Note: Descriptions are shown in the official language in which they were submitted.
2i86422
p~w~ TQO~I ~
Field Q~E l h~ lnVf'ntiOIl
The present invention relates to actuators f or
power tools and, more particularly, to paddle actuators
5 having a lock-on mechanism.
Back~rQlmd o~ the Tnv~ntio~
Trigger-type menh~n;c~ for activating a power
tool where the trigger must be cnntlnll~l ly depressed
closing the switch circuit to provide power to the power
10 tool motor are known. It is also known to provide these
power tnols with lock-on meeh~n~cmc so as not to require an
operator to ~nntlnll~l ly depress the trigger mechanism to
operate the tool. Such lock-on meeh~n~mf~ avoid operator
fatigue and thereby enhance an operator' s control of the
15 tool.
While these locking m~h~nl ~mR are known, they
are typically removed from the triggering mechanism such
that they of ten require an operator to move: their hand to
adjust their grip on the trigger, or use their other hand,
20 so as to move the locking mechanism into its operative
locked state. Utilizing both hands to activate the tool
and employ the lock-on mechanism is undesirable in t~at it
complicates the use of the lock-on mechanism and prevents
the other hand from being used for other functions during
25 tool operation.
In addition, where~the lock-on me~h~n~mq can be
simultaneously engaged by the same hand operating the
trigger, the locking meeh~ni cmR still generally require a
movement distinct from the movement of the trigger as in
30 opposite or transverse directions, again complicating
application of the lock-on mechanism. Where the hand on
the trigger can be used, the distinct IV~ -ntq required
and the relative position of the triggering and lock- on
mechanisms which usually entails an adjustment to the
35 operator' s grip on the trigger to allow the operator to
-
2 1 86422
-- 2
properly engage and employ the lock-on mechanism as men-
tioned above both enhance the potential for the operator to
decrease the pressure being applied to the trigger with
their hand upon engagement and employment of the lock-on
5 mechanism w~th the same hand. Such decrease in pressure
applied to the trigger can correspondingly allow the
triggering mechanism to move from its depressed position 80
as to disable the motor and re~uires the operator to re-
depress the triggering mechanism and once more attempt to
10 engage and move the lock-on mechanism without deactivating
the motor. This is especially undesirable where the tool
already has its working element in engagement with the
working surface as abrupt cut-offs of power to the tool and
the accompanying rapid deceleration in speed of the working
15 element can cause damage to the working surface and/or the
tool .
Where the power tool drives its working element
in an orbital path, such as with orbital polishers and
their associated pads, the operator experiences a signifi-
20 cant increase in the vibratory response from the tool overother tools which do not drive their working element in
orbital paths. Such vibratory response sharpens the need
for an easy-to-use actuator and lock-on me~n1cmF~, partic-
ularly as the operator moves the polisher away from their
25 body to reach remote areas, such as on a car's exterior
surfaces, from a relatively stationary position. As the
operator extends their arms, the weight of the polisher is
accordingly cantilevered further outwardly making control
over the polisher and, therefore, continued application of
30 the actuator, more difficult. In such an extended posi-
tion, it is especially desirable that the lock-on mechanism
for the actuator be ergonomically located and usable 80 as
to easily and readlly allow for~ its- employment.
21 86422
-- 3
Summa~ of the Inventlon
In accordance with the present invention, a power
tool having an actuator and lock-on mechanism i9 provided
which overcomes the aforementioned problems of the prior
art. =-
In one form of the invention, the power tool
includes a main housing containing a motor for driving a
w~rking element and a hollow handle connected to the
housing. An actuator paddle is mounted for pivotable
movement relative to the handle and is pivotable between
(1) an open position wherein the motor i9 disabled and
(2) a closed position wherein the motor is activated to
drive the working element. With the paddle in the closed
position, release o~ the paddle~ causes the paddle to return
to the open ~osition to disable the motor. A locking
member is mounted to the paddle to be movable therewith
whereby with the paddle in the closed position the member
is capable of maintaining the paddle in the closed position
when the paddle is released. With the locking member
mounted to the paddle so as to move with the paddle-as the
paddle is pivoted, the power tool herein makes it signifi-
cantly easier for an operator to engage the locking member
over :prior lock-on mechanisms which were not mounted for
movement with the triggering mechanism.
In one form, the handle has an elongate, arcuate
shape and extends away from the housing and the padd~e has
an elongate, arcuate shape substantially conforming to the
handle shape The handle can include a paddle recéiving
slot along the length thereof with the paddle being mounted
to the handle to project from the slot and allowing the
paddle to be depressed in the slot as it is moved from the
op~en position to the closed ~ position The elongate,
arcuate matching or confor~Ling shape of the actuator to the
handle provides for an ergonomic actuating mechanism in
that an operator can readily activate the tool while
2~ 86422
- 4
gripping the arcuate handle at a variety of positions along
its reach.
The paddle can include an aperture with the lock-
ing member including a button portion pro~ ecting through
the paddle aperture and a cam portion in the hollow handle.
A flange can be mounted in the hollow handle such that with
the paddle moved to the closed position, the button member
can be depressed in the paddle aperture to cause the cam
portion to latch onto the flange and maintain the paddle in
the closed position when the paddle is released.
The handle can include switching structure
mounted therein for activating the motor and the paddle can
in:clude an actuating member with the paddle mounted to the
handle so that in the open position the~actuating member is
spaced from the switching structure~ an~d the motor is dis-
abled and in the closed position, the actuating member
engages the switching structure to activate the motor.
In one form, cam structure is provided cooper-
ating between the handle and the locking member for moving
the locking member between ~1 ) an unlocked position where
the paddle is freely movable between its open and closed
positions and (2) a lock position wherein the paddle is
mi:l;nti:l;n~fl in the closed position. The handle can include
a flange mounted therein and the locking member can include
a portion l~srt~nrl;ng into the handle. The cam structure can
include a cam surface on at least one of the flange and the
locking member: portion which allows the portion to latch
onto the flange as the locking member is moved from the un-
locked to the locked position.
In one form, the paddle has a length and spaced
ends and the locking member is pivotably mounted to one end
of the paddle and the paddle is pivotably mounted to the
housing at the_other end of the paddle.
In another: form of the invention, the power tool
has an actuator paddle mounted for pivotable movement
relative to the handle where movement of the handle to an
_ _ _ .. , . _ _ . . _ . _ . . ... . . . _ _
21 86422
-- 5
operative po-sition in a f irst direction causes the motor to
drive the working element. A locking member is mounted for
pivotable movement relative to the paddle, wherein movement
of the locking member in the first direction 18 capable of
locking the paddle in the operative position. With the
locking member mounted to the paddle and the paddle to the
handle such that movement of elther in the same direction,
i.e., depressed towards the interior o~ the handle, can
activate the power too~ motor, an operator is no longer
faced with two aistinct movements which must be performed
with the hard gripping the power tool handle 80 as to lock
the tool in its operative state. This significantly
simplifies the employment of the lock-on mechanism of the
pre8ent invention.
Preferably, the handle has a hollow interior and
includes a slot. The paddle can be mounted in the slot
with the paddle being depressible in the slot in the f ir8t
direction towards the interior of the handle to thereby be
moved to its operative position.
In one form, both the paddle and the locking
member can be depressed in the first direction towards the
interior of the handle to thereby maintain the paddle in
its operative position and readily allow one-handed opera-
tion of the tool.
~ In yet another form of the_invention, a switch in
the handle is electrically connected to the motor and has
on and off states ~such that with the switch in the on
8tate, the motor is energized to drive the working element
and in the of:f 8tate, the motor is de-energized A paddle
aotuator is mounted for movement relatlve to the handle
between ~1) an extended position wherein the actuator
extends a first distance from the handle and the switch is
in the off state and (2) a first depressed position wherein
the actuator extends a second distance ~rom the handle less
than the first distance and the switch is in the on state
A locking member is ca~ried by the paddle actuator and is
... . . , _ . _ , , .. ,, _ _ _ _ _
2 ~ 86422
-- 6
capable of being depressea with the paddie ln the depressed
po-sition to lock the paddle in the depressed position.
With the paddle in the first locked, depressed po~ition,
the paddle can be depres8ed further to a second aepressed
5 position whereln the paddle actuator extends a third dis-
tance from the handle le8s than the ~econd distance. In
the second deprèssed poeition, 'che locking member and
paddle are released from the first, locking position to
allow the paddle to move. to lts P~tPnfl~rl ~sition upon
lO release o~ the paddle by the operator to turn the switching
mechanism and, therefore, the power tool, to its off state.
In this manner, the power tool can be activated, locked in
the activated state and then released from its locked state
all by movement of the paddle and=associated locking member
15 in a single direction, thu~ providing a power tool which is
~ignificantly 8impler to use-o~er tho8e rer~uiring different
m~v~ -nts to apply and to release their lock-on merh~n1cm~
from the movement of their trigger.
In one form, a lock flange is mounted in the
20 hollow handle and the locking member include a cam member
in the hollow handle arranged that 80 with the paddle in
its first depre~38ed position, the button member can be
depressed in the paddle aperture to cause the cam member to
cam over and latch onto the :elange and mA1nt~1n the paddle
25 in: the ~irst depressed position when the paddle i~
rel cased. ~ - -
Brlef ~oAcri~ Qf f-hC- Praw$Il~s
FIG. l is a perspective view of an apparatus for
waxing, buffing, polishing or the like according to the
30 present inventioni
FIG. 2 is a left side elevational view of the
apparatu~ shown in FIG . l, including a f ront handle and a
rear handle and a paddle actuator on the rear handle;
FIG. 3 i~ a top plan view of the apparatus 8hown
35 in 7IG. l showing details of the engagement of a first and
~ 2~86422
-- 7
a ~econd rl ;Imq~c~1 1 housing member which def ine a cord lock
and a collar for a male receptacle;
FIG. 4 is a right side elevational view of the
apparatus shown in FIG. l;
~ FIG. 5 i8 a rear elevational view of the
apparatus shown in FIG. l;
FIG. 6 is a bottom plan view of the apparatus
shown in ~IG. 1 showing the counterweight assembly
including a sIuick-change post for mounting a buffer pad
thereDn;-
FIG. 7 is an enlarged top plan view of the cord
lock and the cDllar and male receptacle assembly of the
apparatus shown in FIG 1, as seen i~n- FIG. 3;
FIG. 8A is a side sectional view taken along
lines 8A- 8A of FIG . 7;
FIG. 8B is a side sectional view taken along
lines 8B-8~ of FIG. 7;
FIG. 9 is a rear sectionaI view taken along line
9-9 of FIG. i;
: FIG. lO is an exploded~perspective view of the
apparatus shown in FIG. l showing details of the arrange-
ment of a DC ~otor havlng a support plate and rectifier
assembly, the paddle actuator with a lock-on button, and
the counterweight and pad assembly;
: FIG. 11 is a~ enlarged perspective view of the
motor and support p:Late asse-mbly and the paddle actuator
and its lock- on button mounted in the ~irst rl ~m
housing memb~r shown in FIG. lO;
FIG 12 is an exploded perspective view of the
3 o paddle actuator and lock- on button: assembly shown in FIG .
16;
FIG. 13 is a side elevational view, partially in
section, of the assembled paddle actuator and lock-on
button assembly shown in FIG. 10;
FIG. 14 is a perspective view of the assembled
support plate and rectlfier assembly shown in FIG. lO;
- 8 2186422
FIG. 15 is an exploded vlew of the support plate
and rectif ier assembly shown in EIG . 14;
FIG. 16 is a ~lde sectional view of the counter-
weight and buf f er pad assembly showing a mounting plate of
5 the pad and a mounting post and detent ball inserted
through an axial lining of the buffer pad mounting plate;
FIG. 17 is an enlarged sectional view of the
support post and the axial lining shown in FIG. 16 showing
a circumf erential groove in the axial lining with the
10 detent ball in the gr~ove;
FIG. 13 i8 an~ enlarge¢ sectional view of a
portion of the apparatus shown in FIG. 17, showing the post
inserted through the axial lining with the detent ball
abutting the bottom of the lining to removably secure the
15 pad to the post;
FIG. 19 is a ~qide sectional Yiew of the post
showing the detent ball attached to a pla~qtic backing which
is :attached in a recess of the post;
FIG. 20 is an e~larged perspective view of the
20 first ~7~mqhl~1l housing member;
FIG. 21 is an e~larged perspective view of the
seconl-d clamshell housing member; and
FIG. 22 is an electrical qchematic diagram of the
DC motor assembly according to the present invention.
: I)etailed De~cri~tinn Q~ ~h~ pre~f~rred ~ ~nfl~ t
FIG. l illustrates an ergonomic apparatus 10 for
waxing, polishing, buffing or the like, according to the
present invention. ~he inventive . apparatus 10 has a
symmetrical design about a vertical re~erence plane, not
shown, ,=~t~nfl~ng centrally from a forward end 12 to a
rearward end ~14 The apparatus 10 includes a housing 16
preferably having a c~mqh~ design with a first cl~mqhf~ll
housing member 13 and a second ~ l ~mqhl~l 1 housing member 20
which, when connected to 4~ach other, define a part line 21
which extends in~ the vertical re~erence plane about which
21 8642~
the houslny 1~ ls symmetrical, as shown in FIG. 3. Prefer-
ably, the first and second ~l~mRh~ll housing members 18 and
20 are molded plastic parts with their~various portions
described herein being formed integrally with each other.
5 Corresponding portions on each of the symmetrical housing
members 18 and 20 are identified by the same reference
numeral with the portion~ on the first housing member 18
additionally provided with letter ~'a" and portions on the
second housing member provided with the letter "b".
The housing 16 includes a main central housing 22
in~ which the motor assembly 24 is mounted, as best seen in
FIGS 10 and 11. The main housing 22 includes a front
handle 26 and a rear handle 28 Pl~t~n~11ng therefrom. As
illustrated in FIGS. 1-6, ~he main housing 22 includes a
15 substantially ~lat top 30 and a bottom 32 and the front and
rear handles 26 and 28 extend transversely to each other
with the front handle 26 extending horizontally outwardly
towards the forward end 12 from the main housing 22 between
and substantially parallel to the top 3 0 and bottom 32
20 thereof while the rear handle 28 extends outwardly towards
the rear~ end 14 from the main housing- 22 and extend~
vertically and arcuately between the top 30 and bottom 32
of ~ the main housing 22
The rear handle 28 has a hollow interior 34 in
25 which a box-shaped switch housing 36, for a switching
mechanism 37 illustrated schematically in FIG. 22, and an
actuator paddle- 38 are mounted. The actuator paddle 38
extends from the interior 34 through a bottom slot 35
formed in handle 28 to a predetermined distance outside the
30 rear handle interior 34 in a rear gripping aperture 39
bounded by the rear handle 28. The paddle 38 has an
arcuate shape substantially matching the contour of the
rear handle 28 so as to be easily and readily operable when
the user grips the rear handle 28 along its arcuate portion
35 as more fully described hereafter.
2 ~ 864~2
- 10 -
At the top 30 of the housing 16, a raised wedge-
shaped collar reglon 40 is defined into which a male recep-
tacle or plug plate 42 can be mounted for receiving a
female socket head of an electrical cord (not shown) for
5 electrically connecting an alternating current power
source, for 110 volts at 60 Hz, to the motor assembly 24.
Adjacent the collar region 40 towards the rearward end 14
of the housing 16, a cord locking mechanism 44 is def ined
in the housing top 30, as shown in FIGS. 7-9. The cord
10 locking mechanism 44 erevents ~ nt~1 disconnection of
the female socket head connected in the collar reg-ion 40 to
the male receptacle 42. Thus, with the motor 24 activated
to~ drive a working element, such as a buffer pad 46, and
with the buffer pad 46 driven in an orbital path as will be
5 described more fully herein, the above-described design of
the housing 16 allows an operator to easily manipulate the
apparatus 10 of the present invention with two hands to
exert bi-planar control over the apparatus 10 while the
buffer pad 46 is moved along the working surface in lts
20 orbital path without having to grab the main housing 22 to
effectively and accurately guide and control the pad 46
along the working surface. Also, the placement of the
electrical connection between the apparatus 10 and the
electrical cord supplying AC=~ power thereto in a recessed
25 location on the housing top 30 and with the cord-locking
mechaniam 44 adjacent thereto m~int~1n~ the cord in place
remotely from the interface between the pad 46 and the
surface being worked upon, such as a car finish, while at
the same -time limiting disconnections interrupting the
30 waxing, buffing or polishing process for which the
apparatus 10 can be used.
Referring now more specifically to the configura-
tion of the housing 16, it will be noted that the
symmetrical ~ m~hPl 1 housing members 18 and 20 cooperate
35 to: form the front and rear handles 26 and 28, the collar
region 40 and the cord-locking mechanism 44 described
, ~ _ , . , , , , . , _ _ _ _ _ . . _ _ _ _ _ _ _
21 86422
11 -
above More specifically and referencing FIG. 3, the
~1 ~mqh~7 1 housing member 18 includes main housing portion
half 22a, front handle half 26a, rear handle half 28a,
collar region half 40a and cord locking mechanism half 44a.
5 I,ikewise, second rl ~mqh~l 1 housing member 20 includes main
housing portion half 22b, front handle half 26b, rear
handle half 28b, collar region Aalf 40b and cord locking
mechanism half 44b. TAe first rl~mqhi~ll housing member 18
i5 provided with threaded bosses 48 and the second clam-
10 shell housing member 20 has countersunk recesses 50 formedtherein with each of the recesses 50 leading to a threaded
boss 52, as seen in FIGS. 10, 20 ana 21.
To assemble the apparatus 10, the internal com-
ponents including the motor assembly 24, the switch housing
15 36, the actuator paddle 38 and the male receptacle 42 are
mounted to the first t~l ~mqh~l 1 housing member 18, ae Yeen
in FIG 11, wlth the second ~ l ~mqh~l 1 housing member 20
then being arranged against the first rl~rnqhf~ll housing
member 18 90 as to align the tAreaded bosses 52 of the
20 housing member 20 with the corresponding threaded bosses 48
of the first clamshell housing member 18. With the housing
members 18 and 20 80 aligned, screws 54 received in
threaded bosses 52 can be, in turn, received in corre-
sponding bosses 48 to clamp the ~ l ~mqhGl 1 housing members
25 18 and 20 to each other with the heads of the screws 54
seated within the countersunk recesses 50 of the second
housing member 20 80 as not to protrude therefrom.
With the first and second clamshell housing
members 18 and 20 attached to each other, the main housing
30 portions 22a and 22b cooperate to define an' interior space
56 in which the motor assembly 24 is mounted. As best seen
in FIG. 3, the main housing portion 22 so formed has a
pear-shaped cross-sectional configuration. The raised
collar region 40 has a triangular shape in cross-section
35 and, as previously mentioned, proiects from the substan-
tially flat top 30 of the housing 16. The wedge-shaped
.. _ _ .. .. _ . _ _ _ _ . _ .
2 1 86422
- 12 -
collar region 40 has an oblong central recessed area 58
into which the male receptacle 42 is placed.
Turning to the configuration of the front handle
26, each of the main housing portions 22a and 22b includes
5 a triangular attached portion 60a and 60b, respectively,
which extends horizontally outward and forward ~rom the
respective main housing portions 22a and 22b between and
substantially parallel to the top 30 and the bottom 32 of
the housing. From the outermost forward corner of the
lO triangular portions 60a and 60b extend respective outer
channel - shaped straight sections 62a and 62b such that with
the el ~ Pl 1 housing members 18 and 20 attached to each
other, the outer straight sections 62a and 62b extend
substantially parallel to one another and the channels open
15 towards each other. The straight sections 62a and 62b
extend forwardly to angled channel-shaped gripping portions
64a and 64b, raspectively, which extend at an angle from
their respective straight sections 62a and 62b ~orwardly
towards each other to distal ends 66a and 66b which abut
20 on-e ànother along the part line 21 and define a bent
section sf the front handle 26 where the ~h;lnn~l ~ open
rearwardly towards the main housing 22 with the clamshell
housing members 18 and 20 attached.
Intermediate horizontal supporting members 67a
25 and 67b extend within the channels of the respective
straight sections 62a and 62b and angled gripping portions
64a and 64b, as best seen in FIGS. 20 and 21. Correspond-
ing bosses -48 and 52 are formed on the intermediate
supporting members 67a and 67b at the distal ends 66a and
30 66b and can be aligned with each other when the housing
members 18 and 20 are brought together such that one of the
screws 54 received in the aligned front handle threaded
bosses will provide an attachment between the housing
members 18 and 20 at the front handle distal ends 66a and
35 66b. In t~lis manner, the front handle 26 is formed
defining a forward gripping aperture 69 by the above-
.. , . . , _ _ _ _ _ _ _ _ _ . _
2 1 86422
- 13 -
described connection between the angled portions 64a and
64b .
The rl ~m~h~l 1 housing members 18 and 20 also
include rear handle arcuate gripping portions 68a and 68b
which extend integrally from near the rear end oE the top
30 of the main housing 22 and, more specifically, from the
rear o~ the cord locking mechanism 44. The arcuate
gripping portions 68a and 68b .-,)ntinll,~ rearward and
vertically downward to a point aligned with the bottom 32
of the main housing portion 22 80 ag to extend substan-
tially through a quarter- circle arc . At this point, the
rear handle 28 includes straight joining sections 70a and
70b, respectively, which extend from their respective
arcuate gripping portions 68a and 68b back to the main
housing portions 22a and 22b at the bottDm 32 thereo~. To
join the rear handle portions 28a and 28b, one of the
threaded bosses 48 is formed in the arcuate gripping
portions 68a and one is formed in the straight ioining
section 70a along with corresponding ~hr~ i bosses 52 in
the arcuate gr~pping portion 68b and straight joining
section 70b such that with screws 54 received in the rear
handle aligned bosses 48 and 52, the rear handle portions
2 8a and 2 8b are secured to each other to f orm the rear
handle 28 and define the rearward gripping aperture 39.
~s shown in PIGS. 20 and 21, the rear handle
portions 28a and 28b are formed as channel-like members
having opposing sidewalls with each including a smaller
inner sidewall 72a and 72b and a larger outer sidewall 74a
and 74b and a connecting web wall 76a and 76b spanning
their respective irner and outer side~alls 72 and 74 such
that when the rear handle portions 28a and 28b are
connected, they define a hollow rear handle 28 with the
rear handle interior space 34 in which the switch housing
36 is mounted. Further, the inner sidewalls 72a and 72b
each include respective cut-out sections aOa and 80b along
the arcuate gripping portions 68a and 68b such that, with
= ~ . _ _ _ _ _ _ _ _ _ .. . . .... .
2 ~ 86422
- 14 -
the rear handle portions 28a and 28b co~nected, the cut-out
sections 80a and 80b cooperate to define the bottom slot 35
for the actuator paddle 38. With the actuator paddle 38
mounted in the rear handle interior space 34, the actuator
5 paddle 38 includes a portion which extends through the
bottom slot 35 into the rearward gripplng aperture 39
spring bia~ed to a predetermined dlstance beyond the inner
sidewall 72
The conf iguration of the cord locking mechanism
10 44~ adjacent the collar region 40 will next be described
with reference to FIGS. 7-9, 20 and 21. A~ previously
mentioned, the cord locking mechanism 44 is disposed rear-
wardly of the raised wedge-s~iaped collar region 40 and
includes a trough or well surface 82 defined by recessed
15= U-shape~ ~surfaces ~82a and 82b in the respective main
housing top portions 30a and 30b, as best ~een= in FIGS. 8A
and 8B. An upstanding flange 8g extends from the bottom of
the trough portion 82b to the top - of the proj ecting wedge
collar region 40 with a tab 86 formed thereat at right
20 angles to the flange 84 and pro ~ ecting over the trough 82
80 that the top of the tab 86 is flush with the top of the
wedge collar 40. Trough portion 82a has upstanding
parallel side ~langes 38 and 90 spaced from each other
along either ~ide of the ~rough portion 82a and having
25 re~pective overhung lip portions 92 and 94 which project
towards each other over the trough portion 82a.
Thus, when the housing members 18 and 20 are
aligned and clamped together, the cord locking mechanism 44
is formed. With the female socket head on an electrical
30 cord attached in the collar region 40 to the prongs 43 of
the plug plate 42, the portion of the~ cord adjacent the
female head can be inserted through the zig- zag entry slot
96 defined between the overhung lip portions 92 and 94 and
the tab 86. The section of the cord ad~acent the female
35 head lnserted through the entry slot 96 can be positioned
80~ that it is clamped between the trough surface 82 and the
~ 2~ 86422
- 15 -
overhung tab 86 positioned thereabove with the ends of the
cord section extending around the upstanding flange 84 and
through access openings 98 and 100 formed in the sidewall
portion 102 of ~the trough surface 82b on either ~ide of the
5 flange 84. In practice, when the apparatus 10 is being
used=and the slack in the cord i~ taken up, a~ when the
apparatus 10 is moved further away from the electrical
outlet, tension created by tightening of the ~lack in the
cord~ will be ~ubstantially taken up by the frictional
10 engagement of the cord between the well surface 82 and the
overhung tab 86 and lip portions 92 and 94 such that the
interface of the female head with the male prongs 43 will
experience little or no tension during normal usage of the
appliancè, thereby significantly reducing the potential
15 occurrences of ac- l.lPl~t~l disconnection at the interface.
Turning to FIGS. 12 and 13, the co~struction and
operation of the actuator paddle 38 including a lock-on
mechanism 104 which is mounted in nested relation therewith
is illuctrated. The actuator paddle 38 has an arcuate
20 elongate channel-shape with a bottom cur~ace 106 having an
arcuate portion 107 provided with a radius of curvature
substantially the same as the rear handle arcuate gripping
portion 68 and=being adapted to be gripped by an operator.
Two upstanding parallel sidewalls 108 and 110 extend along
25 either side of the bottom wall 106 such that the channel of
the elongate arcuate-shaped actuator paddle 38 openE3
towards the rear handle interior space 34.
The elongate actuator paddle 38 has a- forward end
112 and a rearward end 114 and includes a pair of trunnion
30 pivots 116 and 118 extending laterally each from one of the
sidewalls 108 and 110 at the forward end 112 of the paddle
38. The paddle 38 is mounted ln the rear handle interior
space 34 by a pair of corresponding trunnion mounts 120 and
122 in respective housing members 18 and 20. The trunnion
35 mounts 120 and 122 are disposed adjacent the well 82 rear-
wardly thereof such that with the housing members 18 and 20
.. .. .. .. . , . . . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . .. . ...
2 ~ g6422
- 16 -
connected, the actuator paddle 38 will extend from the base
of the well 82 along the curve. of the arcuate rear handle
grlpping portion 68 to the rear end of the cut-out 80
therein. At the rearward end 114 Qf the pàddle 38, a
5 suppQrt 124 for the lock-on mechani8m 104 is formed. With
the trunnions 116 ana 118 mounted in their respective
trunnion mounts 120 and 122, the support 124 extends sub-
stantially horizontally and is normally biased into
engagement with a transverse portion,126 o:E the inner
10 sidewall 172 at the rear of the cut-out 80. A pair of
spring pedestal~ 128 and 130 are formed on~the bottom wall
106 with the forward pedestal 128 located on the arcuate
portion 107 of the bottom wall 106 and the rear pedestal
130 located on the horizontal support portion 124 of the
15 bottom wall 106.
The paddle 38 is further provided with an
aperture 132 formed along its arcuate portion 107 in the
bottom wall 106 and sidewalls 108 and 110 for receipt of
the lock-on mPrh~nl~m 104 therethrough. More speclfically,
20 the lock-on mPrh~nl~m 104 ;nrl~ P~~ a button 134 and a
substantially flat base member 136 extending rearwardly
therefrom. With the lock-on mPrh~n~ ~m 104 assem,bled in
nested relation tD the actuator paddle 3 8 and the button
134 projectirg through the paddle aperture 132, the base
25 13'6 exter,ds from a support portion 137 formed on the
backside of the arcuate portion 107 adjacent the rear of
the button aperture 132 in the channel of the actuator
paddle 3a and into the channel of the support portion 124
where the base 136 has a curved end 138 whlch i8 adapted to
30 engage a pivot rod 140 fixed to the paddle 38 extending
across the sidewalls 108 and 110 in the support portion
124. Partition wall 141 extends along the back of the
button 134 and the flat portion of the base 136 and upward-'
ly beyond the, channel formed by the paddle 38 where it ends
35 at a transverse wall 142 upstanding ~rom the base 136 with
the transverse wall 142 similarly extending upwardly beyond
_ _ _ _ _ . . , _ ,, _ _ . ... , .. . , , _ _ _
2 ~ 86422
- 17 -
the channel of the paddle 3 8 . At the top of the transverse
wall 132, a curved cam surface 144 is formed for locking
the paddIe 138 in a closed position, as will be more fully
described hereafter.
Above the curved end 138 and below the curved cam
surface 14g, an ~ntPrmP~l~te sprlng engaging member 146
extends rearwardly from the~ tran8verse wall 142 . A small
spring 148 is mounted in compression between the inter-
mediate spring engaging member 146 and the bottom wall 106
in the support 124 encircling the spring pedestal 13 0 . In
this manner, the lock- on mechanism 104 is normally biased
about pivot rod 140 80 that the button member 134 extends
through the paddle aperture 132~ The rear handle portion
28a includes a spring-engaging flange 150 formed in the
rear handle interior space 34 disposed along the cut-out 80
of the rear handle 28. A large spring 152 is mounted in
compression between the spring-engaging flange 150 and the
base 136 and encircling the spring pedestal 128 to normally
bias the actuator paddle 38 to an open position where the
paddle 38 pro~ects from the slot 80 in the rear handle
inner sidewall 82 into the rear gripping aperture 39.
The rear handle portion 28 has switch supporting
bracket r~bs 154 and 156 fDrmed in the rear handle interior
space 34 along the cut-out slot 80 with the ribs 154 and
156 framing and supporting either side of the box switch
housing 36. The switch housing 36 includes an activation
plunger 158 (see FIG. 11) P~tPnfl;ng there~rom and the
actuator paddle 3 8 includes an upstanding trapezoidal
flange or actuating member 160 forwardly of the aperture
132 and the pedestal 128 adapted to engage the activation
plunger 158 when the paddle 38 is depressed.
In practice, an operator can readily use one hand
wrapped about the rear handle 28 to properly orient the
buffer pad 46 over :the surface on which work, e.g., buff-
ing, polishing or the like, is to be performed. As the
rear handle 28 extends back from the main housing 22, below
_ _ _ . . , , , ,, . , , , , _ _ _ _ _ _ _ _ _ _ _ , _
2 ~ ~6422
- 18 -
which is mounted the pad 46, the operator can use the rear
handle 28 to reach a large region OI a work surface from a
reiatively stationary position. Once the pad 46 is proper-
ly oriented above the work surface, the actuator paddle 38
can be depressed against the spring bias to a closed
position with the paddle 38 pivoting about its forward
trunnions 116 and 118 and carrying the lock-on m~rh~n; nm
104 therewith as by engagement of the support portion 137
with the base 136 of the lock-on mechanism 104. With the
paddle 38 so depressed, the flange 160 engages and likewise
depresses the activation plunger ~58 closing the switch
circuit (see FIG. 22) to activate the motor assembly 24 and
drive the pad 46 in its orbital path.
By providing an elongate, arcuate paddle 38 which
follows the contour of the arcuate rear handle gripping
portion 68 an operator can grab the rear handle 28 at
various positions along the gripping portion 68, while
still being able to depress the paddle 38 to lts operative
position without requiring an independent operation with
their other: hand and/or before the operator is ready to
support and maneuver the apparatus ~0 by the rear handle 28
during operation thereof. To deactivate the motor assembly
24, and therefore the apparatus 10, an operator need merely
release the actuator paddle 38 which, by virtue of being
sprlng Ioaded to its extended open position, will deacti-
vate the motor assembly 24 by disengagement of the flange
160 from the activation plunger 158 to ope~ the switch
circuit .
In addition, if an operator does not wish to
Aont;nll~lly depress the paddle 38 during operation of the
apparatus 10, the lock- on mechanism 104 can be readily
accessed and utilized in an easy manner without interrupt-
ing operation of the apparatus 10 and/or requiring use of
the operator~ s other hand. As previously mentioned, the
lock-on mechanism 104 includes the =transverse wall 142
extending into the rear handle interior space 34. In the
~ 1 86422
- 19 -
interior space 34, a locking flange 162 is connected to the
outer sidewall 74a disposed over the inner sidewall trans-
verse portion 126 and ;n~ Pc a horizontal portion 164 and
a connected vertical portio~ 166 Cooperating with the
lock flange 162 is a guide flange 168 connected to the
outer sidewall 74a and spaced ~orwardly f rom the vertical
portion 166. =
The paddle 38 and lock-on mechanism 104 are
arranged so that with the paddle 3 8 depressed to its opera-
tiYe position, the cam end 144 will be positioned near the
top of the vertical portion 166 between it and the guide
3~lange 168. To continuously use the apparatus 10 without
having to correspondingly cnn~; nllm1~1y depress the paddle
38 to its operative position, the button member 134 can be
depressed towards the rear handle interior space 34, i.e.,
in the same direction in which the actuator paddle 38 is
being depressed, against the bias of spring 148, causing
the outside of the curved cam surface 144 to cammingly
engage the guide flange 168 and be directed over the top of
the vertical portion 166 of the lock flange 162 and latch
onto the lock flange vertical portion 166 under the
in~luence of large :spring 152 with the actuator 38 being
maintained in its closed operative position by the lif ting
force applied by the curved end 138 on the~ pivot rod 140.
To effect =release of the actuator paddle 38 ~rom the locked
position, t~e operator merely depresses the paddle 38
slightly further to reduce the influence of large spring
152 suf ~iciently so as to allow the spring 148 to urge the
curved cam end 144 over the top of the lock flange vertical
pc~rtion 166 and against the guide ~lange 168 as by the
pivoting action o~ the curved end 138 about the pivot rod
140. Thereafter, the paddle 38 is released with the spring
150 bia~ing the paddle 38 to the open position to
deactivate the motor assembly 24.
= To provide electrical power from the plug plate
42 to the motor assembly 24, the switching mechanism 37
21 86422
- 20 -
includes an input terminal 170 and an output tPrm;n~l 172
extending through sides of the switch housing 36. As best
seen in FIG . 10 ~ a lead 174 is electrically connected to
the plug plate 42 and extends to the switehing mechanism
5 input tPrmln~l 170 while another lead 176 extends from the
output tPrm;n~l 172 to a fullwave reetifier 178 for the DC
motor as~3embly 24. A lead 181 is eleetrieally eonneeted to
the plug plate 42 and extends direetly to the reetifier
178 . As is conventional, the rectif ier 178 eonverts AC
10 power reeeived at the plug plate 42 to DC power for appli-
eation to the DC motor assembly 24. Thus, with the switeh-
ing circuit closed as cau~ed by depres~ing the paddle 38 to
its operative posltion, DC electrical power will be
provided to the armature coils, a~ more ~ully discussed
15 herein.
The variou~ motor assembly components are
supported and oriented directly by the rl ~mqhPl 1 housing
members 18 and 20 which, when connected, cooperate to clamp
the motor in place in the main housing 22 without employing
20 an!extended yoke as a rrnt~;nPr to support and position the
variou~ motor components and/or a separate base or frame
member to~support the yoke in the housing. Referring to
FIGS. 10 and 11, the motor assembly 24 consists of an
armature 180 which can be of standard construction,
25 including a core and windings 182 aligned around a shaft
134 on which is also mounted the rrlmmllt~trr 186. A steel
stator yoke 18a of open cylindrical shape is provided and
can have a pair of large semi-cireular pPrm~nPnt magnets
190 and 192 pressed therein with the magnets 190 and 192
30 having a half-ineh gap between eaeh other in the yoke 188
at their ends.
A support plate 194 mounts the brushes 196 and
198 in respeetive brush housings 200 and 202 thereon and
the rectifier 178 in a rectifier well 204 formed therein,
35 as illustrated in FIGS. 14 and 15. Referring to FIGS. 10
and 11; the armature shaft 184 includes top and bottom ends
.. . , . . , . .. . . . . , . . . . _ _ _
~ 6422
- 21 -
206 and 208 with a spherical bushing 210 being mounted
about the top end 206 of the shaft 184 and a ring ball
bearing 212 being mounted about the shaft 184 nea~ its
bottom end 208.
The ~irst and second housing members 18 and 20
each include a plurality of alignment and support members
generally designated 214 which are symmetrically arranged
about a longitudinal axis 216 P~tPn~ng centrally through
the main housing~ 22. The alignment and support members 214
clampingly engage the outer sur:~ace 218 o~ the yoke 188 and
tightly capture the top and bottom bearings 210 and 212
when the housing members 18 and 20 are secured to each
other so that the yoke 188 and the armature 180 are in
alignment along the longitudinal axis 216 with the armature
shaft 184 extending therealong and the cylindrical yoke 188
enGircling the armature 180. In this manner, the motor
assembly 24 and the housing 16 are as~embled together in
one manuLacturing operation without requiring a separate
assembly operation ~or the motor before it is mounted in
the: housing. In= addition, the:motor circuitry including
the~ switch housing 3-6, the pIug plate 42 and the support
plate 194, including the brushes 196 and 198 and the recti-
fier 178 can be asse~bled as a sub-assembly before the they
are mounted to the housing 16.
More speci~ically and ref rring to FIGS. 14 and
15,~ the support plate 194 preferably has a U-shape-having
opposed leg portions 220 and 222 and a transverse foot
portion 224 which extends between an-d cooperates with the
leg~ portions 220 and 222 to de~ine a central -commutator
space 226. The support plate 194 is mounted in the housing
16 such that the leg portions 220 and 222 are spaced on
either side of the commutator 186 with the commutator 186
positioned.in the central space 226. The brush housing 200
i9 mounted on leg portion 220 -and the brush housing 202 is
mounted on leg porti~n 222 spaced 180~ from each other
around the commutator 1~6. The brush hous1ngs 200 and 202
.. .. . .. ..
2 ~ 86422
- 22 -
each include a main body 228 and 230, respectively, having
respective brush-receiving bores 232 and 234 ~ Pntl;nr
therethrough. Central guide slots 236 and 238 are formed
in the top of the main :bodies 228 and 230, respectively,
with the guide slots 236 and 238 communicating with respec-
tive bores 232 and 234. The brushes 196 and 198 are
received in' their respective brush-receiving bores 232 and
234 and include attached leads 240 and 242, respectively,
each having respective flag trrm;n~ 244 and 246 for:
10 electrically connecting the brushes 196 and 198 to the
rectif ier 178 .
With the brushes 196 and 198 placed in their
bores 232 and 234, and the. support plate 194 mounted ln the
housing 16 about the commutator 186, the brushes 196 and
15 198 are biased so that at least a portion thereof extend
into the central space 226 into contact with the outer
surface 218 of the commutator 186. In this manner, the
brushes 196 and 198 slidingly ride along the commutator
outer surface Z18 as it rotates on the armature shaft 184
20 to .thereby electrically connect the power source to the
armature coils. To urge the brushes 196 and 198 into
contact with the commutator 186, each of the houslngs 200
and 202 inGlude respective caps 248 and 250 and springs 252
and 254 The main body 228 and the main body 230 include
25 enlarged outer ends 256 and 258,- respectively. The
enlarged outer end 256 includes oppositely- facing ramp
surfaces 260 and :262 extending inwardly to respective
straight shoulder surfaces 264 and 266. Likewise, enlarged
end 258 includes oppositely- facing ramp surfaces 268 and
30 270 extendlng inwardly to re8pective straight shoulder
surfaces 272 ana 274.
For capturing and locking the cap 248 on the main
body 228, the cap 24a ;nrll]~l~Y a pair of ramp surfaces 276
and 278 extenaing from either side thereof to respective
35 inner shoulder surfaces 280 and 282. Likewise, cap 250 is
provided with ramp surfaces 284 and 236 extending from
, , ,, , , _ . _ _ . ,, , _ ,, _ _ _ _ _
~ 2 ~ 86422
- 23 -
either side thereof to re8pective shoulder surfaces 288 and
29~0 The inne~ rear surfaces of each of the caps 248 and
250 is provided with a slightly raised spring locating boss
292 and 294, respectively.
To assemble the brushes 196 ana 198 in their
respective housings 200 and 202, the brushes 196 and 198
are inserted into their respective bores 232 and 234 with
their lead wires 240 and 242 extending from the bores 232
and 234 through the slots 236 and 238 thereof with the flag
lQ terminals 244 and 246 then being connected to appropriate
output tprmln~l~ on the rectifier 17~8, as will be described
herein. To urge the b~ush 196 through the bore 232 of the
housing 228 and into the central space 226, the spring 252
is placed in the bQre 232 with one end in contact with the
brush 196 and its other end located on the boss 292 with
the cap 248 then being press fit onto the enlarged end 256
of the main body 228 of the housing 200. The cap 248 is
press fit onto the main body 228 by moving the ramp
surfaces 276 and 278 against and along the ramp surfaces
260 and 262 so- as to urge t~e cap sides o~twardly as the
cap 248 is pushed onto the main body 228. Once the ramp
surfaces are pushed past each other, the sides of the cap
248 will rebound to their original, straight configuration
with the cap shoulder surfaces 280 and 282 confronting
respective shoulder surfaces 264 and 266 on the main body
so as to lock the cap 248 thereon. With the cap 248 locked
in place, the spring 252 will act to bias the brush 196 so
that it e~tends out from the central bore 232 into the
central space 226, limited by the engagement of the lead
240 with the inner end of the guide slot 236, as best seen
in FIG. 13. The cap 250 is slmilarly press-fit and locked
onto the main body 230 so as to bias the brush 198 through
the bore 234 into the central space 226.
In the foot portion 224 of the support plate 194,
the recessed rèctifier well 204 is formed. The rectifier
well 204 inrll~P~ a pair of= resilient upstanding locking
.. _ . , . , . .. , , _ _ _ _ _ . . . . .
1 21 86~22
- 24 -
members 296 and 298 therein, with the locking members 296
and 298 each having an enlarged locking portion 300 and 302
at their respective upper ends . The rectifier 178 l nr~ r~R
a body portion 304 with a pair of input t~rmln~l~ 306 and
5 308 and a pair of output tF~rm;n~1~ 310 and 312 extending
from the body portion 304. The rectifier 178 i~ assembled
in the rectifier well 204 by pushing the rectifier body
portion 304 against the enlarged ends 300 and 302 of the
resilient locking members 296 and 298. This causes the
10 locking members 296 and 298 to be urged outwardly thereby
a~lowing the rectifier body portion 304 to be pushed past
the enlarged ends 300 and 302 to seat in the well 204 with
the resilient locking members 296 ~ and 298 then snapping
back to a locking po~3ition with the enlarged ends 300 and
15 302 abutting against the upper face of the body portion 304
to tightly capture the rectifier 178 in the recesE3ed well
204 .
A pair of lead guiding stakes 314 and 316 extend
from the support plate 194 substantially at the juncture~
20 of the ~upport=plate foot portion 224 with the leg portion~
220 and 222 The sub-a~sembly of the plug plate 42, the
switch housing 36, and the rectifier 178 and brushes 196
and 19 8 on the support plate 194 includes lead electrical
connection~ as described below. As one skilled in the art
25 will appreciate, various arrangements of lead wires can be
utilized with the motor assembly 24 to tran~mit electrical
power thereto. ~ Preferably, the lead 174 is electrically
connected at one end to the plug plate 42 and at itE3 other
end it has a flag terminal 174a which is electrically
30 connected to the input terminal 170 of the switching
mechanism 37. The lead 176 has a flag terminal 176a
attached to the output terminal 172 of the switching
m~rh~n~ cm 27 with itg other ~lag terminal 176b at the other
end of the lead 17 attached to one of the input terminals
35 30-~ and 308 of' the rectifier 178. The lead 181 is elec-
trically connected at one end to the plug plate 42 and at
.. , . .. .... . , . _ _ _ _ _ _ _ _ _ _ _ _ _ . _ _
2 1 86422
- 25 -
its other end lt has a flag terminal 181a which is attached
to the other one of the rectifier input term;n~l ~ 306 and
308. The brush leads 240 and 242 are each electrically
connected to Qne of the output t~rm;n~ 310 and 312
5 pre~erably with f lag terminal 244 connected to output
tPrm;n~l 310 and flag terminal 246 connected to output
termirlal 312, as seen in FIG. 14. To ensure that the non-
insulated braided lead wire 242 is isolated from the other
similarly non- insulated braided wires, the lead wire 242
10 extends from the guide slot 238 around the lead guiding
stake 316 and to the output tPrm~n~i 312. As is apparent,
the lead guiding stakes 314 and 316 can be used to guide
the lead wires connecting to the rectifier t~rmln~31 s in
various arrange~nents 80 a~r to prevent the non- lnsulated
15 lead wires from contacting each other.
For mounting of the rectif ier and brush support
plate 194 in: the housing interior space 56, cut-outs
defining shoulders 318 and 320 are formed along the outer
edges of the support plate leg portions 220 and 222,
20 respectively. Referring to FIGS. 11 and 20, the alignment
and support members 214 of the houslng memaer 18 include a
pair of notched vertical ribs 322a and 324a with each of
the vertical ribs including a horizontal abutment member
326a and 328a extending laterally from the notched area to
25 the housing member 18. The vertical ribs 322a and 324a are
laterally spaced from each other in the housing internal
space portion 56a with the spacing carre6ponding to the
distance between the support plate s~ Prs 318 and 320 so
as to snugly receive the support plate shoulders 318 and
30 ~3Z0 in the vertical rib notches against the abutments 326a
and 328a when the plate 194 is raounted to the housing
member 18. With the support plate 194 60 mounted, the
longitudinal axis 216 extends through the support plate
central space 226. - ~ ~
35 . == To clamp the supFort plate 194 in the housing
interior space 56, corresponding notched vertical ribs 322b
~ ~64~
- 26 -
and 324b are formed in housing member 20 (see FIG. 21) with
their notches being vertically aligned with the notches in
the vertical ribs 322a and 324a when the housing members 18
and 20 are connectea. The notched vertical ribs 322b and
5 324b engage the ends 334 and 336 of the support plate leg
portions 220 and 222 projecting beyond the respective brush
housing 228 and 230 -90 as to clamp the support plate 194
against movement in the 4Ousing interior space 56.
To mount the armature 180 in the housing interior
10 space 56 with ~the armature = sha~t 184 aligned along the
longitudinal axis 216, the alignment and support members
214 include upper and lower bearing engaging members 338a
and 340a in housing member 18 and corresponding upper and
lower bearing engaglng members 338b and 340b in housing
15 member 20 which cooperate to form top and bottom pockets in
the housing interior space 56 with the longitudinal axis
216 extending through these pockets. The pockets formed by
the bearing engaging members 338 and 340 are configured 90
as to securely capture the respective top and bottom bear-
20 ings 210 and 212 against movement in the housing interiorspace 5 6 .
More specifically, since the top bearing 210 is
preferably a spherical bearing, the top bearing engaging
member 338 is formed with a pair of curved sidewalls 342
25 -and 344 with the radius of curvature of the sidewalls 3g2
and 344 substantially matching that of the spherical bear-
ing 210.~ -In this manner, the spherical bearing 210 is
prevented from moving axially along the longitudinal axis
216 when captured by the upper bearing engaging member 338
30 in the housing interior space 56. In addition, the curved
sidewalls 342 and 344 are connected by horizontal top and
bottom members 346 and 348 with the top and bottom members
346 and 348 being curved at their ends adjacent the longi-
tudinal axis 216. Extending between the curved sidewalls
35 342 and 344 intermediate the top and bottom members 346 and
348 is a horizontal support rib 349 having a curved end
- 27 - 2 'I 8 6 4 2 2
which does not extend as far toward3 the axis 216 as the
ends of the top and bottom members 346 and 348 to accommo-
date and match the shape of the spherical bearing 210.
Thus, the diameter across the curved ends of the inter-
5 mediate support ribs 349a and 349b in each of the housingmembers 18 and 20 when attached is substantially the same
as the largest ~l; Am~t~r extending across the middle o~ the
spherical bearing 210. Similarly, the diameter across the
curved ends of the horizontal top and bottom members 346
10 and 348 subst~nt;~ly matches the smaller diameter across
the top and bottom of the spherical bearing 210 so as to
prevent the same f rom moving in a -lateral direction when
clamped and captured in the housing interior~ space- 56 .
The lower bearing engaging member 340 is con-
15 ~tructed similarly to the top bearing engaging member 338except that it is conf igured so as to capture the lower
bearing 212 which is preferably in the form of a ring ball
bearing. Thus, the lower bearing engaging member 340 has
a pair o~ spaced etraight sidewalls 350~and 352. The side-
20 walls 350 and 352 are interconnected by horizontal top andbottom members~354 and 356 with the top and bottom members
354 and 356 having curved ends which terminate in straight
end portions extending to the respective tops and bottoms
of sidewalls 350 and 352. With the housing members 18 and
25 20 attached, the curved ends of the top and bottom members
354a and 354b and 356a and 356b define a diameter slightly
smaller than the outer diameter of the ring bearing 212.
Thus, with the ring bearing 212 secured and mounted in the
lower bearing engaging member 340, the top and bottom
30 members 354 :and 356 prevent the bottom ring bearing 212
from moving axially along the longitudinal axis 216.
~ 7ct~nr~;n~ between the sidewalls 350 and 352
intermediate the top and bottom members 354 and 356 is a
horizontal support rib 353 having a curved end terminating
35 at~ the sidewalls 350 and 352 cuch that with the housing
members 18 and 20 connected together, the intermediate
2~ 86422
- 28 -
horizontal support rib portions 358a and 358b of each of
the housing members define a diameter across their curved
ends substantially corresponding to the outer diameter of
the ring bearing 212 so as to capture the same against
5 movement in a lateral direction in the housing interior
space 56. Thus, with the armature 8haft 184 mounted for
rotation in upper spherical bearing 210 and the lower ring
bearing 212 and with the bearings 210 and 212 clamped in
the housing interior space 56 in the pockets formed by the
10 bearing engaging members 33~8 and 3~0, the armature 180
along with it8 commutator 186 will be aligned for rotation
on the shaft 184 extending along the longitudinal axis 216.
The cylindrical stator yoke 188 is mounted in the
housing interior space 56 so that it encircles the armature
15 core and winding8 182 in alignment_about the longitudinal
axis 216. To mount the cylindrical yoke 188 in alignment
about the axis 216, the alignment and support men~bers 214
include horizontal arcuate ledges 360, vertically spaced in
the housing members 18 and 20, as best seen in FIGS. 20 and
20 21~. Interconnecting pairs of vertically-spaced arcuate
ledges 360 are vertical reinforcing rib~s 362. The ledges
360 incluae uppermost arcuate ledges 364 and lowermost
arcuate horizontal ledges 366 which extend hor1 ~nti:ll ly
slightly further towards the axis 216 than do the other
25 arcuate ledges 360 therebetween so that when the housing
members 18 and 20 are attached, aligned uppermost ledges
364a and 364b in respective housing mer~bers 18 and 20 and
aligned lowermost ledges 366a and 366b in respective
housing members 18 and 20 cooperate to define a diameter
30 which is slightly less than the diameter acro=ss the yoke
outer surface~ 218. In this manner, the uppermost ledges
364 extend over the top end surface 368 of the yoke 188 and
the bottom ledges 366~extend below the bottom end surface
370 of the yoke 188 so that the yoke 188 is tightly
35 captured between the upper and lower ledges 364 and 366
against axial movement along the longitudinal axis 216
.. ,, . . .. , , . ,, _ . . . , _ _ , .
21 86~22
- 29 -
To capture the yoke 188 against lateral movement
in the interior space 56, the intPrmPfl;~te arcuate ledges
360 have a radius of curvature subst~ntli~lly matching the
radius of curvature of the cylindrical yoke 188 80 that
5 together the arcuate ledges 360 define a diameter~substan-
tially the same as the yoke outer surface diameter. As
previously mentioned, the housing members 18 and 20 are
preferably molded plastic parts and the alignment and
support members 214 including the horizontal ledges 360 are
lO preferabIy integrally formed therewith In this manner,
the arcuate ends of the plastic ledges 360 can resiliently
engage the outer surface 218 of the yoke 188 when the
housing members 18 and 20 are connected to each other so as
to clamp the yoke 188 wlthin the interior space 56 in
15 alignment about the longitudinal axis 216 and in encircling
relation to the armature core and windings 182 with the
clamping force~being transmitted from the force applied in
inserting the screws 254 in aligned=bosses 48 and 52.
The mounting of the DC motor components directly
20 to the housing members 18 and 20 by the clamping action
therebetween provides significant= cost savings in the
manufacture of the apparatus 10 as the motor assembly 24 no
longer needs to be assernbled in a separate assembly opera-
tion and, instead, can be incorporated into the same
25 assembly operation for the apparatus 10. In addition, the
motor assembly 24 does not require the "can" form for the
yoke 188 which required an P~tPnflPfl yoke having cap and
bearing plates to close the cylindrical yoke ends nor does
the motor assembly 24 require an independent base or frame
30 for mounting the "can" motor thereto. Typically the
rectifier is mounted adjacent to the "can" motor, as on the
motor frame, with provision being made to allow the leads
from the motor brushes to extend through the motor housing
to be electrically connected to the rectif ier exterior of
35 the motor housing Thus, cost savings are obtained by
minimizlng the time required for assembly as well as by
30 2 l 86422
el;m;n~t;ng parts associated with a "can" type motor and
allowing for uninterrupted paths for the leads between the
brushes and rectif ier .
As previously mentioned, preferably the apparatu8
5 10~ mounts a pad 46 for buffing, waxing, polishing or the
like. In this form, the housing 16 can be provided with a
sheath 372 formed at the bottom thereof with the sheath 372
having an annular portion 374 extending outwardly from the
bottom 32 of the main housing portion 22 aligned about the
10 longitudinal axis 216. Depending from the annular portion
374 is a circumferential skirt 376 ~rom which the buffer
pad 46 can proj-ect.
To allow the buffer pad 46 to stably move in an
orbital path as it is driven, a countérweight assembly 378
15 i8; provided.= The counterweight assembly 378 includes a pad
mounting post 380 mounted thereto for allowing the pad 46
to be quickly mounted to the apparatus lO and removed
theref rom .
I!lore specifically and referring to FIGS. 16-19,
20 the counterweight assembly 378 includes a flat, elevated
mounting portion 382 and a lower counterweight portion 384
off8et from the elevated mounting 332. The elevated mount-
ing portion 382 includes a threaded aperture 386 there-
through for receiving the threaded end 208 of the armature
25 shaft 184 proiecting through the ring ball bearing 212.
Thus, with the armature shaft end 208 threaded in the
aperture 386, the counterweight assembly 378 is mounted to
the apparatus 10 for rotation with the shaft 184.
The quick-change pad mounting post 380 i8
30 con~ected to elevated mounting portion 382 adjacent the
threaded aperture 386 and mounts the buffer pad 46 suc~
that rotation of the counterweight a8sembly 378 by virtue
of the attachment of the armàture shaft 134 in the apertur~
386 produces a substantially circular orbital path in which
35 the pad 46 ie moved about the shaft 184 and thu8, the
longitudinal axis 216. Since the mounting post 380 will be
_ _ _ . , . ,, . . _ , _ . . _ . . _ _ .. . ..
2~ 86422
- 31 -
aligned with the center oi the pad 46 as described herein
and the shaft 184 is between the post 380 and the counter-
weight portion 384, as the counterweight assembly 378 is
rotated, the counterweight portion 384 will always be
5 disposed over the smaller~portion of the pad as defined by
a chord line drawn so as to extend across the circular pad
46 through the shaft 184 and acrDss the width of the
counterweight assembly 378. In this manner, the counter-
weight portion 384 acts to counter forces generated during
10 rotation of the pad 46 in its orbital path which otherwise
would tend to de-stabilize the apparatus 10.
The pad 46 can be of conventional construction
and, in a preferred form has a 9-inch diameter. The pad 46
includes a plastic pad mounting plate 388 attached to its
15 top surface. Pro~ecting upwardly from the center of the
pad mounting plate 388 is an annular post receiving member
390 having a central bore 392 extending therethrough in
alignment with the central axial bore Df the pad 46. The
central bore 392 can have an axial sleeve 394 fixed therein
20 with an axial lining 396 rotatably mountçd in the axial
sleeve 394 as by bearings (not shown).
The post 380 has a recess 398 machined near the
lower end 400 of the post 380. For removably mounting
mount the pad 46 to the quick-change pa~ mounting post 380,
25 a detent ball 402 attached to a plastic backing 404, such
as polyurethane, is secured in the recess 398. The recess
398 has a diameter across its opening slightly larger than
the diameter o~ :the detent ball 402 such that the ball 402
is snugly received in the recess 398 when attached thereln.
30 With the ball 4Q2 attached in the recess 398 by way of the
plastic backing 404, the ball 402 protrudes at a predeter-
mined distance beyond the surface Df the post 380 to an
extended position. As the ball 402 is mounted on the
plastic backing 404, the ball 402 can be depressed by
35 exerting a force on the ball 402 which compresses the
2 1 86422
- 32 -
plastic backing 404 80 that the ball 402 is flush with the
surf ace of the pos t 3 8 0 .
To move the detent ball 402 to itg depressed
position, the axial lining 396 has a diameter substantially
5 t~e same ag the diameter of the~pad mounting post 380 so
that insertion of the post 380 in the lining 396 cauges the
lower curved surface portion 406 of the ball 402 to
initially engage the upper annular end 405 of the sleeve
394. Continued downward force applied to the counterweight
10 assembly 398, and thus to the post 380, causes the axial
lining 396 to cam over the curved surface portion 406 by
application af a predetermined inwardly directed force to
move the ball 402 radially inwardly to a position flush
with the post surface against the bias provided by the
15 plastic backing 404.
With the ball 402 in its depressed, flush
position relative to the post 380, the post 380 can be
readily pushed through the axial sleeve 394 until the
bottom 408 of the elevated mounting portion 382 rests
20 against the top 410 of the raised annular member 390 with
the counterweight portio~. 384 adjacent thereto. Thus, with
the post 380 ingerted through the axial lining 394, the pad
4Ç is in its releasably gecured state to the post 380. In
the releasably secured state, the lower end 400 extends
25 beyond the axial lining 396 such that the ball 402 no
longer is~ engaged by the axial lining 396. Accordingly,
the predetermined force applied to the curved surface
portion 406 is removed therefrom go as to allow the detent
ball 402 to rebound under the influence of the plastic
30 backing 404 to its extended position beyond the radius of
the post 380. The ball 402 is mounted on the post 380 at
a predetermined distance from the bottom 408 of the
elevated mounting partion 382 and the length of the axial
sleeve 394 is also predetermined so that with the pad 46 is
35 releasably secured to the post 408 and the ball 402 in its
extended position, the upper curved surface portion 412
. . =,, . . _ _ _ _ _ .
2~ 86422
will abut against the lower annular end or shoulder 414 of
the axial sleeve 80 that there ie no loose space or play
between the ralsed post-recelvlng member 390 and the
counterwelght aseembly 308.
5 ~ Wlth the pad 46 mounted to the qulck-change pad
mounting post 380 having the detent ball 402 thereon and
when: an operator wants to change pads to go to a dlfferent
type of pad or because the pad 46 needs replaclng due to
wear: or damage or the like, the pad 46 can qulckly and
10 eaeily be removed from its mounting to the apparatus 10
without requiring substantial time or disaseembly which
would otherwise compllcate the pad changlng process. To
remove the pad 46, an operator need merely exert a downward
force away from= the pad mounting post 380 on the pad mount-
15 lng plate 388 sufflcient to cause the lining annular bottomehoulder 414 to cam over the upper curved surface portion
412 so as to urge the ball 402 to its depreesed position
flush with the post surfa~e againet the normal bias of the
plastic backing 404. Wlth the ball 402 ln lts depressed
20 position~ continued downward force on~ the pad mounting
plate 388 causes the linlng 396 to slide off of the post
380 until the pad mountlng plate 388 and the attached pad
46 are dlsengaged from the post 380,
Although the ball 402 and pad mountlng post 380
25 provide a secura mo'unting of the, pad 46 to the apparatus
10, it is possible that during use of the apparatus 10, a
force sufficient to cause the detent ball 402 to move to
its depressed position could be applied to the pad 46
and/or pad mounting plate 388. In the event of such an
30 occurrence, the a~ial lining 396 ls provlded wlth an inter-
medlate circumf erential groove 416 spaced above the detent
ball 402 to prevent the post 380 from sliding completely
through the a-xial sleeve -394 to the disengaged posltion.
The circumferential groove 416 has a predeter-
35 mined radius sized so as to be capable of capturing thedetent ball 402 in an F~ nflc~(l poeition where it protrudes
2~6422
- 34 -
beyond the sur~ace of the post 380 as it passes thereover.
Thus, with the pad 46 mounted to the post 380 and with an
unexpected force applied to the pad mounting plate 388 or
the attached pad 46 cau~ing the ball 402 to move to it6
5 depressed posltion within the axlal lining 396, cont1n
movement of the post 380 through the axial lining 396 will
eventually cause the ball 402 to encounter the groove 416.
The urging of the plastic backing 404 will push the ball
402 into an P~tPn~lPf9 position ir the clrcumferential groove
10 416 and thus arrest ~ ntln~lP~l movement of the post 380
through the sleeve 394 80 a~ to provide subst~nt~ y fail-
safe operation of the apparatus 10 when the pad 46 is
secured on the pa~ mounting post 380.
While there have been illustrated and described
15 various featur~s for use with an electrically-powered waxer
or~buffer, it will be appreclated that these features can
be utilized with other tools. In addition, it will be
apparent that numerous changes and modifications will occur
to those skilled in the art, and it is intended in the
20 appended =claims to cover all those changes and modifi-
cations which fall within the true spirit and scope of the
present invention.
