BACKGROUND Many buildings have concrete floors and/or walls for structural strength and stability. Some also include concrete or sinter block and/or stone construction. The floors and walls are formed at the very early stages of construction well before building mechanical, electrical and plumbing systems are put in place.
As these and other systems are installed, the floors tend to get fouled with materials like grout, cement, drywall mud and particles, paint and/or epoxy droppings/spills, etc., which are not easily removed. In other examples, concrete floors may have high and low spots resulting an uneven or non-flat surface that can obstruct doors and even pose a walking hazard. In order to prepare these floors for finishing, a floor grinder is applied to remove foreign substances and/or level the uneven spots. This grinding process also exposes clean concrete, which may be useful for the final finishing material and/or process.
Generally, the grinding process can be performed dry or wet. In either case, the grinding process grinds the foreign substances and/or layer of concrete into small dust particles. In a dry grinding process, the dust is vacuumed away from the surface by air. In a wet grinding process, water is used to mix with the dust particles and a wet vacuum is used to vacuum away the dirty water. Such vacuuming (dry or wet) of the dust particles assists in keeping the job site safe and clean.
What is desired are systems and methods of floor grinding that addresses these and other aspects of preparing surfaces.
SUMMARY Systems and methods for grinding are provided. In one embodiment, systems and methods for grinding are provided having a floating or self-adjusting dust collector or means. This allows the dust collector or guard to retract or adjust its position relative its support member to allow for uninterrupted grinding operations as the grinding element(s) wear away. Biasing and guiding assemblies or means are provided that allow the dust collector/guard to be guided closer to its support structure to compensate for the grinding elements become smaller as they wear away during the grinding operation.
BRIEF DESCRIPTION OF THE DRAWINGS In the accompanying drawings which are incorporated in and constitute a part of the specification, embodiments of the inventions are illustrated, which, together with a general description of the inventions given above, and the detailed description given below, serve to example the principles of the inventions.
FIG. 1 shows of one embodiment of a system and method for grinding surfaces.
FIGS. 2 is a side view of the embodiment of FIG. 1.
FIG. 3 is a top view of the embodiment of FIGS. 1 and 2.
FIG. 4 is a side view of one embodiment of a grinding assembly.
FIG. 5 is a bottom perspective view of the embodiment of FIG. 4.
FIG. 6 is a top perspective view of the embodiment of FIG. 4.
FIG. 7 is an exploded view of the embodiment of FIG. 4.
FIG. 8 is a cross-section perspective view taken along section line A-A of FIG. 6.
FIG. 9 shows of another embodiment of a system and method for grinding surfaces.
FIG. 10 is a side view of the embodiment of FIG. 1.
FIG. 11 is a top view of the embodiment of FIGS. 1 and 2.
FIG. 12 is a perspective view another embodiment of a grinding assembly.
FIG. 13 is an exploded perspective view of the grinding assembly of FIG. 12.
FIG. 14 is a cross-sectional perspective view taken along line B-B of FIG. 12.
FIGS. 15A-C illustrate various embodiments of biasing and/or resilient elements for a grinding assembly.
DESCRIPTION As described herein, when one or more components are described or shown as being connected, joined, affixed, coupled, attached, or otherwise interconnected, such interconnection may be direct as between the components or may be indirect such as through the use of one or more intermediary components. Also, as described herein, reference to a member, component, or portion shall not be limited to a single structural member, component, element, or portion but can include an assembly of components, members, elements, or portions.
Embodiments of the present inventions provide, for example, a floor grinder having improved dust collection/guard capability. This provides for better dust collection resulting in a cleaner concrete floor and cleaner and safer job site. Job efficiency is also enhanced because a cleaner concrete floor requires less preparation for finishing than a dusty concrete floor. Job efficiency is further enhanced because less time is needed to clean and clear a job site once the grinding work is done.
Job efficiency is further enhanced by not having to swap or change the size, e.g., to shorten, the floor grinder's dust collector and/or guard as the grinding element(s) wear away during use. A longer dust collector and/or guard was typically used with a new grinding element and, as the grinding element wore away, that dust collector and/or guard would begin to bear against the floor thereby potentially interfering with the grinding process. That first-sized dust collector and/or guard was typically exchanged for a second-sized, and usually shorter, dust collector and/or guard that would not bear against the floor and therefore not interfere with the grinding process. This was problematic in that multiple dust collectors and/or guards were needed to be carried around and it took time to make the changes when there were required.
It also meant that the dust collector was always changing its position relative to the floor as the grinding element wore way. This interfered with the floor grinder's ability to create a proper vacuum to draw the dust particles. Too large a gap between the dust collector and the floor resulted in a weak vacuum inside the dust collector. Too little a gap resulted in restricted air low within the dust collector thereby reducing the vacuum's ability to draw air and dust particles.
The embodiments of the present inventions provide a grinding assembly having a dust collector and/or guard that does not need to be replaced or modified as the grinding element wears away. The dust collector and/or guard has a floating or self-adjusting arrangement that allows it to be in its proper position whether the grinding element(s) are new or in a state of wear. This allows for a proper vacuum within the dust collector to draw dust and other particles without having to replace or modify the dust collector as the grinding element(s) wear away. Work and jobsite cleanliness, safety and efficiency are thus improved.
Illustrated in FIG. 1 is one exemplary embodiment of a grinder in the form a floor grinder 100. A floor grinder is typically used to grind, for example, a concrete floor to remove foreign materials (e.g., paint, primer, epoxy, etc.) that may have attached themselves to the floor during job site work or to level the floor by grinding down high areas. This provides clean concrete surface that is prepared for finishing work (e.g., tiling, wood, etc.)
Referring to FIGS. 1 through 3, floor grinder 100 includes a handle bar 102, wheels 104, support frame or means 106, and motor 108. Handle bar 102 is adjustable and is used to push and direct the floor grinder's movement. Wheels 104 are mounted on the support frame 106 proximate a rearward portion that allows for easy tilting of the floor grinder's front portion (e.g., 110) to assist in the floor grinder's movement and direction. Motor 108 is also mounted on the support frame and provides mechanical power for rotating at least one grinding disc (e.g., see FIG. 5, element 500).
Frame 106 includes a head support or means 112 for supporting a grinding assembly 110. Grinding assembly 110 includes, for example, a flexible hose or tube 114, dust guard 116, brush holder 118, brush 120, and at least one grinding disc 500 (e.g., see FIG. 5). A vacuum connector tube/port 122 is also provided for connecting the grinding assembly 110 to a vacuum source (e.g., wet and/or dry vacuum). In the embodiment shown in FIGS. 1 through 3, an electrical power connector 124 is provided for connecting motor 108 to a source of AC electrical power. In other embodiments, motor 108 can be connected to a source of DC electrical power like a battery. In yet other embodiments, motor 108 may be in the form of a gasoline engine that is powered from a fuel tank or reservoir mounted to support frame 106.
In the embodiment illustrated, a coolant connector 124 is also provided. In this manner, a coolant such as, for example, water, can be provided to the grinding assembly 110 in order to cool the grinding assembly as it grinds the concrete floor and/or to reduce dusting by allowing the dust to mix with the water. In other embodiments, coolant connector 124 may be omitted and the grinding process may be performed dry.
Referring now to FIG. 4, a side elevational view of grinding assembly 110 is shown. The assembly 110 includes at least one flexible hose or tube 114 connected to a head support plate or means 400 and on the other end to dust guard 116. Dust guard 116 includes at least one vacuum port/tube 402 for connection to a vacuum source. Dust guard 116 is further connected to brush holder 118 and brushes 120. Brushes 120 include, for example, a plurality of flexible bristles that guard or minimize dust escaping from the assembly while also allowing adequate air flow for the vacuum to draw dust out from the assembly through vacuum port 402. Also shown in the embodiment of FIG. 4, a lubrication port 404 and spindle/bearing assembly 406 for rotating grinding disc 500 (FIG. 5) and grinding element 408 are provided. Lubrication port 404 allows lubricant to be added when needed to ensure that spindle/bearing assembly 406 can rotate smoothly.
In the embodiment shown, grinding assembly 110 also includes a biasing or resilient means/element 410. Biasing or resilient element 410 can take several forms including, for example, a coil spring, wrapped around or integrated into the wall 412 of flexible hose 114. In other embodiments, biasing or resilient element 410 can take the form of, for example, an elastomeric material (e.g. polymer, rubber, etc.) that forms some or all of wall 412. In this form, wall 412 itself can act as a biasing or resilient element/means 410. In yet other embodiments, biasing or resilient element 410 can be a leaf spring that flexes to compress and expand.
Constructed as such, biasing or resilient element 410 can compress and/or expand thereby shortening or extending the length of flexible hose/tube 114. As shown in FIG. 4, such compression and/or expansion allows dust guard 116 to move closer (i.e., retract) or further away (i.e., expand) from head support plate 400 as represented by arrows 414. Therefore, as the grinding elements (e.g., 408, 502, and/or 504) of grinding disc 500 wear away, dust guard 116 (and brush holder 118 and brushes 120) is correspondingly free to move closer (e.g., up) to head support plate 400. This self-adjusting movement as represented by arrows 414 allows dust guard 116 (and brush holder 118 and brushes 120) to move so that the grinding elements (e.g., 408, 502, and/or 504) remain in contact with the surface being ground as they wear away. The user does not have to stop the grinding process to exchange (or modify) dust guard 116 for a shorter (or different sized) dust guard and does not have to maintain multiple-sized dust guards for the grinding operation. Thus, grinding assembly 110 has a floating or self-adjusting dust guard assembly.
FIG. 5 illustrates a bottom perspective view of grinding assembly 110 showing one embodiment of grinding disc 500 and grinding elements 408, 502, and 504. As described above, as grinding elements 408, 502, and 504 grind away, grinding disc 500 moves closer to the floor and dust guard 116 (and brush holder 118 and brushes 120) correspondingly move closer to head support plate 400. This floating or self-adjusting movement is provided by the compression of biasing or resilient member 410 and allows continued grinding of the floor.
FIGS. 6-8 illustrate top, exploded, and sectional perspective views, respectively of grinding assembly 110. One exemplary embodiment of a guiding and alignment means or assembly is illustrated for dust collector 116. As shown in FIGS. 6 and 7, head support plate 400 includes a plurality of apertures 600-606 and dust collector 116 includes a plurality of guide apertures 700-706. While four are illustrated for each, less than four can be used such as, for example, three or two. FIG. 8 illustrates that a guide screw or bolt (e.g., shoulder screw 804, 806) extends through each corresponding pair of apertures in head support plate 400 and dust collector 116. The guide screws/bolts each have a long body with a head at one end that includes a large shoulder. The other end that is proximate the head support plate 400 is secured with a threaded nut thereto though the arrangement can also be reversed. The body can be of any shape including, for example, cylindrical, polygonal, elliptical, etc. Dust collector 116 can generally move up and down via the guide apertures 700-706 as indicated by arrows 808 along the body of each guide screw/bolt and can be limited by the shoulders. As previously described, this guided upward (and downward) movement of the dust collector 116 occurs under the bias of biasing or resilient element 410 to provide a floating or self-adjusting dust collector as the grinding element(s) wear away.
Referring now to the exploded perspective view of FIG. 7, thus collector 116 includes a means for connecting biasing or resilient element 410 (and flexible hose 116 as may be the case) thereto. Dust collector 116 includes an inner top surface 708, outer top surface 712 and a cylindrical wall 710 extending from one or the other or both surfaces. In one embodiment, cylindrical wall 710 is sized to form a friction fit with the biasing or resilient element 410 shown as a coil spring. The friction fit is formed between the inner diameter dimension of the coil spring and the outer diameter dimension of the cylindrical wall 710. Other configurations are also possible including reversing the friction fit arrangement and/or including fasteners to fasten the two components together.
When flexible hose 114 and biasing or resilient element 410 are combined (e.g., as shown in FIG. 7), one end 714 thereof bears against a surface of dust connector 116 and the other end 716 thereof bears against and/or is connected to head support plate 400. As previously described, this allows dust collector 116 to float or self-adjust its position relative to the head support plate 400 under the bias of biasing or resilient element 410.
Referring now to the cross-sectional view of FIG. 8, in one embodiment dust collector 116 is connected to brush holder 118 via slotted friction fit arrangement. Brush holder 118 includes a slot 800, which can be circumferentially around the body of brush holder 118 or partially circumferential at one or locations around the body of brush holder 118. Slot 800 is configured to frictionally receive a portion of the outer wall of dust collector 116 so as to connect the two components together. The body of brush holder 118 also includes a second slot 802, which can be generally similarly configured to slot 800, for frictionally receiving a portion of brush 120 to connect these components together. In alternate embodiments, friction or interference fits may be replaced with fasteners and/or tongue and groove connectors, keyed slots, or other similar structures.
The dust collector and/or guard thus has a floating or self-adjusting arrangement that allows it to be in its proper position whether the grinding element(s) are new or in a state of wear. This allows for a proper vacuum within the dust collector to draw dust and other particles without having to replace or modify the dust collector to another size as the grinding element(s) wear away. Work and jobsite cleanliness, safety and efficiency are accordingly improved.
FIGS. 9-11 illustrate another embodiment of a grinding assembly 110 attached to a floor grinder 900. This embodiment includes, for example, a grinding assembly having a plurality of grinding discs 500 (e.g., see FIG. 13). Grinding assembly 110 in this embodiment includes handle bar 102, wheels 104, support frame 106, motor 108. Handle bar 102 is adjustable and is used to push and direct the floor grinder's movement. Wheels 104 are mounted on the support frame 106 proximate a rearward portion that allows for easy tilting of the floor grinder's front portion (e.g., 110) to assist in the floor grinder's movement and direction. Motor 108 is also mounted on the support frame and provides mechanical power for rotating at least one grinding disc (e.g., see FIG. 13, elements 500) and can be electrical or gasoline powered.
Frame 106 includes a head support 902 for supporting a grinding assembly 110. This embodiment of grinding assembly 110 includes, for example, a plurality of flexible hoses or tubes 904 and 906 (having biasing or resilient elements), dust guard 908, brush holder 910, brush 912, and a plurality of grinding discs 500 (e.g., FIG. 13). A vacuum connector tube/port 914 is also provided for connecting the grinding assembly 110 to a vacuum source (e.g., wet and/or dry vacuum). In the embodiment shown in FIGS. 9 through 11, motor 108 is in the form of a gasoline engine that is powered from a fuel tank or reservoir mounted to support frame 106. In other embodiments, an electrical motor can be used, and a power connector can be provided for connecting the motor to a source of AC electrical power. In yet other embodiments, motor 108 can be connected to a source of DC electrical power like a battery.
In the embodiment illustrated, a coolant connector 124 is also provided. Coolant such as, for example, water, can be provided to the grinding assembly 110 in order to cool the grinding assembly as it grinds the concrete floor and/or to reduce dusting by allowing the dust to mix with the water. In other embodiments, coolant connector 124 may be omitted and the grinding process may be performed dry.
Referring now to FIGS. 12 and 13, a perspective and exploded perspective views of the grinding assembly 110 of FIGS. 9-11 is shown. The assembly includes a plurality of flexible hoses or tubes 904 and 906 connected to a head support 902 and on the other end to dust guard 908. Dust guard 908 includes at least one vacuum port/tube 914 for connection to a vacuum source. Dust guard 902 is further connected to brush holder 910 and brushes 912. Brushes 912 include, for example, a plurality of flexible bristles that guard or minimize dust escaping from the assembly while also allowing adequate air flow for the vacuum to draw dust out from the assembly through vacuum port 914.
In the embodiment shown, grinding assembly 110 also includes a biasing or resilient means/elements 1200 that are similar to elements 410 of the embodiment of FIGS. 1-8. For example, biasing or resilient elements 1200 can take several forms including, for example, a coil spring, wrapped around or integrated into the wall of flexible hoses 904 and 906. In other embodiments, biasing or resilient element 1200 can take the form of, for example, an elastomeric material (e.g. polymer, rubber, etc.) that forms some or all of the tube or hose wall. In this form, the hose or tube wall itself can act as a biasing or resilient element/means 1200. In yet other embodiments, biasing or resilient element 1200 can be a leaf spring that flexes to compress and expand.
Constructed as such, biasing or resilient elements 1200 can compress and/or expand thereby shortening or extending the length of flexible hoses/tubes 904 and 906. As shown in FIG. 12, such compression and/or expansion allows dust guard 908 to move closer or further away from head support 902 as represented by arrows 1202. Therefore, as the grinding elements (e.g., 502, and/or 504) of grinding discs 500 wear away, dust guard 908 (and brush holder 910 and brushes 912) is correspondingly free to move closer (e.g., up) to head support structure 902. This self-adjusting movement as represented by arrows 1202 allows dust guard 908 (and brush holder 910 and brushes 912) to move so that the grinding elements (e.g., 502, and/or 504) remain in contact with the surface being ground as they wear away. As in the previous embodiments, the user does not have to stop the grinding process to exchange (or modify) dust guard 908 for a shorter (or different sized) dust guard and does not have to maintain multiple-sized dust guards for the grinding operation. Thus, this embodiment of grinding assembly 110 also has a floating or self-adjusting dust guard assembly for when multiple grinding discs are used.
Referring now to the exploded perspective view of FIG. 13 and the cross-sectional view of FIG. 14, this embodiment of a grinding assembly 110 also includes a guiding and alignment means similar to that of the embodiment of FIGS. 1-8. A plurality of guide screws or bolts (e.g., shoulder screws 1310-1320) are provided. Each extends through a corresponding pair of apertures in head support 902 and dust collector 908. For example, head support plate 1400 includes apertures 1404 and dust collector 908 includes corresponding guide aperture 1402. As previously described, the guide screws/bolts (e.g., see shoulder screws 1312 and 1318 in FIG. 14) each have a long body with a head at one end that includes a large shoulder. The other end that is proximate the head support plate 1400 is secured with a threaded nut thereto (though the arrangement can also be reversed). The body can be any shape including, for example, cylindrical, polygonal, elliptical, etc. Dust collector 908 can generally move up and down along the body of each guide screw/bolt via the guide apertures (e.g., 1402) and this movement can be limited by the shoulders. As previously described, this guided upward (and downward) movement of the dust collector 908 occurs under the bias of biasing or resilient elements 1200 to provide a floating or self-adjusting dust collector as the grinding element(s) wear away.
Dust collector 908 includes a means for connecting a plurality of biasing or resilient elements 1200 (and flexible hose(s) 904 and 906 as may be the case) thereto similar to that of the embodiments of FIGS. 1-8. The means will be described in connection with biasing or resilient element 1200 and flexible hose or tube 904 with the understanding the same description applied to biasing or resilient element 1200 and flexible hose or tube 906. Dust collector 908 includes an inner top surface 1300, outer top surface 1304 and a cylindrical wall 1302 extending from one or the other or both surfaces. In one embodiment, cylindrical wall 1302 is sized to form a friction or interference fit with the biasing or resilient element 1200 shown as a coil spring 1200. The friction fit is formed between the inner diameter dimension of the coil spring 1200 and the outer diameter dimension of the cylindrical wall 1302. Other configurations are also possible including reversing the friction fit arrangement and/or including fasteners to fasten the two components together.
When flexible hoses 904 and 906 and biasing or resilient element 1200 are respectively combined (e.g., as shown in FIG. 12), one end 1306 thereof bears against a surface of dust connector 908 and the other end 1308 thereof bears against and/or is connected to head support 902. As previously described, this allows dust collector 908 to float or self-adjust its position relative to the head support 902 under the bias of biasing or resilient elements 1200.
Referring now to the cross-sectional view of FIG. 14, in one embodiment dust collector 908 is connected to brush holder 910 via slotted friction or interference fit arrangement. Similar to the embodiments of FIGS. 1-8, brush holder 910 includes a slot 1406, which can be circumferentially around the body of brush holder 910 or partially circumferential at one or locations around the body of brush holder 910. Slot 1406 is configured to frictionally receive a portion of the outer wall of dust collector 908 so as to connect the two components together. The body of brush holder 910 also includes a second slot 1408, which can be generally similarly configured to slot 1406, for frictionally receiving a portion of brush 912 to connect these components together. In alternate embodiments, friction or interference fits may be replaced with fasteners and/or tongue and groove connectors, keyed slots, or other similar structures.
The dust collector and/or guard 908 of FIGS. 9-14 thus has a floating or self-adjusting arrangement that allows it to be in its proper position whether the grinding element(s) of multiple grinding discs are new or in a state of wear. This allows for a proper vacuum within the dust collector to draw dust and other particles without having to replace (or modify) the dust collector to another size as the grinding element(s) wear away. Work and jobsite cleanliness, safety and efficiency are accordingly improved.
FIGS. 15A-C illustrate various embodiments of biasing and/or resilient members for a grinding assembly. These embodiments illustrate the biasing and/or resilient element can be part of the guiding and alignment assembly. FIG. 15A illustrates an embodiment of a biasing and/or resilient element 1500 that is, for example, a coil spring 1500 around the body of the one or more shoulder screw/bolt(s) (e.g., 804-806, etc. of FIG. 8 and e.g., 1306-1320 of FIG. 13). Coil spring 1500 can extend between head support surface 400 and dust collector 116. Arranged as such, coil spring 1500 exerts a force on dust collector 116 as the grinding elements of discs 500 wear away. This force allows dust collector 116 to float or self-adjust to stay in the proper position with respect to the surface being worked on as the grinding elements (e.g., 502, 504, etc.) wear away.
FIG. 15B illustrates another embodiment in the form of a rubber or polymer resilient sleeve or block 1502. The sleeve or block has a central opening for receiving the body of a shoulder screw/bolt (e.g., 804-806, etc. of FIG. 8 and e.g., 1306-1320 of FIG. 13). Sleeve or block 1502 can extend between head support surface 400 and dust collector 116. So arranged, sleeve or block 1502 when compressed as indicated at 1504 pushes back to exert a force on dust collector 116 as the grinding elements of discs 500 wear away. This allows dust collector 116 to float or self-adjust to stay in the proper position with respect to the surface being worked on as the grinding elements (e.g., 502, 504, etc.) wear away.
FIG. 15C illustrates another embodiment in the form of a leaf spring 1506. Leaf spring 1506 can comprise, for example, one or more leaves around the body of a shoulder screw/bolt (e.g., 804-806, etc. of FIG. 8 and e.g., 1306-1320 of FIG. 13). Leaf spring 1506 can extend between head support surface 400 and dust collector 116. Arranged as such, leaf spring 1506 when compressed as indicated at 1508 pushes back to exert a force on dust collector 116 as the grinding elements of discs 500 wear away. This allows the dust collector 116 to float or self-adjust to stay in the proper position with respect to the surface being worked on as the grinding elements (e.g., 502, 504, etc.) wear away. In other embodiments, structures similar to shoulder screw(s)/bolt(s) can be used including for example, elongate rivets, capped or shouldered cylinders (or other elongate body geometries (e.g., polygonal, elliptical, etc.), capped or shouldered telescoping tubular bodies, etc.
While the present inventions have been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the descriptions to restrict or in any way limit the scope of the disclosure to such detail. Additional advantages and modifications will readily appear to those skilled in the art. For example, the geometry or structural configuration of many components can be changed and still serve the purposes described herein. The flexible hoses or tubes do not have to be circular in cross-section but can be any shape including rectangular, square, triangular, elliptical, polygonal, hexagonal, etc. Similarly, the biasing or resilient members do not have to be in a cylindrical coil arrangement but can be a coil of any shape including polygonal, rectangular, square, elliptical, etc. Also, the dust guard does not have to be circular or cylindrical in cross-section but can be polygonal, rectangular, square, triangular, elliptical, hexagonal, etc. and with or without rounded corners. And, as described, the basing or resilient members can be integrated into the guiding and alignment assembly instead of the flexible hose. Therefore, the inventions, in broader aspects, are not limited to the specific details, the representative apparatus, and illustrative examples shown and described. Accordingly, departures can be made from such details without departing from the spirit or scope of the general inventive concept.
