate. In one preferred embodiment, the particulate material is cerium oxide.

Upper portion 20 is not designed to polish. Therefore, no impregnated material for polishing is used in upper portion 20 in the preferred embodiment.

Preferably, lower and upper portions 18, 20 are molded together such that the layers are heat fused together. One preferred elastomeric material is expanded urethane. LP66 designation by Universal Photonics of Hicksville, N.Y. is one material for layer 18 that can be used. LP66 material includes impregnated cerium oxide.

To indicate wear of lower portion 18 to the user, a colorant is added to one or both of lower portion 18 and upper portion 20. The colorant or colorants are selected so as to provide a visual contrast between lower portion 18 and upper portion 20. Such contrast provides a visual indication to the user when lower portion 18 is worn away, or is otherwise sufficiently removed to no longer be desired for continued use in further polishing operations. For example, lower portion 18 can be rust in color, and upper portion 20 can be gray.

Secondary flutes 44 reduce the lower surface area and allow for an increase in the workload on the wheel by minimizing the square area in contact with the surface being polished. Such increase in the workload will allow the polishing operation to be accomplished faster. The arrangement of flutes as shown in the Figures also helps to more evenly distribute the polishing material across the polishing surface 26, to minimize distortion. One problem with prior art devices is that inexperienced users can apply excessive pressure and cause uneven polishing, and possibly distortion, to the glass. By providing an arrangement of polishing surface 26 as described above, less distortion and less uneven polishing results.

FIGS. 5-7 show an alternative embodiment of a polishing wheel 100 including a body 112 having some similar features as polishing wheel 10. Polishing wheel 100 includes a smaller polishing surface 126. Polishing wheel 100 is useful for polishing smaller areas, or areas near the edges of windshields.

Body 112 includes a central axis 114 and a central passage 116 including a T-nut 146 which permits mounting of polishing wheel 100 to the rotating tool. Lower portion 118 includes a different color from upper portion 120. Body 112 includes a side taper 130 which tapers down to polishing surface 126.

In the illustrated embodiment, polishing wheel 100 includes a plurality of radially extending flutes 140 extending from central passage 116 to an outside edge of lower portion 118.

A further alternative embodiment of a polishing wheel 200 is shown in FIGS. 8-10. Body 212 is more cylindrical in shape relative to the earlier described embodiments. Body 212 includes a central axis 214 and a central passage 216 including a T-nut 246 which permits mounting of polishing wheel 200 to the rotating tool. Body 212 includes a lower portion 218 having a different color from upper portion 220. Polishing surface 226 includes a plurality of radially extending flutes 240 extending from central passage 216 to an outside edge of lower portion 218.

Another alternative embodiment of a polishing wheel 300 is shown in FIGS. 11-22. Body 312 includes a central axis 314, and a central passage 316. A T-nut similar to those described above, can be used to mount polishing wheel 300 to the rotating tool. FIGS. 21 and 22 show an example T-nut 352. T-nut 352 can be pressed into place. T-nut 352 can be held with adhesive to further maintain it in place.

Polishing surface 326 of polishing wheel 300 includes a plurality of radially extending main flutes 340 extending from central passage 316 to an outer edge 338 of lower portion 318. Polishing surface 326 also includes a plurality of radially extending secondary flutes 344. Secondary flutes 344 extend from adjacent to, but not in fluid communication with, central passage 316. Secondary flutes 344 extend outward to outer edge 338.

Main flutes 340 include a width W₁, and a depth D₁ adjacent to central passage 316. At outer edge 338, the depth of main flutes 340 is reduced to depth D₂ Main flutes 340 each have a variable depth portion 342 from depth D₁ to D₂. In the illustrated embodiment, the variable depth portion 342 has a curved surface 346. Exit passages 347 form reduced profile passages for the polishing fluid to exit out from wheel 300.

Secondary flutes 344 include a width W₂, and a depth D₃ adjacent to outer edge 338. Adjacent to central passage 316, the depth of each second flute 344 reduces from depth D₃ to a zero depth where it terminates at polishing surface 326. Preferably, each secondary flute 344 includes a variable depth portion 348. In the illustrated embodiment, the variable depth portion 348 has a curved surface 350.

FIG. 18 illustrates one system 400 for forming polishing wheel 300. A disk-shaped body 402 is mounted on an indexing machine 404. Indexing machine 404 can move disk 402 horizontally in two directions and rotationally about the central axis of the body 402. A circular saw 408 is used to cut the main and secondary flutes 340, 344, respectively, as described in FIGS. 11-17. Saw blade 410 cuts the various grooves in disk-shaped body 402 to form the flutes. In the preferred embodiments, widths W₁ and W₂ are the same. One example width is 0.12 inches cut by a 1½ inch diameter, 3/32 inch wide jeweler's saw. The variable depth portions 342 and 348 have a 0.75 radius curved shape. In the example embodiment: D₁=0.325 inches; D₂=0.05 inches; and D₃=0.32 inches. Indexing machine 404 moves body 402 in the desired manner relative to saw blade 410 so saw blade 410 can cut each of the flutes 340, 344.

Referring now to FIGS. 19 and 20, polishing wheel 300 is shown to illustrate use over time. During polishing, polishing surface 326 will wear away, such as down to plane 360. At plane 360, main flutes 340 will no longer communicate between central passage 316 and outer edge 338. Exit passages 347 will be closed or too small to allow effective slurry flow. Slurry will be trapped in flutes 340, preventing effective polishing. Polishing wheel 300 allows for new reduced profile portions 357 to be reformed by a user in the filed. By using a cutting tool, such as a knife, body portions 358 can be removed to reestablish fluid communication between central passage 316 and outer edge 338.

The recutting process can be repeated as the newly recut reduced profile portions 357 are worn away. For example, it is preferred that polishing wheel 300 can be recut at least twice, and more preferably more than twice, such as 3-5 times.

Any of the polishing wheels 10, 100, 200 described above can also be made in accordance with the flute features provided in wheel 300. Specifically, the materials, shapes and constructions including the attachment nuts can be used with the flute shapes and methods described with respect to FIGS. 11-22.

The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.

Claims

1. A polishing wheel comprising:

a body defining a central longitudinal axis and a central passage coaxial with the longitudinal axis, the body mountable to a rotating polishing tool;

the body having a lower polishing surface defining a planar portion;

wherein the lower polishing surface includes a plurality of main radial flutes extending from the central passage to an outer edge of the polishing surface;

wherein secondary radial flutes are provided in the lower polishing surface extending from the outer edge and terminating in an area before the central passage, and further wherein the secondary radial flutes are not in communication with the main radial flutes;

wherein the main radial flutes have a reduced profile adjacent to the outer edge, relative to a portion of the main radial flutes disposed radially inwardly, wherein the reduced profile of each of the main radial flutes is defined by a varying depth portion for each of the main flutes adjacent to the outer edge.

2. The polishing wheel of claim 1, wherein six main radial flutes are provided, and six secondary radial flutes are provided, equally spaced around the longitudinal axis.

3. The polishing wheel of claim 1, wherein the secondary radial flutes have a varying depth portion, wherein each of the varying depth portions of the main radial flutes and each of the varying depth portions of the secondary radial flutes are defined by a curved surface.

4. The polishing wheel of claim 1, wherein the central passage includes a threaded portion, the threaded portion of the central passage mountable to a threaded shaft of the rotating polishing tool.

5. A polishing wheel comprising:

a body defining a central longitudinal axis and a central passage coaxial with the longitudinal axis, the body mountable to a rotating polishing tool;

the body having a lower polishing surface defining a planar portion;

the body having a lower portion defining the lower polishing surface;

the body having an upper portion, the upper portion disposed on an opposite side of the lower portion from the lower polishing surface;

the lower portion including a first material and having a first color;

the upper portion including the same first material, and having a second color visually different from the first color;

the lower portion including a polishing material impregnated in the first material;

the lower polishing surface including a plurality of main flutes extending from the central passage to an outer edge of the polishing surface;

the lower polishing surface including secondary flutes extending from the outer edge and terminating in an area before the central passage, and further wherein the secondary flutes are not in communication with the main flutes;

wherein the main flutes and the secondary flutes extend radially relative to the longitudinal axis;

wherein the main flutes have a reduced profile adjacent to the outer edge, relative to a portion of the main flutes disposed radially inwardly, wherein the reduced profile of each of the main flutes is defined by a varying depth portion for each of the main flutes adjacent to the outer edge.

6. The polishing wheel of claim 5, wherein the upper portion does not include the polishing material.

7. The polishing wheel of claim 5, wherein the first material is a polymeric material.

8. The polishing wheel of claim 7, wherein the polymeric material is a urethane material, and wherein the polishing material is cerium oxide.

9. The polishing wheel of claim 5, wherein six main flutes are provided, and six secondary flutes are provided, equally spaced around the longitudinal axis.

10. The polishing wheel of claim 5, wherein the secondary flutes have a varying depth portion for each of the secondary flutes adjacent to the central passage.

11. The polishing wheel of claim 10, wherein the varying depth portion of each of the secondary flutes is defined by a curved surface.

12. The polishing wheel of claim 5, wherein the varying depth portion of each of the main flutes is defined by a curved surface.

13. The polishing wheel of claim 5, wherein the body includes a threaded nut with an outer projection positioned in the upper portion, wherein the threaded nut is not positioned in the lower portion, the threaded nut including an inner threaded passage coaxial with the central passage and mountable to the rotating polishing tool.

14. A method of polishing a surface comprising a steps of:

a.) providing a polishing wheel including: i.) a body; ii.) a polishing surface; iii.) a central fluid passage through the body; iv.) a plurality of passages extending from the central fluid passage across the polishing surface to an outside edge of the outside surface; v.) a plurality of cutouts in the polishing surface not in fluid communication with the plurality of passages;

b.) passing polishing fluid from the central fluid passage into the plurality of passages;

c.) rotating the body about the central longitudinal axis;

d.) polishing the surface with rotation of the polishing wheel and with the polishing fluid passing from the central fluid passage through the plurality of passages to the outside edge of the polishing surface.

e.) providing flow restriction passages within the plurality of passages, wherein the flow restriction passages are adjacent to the outside edge of the polishing surface, wherein the flow restriction passages are defined by varying depth portions;

f.) restricting fluid flow through the plurality of passages by the flow restriction passages.

15. The method of claim 14, further comprising:

a.) polishing with the polishing wheel until the flow restriction passages are worn down to a predetermined level;

b.) reforming the flow restriction passages to a greater depth with a cutting tool, wherein the reformed flow restriction passages have a reduced area relative to the plurality of passages.

16. The method of claim 15, further comprising:

a) polishing with the polishing wheel until the reformed flow restriction passages are worn to a predetermined level;

b) further reforming the flow restriction passages to a greater depth with a cutting tool, wherein the further reformed flow restriction passages have a reduced area relative to the plurality of passages.

17. A method of forming a polishing wheel comprising:

a.) providing a disk-shaped polishing wheel including: i.) a body; ii.) a polishing surface; iii.) a central fluid passage through the body;

b.) cutting a plurality of main radial flutes extending from the central fluid passage to an outer edge of the polishing surface, wherein the main radial flutes include a varying depth portion adjacent to the outer edge.

18. The method of claim 17, wherein the varying depth portion is curved.

19. The method of claim 17, wherein the plurality of main radial flutes are equally spaced about the central fluid passage.

20. The method of claim 17, further comprising cutting a plurality of secondary radial flutes extending from adjacent to the central fluid passage but not in fluid communication with the central fluid passage, the secondary radial flutes extending to the outer edge, wherein the secondary radial flutes include a varying depth portion adjacent to the central fluid passage.

21. The method of claim 20, wherein the plurality of main radial flutes are equally spaced about the central fluid passage, wherein the plurality of secondary radial flutes are equally spaced about the central fluid passage, wherein the plurality of main radial flutes and the plurality of secondary radial flutes alternate around the central fluid passage.

22. The method of claim 21, wherein the varying depth portion of each of the main radial flutes is curved.

23. The method of claim 22, wherein the cutting steps for the main radial flutes and the secondary radial flutes include cutting the body with a rotating circular saw perpendicularly positioned relative to the polishing surface.

24. The method of claim 23, further comprising providing an indexing machine for holding the body, and moving the indexing machine to equally space the main radial flutes and the secondary radial flutes.

25. The method of claim 16, wherein the cutting steps for the main radial flutes and the secondary radial flutes include cutting the body with a rotating circular saw perpendicularly positioned relative to the polishing surface.

26. The method of claim 25, further comprising providing an indexing machine for holding the body, and moving the indexing machine to equally space the main radial flutes and the secondary radial flutes.

27. The method of claim 17, further comprising the step of recutting only a portion of the main radial flutes adjacent to the outer edge, after the polishing surface is partially worn away during polishing.