SURFACE MODIFYING APPARATUS WITH LIGHT SOURCE FOR ILLUMINATION OF THE WORKPIECE SURFACE

Abstract

 This invention relates to a surface modifying apparatus comprising a housing assembly comprising a first major surface attachable to an abrasive article and at least one source of illumination which projects at least one beam of light. The abrasive article comprises a second major surface wherein the second major surface comprises a reflective surface wherein the at least one source of illumination projects the first beam of light onto the reflective surface, thereby generating a second beam of light.

Description

Technical Field

[0001] The present disclosure relates to a surface modifying apparatus with at least one source of illumination. The present disclosure also relates to a method of modifying a work surface with a surface modifying apparatus as well as to a use of a surface modifying apparatus for sanding or polishing a surface.

Background of the disclosure

[0002] Surface sanding or polishing apparatus have long been used to modify a wide variety of surfaces. A number of different types of surface modifying apparatus exist. For example, hand-held non-powered and powered tools. These typically consist of a housing assembly which can be gripped and an abrasive article attached to one end used for sanding a surface.

[0003] Often a surface needs to be smooth, for example when constructing a piece of wooden furniture, some joints may need to be flush with each other both for appearance of the overall piece and for practical use. Further, smooth lacquered or painted wood surfaces are highly desirable in some cases, e.g. on pianos or high-value furniture.

[0004] In another example a car body surface needs to be smooth for appearance and here minor defects and blemishes are unacceptable. Sanding a car body surface takes many steps starting with coarse abrasives and moving to finer abrasives and at each stage defects need to be visually identified. To ensure a finish as smooth as possible, inspection of the work surface is critical and especially inspection of any defects that are present.

[0005] Generally, a user sanding a car body surface will sand the surface with a particular grade of abrasive, then stop the sanding operation, take a separate source of light and interrogate the work surface for any blemishes. The light source needs to have high luminosity in order to illuminate the work surface effectively. In particular any defects will cast darker shadows with a highly luminous light source. The user then must note each defect and blemish and resume sanding these specific sites of the surface. This process is repeated many times with different abrasive grades until the user is satisfied with the finish of the work surface. This process is very time consuming, as the user has to constantly use two different tools for sanding and inspection. It is labour intensive and therefore also more tiring for the user.

[0006] A surface sanding apparatus with a source of illumination is known, for example in EP2331292. In JP2008023694 another sanding machine with a source of illumination is disclosed.

[0007] There remains a need for an improved sanding apparatus with at least one source of illumination which helps illuminating the work surface.

Summary

[0008] The present disclosure provides a surface modifying apparatus. The surface modifying apparatus comprises a housing assembly comprising a first major surface attachable to an abrasive article and at least one source of illumination which projects at least one beam of light; the abrasive article comprising a second major surface wherein the second major surface comprises a reflective surface wherein the at least one source of illumination projects a first beam of light onto the reflective surface, thereby generating a second beam of light.

[0009] The present disclosure provides a method of modifying a work surface with a surface modifying apparatus. The method comprises providing an abrasive article attached to a first major surface of a housing assembly of a surface modifying apparatus and projecting at least a beam of light from at least one source of illumination attached to the housing assembly to a reflective surface on the abrasive article which produces a second beam of light from the reflective surface to a work surface wherein an angle between the work surface and the second beam of light creates shadows, by defects located at and below the surface to be sanded that are visually discernible, and sanding the work surface with the abrasive article.

[0010] The present disclosure provides a use of a surface modifying apparatus for sanding or polishing a work surface where in the surface modifying apparatus comprises a housing assembly comprising a first major surface attachable to an abrasive article and at least one source of illumination which projects at least one beam of light and wherein the abrasive article comprising a second major surface wherein the second major surface comprises a reflective surface wherein the at least one source of illumination projects the first beam of light onto the reflective surface, thereby generating a second beam of light.

Detailed Description Disclosure

[0011] Before any embodiments of this disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. As used herein, the term "a", "an", and "the" are used interchangeably and mean one or more; and "and/or" is used to indicate one or both stated cases may occur, for example A and/or B includes, (A and B) and (A or B). Also herein, recitation of ranges by endpoints includes all numbers subsumed within that range (e. g., 1 to 10 includes 1.4, 1.9, 2.33, 5.75, 9.98, etc.). Also herein, recitation of "at least one" includes all numbers of one and greater (e. g., at least 2, at least 4, at least 6, at least 8, at least 10, at least 25, at least 50, at least 100, etc.). Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. Contrary to the use of "consisting", which is meant to be limiting, the use of "including," "containing", "comprising," or "having" and variations thereof is meant to be not limiting and to encompass the items listed thereafter as well as additional items.

[0012] Unless explicitly stated otherwise, all embodiments and optional features of the present disclosure can be combined freely.

[0013] The present disclosure provides a surface modifying apparatus. The apparatus comprises a housing assembly comprising a first major surface attachable to an abrasive article and at least one source of illumination which projects at least one beam of light and where in the abrasive article comprising a second major surface wherein the second major surface comprises a reflective surface wherein the at least one source of illumination projects the first beam of light (X) onto the reflective surface, thereby generating a second beam of light (Y). The second light beam (Y) projects onto a work surface, creating shadows caused by defects in the work surface. This allows the defects to be visually discernible by the user whilst sanding.

[0014] It is preferred that the second beam of light (Y) projects onto a work surface at an angle (Z) between the second beam of light (Y) and the work surface. This ensures a low angle of light is achieved when lighting up the defects on the surface allowing for longer shadows to be created. Defects are visually discernible whilst sanding.

[0015] Preferably the abrasive article comprises a foam backed pad and an abrasive surface. Foam backed pads allow the user to alter the amount of force required for using the surface modifying apparatus. Foam density, hardness and pore size can be varied to allow for differences in conformability of the whole abrasive article.

[0016] Preferably the foam backed pad and abrasive surface are releasably or permanently connected. The foam baked pads are generally longer lasting that the abrasive surface and can be more costly so releasable connection allows for the abrasive surface to be replaced more often while maintaining the more expensive foam backed pad.

[0017] Preferably the abrasive surface and foam backed pad are connected using mechanical fastening means. The abrasive surface can be removed from the foam backed pad with ease allowing the user to continue sanding operations without spending time replacing the whole abrasive article.

[0018] Preferably the reflective surface is present on the side outside circumference of the foam backed pad. The angle produced between first light beam (X) and the sides of the foam backed pad allow the reflective surface to further reflect first light beam (X) to produce second light beam (Y) onto the work surface.

[0019] Preferably the angle (Z) between the second beam of light (Y) and the work surface is 45 degrees or less, preferably 30 degrees or less and more preferably 15 degrees or less. A low angle of light directed at the work surface ensure shadows created from defects present in the work surface are longer, and therefore more obvious to the user whilst using the surface modifying apparatus. Angles higher than 45 degrees do not provide the required effect of allowing shadows, and therefore defects to be more readily discernible.

[0020] Preferably the angle (Z) between the second beam of light (Y) and the work surface is at least 0.5 degrees, preferably at least 1 degree and more preferably at least 1.5 degrees. A low angle of light directed at the work surface ensure shadows created from defects present in the work surface are longer, and therefore more obvious to the user whilst using the surface modifying apparatus. A minimum angle is required to ensure a shadow is created from the defect.

[0021] Preferably the angle (Z) between the second beam of light (Y) and the work surface is in the range from 0.5 degrees to 45 degrees, 1 degree to 30 degrees, 1.5 degrees to 15 degrees. A low angle of light directed at the work surface ensure shadows created from defects present in the work surface are longer, and therefore more obvious to the user whilst using the surface modifying apparatus.

[0022] Preferably the angle (Z) between the second beam of light (Y) and the work surface is such that shadows on the work surface are created, by defects located at and below the work surface which are visually enhanced and easily discernible. The reflective surface of the surface modifying apparatus as described herein allows for a much lower angle (Z) between the second beam of light (Y) and work surface to create longer shadows. This provides for a number of advantages, including better inspection of defects whilst using the surface modifying apparatus consequently there is a lesser need to stop sanding for inspection of defects. This in turn leads to faster sanding by the user and more surfaces per user can be handled in a specific time frame. There is also potential the results of the surface modifying operation will be better as the act of sanding is done in longer, smoother motions instead of a stop, start action.

[0023] Preferably the housing assembly comprises a cleaning brush. As the abrasive article removes material from the work surface during the sanding operation, some of the material removed will cover the reflective surface causing reflectivity to decrease. This will have an effect on how the light beam is reflected and therefore how easily discernible the shadows and defects are. Therefore a clean reflective surface is required and a cleaning brush which is attached to the housing assembly, in close proximity to the reflective surface can keep it clean from any debris coming from the work surface.

[0024] Preferably the sanding apparatus is a dual action sander. A dual action sander spins in both a concentric circular action on a spindle and a wider circulating motion. This oscillation prevents excess heat and friction build up but allows enough for some significant surface modification to take place.

[0025] Preferably the at least one source of illumination is selected from incandescent lamps, halogen lamps, light-emitting diode lamps and fluorescent lamps. More preferably the at least one source of illumination is a light emitting diode (LED) lamp. LED lamps are known to have a longer life span compared to other light sources, they are known to be more energy efficient and have flexible design features. LED lamps are known to brighten up quickly, can be used in both hot and cold environments and can be switched on and off frequently. They are more durable and do not generate significant amounts of heat. These flexibilities of LED lamps allow the user to use the sanding apparatus for prolonged periods with just one type of illumination source regardless of the environment.

[0026] Preferably the at least one source of illumination has adjustable luminosity. There may be a need that darker coloured work surfaces, or work surfaces in dark environments require lower illumination whilst lighter coloured work surfaces, or work surfaces in bright environments require brighter illumination. An adjustable luminosity on the at least one source of illumination allows for flexibility in using the surface modifying apparatus under different lighting conditions relative to each work surface.

[0027] The present disclosure also provides a method of modifying a work surface with a surface modifying apparatus wherein the method comprises providing an abrasive article attached to a first major surface of a housing assembly of a surface modifying apparatus, projecting at least a beam of light from at least one source of illumination attached to the housing assembly to a reflective surface which produces a second beam of light from the reflective surface to a work surface wherein an angle between the work surface and the second beam of light creates shadows, by defects located at and below the surface to be sanded that are visually discernible, and sanding the work surface with the abrasive article. The reflective surface allows for a much lower angle between the second beam of light and work surface to create longer shadows. This provides for a number of advantages, including better inspection of defects whilst using the surface modifying apparatus consequently there is a lesser need to stop sanding for inspection of defects. This in turn leads to faster sanding by the user and more surfaces per user can be handled in a specific time frame. There is also potential the results of the surface modifying operation will be better as the act of sanding is done in longer, smoother motions instead of a stop, start action.

[0028] Preferably, the angle (Z) between the second beam of light (Y) and the work surface 45 degrees or less, preferably 30 degrees or less and more preferably 15 degrees or less. A low angle of light directed at the work surface ensure shadows created from defects present in the work surface are longer, and therefore more obvious to the user whilst using the surface modifying apparatus.

[0029] Preferably the angle (Z) between the second beam of light (Y) and the work surface is at least 0.5 degrees, preferably at least 1 degree and more preferably at least 1.5 degrees. A low angle of light directed at the work surface ensure shadows created from defects present in the work surface are longer, and therefore more obvious to the user whilst using the surface modifying apparatus.

[0030] Preferably the angle (Z) between the second beam of light (Y) and the work surface is in the range from 0.5 degrees to 45 degrees, preferably 1 degree to 30 degrees and more preferably 1.5 degrees to 15 degrees. A low angle of light directed at the work surface ensure shadows created from defects present in the work surface are longer, and therefore more obvious to the user whilst using the surface modifying apparatus.

[0031] The present disclosure is directed to a surface modifying apparatus where a work surface to be modified is selected from wood, polymeric material, metal, paint and coating. Preferably the work surface is a car body surface, wherein the car body surface is selected from being coated, lacquered and/or painted.

[0032] The present disclosure further provides a use of a surface modifying apparatus as described previously for sanding or polishing a work surface.

[0033] The disclosure will now be described, by way of example only, with reference to the following drawings, in which:

Figure 1 is a side view of a dual action sanding device on a work surface with a defect

Figure 2 is a perspective view of a dual action sanding device

Figure 3 is a schematic of an abrasive article assembly

Figure 4 is an enlarged schematic of an illumination source and a work surface with a defect

[0034] Figure 1 illustrates a surface modifying apparatus 10, such as a dual action sander for modifying a work surface 23. The surface to be sanded is could be wood, a polymeric material, metal, paint, a coating. Surface modification could include sanding, polishing, cleaning, painting. The surface modifying apparatus 10 comprises a housing assembly 13 which can be graspable by a user to allow for better grip during sanding and to ensure the sanding apparatus is easily guidable. The housing assembly 13 may have a wide variety of sizes and configurations to assist a user in working a work surface.

[0035] The housing assembly comprises a first major surface 15 which is attachable to an abrasive article 17. The abrasive article comprises a foam backed pad 31 and an abrasive surface 33. The abrasive surface 33 can be permanently attached or releasably attached to the foam backed pad 31 in a number of different ways. Known kinds of suitable releasable mechanical type attachment mechanisms may be used including but not limited to hook and loop fastening, pressure sensitive adhesives and other mechanical and adhesive fastening systems. The abrasive surface 33 may be in the form of an abrasive coated disc, abrasive coated film, coated abrasive. Such a disc may be commercially available from 3M Corporation, St. Paul, Minnesota as HookIT™ and HookIT™ II sanding member. It will be appreciated that a wide range of abrasive articles and methods of attachment to foam back up pads may be used.

[0036] The sides of the foam back up pad 31, the second major surface 18, are covered with a reflective surface 19. The reflective surface 19 may be any reflective material, such as a coating, film, laminate. In Figure 1, the reflective surface 19 used is a mirrored surface but it will be appreciated that a wide range of highly reflective and mirror-type surfaces exist. The reflective surface 19 may be attached to the sides of the foam back up pad 31 in a number of different ways depending on the type of reflective surface present. They may be releasable or fixed. Attachment mechanisms suitable for attaching the reflective surface to the foam back up pad include, but are not limited to pressure sensitive adhesives, hook and loop fastening and other mechanical and adhesive fastening systems

[0037] The housing assembly also comprises at least one source of illumination 21. The illumination source 21 may be a single or plurality of light sources. The light sources may be any one or more of an incandescent lamp, halogen lamp, light-emitting diode (LED) lamp, and fluorescent lamp. In Figure 1, LED lamps are the source of illumination 21. Any number of LED lamps may be used at either a fixed or variable height to allow for adjustment according to the work surface and user. Each of the LED lamps may be fitted with a reflector to provide higher light intensities. The LED lamps directs or projects beams of lights of relatively high intensity and are positioned to ensure the light beam X are hitting the reflective surface 19 on the foam backed pad 31 so that light beam Y is projected at the work surface 23 at a shallow angle. It has been noted that the closer the LED lamps are to the reflective surface 19, the resultant light beam Y is stronger and therefore shadows generated by the defect 27 are more easily observed by the user. Preferable this angle X created by light beam Y and work surface 23 is less than 45 degrees. Again, this provides longer shadows created by the defect 27 and ensures the user is able to continue working whilst observing defects in the work surface 23. Typically the defect 27 may range in size from about 1-5mm at and below the work surface 23.

[0038] Figure 4 shows an enlarged view of an illumination source and a work surface with a defect.

[0039] Figure 2 shows a perspective view of the dual action sanding device 10. The housing assembly 13 may be comprised of a shell-like structure and may be made of a lightweight suitable thermoplastic material. Other suitable materials may be used and these include, but are not limited to, metals, composite materials, wood, or the like. The housing assembly 13 is suitably shaped in order to enable a user to handle and effectively guide the sanding device 10 along a work surface in order to inspect the work surface and correct the defects. Fig. 2 shows a plurality of individual light source 21 mounted on housing assembly 23, providing increased brightness to the reflective surface 19 and therefore darker shadows. The illumination source 21 comprises a source of power which is preferably portable, but may also be fixed. The portable source of power may be replaceable batteries (not shown). A fixed source of power may be a power chord to an electrical outlet point (not shown).

[0040] Figure 3 shows the abrasive article 317, otherwise known to the skilled person as a backup assembly. The back-up assembly 317 may include a generally circular shaped planar base member 319 made of a backing material that has opposed first and second major surfaces 321 and 323 respectively. As is known, the back-up pad assembly may be connected to a rotor by a fastener (not shown) or other similar devices joining the centre of the back-up pad assembly to the rotor. The second surface 323 may include releasable mechanical attaching members such as hooks 325 for releasable securing to loop type attaching members 327. The abrasive surface 329 may include an abrasive material on the first major surface 331 for modifying a surface. Such a surface may be one that is commercially available from 3M Corporation, St Paul, MN as a Hookit™ and HookIt™ II sanding member. Other similar and suitable abrasive surfaces may be used consistent with the teachings of the present description.

[0041] This present description may take on various modification and alterations without departing from the scope. Accordingly, this present disclosure is not limited to the above -described exemplary embodiments, but is to be controlled by limitations set forth in the following claims and equivalents thereof. This present description also may be suitably practiced in the absence of any element not specifically disclosed herein.

Claims

1. A surface modifying apparatus (10) comprising;

a. a housing assembly (13) comprising a first major surface (15) attachable to an abrasive article (17) and at least one source of illumination (21) which projects at least one first beam of light (X);

b. the abrasive article (17) comprising a second major surface (18) wherein the second major surface (18) comprises a reflective surface (19) wherein the at least one source of illumination (21) projects a first beam of light (X) onto the reflective surface (19), thereby generating a second beam of light (Y).

2. The surface modifying apparatus (10) of claim 1, wherein the second beam of light (Y) projects onto a work surface (23) at an angle (Z) between the second beam of light (Y) and the work surface (23).

3. The surface modifying apparatus of claim 1 or claim 2, wherein the abrasive article (17) comprises a foam backed pad (31) and an abrasive surface (33).

4. The surface modifying apparatus of claim 3, wherein the foam backed pad (31) and abrasive surface (33) are releasably or permanently connected using mechanical fastening means.

5. The surface modifying apparatus of claim 4, wherein the reflective surface (19) is present on the side outside circumference of the foam back up pad (31).

6. The surface modifying apparatus (10) of any one of the preceding claims, wherein the angle (Z) is 45 degrees or less, preferably 15 degrees or less, more preferably 15 degrees or less.

7. The surface modifying apparatus (10) of claim 6, wherein the angle (Z) is at least 0.5 degrees, preferably at least 1 degree, more preferably at least 1.5 degrees.

8. The surface modifying apparatus (10) of any one of the preceding claims, wherein the angle (Z) is such that shadows on the work surface (23) are created, by defects located at and below the work surface (23) that are visually discernible.

9. The surface modifying apparatus (10) of any one of the preceding claims, wherein the at least one source of illumination (21) is selected from incandescent lamps, halogen lamps, light-emitting diode lamps, fluorescent lamps, preferably from light-emitting diode lamps.

10. A method of modifying a work surface (23) with a surface modifying apparatus (10), the method comprising the following steps

a. providing an abrasive article (17) attached to a first major surface (15) of a housing assembly (13) of a surface modifying apparatus (10)

b. projecting at least a beam of light (X) from at least one source of illumination (21) attached to the housing assembly (13) to a reflective surface (19) on the abrasive article (17) which produces a second beam of light (Y) from the reflective surface (19) to a work surface (23) wherein an angle (Z) between the work surface (13) and the second beam of light (Y) creates shadows, by defects located at and below the surface (23) to be sanded that are visually discernible

c. and sanding the work surface (23) with the abrasive article (17).

11. The method of claim 10, wherein the angle (Z) is 45 degrees or less, preferably 30 degrees or less, more preferably 15 degrees or less.

12. The method of claim 10 or claim 11, wherein the angle (Z), wherein the angle (Z) is at least 0.5 degrees, preferably at least 1 degree, more preferably at least 1.5 degrees.

13. The method of any one of claims 10 to 12, wherein the work surface (13) to be sanded is selected from wood, polymeric material, metal, paint, coating.

14. The method of claim 13 wherein the work surface (13) the surface to be sanded is a car body surface, preferably a metal car body surface.

15. The use of a surface modifying apparatus (10) for sanding or polishing a work surface, wherein the sanding apparatus comprises

a. a housing assembly (13) comprising a first major surface (15) attachable to an abrasive article (17) and at least one source of illumination (21) which projects at least one beam of light (X);

b. the abrasive article comprising a second major surface (18) wherein the second major surface (18) comprises a reflective surface (19) wherein the at least one source of illumination (21) projects the first beam of light (X) onto the reflective surface (19), thereby generating a second beam of light (Y).

Drawing