U.S. patent application number 12/037448 was filed with the patent office on 2008-08-28 for resilient abrasive article and method of manufacture.
Invention is credited to John E. Brown.
Application Number | 20080207099 12/037448 |
Document ID | / |
Family ID | 39716435 |
Filed Date | 2008-08-28 |
United States Patent
Application |
20080207099 |
Kind Code |
A1 |
Brown; John E. |
August 28, 2008 |
RESILIENT ABRASIVE ARTICLE AND METHOD OF MANUFACTURE
Abstract
The present invention provides a resilient hand-held abrasive
article comprising a flexible and/or conformable grip comprising a
top surface, a bottom surface and individual small high-grip pads
attached to each other in a pattern that leaves voids therebetween,
the individual small high-grip pads comprising a top and a bottom.
The top surface of a sanding article is attached, and in certain
embodiments removably attached, to the bottom of the high-grip pads
and a bottom surface having abrasive particles coated thereon. In
certain embodiments, the flexible and/or conformable grip may not
comprise voids.
Inventors: |
Brown; John E.; (Andover,
MN) |
Correspondence
Address: |
Altera Law Group, LLC
220 S 6 St Suite 1700
Minneapolis
MN
55402
US
|
Family ID: |
39716435 |
Appl. No.: |
12/037448 |
Filed: |
February 26, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60903984 |
Feb 28, 2007 |
|
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Current U.S.
Class: |
451/524 ;
451/456; 51/297 |
Current CPC
Class: |
B24D 15/00 20130101;
B24D 9/003 20130101 |
Class at
Publication: |
451/524 ; 51/297;
451/456 |
International
Class: |
B24D 15/04 20060101
B24D015/04; B24D 18/00 20060101 B24D018/00; B24B 55/06 20060101
B24B055/06; B24D 11/00 20060101 B24D011/00 |
Claims
1. A hand-held abrasive article, comprising: a flexible grip
comprising a top surface, a bottom surface and individual small
high-grip pads attached to each other in a pattern that leaves
voids therebetween, the individual small high-grip pads comprising
a top and a bottom; a sanding article having a top surface attached
to the bottom of the high-grip pads and a bottom surface having
abrasive particles coated thereon.
2. The hand-held abrasive article of claim 1, wherein the sanding
article comprises a sanding sponge.
3. The hand held abrasive article of claim 1, wherein the sanding
article comprises an abrasive sheet.
4. The hand-held abrasive article of claim 1, wherein the top of
the high-grip pads are convex.
5. The hand-held abrasive article of claim 1, wherein the bottom of
the high-grip pads are substantially flat.
6. The hand-held abrasive article of claim 1, wherein the high-grip
pads are substantially uniform in size and shape.
7. The hand-held abrasive article of claim 1, wherein the high-grip
pads comprise a foam material.
8. The hand-held abrasive article of claim 1, wherein the flexible
grip is substantially without voids.
9. A resilient, hand-held abrasive article, comprising: (a) a
flexible conformable backing layer having opposed first and second
major surfaces, the backing layer comprising a multiplicity of
separated resilient bodies connected to each other in an array that
provides open spaces between adjacent connected bodies, each body
having a first surface and an opposite second surface; and (b) a
flexible reinforcing layer having a first major surface affixed to
the first surface of the separated resilient bodies, and a second
opposed major surface having abrasive particles arranged thereon,
thereby defining an abrasive surface.
10. The abrasive article of claim 9, wherein each of the resilient
bodies has a size and shape that is substantially uniform.
11. The abrasive article of claim 9, wherein the flexible
reinforcing layer is an abrasive sheet.
12. The abrasive article of claim 9, wherein the flexible
reinforcing layer is a continuous film.
13. The abrasive article of claim 10, wherein the first surface of
each resilient body is dome-shaped.
14. The abrasive article of claim 13, wherein the resilient bodies
comprise a foam material.
15. A method for manufacturing a resilient hand-held abrasive
article, comprising: providing a flexible conformable backing layer
having opposed first and second major surfaces, the backing layer
comprising a multiplicity of separated resilient bodies connect to
each other in an array that provides open spaces between adjacent
connected bodies, each body having a first surface and an opposite
second surface; providing a flexible reinforcing layer having a
first major surface and a second opposed major surface; fixedly
attaching the first major surface of the flexible reinforcing layer
to the first surface of the separated resilient bodies; and coating
the second major surface of the flexible reinforcing layer with
abrasive particles.
16. The method of claim 15, wherein the flexible reinforcing layer
comprises a sanding sponge.
17. The method of claim 15 wherein the flexible reinforcing layer
comprises an abrasive sheet.
18. The method of claim 15, further comprising providing the
separated resilient bodies with convex top surfaces.
19. The method of claim 15, further comprising providing the
separated resilient bodies with substantially flat bottom
surfaces.
20. The method of claim 15, further comprising irremovably
attaching the first major surface of the flexible reinforcing layer
to the first surface of the separated resilient bodies.
21. A hand-held abrasive article, comprising: a flexible grip
comprising a top surface, a bottom surface and individual small
high-grip pads attached to each other in a pattern that leaves
voids therebetween, the individual small high-grip pads comprising
a top and a bottom; a sanding article having a top surface that is
irremovably attached to the bottom of the high-grip pads and a
bottom surface coated with abrasive particles.
22. The hand-held abrasive article of claim 21, wherein the sanding
article comprises a sanding sponge.
23. The hand-held abrasive article of claim 21, wherein the sanding
article comprises an abrasive sheet.
24. The hand-held abrasive article of claim 21, further comprising
pressure sensitive adhesive on the bottom of the high-grip pads and
a removable liner thereon, wherein removal of the liner exposes the
pressure sensitive adhesive to which the top surface of the sanding
article may then be affixed.
25. The hand-held abrasive article of claim 21, further comprising
one part of a hook and loop attachment system attached to the
bottom of the high-grip pads and a second part of the hook and loop
attachment system attached to the top surface of the sanding
article.
26. The hand-held abrasive article of claim 21, further comprising
the sanding article being disk-shaped.
27. The hand-held abrasive article of claim 21, wherein the top of
the high-grip pads are convex.
28. The hand-held abrasive article of claim 21, wherein the bottom
of the high-grip pads are substantially flat.
29. The hand-held abrasive article of claim 21, wherein the
high-grip pads are substantially uniform in size and shape.
30. The hand-held abrasive article of claim 21, wherein the
high-grip pads comprise a foam material.
31. An improved sanding block comprising: a sanding sponge having a
plurality of exterior surfaces, including one abrasive first major
surface and one second major surface and side surfaces and abrasive
material coated onto at least the one abrasive first major surface;
and apertures that extend from the one abrasive first major surface
to the one second major surface.
32. A sanding system comprising: a sanding sponge having a
plurality of exterior surfaces, including an abrasive first major
surface and a second major surface and side surfaces and abrasive
material coated onto at least the abrasive first major surface; a
multiplicity of apertures that extend from the abrasive first major
surface to the second major surface, wherein the flexible resilient
core is configure and arranged to be operatively connected to a
suction device; and a holder configured and arranged to hold the
sanding sponge, the holder being configured and arranged to be
operatively connected to a suction device.
Description
RELATED APPLICATIONS
[0001] This application claims benefit to provisional application
Ser. No. 60/903,984 filed on Feb. 28, 2007 which is hereby
incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to abrasive articles for
abrading a work surface and, more particularly, to resilient
abrasive articles.
[0004] 2. Description of the Related Art
[0005] Hand-held abrasive articles are used in a variety of sanding
operations. The user generally holds the abrasive article in his or
her hand, moving the abrasive article across the surface to be
sanded. Difficulties may arise if the abrasive article does not
provide necessary and sufficient ergonomic accommodations.
[0006] U.S. Pat. No. 6,613,113 to Minick discloses a flexible
abrasive product comprising a flexible sheet-like substrate
comprising a multiplicity of separated resilient bodies connected
to each other in a generally planar array in a pattern that
provides open spaces between adjacent connected bodies. Abrasive
particles are provided on one surface of this product. Such an
arrangement, however, results in premature degradation of the sheet
like substrate due to the forces experienced during use.
[0007] The present invention addresses, inter alia, these listed
deficiencies in the known devices.
[0008] Sanding sponges are also known in the art wherein a
resilient flexible foam material is coated with abrasive particles
providing an abrasive surface on the sanding sponge. Wherein
sanding sponges are in a sheet like form having only one side
coated with abrasive particles, a problem exists in that the
opposite side of the sanding sponge which is gripped by the hand
may be slippery when grasped. In particular this problem exists
when the friction between the abrasive particles and the work
surface is significantly greater than the friction between the hand
and the back of the sanding sponge where it is gripped. This
problem also exists with common sheets of abrasive such as
sandpaper or cloth backed abrasive sheets wherein the cloth or the
paper backing slips off the hand rather than grips the hand when
abrading a surface. The present invention addresses this problem by
providing a grip to the backing of a sanding sponge or an abrasive
sheet. The grip increases the friction between the hand and the
abrasive sheet or sanding sponge thereby reducing the chance of the
abrasive sheet slipping off the hand when abrading. As is well
known by those who use hand held abrasive articles, a degree of
energy is exerted not only in the force applied to an abrasive
article but also a force applied in grasping the abrasive article
so that it will not slip off the hand when abrading. For example
many people grasp a portion of the abrasive sheet between the thumb
and the index finger while abrading thereby preventing the abrasive
sheet from slipping off the hand. It is one of the objects of the
present invention to provide a grip to an abrasive product thereby
reducing the chance of slippage from the hand and reducing the
amount of work or energy expended while abrading. In many
applications it is not necessary to grasp the abrasive sheet
between the thumb and index finger when a grip is applied to the
backing of the abrasive sheet. The grip provides a more ergonomic
abrasive article as well as a flexible resilient backing layer.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention provides a resilient hand-held
abrasive article comprising a flexible and/or conformable grip
comprising a top surface, a bottom surface and individual small
high-grip pads attached to each other in a pattern that leaves
voids therebetween, the individual small high-grip pads comprising
a top and a bottom. The top surface of a sanding article is
attached, and in certain embodiments removably attached, to the
bottom of the high-grip pads and a bottom surface having abrasive
particles coated thereon. In certain embodiments, the flexible
and/or conformable grip may not comprise voids.
[0010] An object of the invention is to provide a flexible, and in
certain embodiments a resilient, article and method of
manufacturing same that provides for a high-grip abrasive device
that is ergonomically comfortable for the user and that is not
damaged during normal use.
[0011] The figures and the detailed description which follow more
particularly exemplify these and other embodiments of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention may be more completely understood in
consideration of the following detailed description of various
embodiments of the invention in connection with the accompanying
drawings, which are as follows.
[0013] FIG. 1 is a perspective view of one embodiment of a
resilient sanding block.
[0014] FIG. 2 is a perspective view of another embodiment of a
resilient sanding block.
[0015] FIG. 3 is a perspective view of yet another embodiment of a
resilient sanding block.
[0016] FIG. 4 is a perspective view of one embodiment of a corner
sanding sponge.
[0017] FIG. 5 is a perspective view another embodiment of corner
sanding sponge of FIG. 4
[0018] FIG. 6 is a perspective view of yet another embodiment of
the corner sanding sponge of FIG. 4
[0019] FIG. 7 is a perspective view of another embodiment of the
corner sanding sponge of FIG. 4
[0020] FIG. 8 is a side view of the corner sanding sponge of FIG.
7
[0021] FIG. 9 is a perspective view of another embodiment of the
corner sanding sponge of FIG. 4.
[0022] FIG. 10 is a side view of the corner sanding sponge of FIG.
9
[0023] FIG. 11 is a perspective view of another embodiment of the
corner sanding sponge of FIG. 4
[0024] FIG. 12 is a perspective view of yet another embodiment of
the corner sanding sponge of FIG. 4.
[0025] FIG. 13 is a perspective view of another embodiment of the
corner sanding sponge of FIG. 4 having attachable handles.
[0026] FIG. 14 is a perspective view of another embodiment of the
corner sanding sponge of FIG. 4
[0027] FIG. 15 is a side view of the sanding sponge of FIG. 14
[0028] FIG. 16 is a perspective view of corner sanding sponge with
holder
[0029] FIG. 17 is a perspective view of another embodiment of a
corner sanding sponge with holder.
[0030] FIG. 18 is perspective view of a corner sanding sponge
[0031] FIG. 19 is a side view of the corner sanding sponge of FIG.
18
[0032] FIG. 20 is a perspective view of another embodiment of the
corner sanding sponge of FIG. 18.
[0033] FIG. 21 is a side view of the corner sanding sponge of FIG.
22.
[0034] FIG. 22 is a side view of an embodiment of the corner
sanding sponge of FIG. 18.
[0035] FIG. 23 is a side view of another embodiment of the corner
sanding sponge of FIG. 22.
[0036] FIG. 24 is a perspective view of a holder for the corners
sanding sponge of FIG. 26
[0037] FIG. 25 is an end view of the holder of FIG. 24
[0038] FIG. 26 is a perspective view of another embodiment of the
corner sanding sponge of FIG. 18.
[0039] FIG. 27 is a perspective view of a holder for the corner
sanding sponge of FIG. 29.
[0040] FIG. 28 is an end view of the holder of FIG. 27.
[0041] FIG. 29 is a perspective view of another embodiment of the
corner sanding sponge of FIG. 18.
[0042] FIG. 30 is a perspective view of a holder for the corner
sanding sponge of FIG. 31
[0043] FIG. 31 is a perspective view of another embodiment of the
corner sanding sponge of FIG. 18.
[0044] FIG. 32 is an inverted overhead perspective view of the
holder of FIG. 30
[0045] FIG. 33 is an end view of the holder of FIG. 30
[0046] FIG. 34 is a perspective view of an embodiment of the holder
of FIG. 24 and the sanding sponge of FIG. 31.
[0047] FIG. 35 is a perspective view of the holder of FIG. 30.
[0048] FIG. 36 is a perspective view of the corner sanding sponge
of FIG. 31.
[0049] FIG. 37 is an inverted overhead perspective view of the
holder of FIG. 37.
[0050] FIG. 38 is a side view of the holder of FIG. 35.
[0051] FIG. 39 is a front view of the end cap of FIG. 38.
[0052] FIG. 40 is a perspective view of a corner sanding sponge of
a dustless sanding system.
[0053] FIG. 41 is a side view of the corner sanding sponge of FIG.
40
[0054] FIG. 42 is a perspective view of a handle of a dustless
sanding system.
[0055] FIG. 43 is a side view of the handle of FIG. 42.
[0056] FIG. 44 is a perspective view of a holder of a dustless
sanding system for a corner sanding sponge.
[0057] FIG. 45 is a side view of the holder of FIG. 44.
[0058] FIG. 46 is a perspective view of a holder of a dustless
sanding system.
[0059] FIG. 47 is a side view of a the holder of FIG. 46.
[0060] FIG. 48 is a perspective bottom view of a resilient sanding
block of a dustless sanding system.
[0061] FIG. 49 is perspective view of a handle of a dustless
sanding system.
[0062] FIG. 50 is a perspective view of a resilient sanding
block
[0063] FIG. 51 is a side view of a drywall corner sanding tool.
[0064] FIG. 52 is an end view of the corner sanding tool of FIG.
51.
[0065] FIG. 53 is a perspective exploded view of a drum sanding
tool.
[0066] FIG. 54 is a perspective view of a flap of the drum sanding
tool of FIG. 53.
[0067] FIG. 55 is a perspective view of an embodiment of the
resilient sanding block of FIG. 1.
[0068] FIG. 56 is an exploded side view of the sanding block of
FIG. 55 showing an attachable abrasive sheet.
[0069] FIG. 57 is a side view of the resilient sanding block of
FIG. 55.
[0070] FIG. 58 is a perspective view of an embodiment of the
resilient sanding block of FIG. 55.
[0071] FIG. 59 is a top plan view of an abrasive sheet used in
conjunction with the sanding block of FIG. 58.
[0072] FIG. 60 is a perspective view of the sanding block of FIG.
58 having an abrasive sheet attached.
[0073] FIG. 61 is a side view of the holder of FIG. 62
[0074] FIG. 62 is a holder of a sanding block of a dustless sanding
system.
[0075] FIG. 63 is a side view of the flexible sanding pad of FIG.
64.
[0076] FIG. 64 is a top plan view of a flexible sanding pad.
[0077] FIG. 65 is a perspective view of a resilient sanding block
of a dustless sanding system.
[0078] FIG. 66 is a perspective view of another resilient sanding
block of a dustless sanding system.
[0079] FIG. 67 is a perspective view of an embodiment of the
resilient sanding block of FIG. 66.
[0080] FIG. 68 is a side view of the resilient sanding block of
FIG. 67.
[0081] FIG. 69 is a top plan view of an abrasive article of a
dustless sanding system.
[0082] FIG. 70 is a side view of the abrasive article of FIG.
69.
[0083] FIG. 71 is an embodiment of the resilient sanding block of
FIG. 1.
[0084] FIG. 72 is a top plan view of the resilient sanding block of
FIG. 71.
[0085] FIG. 73 is an end view of the resilient sanding block of
FIGS. 71 and 72.
[0086] FIG. 74 is a perspective view of another embodiment of the
resilient sanding block of FIG. 1.
[0087] FIG. 75 is a side view of a vacuum attachment device of the
resilient sanding block of FIG. 1.
[0088] FIG. 76 is a top view of the vacuum attachment device of
FIG. 75.
[0089] FIG. 77 is an exploded perspective view of a resilient
sanding block of a dustless sanding system.
[0090] FIG. 78 is a bottom view of the resilient sanding block of
FIG. 77.
[0091] FIG. 79 is a perspective view of a resilient sanding block
of a dustless sanding system.
[0092] FIG. 80 is a bottom view of the resilient sanding block of
FIG. 79.
[0093] FIG. 81 is a bottom view of the resilient sanding block of
FIG. 79 with an abrasive sheet attached.
[0094] FIG. 82 is a perspective view of a vacuum attachment device
for a the resilient sanding block of FIG. 79.
[0095] FIG. 83 is a perspective view of another embodiment of the
vacuum attachment device of FIG. 82.
[0096] FIG. 84 is an end view of the vacuum attachment device of
FIG. 83.
[0097] FIG. 85 shows a perspective view of a sanding block of a
dustless sanding system.
[0098] FIG. 86 shows a perspective view of another sanding block of
a dustless sanding system.
[0099] FIG. 87 shows a perspective view of a sanding pad.
[0100] FIG. 88 shows a side view of the sanding pad of FIG. 87.
[0101] FIG. 89 shows cross sectional view of another sanding
pad.
[0102] FIG. 90 shows cross sectional view of yet another sanding
pad.
[0103] FIG. 91 shows a cross sectional view of an embodiment of the
sanding pad of FIG. 89.
[0104] FIG. 92 shows a cross sectional view of another embodiment
of the sanding pad of FIG. 89.
[0105] FIG. 93 shows a cross sectional view of an embodiment of the
sanding pad of FIG. 90.
[0106] FIG. 94 shows a circular shaped sanding pad.
[0107] FIG. 95 shows a cross sectional view of another embodiment
of the sanding pad of FIG. 90.
[0108] FIG. 96 shows a cross sectional view of another embodiment
of the sanding pad of FIG. 90.
DETAILED DESCRIPTION OF THE INVENTION, INCLUDING THE BEST MODE
[0109] While the invention is amenable to various modifications and
alternative forms, specifics thereof are shown by way of example in
the drawings and described in detail herein. It should be
understood, however, that the intention is not to limit the
invention to the particular embodiments described. On the contrary,
the intention is to cover all modifications, equivalents, and
alternatives falling within the spirit and scope of the
invention.
[0110] FIG. 1 illustrates a tool comprising a sanding sponge 10
having vacuum channels 14 in a grid form recessed into the large
flat surface 15 or surfaces of the sanding sponge. The sponge 10 is
of a type known to the skilled artisan and is commonly used for
sanding wood or drywall. The sponge is typically made of a
resilient material such as urethane foam or foam rubber or sponge
but should not be limited to only these materials and should
include all materials having a resilience including, e.g., rubber
and plastic. The sponge has an abrasive coated on its outer
surfaces. A center vacuum hole 12 is located in the sponge's center
and extends through the thickness of the sponge from one surface to
the apposing surface. Vacuum channels 14 are cut or molded into the
sponge and connect to each other by means of intersecting with each
other and intersecting with the center vacuum hole or aperture 12.
Vacuum is channeled to the center vacuum hole or aperture by means
of a vacuum hose having a nozzle at the end of it that inserts into
the center vacuum hole 12 thereby transferring the vacuum to the
vacuum grooves 14 in the sponge. Vacuum may also be directed to the
center vacuum hole by means of a sponge holding device having a
vacuum channel that directs the vacuum to the sponge.
[0111] Vacuum channels may be molded or cut into the sponge and are
recessed just below the surface of the sponge to allow air to be
sucked into the vacuum grooves 14 from outside the sponge and into
the center vacuum hole 12. The air bringing the dust with it then
travels through the sponge holder device and into the vacuum hose
and into the vacuum cleaner or suction source.
[0112] The channel or groove pattern or grid consists of eight
grooves in the embodiment shown, each approximately 1/8 inch wide
by 1/8 inch deep. These dimensions are approximations and those
skilled in the art will recognize other dimensions that are well
within the scope and spirit of the present invention. The channels
or grooves are in the largest rectangular portion or portions of
the sanding sponge which may be referred to as the top and bottom
surfaces, respectively, or alternatively and equivalently, the
first major and second major surfaces.
[0113] FIG. 1 shows the top, or first major surface, with a vacuum
groove or grid pattern having eight vacuum grooves or channels 14
that make up a vacuum grid pattern. Three grooves or channels
extend the length of the sponge and are recessed below the top
surface. The two outer grooves are positioned approximately 1/8
inch from the edge or sides of the sponge in the illustrated
embodiment. The middle groove is centered between the two outer
grooves and intersects with the center vacuum hole or aperture 12
thereby connecting the grooves or channels to the center vacuum
hole or aperture.
[0114] Two diagonal grooves or channels extend from corner to
corner creating a cross-cross or "X" formation. The two diagonal
grooves or channels also intersect with the center vacuum hole or
aperture 12 thereby connecting the diagonal grooves or channels to
the center vacuum hole or aperture 12.
[0115] The groove or channel pattern allows all grooves or channels
to be interconnected with each other and with the center vacuum
hole or aperture 12 thereby creating a means for the vacuum suction
to be distributed in all vacuum grooves or channels by means of a
single center vacuum hole or aperture 12. Those skilled in the art
will recognize that the illustrated channel grid pattern is
exemplary only and any grip pattern that serves the purpose of
collecting dust while abrading a surface is within the scope of the
present invention.
[0116] Moreover, the sponge should not be limited in the number of
sides coated with abrasive particles. For example, the top and/or
the bottom surfaces, alternatively stated the first and/or second
major surfaces, may comprise abrasive coating. In alternate
embodiments, the side surface(s) may also comprise abrasive
coating.
[0117] It is understood that any combination of sides with or
without abrasive coating or with or without a vacuum grid may be
included in the scope of the invention and the present invention
should not be limited in scope by excluding any such
combination.
[0118] By way of example, FIG. 2 illustrates a sanding sponge
having independent vacuum holes or apertures that are offset and
with one or more surfaces having abrasive coating thereon, e.g.,
the top and/or bottom, i.e., the first major and/or second major
surfaces. Each hole or aperture extends through the sanding
sponge's two large flat surfaces, i.e., the top and bottom
surfaces, alternatively and equivalently stated the first and
second major surfaces, and through the sponge's thickness. This
sanding sponge configuration may be used with commonly known
sanding sponge holders in operative communication or connection
with a vacuum source. In certain embodiments, the known sponge
holder comprises a backing plate as is well known to the skilled
artisan. This known configuration may be modified to comprise a
ridged screen as is well known in the art in replacement of the
known backing plate to assist in distributing the vacuum's air
pressure across the multiple holes or apertures. In this
configuration, the grooves or channels may or may not be provided
on the top and/or bottom, alternatively stated the first major
and/or second major surfaces. A particularly preferred embodiment
comprises multiple vacuum apertures or holes without a groove or
channel grid pattern.
[0119] FIG. 3 shows an alternate embodiment of the dustless sanding
sponge shown in FIG. 2 having hook material 226 commonly known as
Velcro.TM.. attached to one surface, i.e., the top or bottom and/or
first or second major surface. The sanding sponge 250 has no
central vacuum hole rather it uses multiple vacuum holes or
apertures 252 to channel the vacuum to the sanding surface. The
holes extend through the thickness of the sponge. The sanding
sponge is used in the known holder described above in connection
with FIG. 2. Vacuum is transferred to the holes and to the sanding
surface. A sandpaper sheet having a hole or apertured grid pattern
that coincides with the hole pattern in the sponge may be attached
to the sanding sponge.
[0120] FIG. 4 shows a corner sanding sponge used for sanding the
inside corners of drywall having three abrasive sides and two slots
for a handle. The sanding sponge has a triangular longitudinal
shape having three large flat surfaces on the longitudinal portion
and two ends. Two of the large flat surfaces form a right angle 81
which is used to fit into a right angle corner. All three of the
longitudinal surfaces of the sponge are coated with an abrasive.
The two surfaces formed at a right angle 81 have an abrasive 78
preferably of the same particle size or grit. The larger flat
surface 79 having the slots for the handle may have the same grit
size or a different grit size preferably a finer grit for finish
sanding. The side of the sponge opposite the right angle is the
handle side 79. The handle side has two slots 76a perpendicular to
the length of the sponge with one near each end. The slots extend
partially into the sponge approximately 3/4 of an inch, having
enough depth to accept the sponge holder portion of a handle
preferably the sponge holder handle that is known in the art and
having cleats that dig into the sponge ends, however any handle may
be designed with a holder portion that extends into the slots for
the purpose of holding the sponge to the handle. The depth and
length of the slots should not be limited here, for example the
length of the slots 76a may be only a length needed to accept the
portion of the handle that extends into the sponge as shown in the
drawing. Or a slot 77 may extend the entire width of the sponge
surface as shown in FIG. 6 any and all slots used for accepting a
sponge holder device may be formed into the sponge by means of a
knife blade a saw blade or directly molded into the sponge. The
slot may be a simple straight slot or have a Tee shaped slot 77a as
shown in FIGS. 7 and 8. The quantity of slots should also not be
limited. For example FIG. 6 shows a corner sanding sponge having
only one slot 77 located near the center of the sponges handle side
79 and extends the entire width of the sponge, FIG. 5 shows a
corner sanding sponge having two slots 77 one near each end of the
sponge and also extend the entire width of the sponge, They may
also be made shorter in length as shown in FIG. 4.
[0121] A corner sanding sponge may have any combination of slots in
quantity, length, width, depth, and profile, for example a profile
having a T-shape. The slots being used as a means of holding the
sponge by means of a handle or by inserting the fingers directly
into the sponge's slots.
[0122] FIGS. 9 and 10 show an alternate embodiment of the corner
sanding sponge 74a having abrasive 78 on the right angle sides and
no abrasive on the handle side 79 of the sponge. Two slots are
located on the handle side of the sponge one near each end. As
described earlier any combination of slots in quantity, size and
shape may be used. It should also be noted that all embodiments of
the triangular corner sanding sponge may be made with any
combination of slots in size, shape, quantity and with or without
abrasive on the handle side 79 of the corner sanding sponge. The
handle side of a corner sanding sponge may have a hook or loop
fastening material such as Velcro.TM. attached to it so it may be
attached to a handle via hook or loop attached to the adjoining
surface of the handle.
[0123] FIG. 11 shows an alternate embodiment of the corner sanding
sponge 80 having a longer length with four slots so that the sponge
may accept two handles 82 instead of only one. The handle side of
the sanding sponge has no abrasive, but should not be limited to a
sanding sponge having four slots with no abrasive on the handle
side, but should include the corner sanding sponge having four
slots with abrasive on the handle side 79 as well. Again any
combination of slots with abrasive or without abrasive on the
handle side should apply, and any length of the triangular sanding
sponge suitable for sanding a drywall corner could be used and the
scope of the invention should not be limited in length or width of
the sanding sponge. The preferred size of all the embodiments of
the triangular sanding sponge however is approximately 7 inches
long with each of the right angled sides approximately 3 inches in
width and the handle side 79 approximately 41/2 inches in width is
the preferred dimensions of the corner triangular sanding sponge.
These dimensions are only the preferred dimensions and should not
be limited in any way to these dimensions only. For example FIG. 11
shows a triangular sanding sponge nearly double in length but
having the same width as a sponge half its length.
[0124] FIGS. 12 and 13 shows an alternate embodiment of a corner
sanding sponge, having two 90 degree sides 81 and a handle side 79
with two grooves 86 one on each side for gripping the sponge with
fingers, and two small grooves one on each end for a handle to grip
the sponge. The handle side 79 has two slots 76a one near each end
as previously described in previous embodiments. The sanding sponge
is known in the art and is made for a handle to grip the sponge by
the ends, by having the teeth on the handle grip each end of the
sponge and hold onto the handle. The embodiment of the present
invention provides two slots for the handles extended grippers or
teeth to insert into and hold the sponge onto the handle by
gripping the sponge inside the slots. The sponge is made longer
than the design currently known in the art so that the two slots
may be formed into the sponges handle side 79 and still have
approximately 1/2'' to 1'' left over on each side. The space left
over on each side provides support for the handle when abrading a
surface so that the sponge does not become disengaged with the
handle due to force being applied and compressing the sponge
longitudinally thereby disengaging the leading end of the sponge
from the handle. The portion of the sponge 79a between each slot
and the end of the sponge prevents the handle from disengaging from
the sponge. The distance of the slot from each end of the sponge is
only an approximation and should not be limited to the distance
described here, but should include any distance that adequately
provides enough support for the handle to not disengage from the
sponge while abrading a surface. Again the slots should not be
limited in quantity size or shape, for example the slot may extend
across the whole width of the handle side 79 of the sponge as shown
in FIG. 13.
[0125] FIG. 13 shows an alternate embodiment of the sanding sponge
described in FIG. 27 having the handle side 79 coated with an
abrasive 78. The handle side has two slots 76 that extend the
entire width of the handle side of the sanding sponge. A corner
slot 86 is located on the 90 angled side of the sponge and extends
part way into the sponge. The slot intersects both 90 degree
surfaces 81, of the sponge and is located in the center portion of
the sponge and is perpendicular the length of the sponge. The
preferred depth of the slot is approximately one inch but should
not be limited to only one inch. As in other embodiments the slots
should not be limited in size, quantity, or shape. The slot is for
a handle having a corresponding holder that inserts into the slot
thereby holding the sanding sponge to the handle. The handle is
described in FIGS. 17, 30, 32, 33, 34, 35, and 37.
[0126] FIG. 14 shows an alternate embodiment of the triangular
sanding sponge 84 having the handle side 79 and two right angle
sides 81 coated with an abrasive 78. Two slots 77 are located on
the handle side 79 of the corner sanding sponge as described in
previous embodiments and one corner slot 86 is located on the 90
angle side intersecting the two 90 angled sides, The corner slot is
to accept a handle as mentioned in FIG. 12, The handle being
described in FIGS. 31 through 51.
[0127] FIG. 15 shows a front view of the corner sanding sponge
described in FIG. 14. As shown the slots extend through the width
of the sanding sponge. The corner slot 86 intersecting the 90
degree angled sides is located opposite the two slots on the handle
side and centered between them. The location of the slots do not
have to be exactly as described and any number of combination of
slots may work as well and arranged in a fashion that would provide
adequate means of holding the sanding sponge to the handle, or by
inserting the fingers directly into the slots as a means of holding
the sanding sponge. The slots may be made wider to accommodate
fingers.
[0128] FIG. 16 show a handle attached to the corner sanding sponge
having the prongs of the handle inserted into the two slots 77 on
the handle side 79 of the sponge. The corner slot 86 located on the
90 side of the sponge provides a place for the corner support 94 on
the handle 90 shown in FIG. 17 to insert into the sponge as shown
in FIG. 17.
[0129] FIG. 17 shows a handle designed to hold the triangular
sanding sponge with the 90 angled sides 81 of the sponge inserted
into the 90 degree cavity of the handle. This allows the handle
side of the sanding sponge to be flipped over so as to expose the
abrasive on the handle side when held into the corner sanding
sponge holder 89. FIG. 17 demonstrates how the triangular sanding
sponge is held into the handle so as to expose the abrasive 78 on
the handle side, and the handle itself will be described in FIGS.
24 through 37.
[0130] FIG. 18 shows a rectangular corner sanding sponge 95 having
a square profile looking at it from the ends and having 4 sides at
a right angle to each adjacent side. The sponge is longer than the
width of any one side thereby making it a rectangle looking at it
from a side and not the ends. The preferred size of the sanding
sponge is approximately 3'' square on the ends and approximately 7
inches long thereby having 4 sides that make an approximate
3''.times.7'' rectangle. And each side at a 90 degree angle to its
adjacent side.
[0131] Although this is the preferred approximate size, the
invention should not be limited in size as many variations of size
may adequately work. For example a rectangular block of dimensions
33/4''.times.10'' would constitute a sort of super-sized block for
more rapid removal of material when sanding. The preferred size
however provides a lower center of gravity for the handle when
connected to the sanding sponge thereby providing more support to
the sanding sponge and eliminating chatter when abrading. The
rectangular sanding sponge 95 has four corner slots 86 located
perpendicular to its length. The slots are located on two opposing
corners with two slots per corner and each located near opposing
ends of the sanding sponge. The corner slots 86 intersect the 90
degree angled sides of each side that make the 90 degree angle. An
approximation of the preferred depth of the slots are one half the
distance between the tip of the corner and the center of the sponge
looking at it from the side. This would be about 1 1/16'' on a
sponge having a 3'' square end profile. The depth of the slot
should not be limited here and only an approximation is described
as a preferred depth, and it should be obvious that the depth
should correspond to the size of the sanding sponge and to provide
adequate support. The slots provide a means of inserting a portion
of a handle into the slot so as to allow a gripping mechanism or
corner support 94 on the handle to hold the sanding sponge to the
handle.
[0132] The gripping mechanism may be a corner support 94 as shown
in FIGS. 17, 24, 39, 30, 32, 33, 34, 35, and 37. The gripping
mechanism may also be an end cap 92 that inserts into the corner
slots as shown in FIGS. 17, 24,25,34,35 and 37. The gripping
mechanism may also be a corner and handle support 112 as shown in
FIGS. 27 and 28. The gripping mechanisms 94, 92 and 112 may be used
in any combination of arrangements on the handle to correspond with
any combination of slots in the corner sanding sponges and should
not be limited in size shape or quantity, The drawings show
preferred embodiments but it is evident that any combination of any
holding devices or slots in the sponges and handles will work, and
the scope of the invention should not be limited to only those
combinations described here.
[0133] FIG. 19 shows a side view of the rectangular corner sanding
sponge 95 described in FIG. 18. The slots 86 show that they extend
through two adjacent right angled sides on the two opposing corners
one on the top and one on the bottom.
[0134] FIG. 20 shows an alternate embodiment of the rectangular
corner sanding sponge having two corner slots located midway
between the ends of the sanding sponge. The slots are located on
two opposing 90 degree corners used for abrading, with one per
corner. The depth of the slot is the same as previously described
in FIG. 18. The sanding sponge 98 would be held by a handle having
the corresponding gripping mechanism such as the corner support 94
as shown in FIGS. 44 and 46 as the sole means of gripping the
sponge or in combination with a handle having end caps 92 as shown
in FIGS. 17, 24 and 25, 34, 35, and 37.
[0135] FIG. 21 shows an alternate embodiment of the rectangular
corner sanding sponge 100 having eight corner slots 86 instead of
two or four as previously described in FIG. 18 through 20. The
corner slots 86 are located on each of the longitudinal corners of
the sponge that are used for abrading. Four slots are located near
each end of the sponge and at the base of each slot it connects
with the adjacent slot as shown in phantom lines.
[0136] FIG. 22 shows a side view of the rectangular sanding sponge
shown in FIG. 21. Each slot extends through two sides at a right
angle to each other to create a square core of sponge material as
shown in FIG. 21 in phantom lines.
[0137] FIG. 23 shows an alternate embodiment of the rectangular
corner sanding sponge 102 having four corner slots located midway
between the ends of the rectangular corner sanding sponge instead
of two sets of slots one on each end as shown in FIGS. 21 and 22.
The slots are arranged as described in FIG. 22 but having only one
set of slots.
[0138] FIGS. 24 and 25 shows a sanding sponge holder 104 for
holding the triangular or rectangular corner sanding sponges
previously described. The handle is made of plastic or metal or
other rigid material, non rigid materials such as rubber may also
work. The handle has a triangular base having two longitudinal
sides 105 that form a right angle having a corner support 94
located on the inside corner of the right angle and midway between
two end caps 92. A handle 106 is located on the exterior of the
right angled sides at the apex of the corner. The handle is
slightly convex with the convex side up and extends the length of
the holder and is attached to the triangular base by means of two
handle supports 108 having an inside right angle with a convex
curve corresponding with the curve of the handle.
[0139] The convex curve is opposite the end of the support 108
having the inside right angle. The inside angle fits onto the
outside of the triangular base at its apex. The rectangular sanding
sponge 98 shown in FIG. 26 fits into the inside corner of the
holder with the end caps 92 and the corner support 94 which slides
into the slot on the sponge providing support and a means of
gripping the sponge thereby holding the sponge onto the sponge
holder 104. The handle 106 provides a means of holding the sponge
holder 104 with the hand.
[0140] FIGS. 27 and 28 show a rectangular sanding sponge holder 110
having two longitudinal sides 105 that form a ninety degree angle
at the apex of the ninety degree angle a handle 106 is attached by
means of two handle supports 112 having a rectangular bottom and a
convex top. The rectangular bottoms slide into two slots 113 in the
triangular base thereby extending across the inside corner of the
triangular base and creating two independent corner supports
similar to the ones shown in FIGS. 38 and 39 and also creating a
convex shaped handle support on the top of the triangular base. The
rectangular sanding sponge holder will hold the rectangular sanding
sponge as described in FIGS. 18, 19, 21, 22, and 23.
[0141] FIG. 29 shows a rectangular sanding sponge that the holder
will fit onto.
[0142] FIGS. 30, 32 and 33 shows an alternate sanding sponge holder
115 that will hold a triangular or rectangular sanding sponge. A
handle 116 is attached at the apex of two rectangular sides 105
that form a right angle. A corner support 94 is triangular in shape
and is located between the two ends of the holder on the inside
corner of the triangular base. as described in FIGS. 24 and 25. In
this embodiment the only holding mechanism for the sanding sponge
is the single corner support 94. The invention should not be
limited in quantity size or shape of corner supports, and only one
is shown here as an alternate embodiment, it should be obvious that
any number of supports may be used to provide necessary support to
hold the sanding sponge firmly in place.
[0143] FIG. 31 shows a rectangular corner sanding sponge as
described in FIG. 26 for the purpose of demonstrating which type of
sanding sponge would fit the holder shown in FIGS. 30, 31 and 33.
The triangular sanding sponge shown in FIGS. 14 and 15 will also
fit into the holder.
[0144] FIG. 32 is a bottom view of the holder 115 and FIG. 33 is an
end view of holder 115.
[0145] FIG. 34 shows the preferred embodiment of the corner sanding
sponge holder 87 for the rectangular or triangular corner sanding
sponges. The holder 87 is the same as the embodiment described in
FIGS. 24 and 25 except the preferred embodiment has a different
handle. The handle 88 is made of a resilient material such as a
dense foam or a rubber material. The handle has a convex top
portion and the sides are rounded providing a place to grip the
handle with the fingers. The bottom of the handle has a ninety
degree v shape that extends the length of the handle so as to
provide a v shaped channel for the apex or peak of the ninety
degree angle of the triangular base to fit into the channel and be
fastened to the handle. A rectangular shaped sanding sponge 98
having two slots 86 is shown attached to the holder 87.
[0146] FIGS. 35 and 37 are essentially the same as FIGS. 30 and 32.
The only difference is that the holder shown in FIGS. 35 and 37
have an end cap 92 located on each end of the holder. The end cap
provides more holding power to hold the sponge into the holder. The
end cap is comprised of a ridged material that is triangular in
shape having a right angle, and closes off the ends of the inside
cavity of the holder. The end caps 92a and corner supports 94a may
also have prongs or tines 91 similar to protrusions on a cheese
grater. The prongs allow the sponge to slide over them but dig into
the sponge when force is applied in removing the sponge thereby
holding the sponge firmly in the holder. The tines could be v
shaped with the v pointing away from the tool. FIG. 38 shows a side
view of the holder with tines or prongs 91. FIG. 39 shows an
alternate corner support 94a having tines or prongs 91. The tines
or prongs could be applied to any of the sponge holder embodiments.
It should be noted that all the tools and handles described in the
embodiments of the invention could be made of plastic or metal or
other rigid material. Rubber may also work.
[0147] FIG. 36 is a rectangular shaped sanding sponge 98 having two
slots 86 providing a means of attaching the sponge to the holder in
conjunction with the end caps of the holder 92.
[0148] FIG. 40 shows a triangular sanding sponge 120 having a
vacuum grid 124 and center vacuum hole 122 and two slots 77 located
on the handle side of the sponge 79. the vacuum grid is comprised
of channels cut into the sanding sponge as described in FIG. 1. The
vacuum grid is laid out on the abrasive sides of the sponge in the
design shown in FIG. 41 having on each side three vertical vacuum
channels connected to the center vacuum hole by means of two
diagonal vacuum grid channels. This is a combined 6 vertical and 4
diagonal vacuum grid channels. The holders for the triangular
sanding sponge are shown in FIGS. 42 and 43. The slots as described
earlier should not be limited in size quantity or shape.
[0149] FIGS. 44 and 45 show a corner sanding sponge holder 139
having a vacuum attachment. The holder 139 attaches to an existing
vacuum sander. The holder has a top plate 150 having two triangular
ends 146 that extend at a right angle from the top plate and form
and end cap. An inside bottom plate 141 having two triangular ends
148 that extend at a right angle is of the same shape as the top
plate and ends but shorter in length so as to fit inside the top
plate and ends and leave a space in between the two plates and
ends. The space between the two plates and ends is a vacuum chamber
144. The sides of the holder have holes 152 so as to allow air to
be sucked through the holes and out the tool bringing dust created
by abrading drywall with the air. The top plate has two tubes that
extend into the top plate but not into the bottom plate. The tubes
provide a port for the vacuum to enter the vacuum chamber of the
holder, thereby providing a vacuum to the holes in the exterior
side walls that are positioned near the abrading edge of the corner
sanding sponge so as to suck dust into the holder when abrading.
Two prongs 142 having a triangular shape extend downward from the
bottom plate and insert into slots in the triangular sanding
sponge. The prongs may be straight or have an elbow with a right
angle having teeth. The two tubes located on the top of the plate
are distanced apart from each other at an equal distance to the
holes in known vacuum sanders, so that the tubes will slide into
the known vacuum sander holes and create a direct vacuum channel
from the known tool to the vacuum chamber 144 in the corner sanding
sponge holder with vacuum attachment 139. Corner sanding sponge 74
is shown in FIG. 45 attached to the vacuum tool 139.
[0150] FIGS. 46 and 47 show a rectangular sanding sponge holder 154
for a large 9''.times.31/4.times.1'' sanding sponge 16a having a
vacuum attachment that hooks up to a known vacuum sander. The
holder 154 has a top plate 156 having four sides 160 that extend at
a right angle to the top plate so as to create a rectangular dish
with a depth slightly less than the thickness of the sponge it is
designed to hold. The top plate has two tubes 140 that extend into
the top plate of the dish and out the other side 162 extending
slightly into the cavity of the dish and also extending above the
top plate so as to allow the tubes on the top of the tool to insert
into the holes 161 in the known tool in FIG. 49. And the portion of
the tubes extending into the dish would insert into a sanding
sponge having a vacuum grid 14 and two main vacuum holes 12 into
which the gridded vacuum channels in the sponge are directed. The
tubes are located a distance apart from each other equal to the
distance the suction holes in the known vacuum sanders are apart
from each other.
[0151] FIG. 48 shows an alternate version of a dustless sanding
sponge having no diagonal vacuum channels as does the sanding
sponge shown in fig. The sanding sponge may also have perforations
or apertures instead of having vacuum channels as described in FIG.
2.
[0152] FIG. 50 shows a small cube shaped sanding sponge 164 having
abrasive 78 on all 6 sides. The small cube is approximately 11/4
cubic inch and may have different grits on each side or all the
same grit on each cube. The size of the cube is only an
approximation and it is the intent of the inventor to create a
small cube with abrasive on all sides so as to have a small sanding
cube that will fit into a belt loop or into the pocket of a person
such as a painter. The size should be such that it does not become
too small to be useful or to large to loose is useful intention as
a small mini sized sanding sponge that will fit into a belt loop or
easily into the outer edge of a pocket. It may be rectangular or
square so as to fulfill its purpose and have any number of
combinations of grit. It may even be color coded so as to identify
its grit.
[0153] FIGS. 51 and 52 shows a drywall corner sanding tool having a
circular disc shape wherein the disc is folded or bent in half
having two half round sides 176 at a right angle to each other. A
handle having a half round shape with an inside and outside radius,
is positioned in the inside of the ninety degree angle created by
the folded disc shaped walls. The outside radius of the handle 174
is approximately the same as the outside radius of the disc shaped
walls 176. The inside radius 173 provides a place to grip the
handle with fingers. The sides of the tool that create the disc may
be made of plastic or sheet metal having a flexible quality so that
the sides may conform to the angle of the corner. The sides are
laminated with a resilient material such as sponge rubber 178
giving the abrasive discs more ability to conform to the wall angle
as well as a cushion for more effective abrading The sides are also
laminated with a hook material 180 from the hook and loop fastening
system such as Velcro.TM.. The hook allows abrasive discs having
the loop material of the hook and loop fastening system attached to
their back side to be attached to the tool via hook and loop. The
abrasive disks are commonly used with orbital sanding tools. The
common sizes of discs are 5'' and 6'' thereby dictating the
different diameter sizes the tool may be made from. The tool should
not be limited to only the diameter sizes of the popular disc
shapes, although the 5 and 6 inch diameters would be the most
advantageous to readily find abrasive discs.
[0154] FIGS. 53 and 54 show a flap sanding tool having four major
components. The tool has a cylindrical drum 198 having multiple
holes 202 located near the outer diameter and having a slot
connecting the outer diameter of the cylinder to the holes. The
slot 200 extends the length of the cylinder but does not extend out
the other side leaving a small end cap to the cylinder. The drum
has a mandrel 208 located on the closed end of the drum and is used
to attach the tool to a drill or motor. The cylindrical holes
accommodate a series of abrasive flaps 214 mounted onto a molded
rod 216 The rod is of a slightly smaller diameter than the
cylindrical holes 202 so that the rod with the abrasive flaps may
be inserted into the cylindrical holes with abrasive flaps
extending out of the drum. The abrasive flaps may be molded
directly into the rod as a single component. A drum cap 212 is of a
disc shape equal to the diameter of the drum and has a hole through
its center allowing a bolt or screw 222 to extend through the hole
and screw the drum cap to the end of the cylindrical drum thereby
locking in the abrasive flaps.
[0155] FIG. 55 shows an alternate embodiment of the dustless
sanding sponge having a hook material 226 such as Velcro.TM.
attached to one side and vacuum channels 14 cut through the hook
material 226 and into the sponge The tool comprises a sponge or
resilient material 224 having a center vacuum hole 12 that connects
the vacuum to the grooves as described in earlier embodiments. The
sponge has no abrasive coating, rather it uses hook or Velcro to
attach an abrasive sheet 228 FIG. 56 having vacuum ports. The
Velcro is used to hold an abrasive sheet onto the sponge. As
described in earlier embodiments any number of vacuum channel
patterns may be used to achieve the end result of channeling the
dust into the central vacuum hole 12.
[0156] FIG. 56 shows a side view of the dustless sanding sponge
shown in FIG. 55. An abrasive sheet 228 having an abrasive 230 on
one side of the sheet and a loop material 231 of the hook and loop
fastening system such as Velcro is attached to the opposite side as
the abrasive.
[0157] FIG. 57 shows an alternate embodiment of the sanding sponge
shown in FIG. 55 having vacuum channels 232 that are not cut all
the way through the hook material. The vacuum channels are cut into
the hook 226 by cutting away only the hooks themselves leaving the
substrate 227 that the hooks extend from intact, thereby giving
added strength to the surface on which the Velcro is attached.
[0158] FIG. 58 shows an alternate embodiment of the dustless
sanding sponge in FIG. 55 having loop material 234 such as
Velcro.TM. attached to the back of the sponge. The loop holds the
sponge to a vacuum attachment sponge holder such as described in
FIG. 61.
[0159] FIG. 59 shows an abrasive sheet 236 having vacuum holes 238
punched through the sheet in a pattern that coincides with the
vacuum channel pattern in the sanding sponge to which it attaches.
Loop material of the hook and loop fastening system is attached to
the back of the sandpaper sheet allowing it to be attached to a
sanding sponge with hook attached laminated to it.
[0160] FIG. 60 shows the sanding sponge shown if FIG. 55 with a
sandpaper sheet 240 attached via hook and loop. The sandpaper sheet
has an alternate vacuum slot pattern. The pattern comprises four
T-shaped slots 241 with the base of each T overlapping the center
vacuum hole or aperture.
[0161] FIG. 61 shows an alternate embodiment of a vacuum attachment
sponge holder having hook material 226 attached to the bottom
surface of a triangular plate. The tool comprises a vacuum tube 244
having a right angle bend at one end. The end of the bend extends
below the surface of the triangular plate 242.
[0162] FIG. 62 shows the sponge holder shown in FIG. 61. The
triangular plate 242 is shown from a top view.
[0163] FIGS. 63 and 64 show a sanding pad having a perforated or
woven checkered pattern with negative spaces 262 to allow for more
flexibility. The material has a high grip surface for gripping the
hand when used. The material is of the type used for lying under
rugs so the rug does not slip on a floor. The pattern of the
material can be any pattern that allows for negative spaces in the
pattern much like a sanding screen does. The material is of a
sponge like consistency. One side of the pad is coated with
abrasive grit 260 and the other side is not coated and acts as a
high grip surface to grip the pad when sanding. The design should
not be limited to only a checkered design but any design having
negative spaces in the pattern to allow for flexibility. The pad
may also be made out of a high grip material as described and
having no negative spaces but only a flat sheet of spongy high grip
material having abrasive on one side. FIG. 63 shows a side view of
the pad, FIG. 64 shows a top view of the pad showing the high grip
spongy nobules 264 having abrasive grit adhered to the top
surface.
[0164] FIG. 65 shows an alternate embodiment of the vacuum sanding
sponge described in FIG. 55. The sponge is of a rectangular shape
and has a hook material 226 of the type known commonly as
Velcro.TM. laminated to the surface having the vacuum grooves. The
hook 226 or Velcro.TM. material is laminated over the top of the
grooves 14 in the sponge. Tee shaped vacuum slots 241 perforate the
hook and are shaped so that they correspond with sections of the
vacuum grooves in the sponge, and when the hook is laminated to the
sponge the Tee shaped vacuum slots 241 in the hook are positioned
directly over the vacuum grooves 14 in the sponge their by
transferring the vacuum through the hook and onto the work surface.
In this embodiment only one side of the sponge has vacuum grooves
14 it should be noted that one or both sides of the sponge top and
or bottom may have vacuum grooves with hook laminated over them as
described here. It should also be noted that in all embodiments of
the dustless sanding sponge having vacuum grooves, one or more
sides may have vacuum grooves with one or more sides having an
abrasive coating or a means of attaching an abrasive material
including abrasive sheet, sanding screen, abrasive having foam
backing or any other abrasive having a means of transferring vacuum
to its work surface including round or slotted perforations but not
limited to only round or slotted perforations. It should also be
noted that in all embodiment of the dustless sanding sponge that
the material the sponge is made of may be of any resilient material
having adequate resiliency to flex and conform to an irregular
surface. Since the tool is used primarily on flat surfaces high
conformity is not necessary and the range of flexibility or
resilience of the foam can be anywhere from very flexible or soft
to a semi ridged or dense material, and should include foam,
sponge, rubber, gel, or any material having resilient qualities.
Polyurethane foam or sponge that is commonly used for making
sanding sponges is the preferred material. The resilience of the
sponge allows the sanding block to create a seal around the vacuum
grooves when pressed against a flat or semi flat surface, their by
directing the vacuum through the channels or grooves to create
maximum vacuum efficiency. It should also be noted that although
the shape of the dustless sanding sponge described here is
rectangular it should not be limited to only rectangular and should
include any and all shaped described in all embodiments to the
present invention. No one embodiment of the dustless sanding sponge
should be narrowed in scope to any particular size or shape, it
should be obvious that the principle features of the dustless
sanding sponge including the vacuum grooves or perforations
described in the many embodiments may be applied to any number of
shapes and sizes of sanding sponges or blocks and it is impossible
to cover all the shapes and sizes and different materials in the
present invention.
[0165] FIG. 66 shows a thin sanding sponge 266 made of a resilient
material such as urethane foam and has Tee shaped slots 239 that
perforate its thickness. The slots are the same shape as the Tee
shaped slots 241 in the hook material 226 shown in FIG. 88. The
sanding sponge has an abrasive material 240 coated on one side and
loop material 234 on the opposite side. The loop is of the type
commonly known as Velcro.TM.. The loop allows the sanding sponge to
be attached to a dustless sanding sponge that is made of a ridged
or resilient material having corresponding vacuum grooves that
match the slot pattern in the sponge. Although T-shaped slots are
shown in this embodiment of the sanding sponge it should be noted
that the sponge may alternately have perforations or holes or
smaller slots that form a pattern that corresponds with the vacuum
grooves in the dustless sanding sponge or dustless sanding block
made of a ridged material such as plastic as shown in FIG. 109.
[0166] FIGS. 67 and 68 show a thin dustless sanding sponge having
loops 234 of the hook and loop fastening system commonly known as
Velcro.TM. on one side and abrasive 240 on the other side. The
sanding sponge has multiple perforations or vacuum holes 243 that
allow the vacuum to be transferred to the abrasive surface. The
sponge may be attached to a sanding block having corresponding
vacuum holes and hook or Velcro.TM. as a means of attaching the
sanding sponge to the dustless sanding block.
[0167] FIGS. 69 and 70 show a sanding screen 245 comprised a
plastic or synthetic such as nylon. The screen 247 has a loop
material commonly known as Velcro.TM.. Laminated to one side and an
abrasive coated on the other side. The abrasive may also be
ingrained into the plastic or synthetic mesh. The sanding screen
may be used with the dustless sanding sponges having hook material
laminated to it such as described in FIG. 58. Known sanding screens
have a loop material already attached to one side and may be used
with the dustless sanding sponge and may be readily used within the
present invention.
[0168] FIG. 71 shows an alternate embodiment of a sanding sponge.
The sanding sponge has a U shaped recess 288 that is centered in
the top of the sponge and extends the length of the sponge. The U
shaped recess provides a cavity into which a hollow vacuum
connector tube 287 having a right angle nozzle 289 may be recessed
so that the connector tube 287 rests below the top portion of the
handle their by removing it as an obstruction while holding the
block with the hand. The vacuum connector tube 287 is attached to
the end of a vacuum hose that is connected to a vacuum cleaner. A
ridge 291 that is slightly larger in diameter than the connector
tube is positioned at the end of connector tube and acts as a catch
that holds the vacuum hose onto the connector tube. The right angle
nozzle 289 is inserted into the central vacuum hole 12 and
transfers the vacuum to the vacuum grooves 14 in the bottom of the
sponge.
[0169] FIG. 72 shows the top view of the sanding sponge shown in
FIG. 71. The U shaped recess 288 is shown extending the length of
the sponge's top portion. The U shaped recess may also be slightly
closed 285 near the top more like a semi circle than a U shape.
This would allow the vacuum connector tube 287 to snap into the
recess and be held more securely.
[0170] FIG. 74 shows an alternate embodiment of the sanding sponge
shown in FIG. 55 with both top and bottom having vacuum grooves 14
and the sides not coated with abrasive. It should be noted that any
of the vacuum groove or hole patterns may be applied to any of the
dustless sanding sponges described and no one sponge should be
limited to only the vacuum groove pattern shown on that particular
sponge.
[0171] FIG. 75 shows a vacuum attachment device comprising a vacuum
connector tube 294 having a right angle nozzle 32 that extends at a
right angle from the end of the tube. The connector tube has a
round retainer ring 291 that is of a slightly larger diameter than
the connector tube and holds the vacuum hose onto the connector
tube by fitting into a matching recess in the end of the vacuum
hose when it is attached to the connector tube. The nozzle has a
flange 296 at its top. The flange is of a larger diameter than the
nozzle and prevents the nozzle from being inserted to far into the
central vacuum hole, and also provides stability and a vacuum seal
at the top of the central vacuum hole. The nozzle 32 has a tapered
retainer shoulder 272 at its end portion that holds the nozzle into
the central vacuum hole.
[0172] FIG. 76 shows the top view of FIG. 75 showing the flange
296.
[0173] FIG. 77 shows an alternate embodiment of the dustless
sanding sponge shown in FIGS. 71 and 72 comprised of a longer
sponge having no angled end. The longer length requires a vacuum
groove pattern of the type shown in FIG. 78 and is more like two
vacuum grid patterns that are aligned end to end, however having
one common vertical groove in the center as apposed to two grooves
that would be close together in the center if the two grid patterns
were placed end to end. Two central vacuum holes 12 extend from the
bottom of the U shaped recess 288 in the same manner as described
in FIG. 71 and provide vacuum to the vacuum grooves 14 as shown in
FIG. 78. A dual nozzle connector tube 300 as described in FIGS. 82
83 and 84 is shown as it would be inserted into the sponges U
shaped recess 288. It should be noted that the length of the sponge
may be longer and the vacuum grid pattern would change accordingly
by adding more central vacuum holes. Each central vacuum hole would
be in conjunction with each individual vacuum grid pattern added.
For example if the sponge were made so long that more central
vacuum holes needed to be added to supply adequate vacuum to the
grid it would involve placing multiple grid patterns end to end as
previously described with each individual grid pattern as shown in
FIG. 1 having its own central vacuum hole. An individual vacuum
grid pattern may be comprised of a vacuum grid pattern as shown in
FIG. 1 having a single central vacuum hole or aperture 12. By
extending the length of a dustless sanding sponge you would connect
individual vacuum grid patterns as shown in FIG. 78. It should be
noted that the dual nozzle connector tube 300 may be a ridged tube
that does not flex easily or it may be made of a flexible tube that
allows the sanding sponge to flex more easily when it is inserted
into the U shaped recess 288. It should also be noted that The U
shaped recess should not be limited to only the handled sanding
sponge shown here but may be incorporated into a simple rectangular
shaped sponge or any other shaped sponge where it would serve its
intended purpose.
[0174] FIG. 78 is a bottom view of the sanding sponge shown in FIG.
77 and shows the vacuum groove pattern without diagonal
grooves.
[0175] FIGS. 79 and 80 show an alternate embodiment of the dustless
sanding tool shown in FIGS. 77 and 78 having a hook material 226
commonly known as Velcro.TM. laminated over the top of the vacuum
grooves 14 on the bottom of the tool. The hook or Velcro 226 has
vacuum slots 314 that perforate the hook and form a pattern that
creates small rectangles as shown in the diagram.
[0176] FIG. 80 shows the vacuum slots 314 in the Velcro and are
positioned so that they coincide with the pattern of vacuum slots
14 in the large handled sanding sponge 312 as shown in FIG. 78. It
should be noted that any slot pattern may be used so long as the
slot pattern in the hook or Velcro.TM. material matches the slot
pattern in the sponge or block 312. The hook 226 is laminated over
the top of the grooves in the bottom of the sponge so that the
slots in the hook 314 are directly over the slots in the sponge 14
FIG. 78 The vacuum transfers from the grooves in the sponge to the
slots in the Velcro and ultimately to the slots or perforations in
the sanding sheet or sponge that is attached to the hook their by
sucking dust away from the work surface while abrading.
[0177] It should be noted that that the method and means by which
the hook or Velcro is configured on the sanding sponge described in
FIGS. 79 and 80 may be applied to any of the other embodiments of
dustless sanding sponges including the different shapes sizes and
materials and wherein the intended purpose of the hook and the
grooves or slots would serve their intended purpose. In general
applying hook in the manner described in FIGS. 79 and 80 should not
be limited to only the sanding sponge having a handle but should
include any and all shapes of sanding sponges wherein the hook and
grooves would serve their intended purpose. For example a small
sanding sponge having only one central vacuum hole as shown in FIG.
55 may have the hook applied to it in the same manner as shown in
FIGS. 79 and 80, however the vacuum grid pattern would be changed
to fit the sanding sponge, and should not be limited to only one
particular vacuum groove pattern.
[0178] FIG. 80 shows a bottom view of the dustless sanding sponge
312 showing the vacuum slot pattern in the Velcro Material.TM.. The
center vacuum holes 12 and vacuum grooves 14 in the sponge are
shown in hidden lines.
[0179] FIG. 81 shows a thin sanding sponge 316 perforated with
vacuum slots 318 and has a loop fastening system also known as
Velcro.TM. 234 on one side of the sanding sponge and sanding
abrasive 260 on the other side. The thin sponge 316 has vacuum
slots 318 that perforate the thickness of the sponge and are
arranged so that the vacuum slots 318 coincide with the vacuum
slots 314 in the Velcro.TM. hook on the bottom of the sanding
sponge in FIGS. 79 and 80 The loop 234 allows the thin sanding
sponge 316 to be attached to the large dustless sanding sponge 312
via hook and loop fastening system. The vacuum is transferred to
the slots 318 in the thin sanding sponge when attached to the large
dustless sander 312 because the slots 318 align with the slots 314
in the Velcro.TM. which in turn align with the grooves 14 in the
bottom of the tool 312.
[0180] FIGS. 82 and 83 show a dual nozzle vacuum connector having a
vacuum tube 300 and two vacuum nozzles 302 and 304 that extend at a
right angle to the vacuum tube. A hose retainer ring 308 is
positioned on the end of the tube. The dual nozzle vacuum connector
has a long tube 300, having at one end a right angle nozzle 304 and
in the center portion of the tube another right angle nozzle 302.
The nozzle diameter is slightly larger than the center vacuum holes
in the dustless sanding sponge it connects to. The two nozzles 302
and 304 insert into the central vacuum holes in the large dustless
sander shown in FIGS. 77, and 78 their by connecting a vacuum
source to the vacuum grooves 14 in the dustless sanding block. The
vacuum tube 300 recesses into the vacuum tube groove shown in FIGS.
77 and 79. The nozzles insert into the central vacuum holes their
by connecting the vacuum to the center vacuum holes and to the
vacuum grooves and slots in the tool and the abrasive. The hose
retainer 308 allows a vacuum hose to be connected to the dual
nozzle vacuum connector by sliding onto the tubes end and slipping
over the retainer ring their by holding the hose onto the connector
tube 300.
[0181] FIG. 83 shows an alternate embodiment of the dual nozzle
vacuum connector tube having a u shaped bottom and a slightly
convex top. The convex top is of the same radius as the top of the
handle on the dustless sanding sponge 312 shown in FIG. 79.
[0182] FIG. 84 shows an end view of FIG. 83 showing the U shaped
bottom of the tube 320 and the convex top 322.
[0183] FIG. 85 shows a hollow dustless sanding block comprising a
hollow rectangular chamber 324 perforated with vacuum holes 326 and
a hook material 226 commonly known as Velcro.TM. attached to the
side of the block that is perforated. A hose fitting 332 is
attached to the end of the block allowing a vacuum hose to be
attached to the block the vacuum hose is connected to a vacuum
cleaner on the other end a vacuum is created in the hollow vacuum
chamber of the block their by providing vacuum to each individual
vacuum hole 326. Finger grooves 328 having a concave recess are
recessed into the sides of the block. The Velcro allows an abrasive
sanding sponge or sheet having perforations of the same hole
pattern as the dustless sanding block 324 to be attached to the
block their by allowing a vacuum to be transferred to the holes in
the sanding sponge or sheet as they align with the holes in the
sanding block 324. It should be noted that Velcro is only a brand
name for hook and loop fastening system and is only used for
description purposes and the invention should not be limited to
only Velcro as a source for hook and loop, this applies to all
embodiments where hook and loop is used. The vacuum sucks dust away
from the work surface via the holes in the sanding sponge and holes
in the sanding block 324.
[0184] FIG. 86 shows an alternate embodiment of the hollow dustless
sanding block shown in FIG. 85 having vacuum slots 14 instead of
vacuum holes. The vacuum slot pattern is of the same pattern
described in FIG. 1 excluding diagonal channels and has a hook
material or Velcro.TM. laminated over the slots in the block as
described in FIGS. 79 and 80. The Velcro has six horizontal slots
and four vertical slots. Hook or Velcro.TM. provides the means by
which an abrasive sheet or sanding sponge may be attached to the
dustless sanding block. A sanding sponge as shown in FIG. 89 having
a hole or slot pattern that matches the slot pattern in the sanding
block may be attached to the sanding block via hook and loop or
Velcro. A vacuum is transferred to the slots or holes in the
sanding sponge via the vacuum slots 14 in the sanding block. It
should be noted that although plastic is the preferred material for
making the ridged dustless sanding blocks shown in FIGS. 85 and 86
it should not be limited to only plastic. Materials such as
Styrofoam or wood or any ridged material suitable for making the
block may be used.
[0185] FIG. 87 shows a high grip foam sanding pad 263 having
checkered pattern of voids 262 in the pad. The foam pad is
comprised of individual small foam pads 264 that are attached to
each other at their corners leaving voids 262 in a checkered
pattern. The small foam pads 264 have a flat bottom and a pillowy
convex top. The foam pad is made from an existing high grip liner
used for putting under a rug to keep the rug from sliding on a
floor. The pad is of a type well known in the art. The high grip
pad 263 may be laminated with an abrasive as described in
connection with FIG. 88.
[0186] FIG. 88 shows a side view of the high grip sanding pad in
FIG. 87 having an abrasive 260 coated on the bottom of the pad. The
individual foam pads connected at the corners have a convex top 264
and flat bottom that is coated with abrasive 260.
[0187] FIG. 89 shows the high grip foam pad 263 described in FIG.
87 laminated to a thin foam sanding sponge 334 as is well known in
the art. The foam sanding sponge 334 has an abrasive coated to its
bottom surface.
[0188] FIG. 90 shows an alternate embodiment of the high grip foam
pad shown in FIG. 87 having one part of the hook and loop, e.g.,
hook material 226, attachment system also known as Velcro.TM.
attached to the bottom of the pad. The hook allows an abrasive
having a second part of the hook and loop, e.g., loop material,
attachment system known as Velcro to be attached to the pad via
hook and loop, or Velcro.TM..
[0189] FIG. 91 shows an alternate embodiment of the high grip foam
pad 263 having pressure sensitive adhesive laminated to its bottom
with the pressure sensitive adhesive 336 (PSA) having a liner 265
so that the liner may be removed exposing the PSA so that the high
grip foam pad 263 may be laminated to an abrasive sheet or sponge
or any abrasive wherein a high grip surface for the purpose of
holding the pad is desired.
[0190] FIG. 92 shows an alternate embodiment of the high grip
sanding sponge shown in FIG. 89 having a solid high grip pad 338
laminated to a foam sanding sponge 334. The solid high grip pad 338
is known in the art and does not have a checkered pattern of voids
and is thus substantially solid foam. This embodiment comprises the
foam sanding sponge having abrasive 260 coated on its bottom
surface. It should be noted that a solid high grip pad may be
coated with abrasive on one side and not laminated to another
sponge having an abrasive coating. It would comprise a solid high
grip foam pad having abrasive coated on one side.
[0191] FIG. 93 shows an alternate embodiment of the high grip pad
263 shown in FIG. 87 having vinyl or rubber or other substrate
laminated to its bottom for the purpose of attaching an abrasive
having pressure sensitive adhesive as an attachment means.
[0192] FIG. 94 shows a round or disk shaped high grip pad having
the checkered voids 262 in the pad. It should be noted that any of
the embodiments showing the high grip pad could be made into any
shape including round, square, rectangular, triangular or any other
shape.
[0193] FIG. 95 shows an alternate embodiment of the high grip pad
shown in FIG. 89 having a high grip pad 264 laminated to a foam pad
334 having a hook material 226 also known as Velcro.TM. laminated
to its bottom surface for the purpose of attaching an abrasive
sheet having Velcro loop as an attachment means.
[0194] FIG. 96 shows an alternate embodiment of FIG. 95 showing a
high grip pad 263 laminated to the top of a foam pad 334 having a
vinyl or rubber or other flexible material 340 laminated to its
bottom for the purpose of attaching an abrasive material having a
pressure sensitive adhesive as an attachment means. The PSA would
be attached to the vinyl or rubber surface their by attaching the
abrasive sheet to the pad.
[0195] As will be recognized by the skilled artisan, the inventions
and embodiments thereof illustrated in FIGS. 87 and 89 may be
described with equivalent terminology while remaining within the
scope of the illustrated Figures. The same applies for the
inventions illustrated in FIGS. 88 and 91-96. For example, the
hand-held abrasive article may be resilient and/or conformable.
Further, such article may be flexible. The high grip foam pad 263,
e.g., may be referred to alternatively and equivalently as a
flexible grip and/or a flexible conformable backing layer. The high
grip foam pad, flexible grip and/or flexible conformable backing
layer defines and/or comprises a top surface and bottom surface or,
equivalently, a first major surface and a second major surface.
These alternate and equivalent descriptive terms are well
represented in, e.g., FIGS. 87 89 and 91 and, as a result, are well
within the scope and spirit of the present disclosure and
invention.
[0196] Moreover, the individual small high-grip pads that are
attached to each other in a checkered pattern that leaves voids
between the interconnections of the high-grip pads may be
equivalently referred to as separated resilient bodies connected to
each other in an array that provides open spaces between adjacent
connected bodies. Further, each individual small high-grip pad may
be equivalently described as having a top and a bottom or a first
surface and an opposite second surface. The Figures, especially
FIGS. 87, 89 and 91, provide support for such equivalent and
alternate descriptions; each of which is within the scope of the
present invention.
[0197] Similarly, the sanding article having a top surface attached
to the bottom of the high-grip pads and a bottom surface having
abrasive particles coated thereon may be equivalently described as
a flexible reinforcing layer having a first major surface affixed
to the first surface of the separated resilient bodies, and a
second opposed major surface having abrasive particles arranged
thereon, thereby defining an abrasive surface. The abrasive
article, e.g., a sanding sponge or abrasive sheet as discussed and
illustrated herein, provides additional functionality beyond that
shown and described in the U.S. Pat. No. 6,613,113 to Minick,
discussed above. Thus, the present invention provides, inter alia,
reinforcement beyond simply coating the high-grip backing layer
with abrasive. This reinforcement, provided by the abrasive
article, imparts durability to the present invention. Described
either way, the sanding article, e.g., a sanding sponge having
abrasive coating thereon, or an abrasive sheet, or the reinforcing
layer having abrasive particles coated thereon serve the same
purpose with identical structure, i.e., they are equivalents; each
such equivalent is illustrated in the Figures and is within the
scope of the present invention.
[0198] Additionally, though the Figures, e.g., FIGS. 87, 89 and 91,
illustrate a preferred pattern of high-grip pads or resilient
bodies having a substantially uniform size and shape, this
uniformity is not a requirement of the present invention.
Similarly, the Figures illustrate the top or first surface of the
high-grip pads, or resilient bodies, as having a preferred convex
or dome shape, though this particular shape is not a requirement of
the present invention. Further, the high-grip pads, or resilient
bodies, may be preferably manufactured from a foam material, though
equivalent materials will readily present themselves to the skilled
artisan while remaining within the scope and spirit of the present
invention.
[0199] Clearly, no matter how the inventions illustrated herein,
and in particular in FIGS. 87-96, are described using equivalent
nomenclature, the structure and the purpose are the same: providing
a high-grip material upon which an abrasive article, e.g., a
sanding sponge with abrasive coating, or an abrasive sheet is
affixed, either permanently or removably, wherein the high-grip
material is flexible and/or conformable and/or resilient. Each such
equivalent description and associated embodiment is within the
scope of the present invention.
* * * * *