Random orbit sander

Abstract

A random orbit sander includes a housing and a motor enclosed within the housing. The motor includes a motor shaft that is rotatable about a first axis. An eccentric carrier coupled to the motor shaft includes a circular internal bore that defines a second axis that is offset from the motor shaft. A bearing is received within the circular internal bore of the eccentric carrier. A sanding pad is supported by the bearing and is rotatable about the first axis in an eccentrically orbiting manner. The motor shaft and the eccentric carrier are integrally formed as a single piece.

1 .- 103 . (canceled) 
     
     
         104 . A method of assembling a sander, the method comprising:
 providing:
 an eccentric carrier, 
 a dust extraction fan, 
 a radial bearing, and 
 a shaft having a longitudinal axis; 
   sizing an internal bore of the dust extraction fan to be nominally smaller than an external surface of the eccentric carrier;   sizing an internal bore of the eccentric carrier to be nominally smaller than an external surface of the radial bearing;   sizing an internal bore of the radial bearing to be nominally smaller than an external surface of the shaft; and   pressing the eccentric carrier, the dust extraction fan, the radial bearing, and the shaft together with an interference fit between the respective external surfaces and the internal bores of the eccentric carrier, the dust extraction fan, the radial bearing, and the shaft in a direction parallel to the longitudinal axis of the shaft.   
     
     
         105 . The method of  claim 104 , further comprising pressing together the eccentric carrier, the dust extraction fan, the radial bearing, and the shaft such that a plane defined perpendicular to the longitudinal axis of the shaft passes through the eccentric carrier, the dust extraction fan, the radial bearing, and the shaft. 
     
     
         106 . The method of  claim 105 , further comprising pressing together the eccentric carrier, the dust extraction fan, the radial bearing, and the shaft such that the plane passes through a counterweight of the dust extraction fan and through a fan blade of the dust extraction fan. 
     
     
         107 . The method of  claim 104 , further comprising stacking the eccentric carrier, the dust extraction fan, the radial bearing, and the shaft prior to pressing together the eccentric carrier, the dust extraction fan, the radial bearing, and the shaft. 
     
     
         108 . The method of  claim 107 , wherein pressing the eccentric carrier, the dust extraction fan, the radial bearing, and the shaft includes pressing the eccentric carrier, the dust extraction fan, the radial bearing, and the shaft together as a stack. 
     
     
         109 . The method of  claim 104 , further comprising affixing a sanding pad to the shaft. 
     
     
         110 . A random orbit sander comprising:
 a housing;   a motor enclosed within the housing, the motor including a motor shaft rotatable about a first axis;   an eccentric carrier coupled to the motor shaft, the eccentric carrier including a circular internal bore defining a second axis that is offset from the motor shaft;   a radial bearing received within the circular internal bore of the eccentric carrier;   a dust extraction fan rotationally unitized with the eccentric carrier for corotation therewith;   an eccentric shaft having a longitudinal axis; and   a sanding pad supported by the eccentric shaft and rotatable about the first axis in an eccentrically orbiting manner;   wherein the eccentric carrier, the radial bearing, the dust extraction fan, and the eccentric shaft are coupled to each other by press-fit connections.   
     
     
         111 . The random orbit sander of  claim 110 , wherein a plane is defined perpendicular to a longitudinal axis of the eccentric shaft such that the plane passes through the eccentric carrier, the dust extraction fan, the radial bearing, and the eccentric shaft. 
     
     
         112 . The random orbit sander of  claim 111 , wherein the plane passes through a counterweight of the dust extraction fan and through a fan blade of the dust extraction fan. 
     
     
         113 . The random orbit sander of  claim 110 , wherein the dust extraction fan is integrally formed as a single piece with a counterweight to form an integrated fan and counterweight unit. 
     
     
         114 . The random orbit sander of  claim 110 , wherein the eccentric carrier is integrally formed as a single piece with the motor shaft. 
     
     
         115 . The random orbit sander of  claim 110 , wherein a diameter of the sanding pad is less than four inches. 
     
     
         116 . The random orbit sander of  claim 115 , wherein a diameter of the sanding pad is three inches. 
     
     
         117 . The random orbit sander of  claim 110 , wherein a motor housing portion height of the random orbit sander is less than 0.6 times an overall length of the random orbit sander. 
     
     
         118 . The random orbit sander of  claim 110 , wherein the eccentric carrier, the dust extraction fan, the radial bearing, and the eccentric shaft are positioned within a lower cavity of a motor housing portion of the random orbit sander. 
     
     
         119 . The random orbit sander of  claim 110 , wherein the radial bearing and the eccentric shaft are provided within the eccentric carrier, and wherein the dust extraction fan is provided outside the eccentric carrier. 
     
     
         120 . The random orbit sander of  claim 110 , wherein the radial bearing includes two rows of ball bearings positioned between the eccentric shaft and the eccentric carrier. 
     
     
         121 . The random orbit sander of  claim 110 , wherein:
 the housing includes a motor housing portion defining a motor housing axis and a handle portion defining a handle axis transverse to the motor housing axis,   the motor is enclosed within the motor housing portion and oriented vertically within the motor housing portion, and   a battery pack is removably connectable to a rear end of the handle portion.   
     
     
         122 . The random orbit sander of  claim 110 , further comprising a user control panel positioned at a top of a motor housing portion of the housing, wherein the first axis passes through the user control panel. 
     
     
         123 . The random orbit sander of  claim 110 , wherein:
 the housing includes a motor housing portion having a neck portion and a pommel portion, and   a front work light is positioned on a front surface of the neck portion and is positioned below the pommel portion.   
     
     
         124 .- 164 . (canceled)