U.S. patent application number 11/015837 was filed with the patent office on 2006-06-22 for millwork sanding sponge.
Invention is credited to Jonathan M. Lise, John G. Petersen, Michael W. Varner.
Application Number | 20060135049 11/015837 |
Document ID | / |
Family ID | 35789018 |
Filed Date | 2006-06-22 |
United States Patent
Application |
20060135049 |
Kind Code |
A1 |
Petersen; John G. ; et
al. |
June 22, 2006 |
Millwork sanding sponge
Abstract
The present invention relates to a hand-held abrasive article.
In one embodiment, the hand-held abrasive article includes an
elongated resilient body having a perpendicular cross-sectional
surface. The cross-sectional surface of the resilient body includes
at least one internal right angle, at least one internal acute
angle, at least one internal obtuse angle, and at least one curved
portion. At least a portion of the resilient body is coated with
abrasive.
Inventors: |
Petersen; John G.; (Center
City, MN) ; Lise; Jonathan M.; (Woodbury, MN)
; Varner; Michael W.; (Woodbury, MN) |
Correspondence
Address: |
3M INNOVATIVE PROPERTIES COMPANY
PO BOX 33427
ST. PAUL
MN
55133-3427
US
|
Family ID: |
35789018 |
Appl. No.: |
11/015837 |
Filed: |
December 16, 2004 |
Current U.S.
Class: |
451/495 |
Current CPC
Class: |
B24D 15/04 20130101 |
Class at
Publication: |
451/495 |
International
Class: |
B24D 17/00 20060101
B24D017/00 |
Claims
1. A hand-held abrasive article comprising: an elongated solid foam
resilient body having a perpendicular cross-sectional surface;
wherein the cross-sectional surface of the resilient body
comprises: at least one internal right angle; at least one internal
acute angle; and at least one internal obtuse angle; and at least
one curved portion; wherein at least a portion of the resilient
body is coated with abrasive.
2. The hand-held abrasive article of claim 1, wherein the cross
sectional surface comprises: a single internal right angle.
3. The hand-held abrasive article of claim 1, wherein the cross
sectional surface comprises: a single internal acute angle.
4. The hand-held abrasive article of claim 1, wherein the cross
sectional surface comprises: a single internal obtuse angle.
5. The hand-held abrasive article of claim 1, wherein the cross
sectional surface comprises; a single internal right angle; a
single internal acute angle; and a single internal obtuse
angle.
6. The hand-held abrasive article of claim 5, wherein the single
internal acute angle is approximately 60 degrees and the single
internal obtuse angle is approximately 120 degrees.
7. The hand-held abrasive article of claim 1, wherein the entire
elongated resilient body is coated with abrasive.
8. The hand-held abrasive article of claim 1, wherein the elongated
resilient body further comprises: a first end; and a second end,
spaced from the first end; wherein the first end and second end are
substantially planar and parallel to one another and perpendicular
to the elongated resilient body.
9. The hand-held abrasive article of claim 1, wherein the elongated
resilient body further comprises: a first planar major surface; a
second planar major surface; a third planar major surface; a fourth
planar major surface; and a curved surface.
10. The hand held abrasive article of claim 9, wherein: the second
planar major surface is contiguous with the first planar major
surface; the third planar major surface is contiguous with the
second planar major surface; the fourth planar major surface is
contiguous with the third planar major surface; the curved surface
is contiguous with the fourth planar major surface and the first
planar major surface.
11. The hand-held abrasive article of claim 10, wherein: the
intersection of the second planar major surface with the first
planar major surface forms the obtuse angle; the intersection of
the third planar major surface with the second planar major surface
forms the right angle; and the intersection of the fourth planar
major surface with the third planar major surface forms the acute
angle.
12. The hand-held abrasive article of claim 11, wherein: a
cross-sectional length of the first planar major surface is at
least about 2 inches; a cross-sectional length of the second planar
major surface is at least about 0.5 inches; a cross-sectional
length of the third planar major surface is at least about 3
inches; a cross-sectional length of the fourth planar major surface
is at least about 2 inches; the curved portion has a radius of
curvature of at least about 0.25 inches; and the elongated
resilient body comprises an overall length from about 2 inches to
about 10 inches.
13. The hand-held abrasive article of claim 1, wherein the
resilient body comprises an open-celled foam material.
14. A hand-held abrasive article comprising: an elongated solid
foam resilient body having a first end surface and a second end
surface: a first planar major surface extending between the first
end surface and second end surface; a second planar major surface
extending between the first end surface and second end surface and
contiguous with the first planar major surface; a third planar
major surface extending between the first end surface and second
end surface and contiguous with the second planar major surface; a
fourth planar major surface extending between the first end surface
and second end surface and contiguous with the third planar major
surface; a curved surface extending between the first end surface
and second end surface and contiguous with the fourth planar major
surface and the first planar major surface; wherein at least one of
the first planar major surface, second planar major surface, third
planar major surface, fourth planar major surface, or curved
surface is abrasive.
15. The hand-held abrasive article of claim 14, wherein the
elongated resilient body has a transverse cross-section comprising:
at least one internal right angle; at least one internal acute
angle; and at least one internal obtuse angle.
16. The hand-held abrasive article of claim 15, wherein: the
intersection of the first planar major surface and the second
planar major surface forms the obtuse angle; the intersection of
the second planar major surface and the third planar major surface
forms the right angle; the intersection of the third major planar
surface and the fourth planar major surface forms the acute
angle.
17. The hand-held abrasive article of claim 16, wherein: the acute
angle is approximately 60 degrees; and the obtuse angle is
approximately 120 degrees.
18. The hand-held abrasive article of claim 14, wherein the
elongated resilient body comprises an open-celled foam
material.
19. The hand-held abrasive article of claim 14, wherein each of the
first planar major surface, second planar major surface, third
planar major surface, fourth planar major surface, and curved
surface is abrasive.
20. A hand-held abrasive article comprising: a solid foam resilient
body having a first end surface and a second end surface; a first
planar major surface extending between the first end surface and
second end surface; a second planar major surface extending between
the first end surface and second end surface; a third planar major
surface extending between the first end surface and second end
surface; a fourth planar major surface extending between the first
end surface and second end surface; a curved surface extending
between the first end surface and second end surface; wherein the
intersection of two of the planar major surfaces form an acute
angle, the intersection of two of the planar major surfaces form an
obtuse angle, and the intersection of two of the planar major
surfaces form a right angle; wherein at least one of the first
planar major surface, second planar major surface, third planar
major surface, fourth planar major surface, and curved surface is
covered with an abrasive material.
21. The hand-held abrasive article of claim 20, wherein: the second
planar major surface is contiguous with the first planar major
surface; the third planar major surface is contiguous with the
second planar major surface; the fourth planar major surface is
contiguous with the third planar major surface; the curved surface
is contiguous with the fourth planar major surface and the first
planar major surface.
22. The hand-held abrasive article of claim 21, wherein: the
intersection of the first planar major surface and the second
planar major surface forms the obtuse angle; the intersection of
the second planar major surface and the third planar major surface
forms the right angle; the intersection of the third major planar
surface and the fourth planar major surface forms the acute
angle.
23. The hand-held abrasive article of claim 22 wherein: the acute
angle is approximately 60 degrees. the obtuse angle is
approximately 120 degrees.
24. The hand-held abrasive article of claim 20, wherein the first
planar major surface, second planar major surface, third planar
major surface, fourth planar major surface, and curved surface is
abrasive.
25. The hand-held abrasive article of claim 20, wherein the
resilient body comprises an open-celled foam material.
Description
BACKGROUND
[0001] The present invention relates to resilient flexible abrasive
devices typically referred to as sanding sponges, and more
particularly, to a hand-held, disposable abrasive article for
sanding a variety of surface shapes and configurations.
[0002] Common sanding tasks calling for considerable detail work or
access to small confined areas, or for sanding contoured surfaces,
often require that the surfaces be hand sanded. Hand-held sanding
devices for this purpose have essentially consisted of a sanding
block for holding conventional sandpaper wrapped over the block. By
using a sanding block as a sandpaper holder, hand-applied sanding
forces on the sandpaper can be increased and more evenly
distributed.
[0003] The difficulty with the above-mentioned prior sanding
devices is the necessity of installing or wrapping a separate piece
of sandpaper around the device. This installation or wrapping
process presents some inconvenience to the user. For example, if
the paper is improperly installed, it is susceptible to falling
off. Also, the device requires the purchase of separate sheets of
sandpaper that is a further inconvenience in terms of the amount of
supplies needed.
[0004] U.S. Pat. No. 4,887,396 (Lukianoff) discloses a hand-sized
sanding device that eliminates the need for a separate sheet of
sandpaper. The sanding device is provided with its own integral
abrasive surfaces that can be manufactured at a sufficiently low
cost to be disposable. The sanding device of Lukianoff can be
conveniently used to hand sand a variety of standard, contoured, or
shaped surfaces, such as trim or molding surfaces, and for
projecting into exactly defined areas.
[0005] Another type of sanding device is the resilient flexible
sanding sponge. Sanding sponges generally include a layer of
abrasive particles adhered to a foam body by a flexible adhesive.
One such sanding sponge is the 3M Small Area Sanding Sponge
available from 3M, St. Paul, Minn. Typically, a user places the
body against the palm of his or her hand and rubs the abrasive over
a surface to be abraded. The flexible adhesive layer and the foam
body permit the layer of abrasive to conform to the surface being
abraded.
[0006] While such sanding sponges work well to abrade objects
having flat surfaces these sponges are not well suited to sand a
variety of contoured surfaces because the foam body and/or the
layer of flexible adhesive is too stiff to conform to the contoured
surface being abraded. A sanding sponge with high tear strength
body layer is disclosed in U.S. Pat. No. 6,419,573 (Lise et
al.).
[0007] Sanding sponges often only have a projecting right angle to
sand perpendicular corners, and typically do not have a variety of
projecting angles and curves. It may be necessary to sand surfaces
that have contours other than a perpendicular corner. Especially
when sanding millwork, it is often necessary to sand a variety of
contoured surfaces.
SUMMARY
[0008] The present invention relates to a hand-held abrasive
article. In one embodiment, the hand-held abrasive article includes
an elongated resilient body having a perpendicular cross-sectional
surface. The cross-sectional surface of the resilient body includes
at least one internal right angle, at least one internal acute
angle, at least one internal obtuse angle, and at least one curved
portion. At least a portion of the resilient body is coated with an
abrasive.
[0009] In another embodiment, the hand-held abrasive article
includes an elongated resilient body having a first end surface and
a second end surface. The hand-held abrasive article further
includes a first planar major surface, a second planar major
surface contiguous with the first planar major surface, a third
planar major surface contiguous with the second planar major
surface, a fourth planar major surface contiguous with the third
planar major surface, and a curved surface contiguous with the
fourth planar major surface and the first planar major surface.
Each major surface and the curved surface extend between the first
end surface and second end surface. At least one of the first
planar major surface, second planar major surface, third planar
major surface, fourth planar major surface, or curved surface is
abrasive.
[0010] In another embodiment, the hand-held abrasive article
includes a resilient body having a first end surface and a second
end surface. The hand-held abrasive article further includes a
first planar major surface, a second planar major surface, a third
planar major surface, a fourth planar major surface, and a curved
surface. Each major surface and the curved surface extend between
the first end surface and second end surface. The intersection of
two of the planar major surfaces form an acute angle, the
intersection of two of the planar major surfaces form an obtuse
angle, and the intersection of two of the planar major surfaces
form a right angle. At least one of the first planar major surface,
second planar major surface, third planar major surface, fourth
planar major surface, or curved surface is covered with an abrasive
material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of a first embodiment of an
abrasive article according to the present invention.
[0012] FIG. 2 is a sectional view through line 2-2 of the abrasive
article of FIG. 1.
[0013] FIG. 3 is a sectional view of a second embodiment of an
abrasive article according to the present invention.
[0014] FIG. 4 is a sectional view of a third embodiment of an
abrasive article according to the present invention.
[0015] While the above-identified drawings and figures set forth
one embodiment of the invention, other embodiments are also
contemplated, as noted in the discussion. In all cases, this
disclosure presents the invention by way of representation and not
limitation. It should be understood that numerous other
modifications and embodiments can be devised by those skilled in
the art, which fall within the scope and spirit of this invention.
The figures may not be drawn to scale. Like reference numbers,
incremented by 100, have been used to denote like parts.
DETAILED DESCRIPTION
[0016] FIGS. 1 and 2 illustrate the first embodiment of a resilient
flexible sanding sponge 20 according to the present invention. The
sanding sponge 20 includes a resilient body 22. The body 22 may be
an open celled foam material.
[0017] The body 22 is generally elongated along a longitudinal axis
with a first end surface 28 and a second end surface 30. As shown
in FIG. 1, the first and second end surfaces 28, 30 are generally
planar and parallel to one another. However, the first and second
end surface 28, 30 may be non-planar and formed at any angle
relative to the body 22.
[0018] The body 22 includes a first major surface 32, second major
surface 34, third major surface 36, fourth major surface 38, and
curved surface 40. As shown in FIG. 1, the first major surface 32,
second major surface 34, third major surface 36, fourth major
surface 38 are all generally planar and extend from the first end
surface 28 to the second end surface 30. The first end surface 28
and second end surface 30 are generally perpendicular to the major
surfaces. The first major surface 32 is contiguous with the second
major surface 34. The second major surface 34 is contiguous with
the third major surface 36. The third major surface 36 is
contiguous with the fourth major surface 38.
[0019] The curved surface 40 is contiguous with both the fourth
major surface 38 and the first major surface 32. The curved surface
40 also extends from the first end surface 28 to the second end
surface 30.
[0020] FIG. 2 is a sectional view through line 2-2 of the sanding
sponge 20 of FIG. 1. At the cross-section of the body 22, the
sanding sponge 20 includes an obtuse angle 42, a right angle 44, an
acute angle 46, and a curved portion 48. As shown in this
embodiment, the sanding sponge 20 includes only one, or a single
obtuse angle 42, a single right angle 44, and a single acute angle
46. Each internal angle 42, 44, and 46 is a measurement of the
angle through the internal structure of the body 22, between the
meeting of two generally planar major surfaces.
[0021] In the embodiment shown in FIGS. 1 and 2, the first major
surface 32 and second major surface 34 meet to form the obtuse
angle 42. The second major surface 34 and third major surface 36
meet to form the right angle 44. The third major surface 36 and
fourth major surface 38 meet to form the acute angle 46.
[0022] The curved portion 48 corresponds to the curved surface 40
and is therefore adjacent and continuous with the first major
surface 32 and fourth major surface 38. The curved portion 48
includes a radius of curvature 50.
[0023] A flexible adhesive 24 is used to adhere a layer of abrasive
particles 26 to at least a portion of the body 22. The layer of
abrasive particles 26 is shown in FIG. 1 as being adhered to the
first major surface 32, second major surface 34, third major
surface 36, fourth major surface 38, and curved surface 40. As
shown in FIG. 1, the abrasive particles 26 are not adhered to the
first end surface 28 and second end surface 30. The abrasive
particles 26 may be adhered to only a portion of the body 22, or
the abrasive particles 26 may be adhered to the entire body 22.
[0024] The flexible adhesive 24 bonds the layer of abrasive
particles 26 to the body 22 and adheres the abrasive particles 26
together while being sufficiently flexible to conform with the body
22 to the contour of the surface to be abraded by the sanding
sponge 20. A flexible adhesive formulation and method of applying
it is described in U.S. Pat. No. 6,059,850, herein incorporated by
reference, which can be used to form the layer of flexible adhesive
24.
[0025] A layer of hard anti-loading size coating can optionally
extend over the flexible adhesive 24 and the abrasive particles 26
opposite the body 22. A hard anti-loading size coating formulated
and applied using the method described in U.S. Pat. No. 6,059,850,
herein incorporated by reference, is suitable for this purpose.
[0026] The body 22 may be constructed of open-cell polyurethane
foam. One suitable open-cell polyurethane foam is 0H58K Foam
available from Carpenter Co. of Richmond, Va. In some embodiments,
the body 22 may be constructed from high tear strength felted
urethane foam. Further description of suitable body materials can
be found in U.S. Pat. Application Publication 20040038634, herein
incorporated by reference.
[0027] The abrasive particles 26 may be any of the abrasive
particles described in U.S. Pat. No. 6,059,850, herein incorporated
by reference, particularly including particles of aluminum oxide,
ceramic, or silicon carbide in the range of about 36 to 400
grit.
[0028] Sanding sponges are typically made by coating a liquid
adhesive over one or more surfaces of the body 22, depositing a
layer of the abrasive particles 26 on the adhesive coated surface
of the body 22, and then drying the flexible adhesive 24. Further
description of the flexible adhesive and coating process is
described in U.S. Patent Application 20040038634, which is herein
incorporated by reference.
[0029] The user can hold any portion of the sanding sponge 20 that
allows for using the necessary exterior projecting portion of the
sanding sponge 20 to contact the work surface. The body 22
preferably has a cross section of such a size that fits comfortably
into the palm of a user's hand. The cross sectional dimensions of
the body 22 preferably are such that the fingers of the user's hand
will not reach around or beyond the body 22 and thereby greatly
reduce the chances of the user experiencing discomfort in moving
the sanding sponge 20 back and forth in use.
[0030] In one embodiment, at the cross-sectional dimension, the
first major surface 32 has a length of approximately 2.0 to 2.5
inches, preferably about 2.2 inches, the second major surface 34
has a length of approximately 0.5 to 1.5 inches, preferably about
1.0 inches, the third major surface 36 has a length of
approximately 3 to 4 inches, preferably about 3.5 inches, and the
fourth major surface 38 has a length of approximately 2.0 to 2.5
inches, preferably about 2.2 inches.
[0031] In one embodiment, the obtuse angle is approximately 120
degrees, the acute angle is approximately 60 degrees, and the
curved portion 48 has a radius of curvature of approximately 0.25
to 0.5 inches, preferably 0.375 inches.
[0032] The body 22 is preferably resiliently deformable (i.e.,
indentable) when squeezed by the thumb and fingers of the user's
hand and thus is not likely to slip from the hand even if the
fingers are wet or greasy. The body 22 is somewhat resiliently
axially compressible and acts as a cushion between the user's hand
and the work surface as the sanding sponge 20 is being pushed back
and forth to perform the abrading function.
[0033] In one embodiment, at least one of the first major surface
32, second major surface 34, third major surface 36, fourth major
surface 38, and curved surface 40 may be a structured surface.
Structured surfaces are disclosed and described in U.S. Pat.
Application "Resilient Structured Sanding Article," which is 3M
file number 59662US002, filed on even dated, the disclosure of
which is herein incorporated by reference.
[0034] FIG. 3 illustrates a cross sectional view of a second
embodiment of a resilient flexible sanding sponge 120 according to
the present invention. The sanding sponge 120 includes a body 122.
The body 122 may be an open-celled foam material.
[0035] The body 122 is generally an elongated along a longitudinal
axis, similar to that shown in FIG. 1, with a first end surface and
a second end surface. The first and second end surfaces are
generally planar and parallel to one another.
[0036] The body 122 includes a first major surface 132, second
major surface 134, third major surface 136, fourth major surface
138, and curved surface 140. The first major surface 132, second
major surface 134, third major surface 136, fourth major surface
138 are all generally planar and extend from the first end surface
to the second end surface. The first end surface and second end
surface are generally perpendicular to the major surfaces. The
first major surface 132 is contiguous with the second major surface
134. The second major surface 134 is contiguous with the third
major surface 136. The third major surface 136 is contiguous with
the fourth major surface 138. The curved surface 140 is contiguous
with both the fourth major surface 138 and the first major surface
132.
[0037] At the cross-section of the body 122, the sanding sponge 120
includes an obtuse angle 142, a right angle 144, an acute angle
146, and a curved portion 148. Each internal angle 142, 144, and
146 is a measurement of the angle through the internal structure of
the body 122 between the meeting of two generally planar major
surfaces.
[0038] In the embodiment shown in FIG. 3, the first major surface
132 and second major surface 134 meet to form the right angle 144.
The second major surface 134 and third major surface 136 meet to
form the acute angle 146. The third major surface 136 and fourth
major surface 138 meet to form the obtuse angle 142. The curved
portion 148 corresponds to the curved surface 140 and is therefore
adjacent and continuous with the first major surface 132 and fourth
major surface 138. The curved portion 148 includes a radius of
curvature 150.
[0039] A flexible adhesive 124 is used to adhere a layer of
abrasive particles 126 to at least a portion of the body 122. The
layer of abrasive particles 126 is shown in FIG. 3 as being adhered
to the first major surface 132, second major surface 134, third
major surface 136, fourth major surface 138, and curved surface
140. In one embodiment, at least one of the first major surface
132, second major surface 134, third major surface 136, fourth
major surface 138, and curved surface 140 may be a structured
surface.
[0040] FIG. 4 illustrates a cross sectional view of a third
embodiment of a resilient flexible sanding sponge 220 according to
the present invention. The sanding sponge 220 includes a body 222.
The body 222 may be an open-celled foam material.
[0041] The body 222 is generally an elongated along a longitudinal
axis, similar to that shown in FIG. 1, with a first end surface and
a second end surface. The first and second end surfaces are
generally planar and parallel to one another.
[0042] The body 222 includes a first major surface 232, second
major surface 234, third major surface 236, fourth major surface
238, and curved surface 240. The first major surface 232, second
major surface 234, third major surface 236, fourth major surface
238 are all generally planar and extend from the first end surface
to the second end surface. The first end surface and second end
surface are generally perpendicular to the major surfaces. The
first major surface 232 is contiguous with the second major surface
234. The second major surface 234 is contiguous with the third
major surface 236. The third major surface 236 is contiguous with
the fourth major surface 238. The curved surface 240 is contiguous
with both the fourth major surface 238 and the first major surface
232.
[0043] At the cross-section of the body 222, the sanding sponge 220
includes an obtuse angle 242, a right angle 244, an acute angle
246, and a curved portion 248. Each internal angle 242, 244, and
246 is a measurement of the angle through the internal structure of
the body 222 and between the meeting of two generally planar major
surface.
[0044] In the embodiment shown in FIG. 4, the first major surface
232 and second major surface 234 meet to form the right angle 244.
The second major surface 234 and third major surface 236 meet to
form the obtuse angle 242. The third major surface 236 and fourth
major surface 238 meet to form the acute angle 246.
[0045] The curved portion 248 corresponds to the curved surface 240
and is therefore adjacent and continuous with the first major
surface 232 and fourth major surface 238. The curved portion 248
includes a radius of curvature 250.
[0046] A flexible adhesive 224 is used to adhere a layer of
abrasive particles 226 to at least a portion of the body 222. The
layer of abrasive particles 226 is shown in FIG. 4 as being adhered
the first major surface 232, second major surface 234, third major
surface 236, fourth major surface 238, and curved surface 240. The
abrasive particles 226 are not adhered to the first end surface and
second end surface. However, the abrasive particles may be adhered
to the entire body 222 or only a portion of the body 222. In one
embodiment, at least one of the first major surface 232, second
major surface 234, third major surface 236, fourth major surface
238, and curved surface 240 may be a structured surface.
[0047] Although specific embodiments of this invention have been
shown and described herein, it is understood that these embodiments
are merely illustrative of the many possible specific arrangements
that can be devised in application of the principles of the
invention. Numerous and varied other arrangements can be devised in
accordance with these principles by those of ordinary skill in the
art without departing from the spirit and scope of the invention.
Thus, the scope of the present invention should not be limited to
the structures described in this application, but only by the
structures described by the language of the claims and the
equivalents of those structures.
* * * * *