System and Method for Capturing Dust Created By Power Tool Operation

Abstract

A system and method for capturing resultant dust from power tool operation are disclosed. The system comprises a device that includes a housing with a substantially cylindrical shape. The housing has a first end that tapers to an opening for a tool bit and at least one suction port that opens into an interior volume of the housing. The housing has a second end configured to couple to a power tool. An air intake passage attaches to the exterior surface of the housing body such that an interior volume of the air intake passage connects to an interior volume of the housing. An exit passage is coupled to the air intake passage and is configured to couple to a vacuum.

Claims

1. A device for collecting dust from a power tool comprising: a housing comprising an interior volume and an exit passage, the interior volume fluidly communicating with the exit passage and configured to allow a shaft of a tool to pass through the interior volume, the exit passage configured to couple to a vacuum; and a first end coupled to the housing that comprises at least two substantially planar surfaces, and tapers to an opening for a tool bit and that has at least one suction port opening into the interior volume of the housing;

2. The device of claim 1, further comprising a second end coupled to the housing and distal from the first end.

3. The device of claim 1, further comprising a lip coupled to the first end of the housing.

4. The device of claim 1, wherein a clamp is coupled to the second end of the housing.

5. The device of claim 1, further comprising a vent hole located on the housing.

6. A device for collecting dust from a power tool comprising: A housing with a first end that tapers to an opening for a tool bit, wherein a length of the opening for the tool bit is at least twice as large as a width of the opening for the tool bit, and that has at least one suction port opening into an interior volume of the housing, and an opposing exit passage configured to couple to a vacuum; and a second end attached to the exterior surface of the housing such that an interior volume to the air intake passage connects to an interior volume of the housing, and the second end configured to couple to a power tool.

7. The device of claim 6, further comprising a lip coupled to the first end of the housing.

8. The device of claim 6, wherein a clamp is coupled to the second end of the housing.

9. The device of claim 6, further comprising a vent hole located on the housing.

10. A device for collecting dust from a power tool comprising: a first face and a second face, wherein the first face substantially lies within a first plane and the second face substantially lies within a second plane, the planes form an acute angle, the faces are non-intersecting, and at least one of the faces defines at least one suction port; and a casing coupled to the faces and comprising an interior volume and an exit channel, the interior volume fluidly communicating with the exit channel and configured to couple to a power tool, and the exit channel configured to couple to a vacuum.

11. The device of claim 10, further comprising a clamp to couple the casing to a power tool.

12. The device of claim 10, wherein the faces are coupled to the casing by a weld.

13. The device of claim 10, wherein both faces define a plurality of suction ports.

14. The device of claim 10, wherein one of the faces forms an obtuse angle with the interior of the casing.

15. The device of claim 10, wherein the faces, the casing and the vacuum channels comprise substantially the same material.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0040] A more complete understanding of the present invention may be derived by referring to the detailed description when considered in connection with the following illustrative figures. In the figures, like reference numbers refer to like elements or acts throughout the figures.

[0041] FIG. 1 depicts a top view of an embodiment of the invention.

[0042] FIG. 2 depicts a side view of an embodiment of the invention.

[0043] FIG. 3 depicts a clamp according to an embodiment of the invention.

[0044] FIG. 4 depicts a front view of an embodiment of the invention.

[0045] FIG. 5 depicts a top view of a device coupled to a power tool according to an embodiment of the invention.

[0046] FIG. 6 depicts a side view of a device coupled to a power tool according to an embodiment of the invention.

[0047] FIGS. 7-9 depict a top, side, and front view of an embodiment of the invention.

[0048] FIG. 10 depicts a top view of a device coupled to a power tool according to an embodiment of the invention.

[0049] FIGS. 11-13 depict a top, side, and front view of an embodiment of the invention.

[0050] FIGS. 14-16 depict a top, side, and front view of an embodiment of the invention.

[0051] FIGS. 17-19 depict a top, side, and front view of an embodiment of the invention.

[0052] FIG. 20 depicts a device coupled to a stand-up power tool according to an embodiment of the invention.

[0053] FIG. 21 depicts a perspective view of a device with an open clamp according to an embodiment of the invention.

[0054] FIG. 22 depicts a method of making a device according to an embodiment of the invention.

[0055] Elements and acts in the figures are illustrated for simplicity and have not necessarily been rendered according to any particular sequence or embodiment.

DETAILED DESCRIPTION

[0056] In the following description, and for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the various aspects of the invention. It will be understood, however, by those skilled in the relevant arts, that the present invention may be practiced without these specific details. In other instances, known structures and devices are shown or discussed more generally in order to avoid obscuring the invention. In many cases, a description of the operation is sufficient to enable one to implement the various forms of the invention, particularly when the operation is to be implemented in software. It should be noted that there are many different and alternative configurations, devices and technologies to which the disclosed inventions may be applied. The full scope of the inventions is not limited to the examples that are described below.

[0057] Referring to FIG. 1, a top view of a device for collecting dust from a power tool 100 is illustrated according to an embodiment of the invention. The device 100 comprises a housing 110 that may have a substantially cylindrical shape. The housing 110 has a first end 112 that tapers to a tool bit opening 198. The angle and length of the taper may be of any angle or length, but is preferably such that the first end 112 may fit into narrow areas, such as corners of a room or underneath the toe-kick of cabinets. The first end 112 has a plurality of suction ports 122 through which air and dust may flow into the housing 110. A second end 114 of the housing 110 is configured to couple to a power tool. In one embodiment, a clamp 180 is used to couple the housing 110 to the power tool. A plurality of air intake passages 150 are shown coupled to an exterior surface 160 of the housing 110. The air intake passages 150 are coupled to an exit passage 155. The exit passage 155 is configured to couple to a vacuum. The exit passage 155 may be configured to couple to an interior or exterior of a vacuum hose, or may couple to the vacuum by any other method known in the art.

[0058] In some embodiments, the housing 110 may be rectangular, or any other shape capable of coupling to a power tool. The housing 110 may be narrower than illustrated if it is to be coupled to a smaller power tool, or conversely the housing 110 may be broader than illustrated to fit larger tools. In one embodiment the housing 110 may be significantly elongated to fit power tools with long bodies or long actuating distances. In one embodiment the housing 110 may be significantly shorter to fit power tools with a short body or a short actuating distance from the body to the operating end of the power tool. In one embodiment the housing 110 may have suction ports 122 located along any part of its length. The housing 110 may also be referred to as a sheath or a casing.

[0059] The air intake passages 150 are shown coupled to opposite sides of the housing 110. The air intake passages 150, or vacuum channels, may be positioned to maximize the effectiveness of the air flow through the suction ports 122. Additionally, by positioning the air intake passages 150 adjacent to the first end 112, the dust is collected before coming in contact with the power tool, preventing damage and reducing maintenance to the power tool. The use of multiple air intake passages 150 may increase the amount of dust that is capable of being removed from the local atmosphere. In other embodiments, the air intake passages 150 may be located at different positions. For example, the air intake passages 150 may be located adjacent to the second end 114 in order to allow the device 100 to reach narrow access areas. The air intake passages 150 may be curved such that they come together. Alternatively, the air intake passages may be straight or comprise a plurality of straight sections such that they meet at or near the exit passage 155. In one embodiment, the air intake passages 150 do not meet at a common exit passage 155, but rather have separate exit passages 155 that each couple to a vacuum source. Additionally, more than two air intake passages 150 may be used to improve the distribution of air flow throughout the device 100, reducing the chances of clogging.

[0060] In the illustrated embodiment, each air intake passage 150 comprises a first passage sections 150a, and a second passage section 150b. The two passage sections 150a, 150b are substantially straight, and the first passage sections 150a couple to the exterior surface 160 of the housing 110. The second passage sections 150b are coupled to the exit passage 155.

[0061] The first end 112 of the housing 110 comprises at least one suction port 122. The suction ports 122, or suction holes, as shown are circular, however they may be of any shape such as square, elliptical, or rectangular. There may be any number of suction ports 122. For example, there may be a large enough amount of suction ports 122 such that the first end 112 may essentially comprise a screen or grating. While some dust may be collected through the tool bit opening 198, much of the dust is collected through the suction ports 122. The suction ports 122 focus the air flow around the first end 112 such that nearly all ambient dust particles are removed from the local area. This prevents dust from contaminating nearby areas or escaping into the atmosphere. Rather than being formed at an angle perpendicular to the first end 112, the suction ports 122 may be formed substantially parallel to a central axis of the housing 110. This horizontal angle allows the air to flow into the housing 110 with fewer turns, increasing the effectiveness of the dust removal.

[0062] The device 100 further comprises a lip 190. The lip 190 may be made of a durable material such as case-hardened steel, heat-treated steel, or any other material known to one of ordinary skill in the art. The lip 190 is coupled to the first end 112 of the housing 110. The lip 190 comprises the tool bit opening 198, which extends from the first end 112 of the housing 110 through the lip 190 and allows air to flow through the lip 190 and into the housing 110. The lip may further comprise lip suction ports 192. The lip suction ports 192 allow air to flow through, collecting dust and providing a source of ambient air to cool a tool bit which may extend through the lip 190.

[0063] Over an extended period of time, the lip 190 may deteriorate from prolonged use. When the lip 190 is significantly worn out, it may be detached from the housing 110 and a new lip may be installed. This allows the device 100 to have a longer lifespan. The new lip may be welded to the device 100 or attached by any other way known to one of ordinary skill in the art. Alternatively, the device 100 may be used without a lip 190.

[0064] The device 100 further comprises vent holes 170. In this embodiment, two vent holes 770 are located on a top portion of the housing 110 and proximate to the second end 114. However, any number of vent holes 170 may be used, and they may be located on the side or lower portion of the housing 110, or further from the second end 114. The vent holes 170 allow air to flow through the housing 110 in a direction from the second end 114 toward the first end 112. This air flow prevents dust and debris from accumulating inside the first end 114 of the housing 110. This keeps the dust and debris from interfering with any power tool, such as a chipping hammer, which is coupled to the device 100, improving the functionality and lifetime of the power tool. Additionally, the vent holes 170 allow cool air to flow into the housing 110 to cool the power tool and the device 100.

[0065] Referring to FIG. 2, a side view of the device 100 is illustrated according to an embodiment of the invention. The air intake passages 150 are shown extending away from the first end 112 at an angle relative to the housing 110. The angle of the air intake passages 150 may vary according to the desired purpose of the device 100. For example, in embodiments designed to fit into narrow locations, the air intake passages 150 may be positioned at a lesser angle relative to the housing 110 such that the device 100 has a smaller cross-sectional area near the first end 112. The lip 190 may also be tapered. Although only on the top of the housing 110 in this embodiment, the vent holes 170 may also be located substantially at the bottom or sides of the housing 110.

[0066] Referring to FIG. 3, a rear view of the clamp 180 is illustrated according to an embodiment of the invention. The clamp 180 may comprise a hinge 310, two collar members 320, a bolt 330, and neck portions 350. The clamp 180 is designed to quickly attach and detach the device 100 from a power tool. The clamp 180 may further comprise a nut which may be coupled to the neck portions 350 such that the nut remains in place when the nut and bolt 330 are not engaged. Alternatively, the nut may be a separate detachable piece. The bolt 330 may thread into the nut, or alternatively the neck portions 350 may be threaded such that the bolt 330 engages with the neck portions 350, and the nut is not required. The bolt 330 may comprise a locking cam, in which the bolt 330 requires no tools to tighten and loosen the clamp 180. In another embodiment, the bolt 330 comprises a cotter pin to keep it in place. The bolt 330 may further comprise a retaining member that couples to the bolt 330 between the neck portions 350 such that the bolt remains coupled to a neck portion 350 when not engaged with the opposing neck portion 350. An interior portion 360 of the collar members 320 may comprise an elastic material such as rubber in order to make a tight connection with the power tool. Alternatively, an interior portion 360 of the collar members 320 may be comprised of steel, machined to make a tight connection with the power tool. The clamp may further comprise clamp vent holes 370. The clamp vent holes 370 may be located on the collar members 320 and have a similar function to the vent holes 170.

[0067] Referring to FIG. 4, a front view of the device 100 is shown according to an embodiment of the invention. In this embodiment, the device 100 comprises a first face 120 and a second face 125. The first face 120 and the second face 125 may be substantially planar, or one or both may be curved. The first face 120 lies substantially in a first plane, and the second face 125 lies substantially in a second plane. The planes may form an acute angle, and the first face 120 and the second face 125 are non-intersecting. One or both faces 120, 125 may form an obtuse angle with the housing 110.

[0068] One end of the tool bit opening 198 is defined between the first face 110 and the second face 125. In the illustrated embodiment, the tool bit opening is substantially elongated. In this embodiment, the tool bit opening 198 may have a length at least twice as large as its width. However, in other embodiments the relative dimensions may be any ratio sufficient to allow a tool bit to pass through. The tool bit opening 198 in this embodiment may allow a tool bit such as a chisel to pass through. In other embodiments the tool bit opening 198 may be narrower. For example, in an embodiment where the first end 112 is substantially conical, the tool bit opening 198 may be substantially circular, allowing a tool bit such as a drill bit to pass through. In one embodiment either the first face 120, the second face 125, or both faces 120, 125 may be covered by a protective plate. The protective plate may be comprised of the same material as any other part of the device 100 or may be comprised of a different material. In another embodiment the first face 120, the second face 125, or both may be comprised of a single plate or multiple plates. Such plates may be detachable to allow for multiple configurations or replacement of the plates when damaged or may be permanently attached to the device 100.

[0069] In the illustrated embodiment, the first face 120 and the second face 125 are substantially symmetrical. However, it is also contemplated that the first face 120 and the second face 125 are asymmetrical. For example, the second face 125 may be substantially parallel to the housing 110, such that the first plane and the second plane intersect closer to a bottom portion 113 of the device 100. Additionally, in the illustrated embodiment, the suction ports 122 are located on both the first face 120 and the second face 125. In other embodiments, the suction ports 122 may be located on only the first face 120 or the second face 125.

[0070] Referring to FIG. 5 and FIG. 6, a top and side view of the device 100 coupled to a chipping hammer 500 are illustrated. The clamp 180 couples securely to the body 510 of the chipping hammer 500. The device 100 may also be coupled to many other types of power tools including, but not limited to drills, hammer drills, grinders, sanders, dremmels, power saws, or jackhammers. A vacuum hose 520 is shown coupled to the exit passage 155. The vacuum hose may fit around an exterior of the exit passage 155, or fit inside the exit passage 155, or couple by any other means known to one of ordinary skill in the art.

[0071] In this embodiment, the chipping hammer 500 is coupled to a tool bit 530. The tool bit 530 in the illustrated embodiment is a chisel, but may be any other type of tool bit. The tool bit 530 extends through the tool bit opening 198. When in operation, the tool bit 530 chips away tile or other material, and resultant dust is removed from the ambient air through the suction holes 122, tool bit opening 198, and vent holes 170.

[0072] Referring to FIGS. 7-9, a top, side, and front view of another embodiment of the invention are illustrated. In this embodiment, a device 700 comprises a single air intake passage 750 coupled to the housing 110. In this embodiment, the air intake passage 750 is a straight section. However, it may also be curved or comprise several angled sections. The air intake passage 750 may be cylindrical, or any other desired shape. The air intake passage 750 is coupled to the exit passage 155. The air intake passage 750 may be coupled to a top portion 711 of the housing 110.

[0073] Referring to FIG. 10, a top view of the device 700 coupled to a chipping hammer 500 is illustrated according to an embodiment of the invention.

[0074] Referring to FIG. 11 through FIG. 13, a top, side, and front view of a device 1100 is illustrated according to an embodiment of the invention. In this embodiment, two air intake passages 1150 each comprise three straight sections 1150a, 1150b, and 1150c. The air intake passages 1150 are coupled together and also coupled to the exit passage 155.

[0075] Referring to FIG. 14 through FIG. 16, a top, side, and front view of a device 1400 is illustrated according to an embodiment of the invention. The device 1400 comprises two air intake passages 1450. Each air intake passage 1450 comprises three straight sections 1450a, 1450b, and 1450c. A connecting section 1454 is coupled to the two air intake passages 1450. The connecting section 1454 is coupled to the exit passage 155.

[0076] Referring to FIG. 17 through 19, a top, side, and front view of a device 1700 is illustrated according to an embodiment of the invention. The device 1700 comprises to air intake passages 1750. The air intake passages 1750 in this embodiment are substantially curved. The air intake passages 1750 are coupled to the exit passage 155. In this embodiment, a length of the tool bit opening 198 is at least twice as large as a width W of the tool bit opening.

[0077] Referring to FIG. 20, a device 2000 coupled to a stand-up chipping hammer 2050 is illustrated according to an embodiment of the invention. In this embodiment, the device 2000 is similar to the device 100 illustrated in FIG. 1. However, a housing 2010 may be narrower than the housing 110 of FIG. 1 in order to correctly fit the stand-up chipping hammer 2050. Alternatively, a clamp 2080 may be designed such that the clamp 2080 couples securely to any power tool, such as the stand-up chipping hammer 2050, which has a diameter different than that of the housing 2010. In this manner, a single device 2000 may be used on a large number of different power tools. A vacuum hose 2090 is shown coupled to the exit passage 155.

[0078] Referring to FIG. 21, a perspective view of a device 2100 is illustrated according to an embodiment of the invention. The clamp 180 is illustrated in the open position. The clamp 180 comprises a first tongue 2101 and a second tongue 2102. The first tongue 2101 is configured to fit into a groove 2103 on a housing 2110. The second tongue 2102 is configured to grip tightly to a power tool. The second tongue 2102 may be designed to have any radius so that it may secure to any size power tool. The clamp 180 further comprises the hinge 310 which is coupled to the housing 2110. The hinge 310 comprises a bolt that allows the clamp 180 or hinge 310 to be removed if desired. When the clamp 180 is in the open position, the clamp 180 remains coupled to the housing 2110. This prevents any parts of the clamp 180 from being lost, and also allows the device 2100 to be attached and detached from a power tool in less time.

[0079] Referring to FIG. 22, the invention discloses a method for manufacturing a device for collecting dust from a power tool. The method comprises providing a first angled surface and a second angled surface 2210. The first and second angled surfaces may also be referred to as faces. The first and second angled surfaces define a plurality of suction holes and a tool bit opening. A sheath is provided 2220, and the sheath is coupled to the first and second angled surfaces 2230. The sheath is further configured to couple to a power tool. A pipe is provided 2240, and the pipe is coupled to the sheath such that air may flow between the pipe and an interior volume of the sheath 2250. An adapter is provided, and the adapter is coupled to the pipe and configured to couple to a vacuum 2260. A clamp is provided and coupled to an end of the sheath distal to the tool bit opening 2270.

[0080] The various components may be coupled by any method known in the art. In one embodiment, where the device 100 is comprised primarily of steel or aluminum, the components may be welded together. Alternatively, they may be bolted, riveted, screwed, glued, or attached by any other method. In one embodiment some components may comprise plastic and the components may be clamped together. In one embodiment, the components are manufactured with a CNC machine. The components may also be case hardened or heat treated in order to maximize their durability.