FOLDABLE SANDER HEAD

Abstract

A foldable sander head includes a head body with first and second head portions. The first and second head portion are pivotable relative to one another about a pivot joint between a planar configuration and a non-planar configuration. A pivot joint connector couples the first and second head portions to one another. The pivot joint connector includes a slide coupler that is slidably coupled to the first and second head portions, such as by tracks on the first and second head portions. The first and second head portions are selectively lockable relative to one another in the planar configuration and are free to pivot in the non-planar configuration. The pivot joint passes through and orthogonal to a central axis of the head body.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of U.S. Provisional Application Ser. No. 63/479,652, filed Jan. 12, 2023, the entirety of which is hereby incorporated by reference.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to a foldable sander head for a sander.

BACKGROUND OF THE DISCLOSURE

Sanders are used to smooth surfaces. For example, a drywall sander is used in drywall installation. It is used in smoothing the plastering compound that is used during drywall installation. One type is a pole sander, which is a manual sander and includes a sander head that is coupled to a pole. Removable sand paper is attached to a fixed, planar lower surface of the sander head. It may be difficult to efficiently sand corners of walls and ceilings using these conventional sanders.

SUMMARY OF THE DISCLOSURE

In one aspect, a foldable sander head for a sander generally comprises a head body including first and second head portions each having a lower surface; and a pivot joint connector pivotably coupling the first and second head portions to one another so that the first and second head portions are pivotable relative to one another about a pivot joint between a planar configuration, in which the lower surfaces of the first and second head portions are generally coplanar with respect to one another, and a folded configuration, in which the lower surfaces of the first and second head portions define an included angle therebetween that is less than 180 degrees.

In another aspect, a foldable sander head for a sander generally comprises a head body including first and second head portions each having a lower surface. The first and second head portions are selectively pivotable relative to one another about a pivot joint between a planar configuration, in which the lower surfaces of the first and second head portions are generally coplanar and fixed with respect to one another, and a folded configuration, in which the lower surfaces of the first and second head portions define an included angle therebetween that is less than 180 degrees. A latch is coupled to the head body. The latch is configurable between a locked configuration, which locks the head body in the planar configuration to inhibit pivoting of the first and second head portions relative to one another, and an unlocked configuration, in which the first and second head portions are freely pivotable relative to one another. The latch includes a lever coupled to the first head portion, and a catch coupled to the second head portion. The lever is selectively movable relative to the first head portion to i) engage the catch, thereby configuring the latch in the locked configuration, and ii) disengage the catch, thereby configuring the latch in the unlocked configuration.

In yet another aspect, a foldable sander head for a sander generally comprises a head body including first and second head portions each having a lower surface. The first and second head portions are selectively pivotable relative to one another about a pivot joint between a planar configuration, in which the lower surfaces of the first and second head portions are generally coplanar and fixed with respect to one another, and a folded configuration, in which the lower surfaces of the first and second head portions define an included angle therebetween that is less than 180 degrees. The pivot joint is a central pivot joint extending through and orthogonal to a central axis of the head body. The head body is lockable in the planar configuration to inhibit pivoting of the first and second head portions relative to one another about the pivot joint.

Other features will be in part apparent and in part pointed out hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective of an illustrated embodiment of a foldable sander head, the sander head being in an unfolded or planar configuration.

FIG. 2 is a similar to FIG. 1, with a slide coupler and a pole coupler exploded from a head body of the foldable sander head.

FIG. 3 is an exploded view of the pole coupler.

FIG. 4 is a cross section of the head body taken through the plane defined by the line 4-4 in FIG. 2.

FIG. 5 is a perspective of the foldable sander head in a folded configuration.

FIG. 6 is a side elevation of the foldable sander head in a folded configuration, showing the minimum included angle between lower surface of the foldable sander.

FIG. 7 is a perspective of another embodiment of a foldable sander head, the sander head being in an unfolded or planar configuration.

FIG. 8 is similar to FIG. 7, with a slide coupler and a pole coupler exploded from a head body of the foldable sander head.

FIG. 9 is a side elevation of the sander head in FIG. 7.

FIG. 10 is an exploded perspective of the sander head in FIG. 7.

Corresponding reference characters indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION OF THE DISCLOSURE

Referring to FIG. 1, a sander head for a sander (e.g., a pole sander) is indicated generally at reference numeral 10. In general, the sander head 10 is configured to be configurable between a rigid or fixed planar configuration and a foldable configuration to facilitate sanding intersections of surfaces lying in different planes (e.g., a corner of a wall). The illustrated sander head 10 is configured to couple to a pole P (shown schematically), thereby forming a pole sander suitable for sanding drywall or other wall material. In other embodiments, the sander head 10 may be hand-held or configured to be coupled to another device. As used herein for ease of description, terms denoting relative locations or positions of components and structures, such as “upper” and “lower,” denote the relative positions when the head sander 10 is in the orientation depicted in FIG. 1, and are not meant to be used in a limiting sense.

Referring to FIGS. 1 and 2, the sander head 10 includes a head body 12, a pivot joint connector 14, and at least one latch 16 (e.g., two latches), each of which is indicated generally in the drawings. The illustrated embodiment also includes a pole coupler, generally indicated at 20, coupled to the pivot joint connector 14, although in other embodiments the pole coupler may be omitted.

In an unfolded or planar configuration (FIGS. 1-4), the illustrated head body 12 has a generally circular footprint, although the head body may have a different footprint shapes, such as elliptical, rectangular, or other polygonal profile shapes. The head body 12 includes first and second head portions 12A, 12B (e.g., semi-circular portions) connected to one another by the pivot joint connector 14. In the planar configuration, lower surfaces of the head portions 12A, 12B lie generally in the same plane so that a combined lower surface of the head body 12 is generally planar. The lower surface of the head body 12 is configured to enable a sanding pad to the attached thereto. In the illustrated embodiment, the head body 12 consists of the first and second head portions 12A, 12B.

As explained below, the pivot joint connector 14 enables the first and second portions 12A, 12B of the head body 12 to selectively pivot or rotate relative to one another about a pivot joint 15 to a folded configuration (FIGS. 5 and 6) in which the first and second head portions to form an included angle A between the lower surfaces that is less than 180 degrees (i.e., non-planar-the surfaces do not lie in the same plane) and greater than or equal to a minimum angle (the minimum angle A being shown best in FIG. 6). For example, the maximum angle may be from about 90 degrees to about 95 degrees, or from about 85 degrees to about 90 degrees. This enables the sanding pad attached to the sander head 14 to generally lie flat against adjacent walls at corners having included angles down to about 90 degrees. As also explained below, in the illustrated embodiment, the pivot joint connector 14 enables the first and second head portions 12A, 12B to freely pivot or “float” between the fixed or rigid planar configuration (i.e., where angle A is about 180 degrees) and the minimum angle A. In the illustrated embodiment, the pivot joint 15 extends through and is orthogonal to a central axis CA (FIG. 6) of the head portion 12.

Referring to FIGS. 1 and 2, the pivot joint connector 14 is generally in the form of a track-bearing assembly, including a first pair of opposing tracks 22 sildably receiving or slidably coupling to at least one first bearing 24 (e.g., plain bearing(s), such as rods or pins; shown best in FIG. 2), and a second pair of opposing tracks 26 slidably receiving or slidably coupling to at least one second bearing 28 (e.g., plain bearing(s), such as rods; shown best in FIG. 2). In the illustrated embodiment, the first and second bearings 24, 28 each include a pair of opposite bearings, although each bearing may be a single bearing with opposite ends. The first and second bearings 24, 28 are connected to one another by a coupler body 30 (e.g., a plate or link) that spans the across the pivot joint of the head body 12. Together, the first and second bearings 24, 28 and the coupler body 30 define a slide coupler, generally indicated at 32, of the pivot joint connector 14 and may be integrally formed as a single, one-piece component. The first pair of opposing tracks 22 are on the upper side of the first head portion 12A (e.g. integrally formed therewith), and the second pair of opposing tracks 26 are on an upper side of the second head portion 12B (e.g., integrally formed therewith). The first and second pair of bearings 24, 28 are captured within slots 34A, 34B (FIGS. 2 and 4) defined by the corresponding pairs of tracks 22, 26. As shown best in FIG. 4, deflectable first and second stops 36A, 36B of the respective first and second pairs of tracks 22, 26 inhibit the bearings 24, 28 from withdrawing from the slots 34A, 34B. The illustrated deflectable stops 36A, 36B are cantilevered on the head portions 12A, 12B and enable the bearings 24, 28 to snap-fit into the slots 34A, 34B of the tracks 22, 26, thereby assembling the pivot joint connector 14. This provides a quick, easy assembly without the use of separate fasteners.

Referring to FIGS. 1 and 2, the illustrated embodiment includes two latches 16 on opposite sides of the tracks 22, 26. Each latch 16 includes a rotatable lever 40 on one of the head portions 12A, 12B and a catch 42 (e.g., clip) on the other of the head portions. In the illustrated embodiment, one of the levers 40 is rotatable coupled to the first head portion 12A, the other lever is rotatable coupled to the second head portion 12B, the catch 42 associated with the lever coupled to the first head portion is coupled to the second head portion, and the catch associated with the lever coupled to the second head portion is coupled to the first head portion. The levers 40 are rotatable between a locked position (FIGS. 1 and 2), in which the lever is received in the catch 42 and spans the joint of the head body 14, and an unlocked position (FIGS. 5 and 6), in which the lever is withdrawn from the catch and may be received in a lever retainer 48 (e.g., a clip). In the locked position, the head body 14 is in the unfolded or planar configuration and the head portions 12A, 12B are inhibited from rotating relative to one another. Moreover, ends of the bearings 24, 28 may engage the stops 36A, 36B to inhibit the bearings 24, 28 from withdrawing from and sliding within the respective tracks 22, 26. In the unlocked position, the first and second head portions 12A, 12B are free to rotate relative to one another, whereby the bearings 24, 28 freely slide relative to the tracks 22, 26 within the slots 34A, 34B between the stops 36A, 36B and closed ends of the slots. The bearings 24, 28 engage the closed ends of the slots 34A, 34B at the minimum angle between the first and second head portions 12A, 12B to inhibit further rotation passed the minimum angle. Moreover, opposing ends of opposite tracks 22, 26 are beveled to facilitate folding to the minimum angle, as shown in FIGS. 5 and 6.

As shown best in FIGS. 3 and 6, the pole coupler 20 is rotatably coupled to the pivot joint connector 14. The pole coupler 20 includes a clevis 52 rotatably coupled to the pivot joint connector 14 and rotatable about a first rotational axis that is transverse (e.g., orthogonal) to the pivot joint, and a pole connector 54 rotatably coupled to the clevis and rotatable about a second rotational axis that is generally parallel to the pivot joint. In this way, the head body 12 has two degrees of freedom relative to the pole coupler 20. As seen best in FIG. 3, the clevis 52 may be rotatably connected to the pivot joint connector 14 by a snap-fit connection. For example, in the illustrated embodiment one or more male snap-fit components 60 of the clevis 52 may be snap-fit into female snap-fit components 62 of the pivot joint connector 14. The pole connector 54 may be threaded to threadably couple to a pole. The pole coupler 20 may be of other configurations and designs.

The sander head 10 or portions thereof may be formed from plastic or other material. In one embodiment, the first and second head portions 12A, 12B may be formed separately, with the corresponding pair of tracks 22, 26, catches 42, and retainers 48 being integrally formed with the respective first and second head portions. The latches 40 may be formed separate and snap-fit connected to the corresponding head portion 12A, 12B. The slide coupler 32, including the bearings 24, 28, the coupler body 30, and the snap-fit receptacles 62, may be integrally formed as a single, one-piece component. The clevis 52 and the pole connector 54 of the pole coupler 20 may be formed separately and connected (e.g., snap-fit) to one another to provide the relative rotation relative to one another about the second rotational axis.

Referring to FIGS. 7-10, another embodiment of a sander head is generally indicated at reference numeral 110. As can be seen from FIGS. 7 and 8, this sander head 110 is substantially similar to the sander head 10 in that it generally includes: a head body 112 including first and second head portions 112A, 112B that are pivotable or rotatable relative to one another about a pivot joint 115; a pivot joint connector 114 including a first pair of opposing tracks 122 sildably receiving or slidably coupling to at least one first bearing 124 (e.g., plain bearing(s), such as rods or pins), and a second pair of opposing tracks 126 slidably receiving or slidably coupling to at least one second bearing 128 (e.g., plain bearing(s), such as rods); a coupler body 130 (e.g., a plate or link) connecting the first and second bearings 124, 128 to one another to define a slide coupler, generally indicated at 132; a pole coupler 120; and at least one latch 116. Each of these components may be substantially identical or similar to the corresponding components of the first head sander 16 and may operate or function in substantially the same or similar way.

Referring to FIGS. 9 and 10, unlike the sander head 10, the sander head 110 further includes one or more pads (e.g. pads 170) coupled to the lower surfaces of the first and second head portions 112A, 112B. The pad(s) 170 may generally compressible, such as a foam pad. The pad(s) 170 is fixedly coupled to the first and second head portions 112A, 112B, such as by adhesive or a thermal bond. In the illustrated embodiment, each of the first and second head portions include an extension or arm 172 extending downward from the corresponding lower surface, generally adjacent to and along the pivot joint 115. Inner ends of respective pads 170 abut and are coupled (e.g., adhered or thermally bonded) to the corresponding arm 172. Each of the illustrated arms 172 extends inward toward the pivot joint 115 from the corresponding lower surface to define an obtuse included angle between the plane of the lower surface and the arm. In the illustrated embodiment, as can be generally seen in FIG. 9, lower end portions of the arms 172 abut one another when the head body 112 is in its planar configuration, and planar lower surfaces of the arms are generally coplanar with one another and a lower surface of the pad(s) 170.

The illustrated sander head 110 further includes a flexible sheet 178 secured to the lower surfaces of the pads 170 and the arms 172. The sheet 178 may be secured by adhesive or in other ways. The lower surface of the sheet 178 may include a hook and loop fastener for securing sand paper thereto. The sheet 178 may span across the pivot joint 115 and flex or hinge at the pivot joint 115 with the pivoting movement of the first and second head portions 112A, 112B.

Having described embodiments of the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims.

When introducing elements of the present invention or embodiment(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

As various changes could be made in the above constructions, products, and methods without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

Claims

1. A foldable sander head for a sander, the foldable sander head comprising:

a head body including first and second head portions each having a lower surface; and

a pivot joint connector pivotably coupling the first and second head portions to one another so that the first and second head portions are pivotable relative to one another about a pivot joint between a planar configuration, in which the lower surfaces of the first and second head portions are generally coplanar with respect to one another, and a folded configuration, in which the lower surfaces of the first and second head portions define an included angle therebetween that is less than 180 degrees.

2. The foldable sander head set forth in claim 1, wherein the pivot joint is a central pivot joint extending through and orthogonal to a central axis of the head body.

3. The foldable sander head set forth in claim 1, wherein the pivot joint connector includes a track-bearing assembly.

4. The foldable sander head set forth in claim 3, wherein the track-bearing assembly includes

a first pair of opposing tracks fixedly coupled to the first head portion,

a second pair of opposing tracks fixedly coupled to the second head portion,

a first bearing slidably coupled to the first pair of opposing tracks and configured to be slidable along the first pair of opposing tracks, and

a second bearing slidably coupled to the second pair of opposing tracks and configured to be slidable along the second pair of opposing tracks.

5. The foldable sander head set forth in claim 4, wherein the first and second bearings are fixedly coupled to one another.

6. The foldable sander head set forth in claim 5, wherein each of the first and second bearings comprises a plain bearing received in the corresponding one of the first and second pair of opposing tracks.

7. The foldable sander head set forth in claim 4, further comprising a latch coupled to the head body, the latch configurable between a locked configuration, which locks the head body in the planar configuration to inhibit pivoting of the first and second head portions relative to one another, and an unlocked configuration, in which the first and second head portions are freely pivotable relative to one another.

8. The foldable sander head set forth in claim 7, wherein the latch includes a lever coupled to the first head portion, and a catch coupled to the second head portion, wherein lever is selectively movable relative to the first head portion to i) engage the catch, thereby configuring the latch in the locked configuration, and ii) disengage the catch, thereby configuring the latch in the unlocked configuration.

9. The foldable sander head set forth in claim 8, wherein the latch comprises two latches.

10. The foldable sander head set forth in claim 1, further comprising a pole coupler coupled to the pivot joint connector.

11. The foldable sander head set forth in claim 10, wherein the pole coupler is rotatable coupled to the pivot joint connector.

12. The foldable sander head set forth in claim 11, wherein the pole coupler includes a clevis rotatably coupled to the pivot joint connector and rotatable about a first rotational axis that is transverse to the pivot joint, and a pole connector rotatably coupled to the clevis and rotatable about a second rotational axis that is generally parallel to the pivot joint.

13. The foldable sander head set forth in claim 1, wherein the pivot joint connector comprises a slide coupler slidably coupled to the first and second head portions.

14. The foldable sander head set forth in claim 13, further comprising at least one track coupled to the first and second head portions, wherein the slide coupler includes at least one bearing slidably coupled to the at least one track.

15. The foldable sander head set forth in claim 14, wherein the at least one track includes at least one first track coupled to the first head portion, and at least one second track coupled to the second head portion.

16. The foldable sander head set forth in claim 15, wherein the at least one bearing includes at least one first bearing slidably coupled to the at least one first track, and at least one second bearing slidably coupled to the at least one second track.

17. The foldable sander head set forth in claim 16, wherein the at least one first bearing includes at least one first plain bearing received in the at least one first track, wherein the at least one second bearing includes at least one second plain bearing received in the at least one second track.

18. A foldable sander head for a sander, the foldable sander head comprising:

a head body including first and second head portions each having a lower surface, wherein the first and second head portions are selectively pivotable relative to one another about a pivot joint between a planar configuration, in which the lower surfaces of the first and second head portions are generally coplanar and fixed with respect to one another, and a folded configuration, in which the lower surfaces of the first and second head portions define an included angle therebetween that is less than 180 degrees; and

a latch coupled to the head body, the latch configurable between a locked configuration, which locks the head body in the planar configuration to inhibit pivoting of the first and second head portions relative to one another, and an unlocked configuration, in which the first and second head portions are freely pivotable relative to one another,

wherein the latch includes a lever coupled to the first head portion, and a catch coupled to the second head portion, the lever selectively movable relative to the first head portion to i) engage the catch, thereby configuring the latch in the locked configuration, and ii) disengage the catch, thereby configuring the latch in the unlocked configuration.

19. The foldable sander head set forth in claim 18, wherein the latch extends across the pivot joint in the locked configuration.

20. A foldable sander head for a sander, the foldable sander head comprising:

a head body including first and second head portions each having a lower surface, wherein the first and second head portions are selectively pivotable relative to one another about a pivot joint between a planar configuration, in which the lower surfaces of the first and second head portions are generally coplanar and fixed with respect to one another, and a folded configuration, in which the lower surfaces of the first and second head portions define an included angle therebetween that is less than 180 degrees,

wherein the pivot joint is a central pivot joint extending through and orthogonal to a central axis of the head body, and

wherein the head body is lockable in the planar configuration to inhibit pivoting of the first and second head portions relative to one another about the pivot joint.