BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sanding tool attachment and, more particularly, to a steel plate with a diamond embedded surface for attachment to a sanding tool.
2. Description of Related Art Sandpaper and other abrasive products are generally known and used in a variety of industries for removing material from surfaces of various materials, e.g., wood, in order to smooth the surfaces, roughen the surfaces, and/or prepare them for subsequent treatment after one or more top layers of material are removed. These products are consumable and generally have a short work life due to the high degree of wear and tear caused by use. As such, these products rapidly deteriorate, which results in a quickly diminishing service life and performance. Frequently changing out worn out pads in order to maintain a sufficient level of performance is generally a tedious and costly process.
Moreover, attaching sandpaper to sanding tools can be painful for several reasons. First, the sandpaper must be cut to size, which dulls the cutting tool. Second, folding the sandpaper can crease it and leave an uneven fold that ultimately mars the surface to be sanded. Furthermore, sandpaper can tear upon any proud nail, drywall screw, or corner edge. Handling and applying sandpaper is unaesthetic to human ears, producing a “nails-on-chalkboard” effect. As mentioned above, sandpaper must be replaced with regularity, consuming time and money. Finally, sandpaper does not evacuate debris, meaning that during the sanding process, debris builds up and the sandpaper must be replaced.
Therefore, there is a need for a low-cost, long-lasting sanding tool attachment as a replacement for sandpaper.
BRIEF SUMMARY OF THE INVENTION Embodiments of the present invention are directed to a sanding tool attachment. According to one aspect, the attachment includes a substrate having a first layer composed of a corrosive inhibitor and a second layer composed of an abrasive material. The attachment also includes one or more evacuation ports extending through the substrate, one or more recesses extending partially into at least the substrate, and a retaining lip extending around a perimeter of the substrate.
According to another aspect, the attachment includes at least one of a hook strip or a loop strip of a hook and loop connector attached to the first layer. A sanding tool having at least one of a hook strip or a loop strip of a hook and loop connector is attachable to the hook and loop connector of the first layer.
According to a similar aspect, the attachment includes one or more torsional springs extending from the substrate. A sanding tool is connected to the first layer by compression of the torsional spring.
According to an additional aspect, the present invention is a sanding tool system. The sanding tool system includes a sanding plate with a metal composition having a first layer composed of a corrosive inhibitor and a second layer composed of an abrasive material. The sanding plate also has one or more evacuation ports extending through the metal composition, one or more recesses extending partially into at least the metal composition, a retaining lip extending around a perimeter of the metal composition, and a connector attached to or extending from the first layer. The system additionally includes a sanding tool removably attached to the sanding plate via the connector.
According to yet another aspect, the present invention is a method for creating a sanding tool attachment. The method includes the steps of: (i) generating a die having a first portion and a second portion; (ii) placing a metal composition within the second portion of the die; (iii) covering the metal composition with the first portion; (iv) pressing the first portion and the second portion of the die together; (v) removing metal composition from the die and then electroplating the metal composition with a corrosive inhibitor; and (vi) electroplating the metal composition with diamonds of a first size distribution after it is electroplated with the corrosive inhibitor.
These and other aspects of the invention will be apparent from and elucidated with reference to the embodiment(s) described hereinafter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) The present invention will be more fully understood and appreciated by reading the following Detailed Description in conjunction with the accompanying drawings. The accompanying drawings illustrate only typical embodiments of the disclosed subject matter and are therefore not to be considered limiting of its scope, for the disclosed subject matter may admit to other equally effective embodiments. Reference is now made briefly to the accompanying drawings, in which:
FIG. 1 is a table of some varieties of electric sanding tools;
FIG. 2A is a perspective view of a design for a sanding tool attachment die;
FIG. 2B is a top view of a metal composition within a bottom portion of the die;
FIG. 2C is a top perspective view of the top portion of the die;
FIG. 2D is a side perspective view of the closed die in a press;
FIG. 2E is a top view of the metal composition within the bottom portion of the die after it is pressed;
FIG. 2F is a top view of the metal composition removed from the die;
FIG. 3 is a table comparing microscopic images of conventional sandpaper and a diamond embedded plate;
FIG. 4 is a table comprising microscopic images of a multi-layered diamond embedded plate;
FIG. 5A is a cross-sectional view of a Palm shaped sanding plate attached to a sanding tool;
FIG. 5B is a cross-sectional view of an Orbital shaped sanding plate or a Corner shaped sanding plate attached to a sanding tool;
FIG. 5C is a cross-sectional view of a Detail shaped sanding plate attached to a sanding tool;
FIG. 6A is a top view schematic representation of a Corner shaped sanding plate;
FIG. 6B is a perspective view schematic representation of a Corner shaped sanding plate;
FIG. 6C is another top view of a Corner shaped sanding plate;
FIG. 7A is a top view schematic representation of an Orbital shaped sanding plate;
FIG. 7B is a perspective view schematic representation of an Orbital shaped sanding plate;
FIG. 7C is another top view of an Orbital shaped sanding plate;
FIG. 8A is a top view schematic representation of a Palm shaped sanding plate;
FIG. 8B is a perspective view schematic representation of a Palm shaped sanding plate;
FIG. 8C is another top view of a Palm shaped sanding plate;
FIG. 9A is a top view schematic representation of a Detail shaped sanding plate;
FIG. 9B is a perspective view schematic representation of a Detail shaped sanding plate;
FIG. 9C is another top view of a Detail shaped sanding plate;
FIG. 10A is a bottom view of a plurality of embodiments of a sanding plate with one or more connectors attached;
FIG. 10B is a bottom view of a Palm shaped sanding plate with an attached connector:
FIG. 10C is a bottom view of a Detail shaped sanding plate with an attached connector;
FIG. 10D is a bottom view of a Corner shaped sanding plate with an attached connector;
FIG. 10E is a bottom view of an Orbital shaped sanding plate with an attached connector;
FIG. 11A is a bottom view of the sanding plates in FIG. 10 attached to electric sanding tools;
FIG. 11B is a top view of a Palm shaped sanding plate attached to an electric sanding tool;
FIG. 11C is a top view of a Corner shaped sanding plate attached to an electric sanding tool;
FIG. 11D is a top view of an Orbital shaped sanding plate attached to an electric sanding tool;
FIG. 12 is a bottom view of a Detail shaped sanding plate attached to an electric sanding tool;
FIG. 13 is a bottom view of a Palm shaped sanding plate attached to an electric sanding tool;
FIG. 14A is a cross-sectional view of a torsional spring;
FIG. 14B is a cross-sectional view of the torsional spring, in the compressed position, attached to the sanding plate and compressing the sanding tool;
FIG. 14C is a perspective view of a metal coating of the torsional spring;
FIG. 14D is a side view of the torsional spring attached to the sanding plate and compressed by the sanding tool; and
FIG. 14E is a cross-sectional view of the torsional spring, sanding plate, and sanding tool in FIG. 14D
FIG. 15 is a top view of a Palm shaped sanding plate with an attached connector, according to an alternative embodiment;
FIG. 16 is a bottom view of the Palm shaped sanding plate with the attached connector of FIG. 15;
FIG. 17 is a bottom perspective view of the Palm shaped sanding plate with the attached connector of FIG. 15;
FIG. 18 is a side perspective view of a Palm shaped sanding tool; and
FIG. 19 is a top perspective view of the Palm shaped sanding plate of FIG. 15 attached to the Palm shaped sanding tool.
DETAILED DESCRIPTION OF THE INVENTION Aspects of the present invention and certain features, advantages, and details thereof, are explained more fully below with reference to the non-limiting examples illustrated in the accompanying drawings. Descriptions of well-known structures are omitted so as not to unnecessarily obscure the invention in detail. It should be understood, however, that the detailed description and the specific non-limiting examples, while indicating aspects of the invention, are given by way of illustration only, and are not by way of limitation. Various substitutions, modifications, additions, and/or arrangements, within the spirit and/or scope of the underlying inventive concepts will be apparent to those skilled in the art from this disclosure.
Referring now to the figures, wherein like reference numerals refer to like parts throughout, FIG. 1 shows a table of current electric sanding tools 100. The present invention is a sanding tool attachment. The sanding tool attachment is designed to be connected to electric sanding tools 100, such as those shown in FIG. 1. The electric sanding tools 100 vary by grit and shape. The grit designates an approximate number of abrasive grains per linear inch: an inverse of coarseness and roughness. The sanding tool attachments described herein can have any known grit measure. The current electric sanding tools 100 shown in FIG. 1 are available with a grit of 80, 120, 220 and 400.
As shown in FIG. 1, there are four sanding tool shapes: Palm, Orbital, Corner, and Detail. The Palm shaped sanding tool 100A is rectangular with evacuation ports 102 extending through the sanding tool near its edges. The Orbital shaped sanding tool 100B is rounded or circular, as shown. The evacuation ports 102 on the Orbital shaped sanding tool 100B are arranged radially through the sanding tool 100B between the center of the sanding tool and the outer circumference. The Corner shaped sanding tool 100C is a flat-iron shape with one straight edge and two rounded edges that come to a point. The evacuation ports 102 on the Corner shaped sanding tool 100C are arranged as radially as possible, with some extending through the sanding tool 100C near its edges. Finally, the Detail shaped sanding tool 100D is triangular with no evacuation ports 102.
Still referring to FIG. 1, the method of connecting a sanding tool attachment to a current electric sanding tool 100 depends on the shape and size of the electric sanding tool 100. As shown in FIG. 1, sanding tool attachments for Orbital shaped and Corner shaped electric sanding tools 100B, 100C are connected to the sanding tools 100B, 100C using hook and loop connectors. The sanding tool attachments for Palm shaped and Detail shaped electric sanding tools 100A, 100D use alternative methods for connection, such as a compression clip and sticker, respectively. However, this is not a preferred as it creates unnecessary variability and cost, creating a division between traditional sandpaper users (via the Palm shaped sanding tool 100A) and sanding discs (via the Orbital and Corner shaped sanding tools 100B, 100C). In a preferred embodiment, the Palm shaped sanding tool 100A and the Detail shaped sanding tool 100D comprise hook and loop connectors for attaching to the sanding tool attachment to provide uniformity. Uniformity decreases costs across the industry. optimized the evacuation ports to fit most of the major sanding brands.
Turning now to FIGS. 2A-2F, there are shown various views at each step of the process for manufacturing a sanding tool attachment. First, in FIG. 2A, a design for a sanding tool attachment die 200 is rendered. In the depicted embodiment, the die 200 for a 3D sanding tool attachment is created in a computer program, such as CAD. After a design is created, the die 200 is formed using a 3D printer, for example. According to an embodiment, the die 200 is formed in Onyx material. According to another embodiment, the die 200 is printed using a MarkForged Mark II 3D printer. In an alternative embodiment, the die 200 is a stamping die and particularly, a metal stamping die. However, a 3D printer reduces the cost and time for creating the die 200 and provides a faster mechanism for feedback (e.g., for creating multiple variations of the die 200 or correcting mistakes in the die 200).
To create the sanding tool attachment, an abrasive device substrate 300 is placed within a bottom portion 202 of the die 200, as shown in FIG. 2B. In an embodiment, the substrate 300 is a metal composition, such as cold-rolled steel or any other type of metal that can adhere to electroplated nickel. The metal composition 300 can have any thickness as long as it does not significantly impede the vibration (i.e., dampen) amplitude of the sanding tool 100. However, as carbon content increases the metal becomes harder to form and cut. With the metal composition 300 in place within the bottom portion 202 of the die 200, a top portion 204 of the die 200 is placed over the metal composition 300, as shown in FIG. 2C.
In the embodiment shown in FIG. 2C, the top portion 204 of the die 200 comprises optional embossments 206. With the top portion 204 of the die 200 installed, the die 200 is pressed closed (e.g., via a press 400), as shown in FIG. 2D. Thereafter, the die 200 is opened by removing the top portion 204 and revealing the metal composition 300, as shown in FIG. 2E.
The metal composition 300 is then removed from the die 200, as shown in FIG. 2F. As shown in FIG. 2F, the metal composition 300 now comprises a lip 302. The lip 302 extends around the perimeter of the metal composition 300. The lip 302 prevents lateral movement and thereby significantly increases torsional strength. After the metal composition 300 is transformed within the die 200, it is coated with an anti-corrosion layer material and diamonds are embedded thereon to create a sanding tool attachment, such as a sanding plate.
According to an embodiment, the metal composition 300 is pre-plated (i.e., electroplated) with nickel under vertical sulfate chloride at 40-50 Amps for 10 minutes. The nickel pre-plating acts as a corrosive inhibitor, which aids in elongated the work life of the metal composition 300. The evacuation ports 102 can be used during the manufacturing process to assist in providing an electrical connection to an electroplating rack.
To transform the metal composition 300 into a sanding tool attachment, such as a sanding plate, the pre-plated metal composition 300 is then electroplated with nickel and diamonds (e.g., 20 g base diamonds) under horizontal sulfate chloride at 40-50 Amps for a 10 minutes stir. Thus, the resulting sanding plate uses diamonds as an abrasive material. Diamond embedded coating is preferable to traditional sandpaper, which utilizes silicon carbide, because diamond size and distribution is more uniform. Electroplated diamonds are also more secure in a base film than silicon carbide is in resin. Even further, the electroplated base file (containing the diamonds) leaves less residue than silicon carbide resin of traditional sandpaper.
After electroplating the metal composition 300 with nickel and diamonds, a hard coat (e.g., 20 g) is added at 40-50 Amps for a final burial of 15-60 minutes, depending on the preferred grit. The hard coat is a base layer of extra-extra-coarse to coarse diamonds surrounded by lighter “appendages” of fine diamonds. For a final burial of 60 minutes, the grit can be 80 or 120. For a final burial of 30 minutes, the grit can be 220, and for a final burial of 15 minutes, the grit can be 400. The purpose of the hard coat is to increase removal rate while maintaining RMS roughness.
Turning now to FIG. 3, there is shown a table comparing microscopic images of conventional sandpaper and a diamond plate (i.e., an embodiment of a sanding plate). As shown in FIG. 3, the grit of the diamond plate is within a range of: XX, DIAFLAT 95, X, and C, which correspond to grits 80, 120, 220, and 400, respectively. Thus, the size and quantity of diamonds have been optimized to match the grit performance of a 80 grit, 120 grit, etc. However, the diamond plate is essentially indestructible, and the diamond grit has been optimized to match or exceed the performance of traditional sandpaper.
Referring now to FIG. 4, there is shown a table comprising microscopic images of a multi-layered diamond plate. They multi-layered diamond plate is created by mixing grits. In particular, the multi-layered diamond plate is created through the addition of multiple layers of diamond with each layer having its own distinct size distribution to create a stronger bond to the base substrate (e.g., metal composition 300). For example, for the X+F grit, the plate is pre-plated at 40-50 Amps for 10 minutes, as described above. Then, the plate is stirred in 20 g X DP004 and D-plated at 40-50 Amps for 10 minutes. Thereafter, the plate is then stirred in 20 g F DP002, followed by a burial at 40-50 Amps for 30 minutes. A similar process is used for each of the other grits, XX+F, DIAFLAT95+F, and C+F, as shown in FIG. 4, electroplating mixed grits by density and buoyancy. In addition to creation of a stronger bond to the base substrate, mixing grits increases the surface area of the diamond plate and improves heat transfer. As a result of improved heat transfer, the diamond plate generates much less heat than alumina oxide on traditional sandpaper and less swarf will get clogged in the grit.
Turning now to FIGS. 5A-5C, there are shown side view schematic representations of the sanding tool attachment 500 (e.g., diamond plate or other sanding plate) connected to a sanding tool 100. In FIG. 5A, a sanding plate 500 is shown attached to a Palm shaped sanding tool 100A. In the depicted embodiment, the Palm shaped sanding tool 100A has a base composed of hydrophobic foam rubber and the sanding plate 500 has a nickel surface. A hook and loop connector 10 is shown between the sanding tool 100A and the sanding plate 500. In the depicted embodiment, a hook strip 12 of the hook and loop connector 10 is attached to the sanding tool 100A with adhesive 14 and a loop strip 16 of the hook and loop connector 10 is attached to the sanding plate 500 (at the nickel (non-diamond) side) with adhesive 14. In an embodiment, the hook and loop strips 12, 16 are fabricated from nylon.
In FIG. 5B, an embodiment of an Orbital shaped sanding tool 100B or Corner shaped sanding tool 100C. According to the embodiment shown in FIG. 5B, the sanding tools 100B, 100C have a base composed of the hook material 12 of the hook and loop connector 10. The loop 16 of the hook and loop connector 10 is attached to the sanding plate 500 (at the nickel (non-diamond) side) with adhesive 14. In the embodiment shown in FIG. 5C, a base of a Detail shaped sanding tool 100D is composed of porous fiber. As with the embodiment shown in FIG. 5A, the Detail shaped sanding tool 100D is attached to the hook 12 of the hook and loop connector 10 and the sanding plate 500 is attached to the loop 16 of the hook and loop connector 10. The hook 12 and loop 16 of the hook and loop connector 10 are attached to the respective sanding tool 100D and sanding plate 500 (at the nickel (non-diamond) side) using adhesive 14.
In the embodiments shown in FIGS. 5A-5C and described above, the hook strips and loop strips can be attached to the sanding tool 100 and sanding plate 500 without interference with the evacuation ports 102, 502. Further, the adhesive described above can be self-adhering backing on each of the hook and loop strips.
Referring now to FIGS. 6A and 6B, there are shown top and perspective views schematic representations, respectively, of a Corner shaped sanding plate 500C. As shown, the Corner shaped sanding plate 500C comprises one or more evacuation ports 502 extending through its diamond surface 510. In the depicted embodiment, there are three large evacuation ports 502 near each corner (i.e., where any two edges intersect). As also shown in the depicted embodiment, smaller evacuation ports 504 extend radially from an approximate center of the sanding plate 500C.
FIG. 6A-6B additionally shows even smaller recesses 506 extending into the sanding plate 500C. These smaller recesses 506 can be produced through laser scribing. Through laser scribing, a partial cut is performed on the sanding plate 500C into the diamond surface 510, resulting in a recess 506 and not a port (i.e., hole) 502, 504. The recesses 506 also extend radially from an approximate center of the sanding plate 500C. Finally, as shown in FIG. 6B, the sanding plate 500C has a retaining lip 508 extending entirely around its perimeter. The embodiment shown in FIG. 6C is similar to the embodiment shown in FIGS. 6A-6B, but the Corner shaped sanding plate 500C does not comprise recesses 506 in the diamond surface 510.
FIGS. 7A-7B show top and perspective views schematic representations, respectively, of an Orbital shaped sanding plate 500B. The Orbital shaped sanding plate 500B comprises large evacuation ports 502 extending radially around an approximate center of the sanding plate 500B. In the depicted embodiment, the large evacuation ports 502 are near the perimeter or outer edge of the sanding plate 500B. The sanding plate 500B additionally comprises smaller evacuation ports 504, which also extend radially around an approximate center of the sanding plate 500B. Finally, the sanding plate 500B shown in FIGS. 7A-7B comprises smaller recesses 506 (as described above and created by laser scribing) extending radially around the approximate center of the sanding plate 500B and into its diamond surface 510. The smaller evacuation ports 504 are positioned between the larger evacuation ports 502 and the smaller recesses 506. As with the embodiment shown in FIGS. 6A-6B, the Orbital shaped sanding plate 500B also comprises a retaining lip 508 extending around the outer perimeter (i.e., circumference) of the sanding plate 500B. The embodiment shown in FIG. 7C is similar to the embodiment shown in FIGS. 7A-7B, but the Orbital shaped sanding plate 500B does not comprise recesses 506 in the diamond surface 510.
Turning now to FIGS. 8A-8B, there are shown top and perspective views schematic representations, respectively, of a Palm shaped sanding plate 500A. The Palm shaped sanding plate 500A comprises one or more large evacuation ports 502 near its corners (i.e., where two perimeter edges meet). The sanding plate 500A additionally comprises smaller evacuation ports 504, which extend between large evacuation ports 502 of sanding plate 500A, as shown. The sanding plate 500A shown in FIGS. 8A-8B also comprises smaller recesses 506 (as described above and created by laser scribing) extending radially around the approximate center of the sanding plate 500A and into the diamond surface 510. As with the previously described embodiments of the sanding tool attachments, the Palm shaped sanding plate 500A comprises a retaining lip 508 extending around its outer perimeter. The embodiment shown in FIG. 8C is similar to the embodiment shown in FIGS. 8A-81, but the Palm shaped sanding plate 500A does not comprise recesses 506 in the diamond surface 510.
FIGS. 9A-9B show top and perspective views schematic representations, respectively, of a Detail shaped sanding plate 500D. The Detail shaped sanding plate 500D comprises one or more large evacuation ports 102 near its corners (i.e., where two perimeter edges meet). The sanding plate 500D additionally comprises smaller evacuation ports 504, which may extend through the diamond surface 510 of the sanding plate 500D at or near the corners. The smaller evacuation ports 504 can be in a corner without a larger evacuation port 502, as shown, or both can be utilized in the same corner. The sanding plate 500D also comprises smaller recesses 506 (as described above and created by laser scribing) extending into the diamond surface 510 between the evacuation ports 502, 504. As with the previously described embodiments of the sanding plate 500D, the Detail shaped sanding plate 500D comprises a retaining lip 508 extending around its outer perimeter. The embodiment shown in FIG. 9C is similar to the embodiment shown in FIGS. 9A-9B, but the Palm shaped sanding plate 500D does not comprise recesses 506 in the diamond surface 510.
Referring now to FIGS. 10A-13, there are shown various views of embodiments of the sanding plate 500 connected to and disconnected from corresponding sanding tools 100. In FIG. 10A, embodiments of the sanding plates 500 are shown, each with one or more connectors 20 for attaching to a sanding tool 100. In the depicted embodiment, the connector 20 is a torsional spring. FIGS. 10B and 10C show a sanding plate 500 with a hook strip 12 of a hook and loop connector 10 attached to the loop strip 16 of the hook and loop connector 10. The sanding plate 500 in FIG. 10B is a Palm shaped sanding plate 500A and the sanding plate 500 in FIG. 10C is a Detail shaped sanding plate 500D. In FIGS. 10B and 10C, the loop strip 16 is attached to the Palm and Detail shaped sanding plates 500A, 500D with adhesive. For example, the loop strip 16 is shown attached (e.g., via adhesive) to a Corner shaped sanding plate 500C in FIG. 10D and to an Orbital shaped sanding plate 500B in FIG. 10E. The hook strip 12 is removably attached or otherwise connected to the loop strip 16, such as shown in FIGS. 10B and 10C.
The sanding plates 500 are shown connected to the sanding tools 100 via the torsional springs 20 in FIGS. 11A-13. FIG. 11A shows a Palm shaped electric sanding tool 100A, an Orbital shaped electric sanding tool 100B, a Corner shaped electric sanding tool 100C and a Detail shaped electric sanding tool 100D. FIG. 11B shows a top view of a Palm shaped sanding plate 500A attached to the Palm shaped electric sanding tool 100A. Likewise, FIG. 11C shows a top view of a Corner shaped sanding plate 500C attached to the Corner shaped electric sanding tool 100C. Also, FIG. 11D shows a top view of an Orbital shaped sanding plate 500B attached to the Orbital shaped electric sanding tool 100B.
Turning now to FIGS. 14A-14E, there are shown various views of the torsional spring 20. In FIG. 14A shows a side view of the torsional spring 20. The torsional spring 20 is composed of a metal material. The flexible material can also be coated in metal (e.g., metal coating 30 in FIG. 14C). In an embodiment, the flexible material has anti-corrosion characteristics to increase the longevity of the torsional spring 20. As shown in FIG. 14A, the flexible metal is curled, forming a rounded (or circular) end 22. In particular, the rounded end 22 forms an Archimedean spiral.
The torsional spring 20 is shown connected to a sanding plate 500 and compressing a sanding tool 100, in FIG. 14B. In particular, the torsional spring 20 is attached to the sanding plate 500 via its flat end 24 such that the flexible metal curves toward the sanding tool 100, as shown. Thus, the rounded end 22 of the torsional spring 20 compresses against a side 104 of the sanding tool 100. Specifically, FIG. 10-13 show the torsional spring 20 attached to the sanding plates 500 and connecting them to the sanding tools 100. When the rounded end 22 of the torsional spring 20 extends along the side 104 of the sanding tool 100, the torsional spring 20 is in a compression position, as shown in FIG. 14B.
As shown in FIG. 14D, the torsional spring 20 is attached to a sanding plate 500 being compressed by a sanding tool 100. In the depicted embodiment, there is a torsional spring 20 on opposing sides 104 of the sanding tool 100. The torsional spring 20 does not dampen vibratory operation but secures the sanding plate 500 to the sanding tool 100. FIG. 14E shows a cross-sectional view of the embodiment shown in FIG. 14D. The sanding tool 100 is shown with a torsional spring 20 having a metal coating 30 connected thereto. Attached to the torsional spring 20 is a layer of mono-crystalline and/or micro-crystalline diamond (e.g., sanding plate 500). An evacuation port 102, 502 is shown extending from the sanding tool 100 and through the torsional spring layers 20, 30 and diamond layer, sanding plate 500.
Referring to FIGS. 15-19, there are shown various views of a Palm shaped sanding plate 500A, according to an alternative embodiment. As shown in FIG. 15, the sanding plate 500A has large evacuation ports 502 at or near its four corners. In the depicted embodiment, there are four large evacuation ports 502 at or near each corner of the sanding plate 500A. Further, the sanding plate 500A comprises smaller evacuation ports 504. In the depicted embodiment, the smaller evacuation ports 504 are between adjacent corners of the sanding plate 500A and thus, between large evacuation ports 502. In FIG. 15, there are two separate groups of three smaller evacuation ports 504. As also shown in the depicted embodiment, the sanding plate 500A comprises rectangular or square recesses 512 at the corners of the sanding plate 500A and in between at least some of adjacent corners of the sanding plate 500A. The large evacuation ports 502 and smaller evacuation ports 504 are grouped (as described above) in each recess 512. In the embodiment shown in FIG. 15, four large evacuation ports 502 are grouped together in one recess 512 and three smaller evacuation ports 504 are grouped together in another recess.
As with the sanding plate 500A embodiments described above, the sanding plate 500A shown in FIG. 15 comprises a diamond surface 510 and also includes a retaining lip 508 extending around the outer perimeter of the sanding plate 500A. The sanding plate 500A shown in FIG. 15 also has a connector 30 attached thereto. FIG. 16 shows a bottom view of the Palm shaped sanding plate 500A with the connector 30 attached to the retaining lip 508. The connector 30 in FIGS. 15-19 is a strap. The strap 30 is connected to the retaining lip 508. In an embodiment, the strap 508 is connected to an edge 514 (FIG. 15) extending from the retaining lip 508 and in another embodiment, in FIG. 17, the strap 30 is attached directly to the retaining lip 508. The strap 508 is either woven through a slot 516 in the edge 514, as shown in FIG. 15, or through a slot 516 in the retaining lip 508, as shown in FIG. 17.
FIG. 18 shows a side perspective view of a Palm shaped sanding tool 100A. The sanding tool 100A comprises a spring-loaded clip 106. To connect the Palm shaped sanding plate 500A to the Palm shaped sanding tool 100A, the strap 30 shown in FIGS. 15-17 is placed through the spring-loaded clip 106 and locked therein, as shown in FIG. 19. The sanding plate 500A can be removed from the sanding tool 100A by engaging the spring-loaded clip 106 again and releasing the strap 30 therefrom. The strap 30 shown in FIGS. 15-19 can be used in conjunction with any embodiment of the sanding plate 500, including the Orbital, Corner, and Detail shaped sanding plates 500B, 500C, 500D, and sanding tool 100, including the Orbital, Corner, and Detail shaped sanding tools 100B, 100C, 100D, described above.
While embodiments of the present invention has been particularly shown and described with reference to certain exemplary embodiments, it will be understood by one skilled in the art that various changes in detail may be effected therein without departing from the spirit and scope of the invention as defined by claims that can be supported by the written description and drawings. Further, where exemplary embodiments are described with reference to a certain number of elements it will be understood that the exemplary embodiments can be practiced utilizing either less than or more than the certain number of elements.
