DEBRIS COLLECTION AND SPARK-ARRESTING DEVICE
20250296199 ยท 2025-09-25
Assignee
- Toyota Motor Engineering & Manufacturing North America, Inc. (Plano, TX, US)
- Toyota Jidosha Kabushiki Kaisha (Toyota-shi Aichi-ken, JP)
Inventors
Cpc classification
International classification
Abstract
Devices described herein relate to a debris collection device for a pneumatic sanding tool that also arrests sparks. In one embodiment, the debris collection device includes a duct housing detachably connectable to the pneumatic sanding tool. The duct housing includes 1) a debris duct in communication with a debris discharge port of the pneumatic sanding tool and 2) an air duct in communication with an air vent of the pneumatic sanding tool. The debris collection device also includes a spark-arresting device. The spark-arresting device includes 1) a spark-arresting chamber in communication with the debris duct and 2) a toroidal manifold of air nozzles surrounding an exit of the spark-arresting chamber. The toroidal manifold is in communication with the air vent and the spark-arresting chamber. The debris collection device also includes a debris collection bin in communication with the spark-arresting device.
Claims
1. A debris collection device, comprising: a duct housing detachably connectable to a pneumatic sanding tool, the duct housing comprising: a debris duct in communication with a debris discharge port of the pneumatic sanding tool; and an air duct in communication with an air vent of the pneumatic sanding tool; a spark-arresting device, comprising: a spark-arresting chamber in communication with the debris duct; and a toroidal manifold of air nozzles surrounding an exit of the spark-arresting chamber, the toroidal manifold in communication with the air vent and the spark-arresting chamber; and a debris collection bin in communication with the spark-arresting device.
2. The debris collection device of claim 1, further comprising a belt guard pivotally attached to the duct housing and covering an abrasive belt of the pneumatic sanding tool on an opposite side of the abrasive belt from the spark-arresting device and the debris collection bin.
3. The debris collection device of claim 1, wherein the spark-arresting chamber comprises a debris duct inlet that is off-center from the spark-arresting chamber to induce swirling of debris within the spark-arresting chamber.
4. The debris collection device of claim 1, wherein a spark-arresting chamber outlet has a smaller diameter than a main volume of the spark-arresting chamber.
5. The debris collection device of claim 1, wherein a spark-arresting device outlet has a tapered diameter extending into the debris collection bin.
6. The debris collection device of claim 1, wherein the toroidal manifold: is downstream of the spark-arresting chamber; and generates a vacuum to draw debris through the debris duct and the spark-arresting chamber.
7. The debris collection device of claim 1, wherein the debris collection bin: is detachably connected to the spark-arresting device; and comprises: a cylindrical porous filter; a rigid leading plate; and a rigid terminal plate against which air and debris are redirected through the cylindrical porous filter.
8. The debris collection device of claim 1, wherein the debris duct and the air duct are separated from one another within the duct housing.
9. The debris collection device of claim 1, wherein: the duct housing comprises two sub-housings; and portions of the debris duct and the air duct are formed in each sub-housing.
10. The debris collection device of claim 1, wherein: the air duct and the debris duct change an airflow direction and a debris flow direction respectively by between 130-180 degrees; and the spark-arresting device changes the airflow direction and the debris flow direction by 90 degrees.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate various systems, methods, and other embodiments of the disclosure. It will be appreciated that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent one embodiment of the boundaries. In some embodiments, one element may be designed as multiple elements or multiple elements may be designed as one element. In some embodiments, an element shown as an internal component of another element may be implemented as an external component and vice versa. Furthermore, elements may not be drawn to scale.
[0006]
[0007]
[0008]
[0009]
[0010]
DETAILED DESCRIPTION
[0011] Devices associated with improving dust collection and fire hazard prevention in sanding operations are disclosed herein. As previously described, sanding is a regular operation in many manufacturing processes, whether to improve a surface finish or remove surface imperfections such as welding burrs, sharp edges, etc. During sanding, particulate matter such as wood dust and/or metallic flakes are removed from a surface. If not contained, this debris collects on and covers surfaces in the work area. The particulate matter could be inhaled by a technician, leading to negative short- or long-term health consequences and is generally an undesirable byproduct of the sanding process. Also, during the sanding operation, abrasive particles from the sander and fibers from the sanding belt may become dislodged and may disperse throughout a workspace and/or be inhaled by a technician. Moreover, when the sanded surface is metallic, the sanding operation may generate sparks or heated particulate matter that could ignite other particulate material and/or objects within the environment and the tool.
[0012] Accordingly, the present device collects dust and debris generated during sanding and removes such from the surrounding environment. The debris collection device also includes a centrifugal spark-arresting device to reduce the risk of metallic spark ignition of particulate matter in the sanding environment. In general, the debris collection device is a lightweight and compact dust and fiber-collecting device that is directly attached to an existing pneumatically-powered portable belt sander.
[0013] In general, the debris collection device uses the exhaust compressed air from a pneumatic sanding tool to create a negative pressure differential in the device. The pressure differential between the different regions of the device creates an airflow. The airflow carries the airborne dust and debris created by the sanding action of the pneumatic sanding tool to a cylindrical spark-arresting chamber. The dust-laden air enters the cylindrical spark-arresting chamber in a fashion that causes the air to swirl, resulting in a centrifugal force that draws the heavier dust and fiber material to the chamber walls for an extended period. This arrests the sparks that may have formed during sanding. The dust and debris travel towards a detachable collection bin, which uses a porous filter as a separating device, with air escaping and dust, abrasive belt fibers and other debris being retained for disposal.
[0014] Specifically, the debris collection device includes a spark-arresting chamber, an air injection manifold, and an outlet nozzle. An air duct and a debris duct are connected with the debris discharge port and air vent of the pneumatic sanding tool, respectively, and separately direct air and debris to a spark-arresting device. Sanding debris enters a spark-arresting chamber of the spark-arresting device while air enters an injection manifold of the spark-arresting device. The air injection manifold has a toroidal cavity with several small nozzles arranged in a circular pattern and directed away from the spark-arresting chamber. The spark-arresting chamber outlet narrows in diameter downstream of the air injection manifold. The narrow diameter of the spark-arresting chamber outlet forces the air streams from the nozzles to form a single stream of high-velocity, low-pressure air. This creates a region of low pressure in the spark-arresting chamber due to the Venturi effect that draws the cooled debris and air out of the spark-arresting chamber outlet towards the debris collection bin. The debris collection device also includes a hinged belt guard that protects a technician from ejected debris and sparks and generally guides the debris and sparks toward the debris collection bin. The belt guard is hinged to allow access to and removal of tool components such as the abrasive belt.
[0015] In this way, the disclosed device improves dust collection by being compact, lightweight, easily manipulated, and ergonomic. Moreover, the disclosed debris collection device is self-contained in that it does not rely on supplemental power or devices to generate the forces that collect dust and extinguish sparks. Instead, the exhaust air from the pneumatic tool generates the force that draws debris from the work area. The present debris collection device further prevents fire hazards by providing numerous mechanisms that promote spark elimination. Thus, the debris collection device protects an operator from debris inhalation and fire hazards that may result if sparks are not extinguished and promotes a clean, safe, and effective workspace.
[0016] Turning now to the figures,
[0017] A pneumatic sanding tool 102 relies on compressed air, rather than an electric motor, to drive the abrasive belt. As such, a pneumatic sanding tool 102 may be lighter and easier to maneuver around a workpiece than an electric sanding tool. A pneumatic sanding tool 102 may be desirable in a manufacturing facility where an operator spends many hours operating and moving the sanding tool 102.
[0018] As described above, debris is a byproduct of any sanding operation, whether the debris is material removed from a work surface or abrasive material that is dislodged from the belt. When the work surface is metallic, friction between the abrasive particles and the work surface may heat the metal flakes, forming sparks. The debris collection device 100 of the present specification includes structural features that collect the debris to promote a clean and safe work environment and cool the sparks to prevent potential fire hazards.
[0019] Specifically, the debris collection device 100 includes a duct housing 104 detachably connectable to the pneumatic sanding tool 102. The duct housing 104 includes two separate channels, one for collected debris from the sanding operation and another for the exhaust compressed air used to drive the abrasive belt. That is, the pneumatic sanding tool 102 includes separate discharge ports for the debris and the exhaust compressed air and the duct housing 104 maintains these different flows separate from one another. Specifically, as depicted in
[0020] The debris collection device 100 further includes a spark-arresting device 106 in communication with the duct housing 104. The spark-arresting device 106 includes a spark-arresting chamber where ignited particulate matter and/or sparks may cool and/or extinguish. The spark-arresting device 106 also includes a toroidal manifold of air nozzles. The airflow out of the air nozzles 1) is directed away from the spark-arresting chamber and 2) generates a vacuum that draws debris away from the abrasive belt, through the duct housing 104, and ultimately towards the debris collection bin 108. Exhaust compressed air is fed to the toroidal manifold to generate the debris-moving airflow. In an example, the spark-arresting device 106 is a separate component from the duct housing 104 and is connected to the duct housing 104 via an adhesive or another fastening mechanism such as bolts, screws, or rivets. Additional details regarding the structure and operation of the spark-arresting device 106 are provided below in connection with
[0021] The debris collection device 100 further includes a debris collection bin 108 in communication with the spark-arresting device 106. The debris collection bin 108 may be joined to the spark-arresting device 106. In general, the debris collection bin 108 includes a porous cylindrical filter fastened to circular end plates. As depicted in
[0022] In an example, the debris collection bin 108 may be detachably connected to the spark-arresting device 106. For example, one plate of the debris collection bin 108 may include threads that engage with corresponding threads on an outlet of the spark-arresting device 106 to join the two together. Additional details regarding the debris collection bin 108 structure are provided below in connection with
[0023] The debris collection device 100 further includes a belt guard 110 pivotally attached to the duct housing 104. The belt guard 110 covers a portion of the abrasive belt of the pneumatic sanding tool 102 that is on the opposite side of the abrasive belt from the spark-arresting device 106 and the debris collection bin 108. As described above, particulate matter from the work surface or from the abrasive belt becomes dislodged during sanding. While some of the material is directed toward the debris collection bin 108, a portion may be directed elsewhere. The belt guard 110 may block a portion of the uncaptured material, thus promoting a clean and efficient workspace. The belt guard 110 also protects the operator from airborne debris. The belt guard 110 also retains the particulate matter in a region influenced by the debris collection device 100. That is, the belt guard 110 may generally maintain the particulate matter in a region surrounding the abrasive belt where the vacuum generated by the spark-arresting device 106 may draw the debris towards the debris collection bin 108.
[0024] The belt guard 110 also protects the operator from potential injury that may result from contact with the abrasive belt. To remove material, the abrasive belt rotates at a high speed. Injury may occur if the operator were to touch the abrasive belt. Accordingly, the belt guard 110 prevents the operator from touching the high-speed rotating abrasive belt.
[0025] In an example, the belt guard 110 is pivotably attached to the duct housing 104. For example, a hinge pin may pass through respective bores in the duct housing 104 and the belt guard 110 in a fashion that allows the belt guard 110 to pivot about the hinge pin. The hinged connection allows the belt guard 110 to be moved out of position for belt replacement and/or repair. For example, during use, the belt guard 110 is positioned as indicated by solid lines to protect the operator and capture dislodged particulate matter as described above. In this example, the belt guard 110 may include a clasp or other mechanism to secure the belt guard 110 in place adjacent to the abrasive belt. During belt repair and/or replacement, an operator may disengage the clasp or other mechanism to pivot the belt guard 110 to a disengaged position as depicted in dashed lines. In the disengaged position, the operator can repair and/or replace the abrasive belt and perform maintenance on other pneumatic sanding tool 102 components.
[0026] The debris collection device 100 components may be formed of various materials. For example, the components may be formed of a lightweight plastic material such as a nylon-based material such as carbon fiber filled nylon and may be formed via three-dimensional (3D) printing. In another example, the components may be made of another material, such as aluminum. When made of aluminum, the debris collection device 100 may further promote spark elimination as the metallic surface may draw heat away from the sparks.
[0027] In either case, the debris collection device 100 of the present specification provides a compact, lightweight, and ergonomic device that removes dust and other debris from a work area and extinguishes sparks that may be generated during a sanding operation.
[0028]
[0029]
[0030]
[0031] As described above, the debris collection bin 108 may be detachably connected to the spark-arresting device 106, for example, to facilitate cleaning, filter replacement, and/or debris disposal. Accordingly, in one example, the first plate 224 includes internal threads 232 that mate with external threads 230 on the spark-arresting device 106 such that these components may be joined together or separated from one another.
[0032]
[0033] As depicted in
[0034]
[0035] In general, the spark-arresting chamber 438 is a volume where ignited particulate matter and sparks may cool down. A variety of structural features of the spark-arresting chamber 438 facilitate spark elimination. Specifically, the debris duct inlet 220 is off-center from the spark-arresting chamber 438 centerline to induce swirling of debris within the spark-arresting chamber 438 as indicated by the arrow. The collision of the sparks with the inner wall of the spark-arresting chamber 438 may serve to cool some of the sparks. The cooling effect of this interaction is enhanced in the case where the spark-arresting device 106 is formed of a metallic material such as aluminum, which draws heat away from the sparks. Moreover, the swirling motion of the debris in the spark-arresting chamber 438 increases the time the sparks are airborne before reaching the debris collection bin 108. As such, the sparks have more time to cool down.
[0036] As described above, the spark-arresting device includes a toroidal manifold 440 of air nozzles 442 surrounding an exit of the spark-arresting chamber 438. The toroidal manifold 440 is in communication with the air duct 216 such that exhaust compressed air passes through the individual nozzles 442 of the toroidal manifold 440. The reduced size of the nozzles 442 relative to the air duct 216 and the air duct inlet 222 increases the speed of the air exiting the nozzles 442. This creates a low-pressure or vacuum region downstream of the spark-arresting chamber 438. As the toroidal manifold 440 is in communication with the spark-arresting chamber 438, this low-pressure vacuum draws the swirling debris from the spark-arresting chamber 438 out of the chamber and towards the spark-arresting device 106 outlet towards the debris collection bin 108. Additional details regarding the dust collection and spark cooling operations of the spark-arrest device 106 and the debris collection bin 108 are described below in connection with
[0037]
[0038] Moreover, the turbulence of the swirling air may further extinguish sparks. That is, each spark may be surrounded by a pocket of heated air, which may be referred to as a thermal envelope. This thermal envelope insulates the spark and slows the heat dissipation rate from the spark. Turbulence in the spark-arresting chamber 438 breaks down the thermal envelope surrounding a spark. Without the thermal envelope insulating the spark, heat more rapidly dissipates such that the turbulence increases the rate of heat dissipation of a spark.
[0039] Moreover, the turbulence increases the time the sparks remain within the spark-arresting chamber 438. That is, rather than having a direct flow path from the debris duct inlet 220 to the outlet 552 of the spark-arresting device 106, the sparks remain in the spark-arresting chamber 438. This increased time allows the sparks to cool before entering the debris collection bin 108 and potentially igniting other debris.
[0040] In an example, the outlet of the spark-arresting chamber 438 has a smaller diameter than the main volume of the spark-arresting chamber 438. Specifically, the outlet diameter 546 of the spark-arresting chamber 438 is less than the main volume diameter 544. As an example, the outlet diameter 546 may be between 20 and 25 millimeters (mm), for example, 22.15 mm, and the main volume diameter 544 may be between 25-35 mm, for example, 30.15 mm. This structural arrangement may further cool sparks in the sanding debris. That is, before exiting the spark-arresting chamber 438, the vacuum pressure generated by the air passing through the toroidal manifold 440 must overcome the centrifugal force generated by the turbulence within the spark-arresting chamber 438. Overcoming this centrifugal force may take time such that the sparks remain in the spark-arresting chamber 438 and continue the spark-arresting turbulent motion within the spark-arresting chamber 438 until the centrifugal force is overcome by the low pressure generated by the fast-flowing air out of the outlet 552.
[0041] As described above, airflow through the nozzles 442 of the toroidal manifold 440 generates the low pressure that draws the debris and sparks away from the abrasive belt. Specifically, the toroidal manifold 440 is a toroidal cavity in downstream communication with the spark-arresting chamber 438. The toroidal manifold 440 has several small nozzles 442 (e.g., 2.0 mm nozzles 442) arranged in a circular pattern and directed away from the spark-arresting chamber 438. The spark-arresting chamber 438 contains an outlet which passes through the center of the toroidal manifold 440 to a spark-arresting device outlet 552. In an example, the spark-arresting device outlet 552 of the spark-arresting device 106 has a tapered diameter that extends into the debris collection bin 108. Specifically, the spark-arresting device outlet 552 may taper from a first diameter 548, which is between 25-35 mm, for example, 30.15 mm, to a second diameter 550, which is between 20 and 25 mm, for example, 22.15 mm. The small diameter of the nozzles 442 causes the many escaping air streams to travel at an increased velocity relative to the upstream flow. The narrow diameter of the spark-arresting device outlet 552 converges these air streams to converge into a single stream of high-velocity and low-pressure fluid flow. This creates a region of low pressure immediately downstream of the spark-arresting chamber 438 due to the Venturi effect, which states that fluid pressure is reduced as fluid speed increases. As such, the increased fluid speed through a reduced cross-sectional area generates a low-pressure region in the spark-arresting device outlet 552. This pressure differential creates an airflow through the debris duct 218 that draws dust, debris, and sparks from sanding to the spark-arresting chamber 438. That is, as described, the toroidal manifold 440 is downstream of the spark-arresting chamber 438 and generates a vacuum to draw debris through the debris duct 218 and the spark-arresting chamber 438.
[0042]
[0043] As described above, the debris collection bin 108 is formed of a cylindrical filter 226 formed of porous material through which air may permeate but which traps dust and other debris. The dust collection bin 108 further includes a rigid terminal plate 228. The rigid terminal plate 228 deflects air and debris towards the filter 226. That is, as depicted in
[0044] Detailed embodiments are disclosed herein. However, it is to be understood that the disclosed embodiments are intended only as examples. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the aspects herein in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting but rather to provide an understandable description of possible implementations. Various embodiments are shown in
[0045] The terms a and an, as used herein, are defined as one or more than one. The term plurality, as used herein, is defined as two or more than two. The term another, as used herein, is defined as at least a second or more. The terms including and/or having, as used herein, are defined as comprising (i.e., open language). The phrase at least one of . . . and . . . as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. As an example, the phrase at least one of A, B, and C includes A only, B only, C only, or any combination thereof (e.g., AB, AC, BC or ABC).
[0046] Aspects herein can be embodied in other forms without departing from the spirit or essential attributes thereof. Accordingly, reference should be made to the following claims, rather than to the foregoing specification, as indicating the scope hereof.