Random orbit sander with angled battery orientation

Abstract

An orbital sander includes a housing, a motor within the housing and having a drive shaft defining a motor axis, an eccentric drive unit coupled to the drive shaft and configured to convert rotation of the drive shaft to an orbit motion around the motor axis, a sanding pad defining a horizontal work plane and coupled to the eccentric drive unit for orbital motion about the motor axis, and a battery receptacle extending along the housing. The battery receptacle is operable to receive a removable battery pack for providing electrical current to the motor. The battery receptacle defines a battery axis along which the battery pack is installed and the battery axis forms an acute battery angle relative to the work plane.

What is claimed is: 
     
         1 . An orbital sander comprising:
 a housing;   a motor within the housing, the motor including a drive shaft defining a motor axis;   an eccentric drive unit coupled to the drive shaft and configured to convert rotation of the drive shaft to an orbit motion around the motor axis;   a sanding pad defining a horizontal work plane and coupled to the eccentric drive unit for orbital motion about the motor axis; and   a battery receptacle extending along the housing, the battery receptacle operable to receive a removable battery pack for providing electrical current to the motor, wherein the battery receptacle defines a battery axis along which the battery pack is installed, and wherein the battery axis forms an acute battery angle relative to the work plane.   
     
     
         2 . The orbital sander of  claim 1 , wherein the work plane is parallel to a work surface on which the orbital sander is used. 
     
     
         3 . The orbital sander of  claim 1 , wherein the battery angle is greater than or equal to two and one-half degrees (2.5°). 
     
     
         4 . The orbital sander of  claim 3 , wherein the battery angle is less than or equal to thirty degrees (30°). 
     
     
         5 . The orbital sander of  claim 1 , wherein the battery axis extends within a guide plane that is parallel to the motor axis. 
     
     
         6 . The orbital sander of  claim 1 , further comprising a battery isolator within the battery receptacle, wherein the battery isolator is configured to receive the removable battery pack, and wherein the battery isolator is aligned along the battery angle. 
     
     
         7 . The orbital sander of  claim 6 , wherein the battery isolator includes at least one guide rail that is parallel to the battery axis. 
     
     
         8 . An orbital sander comprising:
 a motor housing;   a motor within the motor housing, the motor including a drive shaft defining a motor axis;   a grip portion extending along a top of the motor housing, the grip portion defining
 a grip axis perpendicular to the motor axis, and 
 an end face that is parallel to the motor axis; 
   an eccentric drive unit coupled to the drive shaft and configured to convert rotation of the drive shaft to an orbit motion around the motor axis;   a sanding pad defining a horizontal work plane parallel to the grip axis and coupled to the eccentric drive unit for orbital motion about the motor axis; and   a battery receptacle extending along the motor housing, the battery receptacle including a battery contact face that is parallel to the motor axis, perpendicular to the grip axis, and inset from the end face of the grip portion, wherein the battery receptacle is operable to receive a removable battery pack for providing electrical current to the motor, wherein the battery receptacle defines a battery axis along which the battery pack is installed, and wherein the battery axis forms an acute battery angle relative to the work plane.   
     
     
         9 . The orbital sander of  claim 8 , wherein the battery angle is greater than or equal to two and one-half degrees (2.5°). 
     
     
         10 . The orbital sander of  claim 9 , wherein the battery angle is less than or equal to thirty degrees (30°). 
     
     
         11 . The orbital sander of  claim 8 , wherein the end face of the grip portion is spaced a first distance D 1  from the motor axis, wherein the battery contact face is spaced a second distance D 2  from the motor axis, and wherein the second distance D 2  is less than the first distance D 1 . 
     
     
         12 . The orbital sander of  claim 11 , wherein the battery contact face is inset from the end face of the grip portion by an amount equal to the first distance D 1  minus the second distance D 2 . 
     
     
         13 . The orbital sander of  claim 11 , wherein the second distance D 2  is less than or equal to 0.95 times the first distance D 1 . 
     
     
         14 . The orbital sander of  claim 13 , wherein the second distance D 2  is greater than or equal to 0.6 times the first distance D 1 . 
     
     
         15 . An orbital sander comprising:
 a motor housing;   a motor within the motor housing, the motor including a drive shaft defining a motor axis;   a grip portion extending along a top of the motor housing, the grip portion defining a grip axis perpendicular to the motor axis;   an eccentric drive unit coupled to the drive shaft and configured to convert rotation of the drive shaft to an orbit motion around the motor axis;   a sanding pad defining a horizontal work plane parallel to the grip axis and coupled to the eccentric drive unit for orbital motion about the motor axis;   a battery receptacle extending along the motor housing; and   a battery isolator disposed within the battery receptacle, the battery isolator including at least one guide rail operable to receive a portion of a removable battery pack, wherein the at least one guide rail extends within a guide plane that is parallel to the motor axis and perpendicular to the grip axis, and wherein the at least one guide rail forms an acute battery angle relative to the work plane.   
     
     
         16 . The orbital sander of  claim 15 , wherein the grip portion defines an end face and the battery receptacle includes a battery contact face that is inset from the end face of the grip portion. 
     
     
         17 . The orbital sander of  claim 16 , wherein the end face of the grip portion is spaced a first distance D 1  from the motor axis and the battery contact face is spaced a second distance D 2  from the motor axis that is less than the first distance D 1 . 
     
     
         18 . The orbital sander of  claim 16 , wherein the end face of the grip portion and the battery contact face are parallel to the motor axis and perpendicular to the grip axis. 
     
     
         19 . The orbital sander of  claim 17 , wherein the second distance D 2  is less than or equal to 0.95 times the first distance D 1 , and wherein the second distance D 2  is greater than or equal to 0.6 times the first distance D 1 . 
     
     
         20 . The orbital sander of  claim 15 , wherein the acute battery angle is greater than or equal to two and one-half degrees (2.5°), and wherein the acute battery angle is less than or equal to thirty degrees (30°).