Water Cooled Sanding Table with Room Heater Attachment

Abstract

This invention presents a water-cooled sanding table that uniquely integrates a cooling and thermal energy reclamation system. It features a motor-driven sanding belt, a compressor-regulated cooling system with a water tank, evaporator, and condensing coils, alongside an aluminum plate for direct heat transfer from the sanding process. This setup not only prevents heat damage to both workpiece and sanding belt, allowing for higher speed operations without damage, but also captures and repurposes the generated thermal energy. The expelled heat can be utilized for heating spaces or water, showcasing the invention's contribution to energy efficiency and sustainability. This system's ability to enhance processing quality while conservatively managing energy exemplifies a significant advancement in the field.

Claims

1. A sanding table apparatus comprising: a fluid tank for storing a thermally conductive fluid; a first heat exchange system, comprising an evaporator coil submerged in the thermally conductive fluid within the fluid tank, operationally linked to a compressor and an externally located condensing coil, designed to extract heat from the fluid and expel it into the surrounding air, thereby cooling the fluid; a motor equipped with a variable frequency drive system for adjusting sanding speed, wherein the motor facilitates the movement of a sanding belt, which is tensioned across a lead drum pulley and a tail drum pulley, each of which are bolted to a steel frame; a thermally conductive plate positioned beneath the sanding belt, configured to support a workpiece, and forming part of a second heat exchange system that transfers heat generated from the workpiece during sanding, through the thermally conductive plate and into the thermally conductive fluid; and a pump configured to circulate the fluid between the fluid tank and the thermally conductive plate. Dependent claims

2. The invention of claim 1, wherein the motor is configured to connect to a standard 220V outlet and includes a Variable Frequency Drive (VFD) system capable of converting 220V 2-phase power to 3-phase power.

3. The invention of claim 1, wherein the thermally conductive plate includes multiple bore holes equipped with fittings for facilitating the flow of the thermally conductive fluid.

4. The invention of claim 1, wherein the first heat exchange system includes a blower configured to direct air heated by the condensing coil into the surrounding area.

5. The invention of claim 1, wherein the first heat exchange system includes an attachment configured to direct air heated by the condensing coil into an HVAC duct system.

6. The invention of claim 1, wherein the first heat exchange system includes an attachment configured to utilize the heat extracted by the condensing coil for any application where such heat is beneficial.

7. The invention of claim 1, wherein the second heat exchange system includes an attachment configured to utilize the heated thermally conductive fluid for any application where such fluid is beneficial.

8. The invention of claim 1, further comprising a plurality of guide wheels positioned between the lead drum pulley and the tail drum pulley, designed to maintain the alignment and stability of the sanding belt.

9. The invention of claim 1, further comprising a set of tail pulley adjustment mechanisms, each equipped with an adjustable bolt, allowing for fine-tuning of the sanding belt's tension and alignment by adjusting the position of the tail pulley relative to the lead pulley.

10. The invention of claim 1, further comprising a hinged workpiece fence positioned at the lead end of the thermally conductive plate.

11. The invention of claim 1, further encased within an enclosure on all sides but one, wherein the one open side features two half-doors that partially enclose the open side, allowing access for workpiece manipulation and usage of the invention.

12. The invention of claim 11, further comprising an exhaust mechanism mounted on one of the doors, designed for dust extraction to enhance the operational environment by removing dust generated during sanding operations.

13. The invention of claim 1, wherein the water tank contains 25 gallons of water and includes a compact pump to circulate the water within the tank, enhancing the heat exchange efficiency between the water and the evaporator coil. Independent claim

14. A method for capturing, storing, and repurposing thermal energy generated during sanding, the method comprising: extracting heat from a thermally conductive fluid, stored within a fluid tank, using a first heat exchange system comprising an evaporator coil-located in the tank and submerged in the fluid-a compressor, and a condensing coil located outside the fluid tank; pumping the cooled thermally conductive fluid from the fluid tank through a second heat exchange system, comprising of a closed-loop system involving a thermally conductive plate situated beneath a sanding belt, wherein the plate is configured to support a workpiece during sanding; capturing the heat generated at the interface between the workpiece and the sanding belt, wherein the thermally conductive plate causes the heat generated to be transferred to the thermally conductive fluid; circulating the now heated thermally conductive fluid back to the fluid tank, wherein the first heat exchange system may extract the thermal energy, i.e. heat generated from sanding; and repurposing the thermal energy extracted from the thermally conductive fluid. Dependent Method claims

15. The method of claim 14, where circulating the thermally conductive fluid entails moving the fluid through multiple boreholes within the thermally conductive plate, connected via any configuration of tubbing which results in the flow of fluid.

16. The method of claim 14, further comprising the step of adjusting the flow rate of the thermally conductive fluid through the closed-loop system using a gate valve on the return line to the fluid tank to enhance the efficiency of heat transfer from the workpiece to the fluid.

17. The method of claim 14, wherein repurposing the thermal energy extracted includes utilizing an attachment configured to direct the heated air into an HVAC duct system for heating a space.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0004] The following is a brief description of the drawings included in this patent application, beginning with FIG. 1.

[0005] FIG. 1: This figure presents an image of the three-phase motor (1A), serving as the driving force of the machine. It showcases a 6-inch drive pulley (1B) attached to the motor's output shaft, with a drive belt (1C) extending to a 4.5-inch driven pulley (1D) positioned approximately 14 inches above. The 4.5-inch driven pulley is further connected to a 4-inch drum pulley (1E), responsible for spinning and moving the sandpaper.

[0006] FIG. 2: This figure provides a top-down view of the steel frame (2A) that the 4-inch drum pulleys are bolted to. Because the pulleys and sandpaper are not installed, the figure reveals an otherwise obstructed view of the heat exchange unit (2B), which allows the heat removal from the water. Visible as well is the pump (2C), responsible for circulating water from the water tank through the aluminum plate under the sanding belt, and back to the water tank.

[0007] FIG. 3: Depicted here are the four guide wheels (3A) designed to stabilize and guide the sandpaper belt. Positioned approximately 9 inches from the tail drum pulley, these wheels are approximately 3 inches in diameter and mounted on angle iron approximately 7 inches in length. Each angle iron is connected to the same steel rod, suspended approximately 4 inches above the sandpaper. This arrangement permits slight vertical movement of the guide wheels to accommodate fluctuations in the sandpaper's tension. Also visible are the bushing bearing blocks (3B) through which the 1.5-inch steel shaft (3C), affixed to each drum pulley, is fitted. Both pulleys are mounted at opposite ends of the steel frame, and the 103-inch sandpaper belt is wrapped around them. Additionally, the tail pulley adjustment mechanism (3D) is shown, which includes two steel brackets, each with an adjustable bolt. These brackets are positioned in front of the bearing bushings of the tail pulley. By adjusting the position of the bolts, the tension and therefore alignment of the sanding belt can be finely tuned.

[0008] FIG. 4: This figure illustrates the table along with its partial enclosure, featuring two doors shown in their closed state. The design of the doors deliberately does not enclose the structure completely, thus maintaining an opening for the operator to insert workpieces, while still proficiently containing dust within the enclosure. The motor is mounted securely behind the leftmost closed door, indicating its secure enclosure for safety.

[0009] FIG. 5: This figure presents the first heat exchange system integral to the invention, highlighting the 25-gallon water tank (5A) positioned on the ground beneath the motor. The evaporator coil within it (5B) is clearly visible, along with a small pump (5C) designed to circulate water throughout the tank to aid in the heat exchange process with the evaporator coil. Positioned directly outside the tank are the compressor (5D), as well as the blower (5F) and condensing coil (5E). Also visible are the copper pipes that traverse the tank, forming the connection between the compressor, evaporator coil, and condensing coil-illustrating the system's circulatory pathway for the refrigerant of the first heat exchange system.

[0010] FIG. 6: This figure shows the aluminum block, a crucial component of the cooling mechanism, after being precisely drilled and tapped to create 16 bore holes. These holes have been outfitted with brass fittings on each end, amounting to 32 fittings in total, essential for the circulation of water.

[0011] FIG. 7: This top-down view illustrates the connectivity between the aluminum plate and the water tank. All tubes connected to the aluminum plate are visible, with the water tank positioned on the ground to the left, showcasing the direct path of tubing from the aluminum plate to the water tank. Notably, two vinyl tubes extend from the aluminum plate towards the ground: the return tube (7B), leading into the water tank, returns heated water for re-chilling, and the supply tube (7C), emanating from an off-view pump, designed to transport chilled water from the tank to the aluminum plate. Additionally, the figure shows the workpiece fence (7A) positioned above the sandpaper covered aluminum block, indicating the system's readiness for operation, and emphasizing the thoughtful integration of components for optimal functionality.

[0012] FIG. 8: This final figure presents a comprehensive head-on top-down view of the entire enclosed system with both doors open, capturing the intricate layout and interaction of its key components. The sandpaper (8A), positioned between the two 4-inch drum pulleys, rides directly above the aluminum block, underscoring the seamless integration of the sanding and cooling processes. This view encapsulates the inventive synergy between mechanical motion, thermal management, and workpiece processing, offering a clear visual summary of the system's operational architecture.

DETAILED DESCRIPTION

[0013] This invention pertains to a novel Water-Cooled Sanding Table with Room Heater Attachment, which is characterized by two primary functional components: the Sanding Assembly and the Cooling Mechanism.

Sanding Assembly Description

[0014] The Sanding Assembly is a foundational component of the Water-Cooled Sanding Table, and is distinguished by several key features: [0015] Motor and Speed Control: Central to the Sanding Assembly, the motor is engineered to provide a consistent and variable rotational speed, accommodating diverse sanding requirements. This adaptability is achieved through the integration of a Variable Frequency Drive (VFD) system, capable of attaching to any standard 220V outlet, making it suitable for residential use. The VFD converts 220V 2-phase power into 3-phase power, driving the three-phase motor. This setup permits virtually unlimited adjustments of the machine's revolutions per min (RPM). The motor is equipped with an output shaft connected to a drive pulley, with a drive belt extending to a driven pulley positioned at a calculated distance above the motor's output shaft. (FIGS. 1A-1D). Pulley ratios can be changed to increase or decrease the RPM of the driven pulley. [0016] Sanding Belt Pulleys: Essential to the operation of the sanding belt, the assembly incorporates two drum pulleys, each 4 inches in diameter and 18 inches in length (1E). Mounted on a 26-inch steel shaft that is 1.5 inches in diameter (3C), these pulleys are supported by bearing bushing blocks attached to a steel frame (3B & 2A). The motor's driven pulley is connected to the lead drum-pulley's shaft, directly engaging the leading drum pulley to initiate the rotation of the sanding belt (1E). [0017] Sanding Belt: The sanding belt is 103 inches long and operates in a continuous loop. The invention can accommodate any width sanding belt between 1 and 18 inches (FIG. 8). [0018] Guide Wheels: To further enhance the functionality and precision of the Sanding Assembly, this invention incorporates two sets of four guide wheels. These wheels are positioned between the two 4-inch drum pulleys, approximately 9 inches from each pulley (3A). Their primary purpose is to maintain the alignment and stability of the sanding belt, ensuring it remains perfectly centered during operation. This feature is vital for preventing the belt from veering off course, thus guaranteeing consistent sanding results and extending the life of the sanding belt. [0019] Tail Pulley Adjustment Mechanism: To ensure optimal tension and alignment of the sanding belt, the apparatus incorporates a tail pulley adjustment mechanism. This mechanism consists of two steel brackets, each equipped with an adjustable bolt. These brackets are bolted to the steel frame in front of the bearing bushings of the tail pulley. By adjusting the position of the bolts, the alignment or tension of the sanding belt can be finely tuned by allowing the adjustable bolts to manipulate the position of the tail pulley relative to the head pulley (3D). [0020] Work piece Fence: Positioned at the lead end of the aluminum block, the fence serves as a reliable guide for the workpiece, ensuring it remains flush and stable against the sanding belt for uniform surface treatment (7A). Notably, the fence is hinged, allowing it to be easily moved out of the way when changing the sanding paper. [0021] Enclosure with Doors: The entire machine is encased within an enclosure, featuring two doors that allow only enough space for the worker to work the workpiece as it is sanded. This system not only maintains a cleaner working environment but also significantly reduces the risk of accidental contact with the moving parts of the motor. (FIG. 4).

Dual Heat Exchange System

[0022] The Cooling Mechanism plays the crucial role of managing heat during the sanding process and introduces a unique dual heat exchange system.

Heat Exchange System OneAbsorption of Heat from Water:

[0023] The first heat exchange system is designed to pull heat from the water located in the water tank and expel it into the surrounding environment. It consists of a closed system between a compressor, evaporator coil and condensing coil, with refrigerant pumped throughout (2B). [0024] Water Tank: The water tank acts as a storage unit for the water used in the process of absorbing heat. It is part of a closed-loop system that contains 25 gallons of water (5A). Within the tank, there's a compact pump designed to circulate the water inside the tank to facilitate effective heat exchange between the water and evaporator coil (5C). [0025] Compressor: The compressor, located outside the water tank and between the evaporator and condensing coils, begins the water-cooling cycle (5C). The primary function of the compressor is to increase the pressure of the refrigerant and move the refrigerant throughout the system, thus driving the refrigeration cycle. [0026] Evaporator Coil: Located within the water tank, the evaporator coil allows direct interaction between the water and the refrigerant inside the evaporator coil (5B). As the refrigerant passes through the evaporator coil, it absorbs heat from the surrounding water. The transfer of heat from the water to the refrigerant effectively cools the water. [0027] Condensing Coil: Positioned outside the water tank, the condensing coil serves to expel the absorbed heat into the environment (5E). An attachment fan facilitates this process by blowing ambient or chilled air over the coil, thus transferring the heat from the refrigerant to the air (5F).
Heat Exchange System TwoAbsorption of Heat from Sanding:

[0028] The second heat exchange system is designed to harness the thermal energy produced during the sanding process. The heat, a byproduct of friction between the workpiece and the sanding belt, is absorbed by the chilled water circulating through an aluminum plate. This mechanism ensures the efficiency of the sanding operation by maintaining a thermally optimal sanding surface. [0029] Pump: This device facilitates the circulation of water from the tank, through the aluminum plate positioned beneath the sanding belt, and back into the tank (2D). [0030] Thermally Conductive Plate: Positioned directly beneath the sanding belt, this aluminum plate serves as a thermal conduit, efficiently transferring heat generated by the workpiece to the circulating fluid. By maintaining thermal contact with the sanding belt, the plate not only cools the belt and workpiece by absorbing heat from the sanding process but also facilitates a continuous, efficient cooling cycle as the heated fluid is returned to the water tank for re-cooling (7B & 7C). Specifically, the thermally conductive block, measuring 18 inches by 18 inches, is machined to feature 16 bore holes, each with a diameter of inch, as illustrated in FIG. 6. These bore holes are critical for the circulation of the fluid, ensuring effective heat absorption from the sanding process. A gate valve on the return line is used to adjust the fluid's pressure, enhancing the system's ability to control the cooling process dynamically based on operational requirements.

[0031] The present invention uniquely captures and repurposes thermal energy generated during sanding operations; an advancement not seen in prior art. By efficiently transferring heat generated by friction to the system's water, it harnesses energy typically lost in the process. Attachments can be fitted which are used for directing heated air, expelled by the condensing coil at temperatures over 118 F., into residential or commercial heating ducts, offering a novel method for workspace or home heating.

[0032] This capability for thermal energy reclamation positions the invention as a significant step forward in energy-efficient and sustainable material processing technology, reducing operational costs and minimizing environmental impact by leveraging waste heat in practical applications.

Independent Claim