Orbital sander

Abstract

An orbital sander (10) comprises a housing (14) and a drive unit (50) in the housing (14). The drive unit (50) includes an electric motor (58) and a drive shaft (68). The electric motor (58) has a motor output shaft defining a rotational axis (62). The drive shaft (68) is coupled for co-rotation with the motor output shaft about the rotational axis (62). The drive shaft (68) has an eccentric portion (70) configured to orbit about the rotational axis (62). A sanding pad (100) is coupled to the eccentric portion (70). A handle (16) extends from the housing (14) at an oblique angle greater than 90 degrees relative to the rotational axis (62). A battery pack (26) is coupled to the handle (16) for providing power to the electric motor (58). The orbital sander (10) is convenient for users to grasp.

1 . An orbital sander comprising:
 a housing;   a drive unit within the housing, the drive unit including
 an electric motor defining a rotational axis, 
 a drive shaft configured to receive torque from the electric motor for rotating the drive shaft about the rotational axis, the drive shaft having an eccentric portion configured to orbit about the rotational axis; 
   a sanding pad coupled to the eccentric portion of the drive shaft for orbital motion about the rotational axis;   a handle portion extending from the housing at an oblique angle greater than 90 degrees relative to the rotational axis; and   a battery pack coupled to the handle for providing power to the electric motor.   
     
     
         2 . The orbital sander of  claim 1 , further comprising:
 an electronic controller;   a trigger switch configured to provide an input signal to the controller to activate and deactivate the motor in response to actuation of the trigger switch; and   a variable speed control configured to provide a speed parameter to the controller to limit an operating speed of the motor.   
     
     
         3 . The orbital sander of  claim 2 , further comprising a lock-on button configured to maintain the trigger switch in an actuated state. 
     
     
         4 . The orbital sander of  claim 1 , further comprising:
 an electronic controller; and   a trigger switch configured to provide an input signal to the controller to activate and deactivate the motor in response to actuation of the trigger switch, wherein the trigger switch includes a trigger travel of  1 . 5  times a width of a user's finger.   
     
     
         5 . The orbital sander of  claim 1 , wherein an overall height of the motor housing is 110 millimeters to 120 millimeters as measured between an upper plane passing through an uppermost portion of the orbital sander and a lower plane passing through lowermost portion of the orbital sander. 
     
     
         6 . The orbital sander of  claim 2 , wherein a distance between the trigger switch and a work surface measured between a trigger plane and a work surface plane is 40 millimeters to 60 millimeters. 
     
     
         7 . The orbital sander of  claim 1 , wherein a handle angle between a longitudinal axis of the handle portion and a longitudinal axis of the motor housing is ninety-five degrees (95°). 
     
     
         8 . The orbital sander of  claim 1 , wherein an overall length of the orbital sander measured between a foremost plane of the orbital sander and an interface plane at an interface of the handle portion and the battery pack is 220 millimeters to 240 millimeters. 
     
     
         9 . The orbital sander of  claim 1 , further comprising a work light coupled to the housing and configured to project light onto a work surface and at least a portion of the sanding pad. 
     
     
         10 . The orbital sander of  claim 9 , wherein the housing comprises a motor housing portion in which the electric motor is located, and wherein the work light is mounted near a top, front of the motor housing portion. 
     
     
         11 . The orbital sander of  claim 10 , wherein the handle portion extends from a rear of the motor housing portion. 
     
     
         12 . The orbital sander of  claim 10 , wherein the work light forms a beam angle with respect to a rotational axis of the electric motor, and wherein the beam angle is thirty-five degrees (35°). 
     
     
         13 . The orbital sander of  claim 9 , wherein the sanding pad includes a sanding pad surface area, and wherein the work light projects an illumination area that is at least six times greater than the sanding pad surface area. 
     
     
         14 . The orbital sander of  claim 1 , wherein the housing includes a motor housing portion in which the electric motor is located and a handle portion extending from the motor housing portion, wherein the electric motor includes a stator, and wherein the orbital sander further comprises one or more battery terminals situated within the handle portion and located between respective planes coinciding with opposite ends of the stator. 
     
     
         15 . The orbital sander of  claim 14 , wherein the planes are parallel to the sanding pad. 
     
     
         16 . The orbital sander of  claim 15 , wherein the planes are parallel to a longitudinal axis of the handle portion. 
     
     
         17 . The orbital sander of  claim 1 , wherein the housing includes a motor housing portion in which the electric motor is located and a handle portion extending from the motor housing portion, and wherein the orbital sander further comprises an electronic controller within the handle portion and oriented at an oblique angle relative to a longitudinal axis of the handle portion. 
     
     
         18 . The orbital sander of  claim 17 , wherein the electronic controller has an oblong shape. 
     
     
         19 . The orbital sander of  claim 17 , wherein the controller is positioned within the handle portion at an angle of thirty-five degrees (35°) with respect to the rotational axis of the motor. 
     
     
         20 - 48 . (canceled)