US20110312250A1

US20110312250A1 - Speed sand 90 systems

Info

Publication number: US20110312250A1
Application number: US13/207,695
Authority: US
Inventors: Peter Wilson
Original assignee: Individual
Current assignee: Individual
Priority date: 2009-12-28
Filing date: 2011-08-11
Publication date: 2011-12-22

Abstract

Speed Sand 90 is a device designed to quickly and efficiently create accurate ninety-degree angles while sanding new drywall. The device may be modular and/or a non-modular. The non-modular version may comprise two main parts: a replacement pad and a tool portion (a perpendicularly-angled mounting beam and manipulator securer). The replacement pad may be a ninety-degree sponge with two aggregated sides. The tool portion of the device may comprise plastic or other suitable durable material. A universal ball joint, designed to accept any standard corner flushing handle, can be located at the center-back portion of the tool. The replacement pad may attach to the perpendicularly-angled mounting beam with adhesive material. The modular version may comprise slidably-removably-attachable wings having leading and trailing edges providing that the sanding device can be efficiently and effectively used in conjunction with an abrasive sponge to sand inside corners.

Description

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a Continuation-in-Part (OP) related to and claims priority from prior provisional application Ser. No. 61/290,289, filed Dec. 28, 2009 and pending non-provisional application Ser. No. 12/971,706 filed Dec. 17, 2010 which applications are incorporated herein by reference.

COPYRIGHT NOTICE

A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. 37 CFR 1.71(d).

BACKGROUND OF THE INVENTION

1. Field of the Invention
The present invention relates generally to the field of sanders and more specifically relates to drywall sanders.
2. Description of the Related Art
Modern housing often comprises drywall sheeting as an interior finishing means. Drywall panels are typically made of gypsum plaster pressed between two thick sheets of paper, the panels are used to make interior walls and ceilings. Installing and finishing drywall may prove to be a difficult and time-consuming process. Traditional methods for sanding drywall may be inefficient. Standard pole sanders may be capable of sanding only one side of a corner at a time, which can cause damage to the opposing side. Alternately, consumers may use hand sanders, which can be slow, tedious work and require a great deal of effort to operate. Reaching odd-height corners may require consumers to climb, stoop, or reach outside of their comfort zones, which may cause work-related injuries. Conventional sanders may produce lackluster results, prompting consumers to perform tedious touch-ups. These mentioned problems may prevent individuals and entities from being cost-efficient during construction and drywalling operations.
Standard pole sanders presently used can only sand one side of an inside 90 degree angle at a time, thus cannot sand all the way into a corner without creating scratches or other damage to the other side of the corner. Sanding systems with hard sides or ends/edges can do significant damage to an angle when first placed into an angle to begin sanding. This is due to the fact that modern day materials are manufactured soft in order to make them “sanding friendly”. Typical sanding systems having hard ends may not be able to work all the way into a 3-way without hitting the opposing surface and causing significant damage.
Most corner sanders are designed to be hand held. Most sanding systems can only efficiently sand either the edge of a corner, or the center of a corner at one time. This creates a need for using a bench, ladder or stilts in order to reach your work which may prove conducive to falling. Without the mechanical advantage of a long handle, the user sander will expend a lot more energy. Sanding systems that use multiple pieces of sand paper or sponges at once will almost always leave scratches or un-sanded areas where the abrasives meet; an unsatisfactory finished condition. Most corner sanding systems that do accept a pole, either uses a proprietary pole or a painter's style pole. This type of pole requires the user to stand in a position that causes the tool to bisect the angle in order to apply even pressure on both sides of the angle. This is not always possible in small, narrow, short, tall, or crowded areas, such as in closets, hallways, vestibules. Many short-comings exist with sanding systems presently used.
Various attempts have been made to solve the above-mentioned problems such as those found in U.S. Pat. Nos. 7,264,541; 6,325,708; 4,825,597; 2,817,931; 5,885,145; and 5,718,622. This prior art is representative of sanders. None of the above inventions and patents, taken either singly or in combination, is seen to describe the invention as claimed.
Ideally, a Speed Sand 90 should require minimal maintenance and, yet would operate reliably and be manufactured at a modest expense. Thus, a need exists for a reliable Speed Sand 90 systems to efficiently feather-edge and shape drywall corners at crisp ninety-degree angles and to avoid the above-mentioned problems.

BRIEF SUMMARY OF THE INVENTION

In view of the foregoing disadvantages inherent in the known sander art, the present invention provides a novel Speed Sand 90 system. The general purpose of the present invention, which will be described subsequently in greater detail is to provide efficient means to feather-edge and shape drywall corners at crisp ninety-degree angles. The present invention substantially reduces the effort required for sanding new drywall and effectively eliminates the need for touch-ups and hand sanding, because it sands both sides of an inside 90 at the same time.
Speed Sand 90 System of the preferred embodiment “feathers off⇄ both edges and properly shapes the center of a corner in one operation. It does virtually no damage to the corner because there is nothing but the novel (specially designed) sponge touching/contacting the drywall. The single sponge system that that overhangs the entire hard tool allows the user to vigorously run the tool into a 3-way and not do any damage. This effectively eliminates the majority of hand sanding instances. Speed Sand 90 System is designed to fit on a standard “flusher” handle. This eliminates the need for using a bench, ladder or stilts in most cases. This saves the user sander both time and energy making the present invention cost-effective in use.
Speed Sand 90 System, as mentioned above, accepts a standard “flusher” pole. This pole may be equipped with a gooseneck that allows the user to bisect an angle from most positions simply by rotating the pole in his or her hand. Professional drywall finishers are well versed in this procedure so getting even pressure on both sides of any angle (very important) will come naturally. Speed Sand 90 System is designed so that one end of the tool is 90-degrees, and as you move along the tool it gradually changes (tapers) to 100-degrees (creating leading and trailing edges), thus not being one angle along its length. This means that any pressure applied to the tool will be displaced in such a manner that one end will concentrate its pressure on the center and the other end on the edges.
Speed Sand 90 System uses a single sponge. This sponge is approximately 7″ long. Its width along the abrasive side is just over 4″. The sponge is preferably approximately ¾″ thick and is a right angle. The abrasive coating is on the outside of the sponge and is continuous. This substantially ensures that there will be no outstanding scratches or voids in the sanding pattern.
The professional taper (finisher) has a choice of using a multitude of finishing heads in his inside 90-degree corners. The most common sizes are 2″; 2.5″; 3″; 3.5″; and 4″ heads. The present corner sanding system can be optimized or adjusted to sand all of these different sized corners equally well. The Speed Sand 90 System uses the same size of sponge (with varying grits) for all sizes of angles. The inventor has found that adjustments are best made in the tool itself. Tools with metal construction make 5 different sizes of tool(s) in order to optimize. If the tool is made of some sort of composite, it will preferably be comprised of a central hub with an adjustable ball joint. This particular device will have replaceable side rails of assorted sizes to line up with virtually any size of finishing head.
An alternate embodiment of the present invention comprises the composite version of the tool. This particular version has a ball joint position as well as removable wings (side rails) such that the user could optimize the tool for a 2″, 2.5″, 3″, 3.5″ or 4″ corner, standard sizes for corner finishing tools.
A further embodiment of the present invention may take the form of a one-piece L-shaped perpendicularly-angled mounting beam measuring about 60 mm by 145 mm with an inset swivel cap. The swivel cap is open on the bottom to receive a handle with a swivel and is integral with a channel. The perpendicularly-angled mounting beam in this particular embodiment has a center cutout wherein the swivel cap is recessed such that the face has an inset opening (that the sponge will cover when installed.) The profile is similar to that of a hide-a-away hitch ball integral with the channel that acts as the support crossbeam. The advantage of this embodiment is that it is a single-piece construction and can be manufactured relatively inexpensively.
A drywall corner sanding assembly of an alternate embodiment for use on interior drywall corners is as also disclosed herein (as disclosed previously in application Ser. No. 12/971,706) comprising: a perpendicularly-angled mounting beam having two adjacent planar mounting surfaces (two sides contiguous—forming a right angle); a manipulator securer having a universal ball joint; an attachable manipulator pole for reaching a greater vertical distance; and at least one replacement abrasive pad. The manipulator securer is center-back-mounted to the perpendicularly-angled mounting beam for removable attachment to the manipulator pole. The replacement abrasive pad is removably mountable to the two adjacent planar mounting surfaces on the perpendicularly-angled mounting beam (once piece at the same time—in the present embodiment the replacement abrasive pad comprises an indivisible one-piece L-construction). In this way the drywall corner sanding assembly may be used to simultaneously abrasively remove excess drywall compound from both a first and second side adjacent the interior corner. In this particular embodiment the drywall corner sanding assembly comprises plastic; however in alternate embodiments it may comprise different ferrous and/or non-ferrous materials such as aluminum, composite or other. The drywall corner sanding assembly is for use on interior corners comprising a ninety degree angle, however other angled versions may be envisioned within the scope of this invention.
The replacement pad (indivisible one-piece L-construction) comprises a ninety degree sponge with two aggregated surfaces at about 7 inches long and about ¾ inch thick. The perpendicularly-angled mounting beam is about 5¾ inches long and about ⅞ inch wide. The ninety degree sponge with two aggregated surfaces comprises a flexible porous interior and a semi-flexible exterior.
The universal ball joint of the manipulator securer is designed to accept at least one (preferably OEM) corner flushing handle. The perpendicularly-angled mounting beam receives the replacement abrasive pad using a fastener such as adhesive, hook and loop fasteners or other such (removable) fastening means. The drywall corner sanding assembly preferably also further comprises a slider-biasing-clip for engaging the attachable manipulator pole (which may be telescopic). The manipulator securer comprises a wedge profile, an opposed-facing inner slider track wherein a slider-biasing-clip can be moved to biasingly engage and/or disengage from the attachable manipulator pole.
The ninety degree sponge with two aggregated surfaces is manipulatable such that simultaneous abrasive removal of excess drywall compound (mud) from both and/or either the first side adjacent and second side adjacent the interior corner occurs when used. The simultaneous abrasive removal of excess drywall compound from the interior corner using the present invention does not cause gouging in either of the first side adjacent and/or the second side adjacent the interior corner.
A kit is also disclosed herein for use in manufacturing and selling the present invention, wherein the kit includes the perpendicularly-angled mounting beam with the manipulator securer, the attachable manipulator pole; and at least one replacement abrasive pad.
A method for using a drywall corner sanding assembly on interior corners is also disclosed herein comprising the steps of: attaching a replacement abrasive pad comprising an L-shaped sponge via adhesive, hook and/or loop fasteners to a surface of a perpendicularly-angled mounting beam via a fastener; inserting an attachable manipulator pole into a manipulator securer located on a back portion of the perpendicularly-angled mounting beam; sliding a slider-biasing-clip in a track on the manipulator securer to biasingly engage to the attachable manipulator pole; and sanding an interior corner of drywall such that simultaneous abrasive removal of excess drywall compound from both a first side adjacent and a second side adjacent the interior corner occurs when the device is used and does not cause gouging in either of the first side adjacent and/or the second side adjacent the interior corner.
The present invention holds significant improvements and serves as a Speed Sand 90 system. For purposes of summarizing the invention, certain aspects, advantages, and novel features of the invention have been described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any one particular embodiment of the invention. Thus, the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein. The features of the invention which are believed to be novel are particularly pointed out and distinctly claimed in the concluding portion of the specification. These and other features, aspects, and advantages of the present invention will become better understood with reference to the following drawings and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The figures which accompany the written portion of this specification illustrate embodiments and method(s) of use for the present invention, Speed Sand 90 systems, constructed and operative according to the teachings of the present invention.

FIG. 1 shows a perspective view illustrating a drywall corner sanding assembly of Speed Sand 90 systems an in-use condition according to an embodiment of the present invention.

FIG. 2 is a perspective rear view illustrating a perpendicularly-angled mounting beam and manipulator securer of the drywall corner sanding assembly in relation to a replacement abrasive pad according to an embodiment of the present invention of FIG. 1.

FIG. 3 is a perspective view illustrating the replacement abrasive pad having an indivisible one-piece L-construction according to an embodiment of the present invention of FIG. 1.

FIG. 4 is a perspective view illustrating the perpendicularly-angled mounting beam as fitted with the replacement abrasive pad according to an embodiment of the present invention of FIG. 1.

FIG. 5 is a perspective view illustrating a modular beam according to a preferred embodiment of the present invention of FIG. 1.

FIG. 6 is a perspective view illustrating the modular beam as fitted with the replacement abrasive pad as for use in efficiently sanding a corner of a wall according to a preferred embodiment of the present invention of FIGS. 1 and 5.

FIG. 7 is a perspective view illustrating the modular beam and relative angling between the components (leading and trailing edges) according to a preferred embodiment of the present invention of FIGS. 5 and 6.

FIG. 8 is a perspective view illustrating the modular beam as disassembled showing a first wing and a second wing according to a preferred embodiment of the present invention of FIG. 5.

FIG. 9 is a perspective view illustrating a center portion of the modular beam (having reinforcement ribs) according to a preferred embodiment of the present invention of FIG. 5.

FIG. 10 is a front perspective view illustrating the modular beam without the replacement abrasive pad attached according to a preferred embodiment of the present invention of FIGS. 5 and 9. Also shown in FIG. 10 is a one-piece stamped modular beam according to another embodiment of the present invention.

FIG. 11 is a flowchart illustrating a method for using the drywall corner sanding assembly on interior corners according to embodiments of the present invention of FIGS. 1-10.

The various embodiments of the present invention will hereinafter be described in conjunction with the appended drawings, wherein like designations denote like elements.

DETAILED DESCRIPTION

As discussed above, embodiments of the present invention relate to a sanding device and more particularly to a Speed Sand 90 system as used to improve the efficiency in feather-edging and shaping of drywall corners at crisp ninety-degree angles. Additionally, the present invention substantially reduces the effort required for sanding new drywall and effectively eliminates the need for touch-ups and hand sanding. By sanding both sides of an interior angle at once, the device produces a crisp perpendicular corner as desired in industry.
Speed Sand 90 of the present invention comprises a device and method designed to quickly and efficiently create accurate ninety-degree angles while sanding new drywall installations. Referring to the drawings by numerals of reference there is shown in FIG. 1, a perspective view illustrating drywall corner sanding assembly 110 of Speed Sand 90 systems 100 an in-use condition 150 according to an embodiment of the present invention.
Referring now first to the preferred embodiment as illustrated in FIGS. 5-10, showing perspective views generally illustrating modular beam 126 of speed sand 90 systems 100 according to a preferred embodiment of the present invention of FIG. 1.
Speed sand 90 systems 100 is designed to sand both sides of an inside 90 (interior corner 180—including first side adjacent 182 and second side adjacent 184), simultaneously. Speed Sand 90 System 100 of the preferred embodiment “feathers off” both edges of first side adjacent 182 and second side adjacent 184 and properly shapes the center of interior corner 180 at once (in a single operation.) It is designed to not cause damage to interior corner 180 because there is nothing but the novel (specially designed) sponge touching/contacting the drywall.
The single sponge system (comprising one-piece L-construction 168) that overhangs the entire tool (sharp edges and all) allows the sander-user to vigorously run the tool into a 3-way (where vertical corner planes meet a ceiling plane) and don't cause any damage during in-use condition 150 (as shown in FIG. 1). This effectively eliminates the need to finish with hand sanding, thus increasing efficiency and cost-effectiveness of the drywall finishing process. Speed Sand 90 System 100 is designed to fit on a standard “flusher” handle within the preferred embodiment. This substantially eliminates the need for a bench, ladder or stilts in most cases. This feature also saves the user both time and energy.
Speed Sand 90 System 100 may be designed to accept a standard “flusher” pole. This pole is preferably equipped with a gooseneck that allows the sander-user to bisect an angle from most positions simply by rotating the pole in his or her hand. Professional drywall finishers are well versed in this procedure so getting even pressure on both side of any angle, which is very important, will tend to come naturally. Speed Sand 90 System 100 is designed so that one end of the tool is 90-degrees, and as you move along the tool it gradually changes to 100-degrees, thus not being one angle along its length (between leading and trailing edges along length of first wing 127 and second wing 128), as best illustrated in FIGS. 7-10. Modular beam 126 tapers from about 100 degrees to about 90 degrees along its length, as mentioned, defining leading edge and trailing edge, advancing by the leading edge on the upstroke of speed sand 90 systems 100.
This novel feature provides that any pressure applied to the tool (modular beam 126) is suitably displaced in such a manner that one end will concentrate its pressure on the center (center portion 129) and the other end on the edges of first wing 127 and second wing 128. This displaced pressure is correspondingly directed to first side adjacent 182 and second side adjacent 184 of interior corner 180, thus enabling leading and trailing edges to work as intended. The displaced pressure is transferred via reinforcement ribs 131 as shown in FIGS. 6-7 & 9. Reinforcement ribs 131 provide structural integrity for modular beam 126 of speed sand 90 systems 100. The amount of flexion of first wing 127 and second wing 128 in relation to center portion 129 is controlled via reinforcement ribs 131. The preferred embodiment using modular beam 126 may be found in kit 104.
FIG. 7 shows center portion 129 as slidably-removably-couplable to first wing 127 and second wing 128 to form modular beam 126. Modular beam 126 is also convenient in that it is user-configurable and ‘breaks down’ for ease of transport and/or storage. FIG. 8 shows first wing 127 and second wing 128 as in a separated condition from center portion 129. Speed Sand 90 System 100 uses a single sponge (one-piece L-construction 168) in preferred and alternate embodiments, having slightly different profiles to match the sanding application. This sponge is approximately 7″ long, its width along the abrasive side is just over 4″, and is approximately ¾″ thick. This sponge is a right angle forming one-piece L-construction 168. The abrasive coating is on the outside of the sponge and is continuous. This provides that there will be no outstanding scratches or voids in the sanding pattern.
The professional taper (finisher) has a choice of using a multitude of finishing heads in his inside 90-degree corners (interior corner 180). The most common sizes are 2″ 2.5″ 3″ 3.5″ and finally 4″ heads. Speed Sand 90 System 100 uses the same size of sponge (with varying grits) for all sizes of angles. Adjustments may be made in the tool itself. A metal construction will make 5 different sizes of tool in order to optimize. If the tool is made of composite, it will be comprised of a central hub with an adjustable ball joint. This particular embodiment preferably has replaceable side rails (first wing 127 and second wing 128 as attachable to center portion 129) of assorted sizes to line up with virtually any size of finishing head.
Referring now to FIGS. 1-4 and 10 showing an alternate embodiment of speed sand 90 systems 100 including drywall corner sanding assembly 110 for use on interior corners 180 preferably comprising: perpendicularly-angled mounting beam 120 having two adjacent planar mounting surfaces 122 and 124; manipulator securer 130 having universal ball joint 132; attachable manipulator pole 140 for reaching a greater vertical distance; and at least one replacement abrasive pad 160. In this particular embodiment perpendicularly-angled mounting beam 120 is non-modular in contrast to modular beam 126 (as shown in FIGS. 5-10).
Manipulator securer 130 is preferably center-back-mounted to perpendicularly-angled mounting beam 120 for removable attachment to attachable manipulator pole 140. Replacement abrasive pad 160 is removably mounted to two adjacent planar mounting surfaces 122 and 124 respectively on perpendicularly-angled mounting beam 120. Drywall corner sanding assembly 110 is used to simultaneously abrasively remove excess drywall compound from both a first side adjacent 182 and second side adjacent 184 interior corner 180, as shown.
Drywall corner sanding assembly 110 preferably comprises plastic because of its relative lightweight making it easier for the user to work for prolonged periods because of minimized fatigue. This is especially important since drywall corner sanding assembly 110 may be at a level above the user's head requiring more effort to operate on a continued basis. Further, the device as manufactured from plastic is durable, efficient to manufacture and corrosion-resistant. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as user preferences, design preference, structural requirements, marketing preferences, cost, available materials, technological advances, etc., other materials such as, for example, ferrous and/or non-ferrous materials, alloys, composites, different types of plastics, rigid rubbers, etc., may be sufficient.
Drywall corner sanding assembly 110 in most embodiments comprises universal ball joint 132 which is designed to accept at least one OEM corner flushing handle for efficiency and ease of use. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as user preferences, design preference, structural requirements, marketing preferences, cost, available materials, technological advances, etc., other handle arrangements such as, for example, short, long, different attachment means, swivel, non-swivel, etc., may be sufficient.
Drywall corner sanding assembly 110 preferably comprises ninety degree sponge 162 with two aggregated surfaces 164 and 166 which are manipulatable such that simultaneous abrasive removal of excess drywall compound 186 (mud) from both first side adjacent 182 and second side adjacent 184 interior corner 180 occurs when used as described herein. Ninety degree sponge 162 with two aggregated surfaces 164 and 166, respectively is manipulatable such that abrasive removal of excess drywall compound 186 from first side adjacent 182 of interior corner 180 occurs, should an individual wish to sand only one side/area independent of the other wall, thereby providing versatility in use. In a similar mode, ninety degree sponge 162 with two aggregated surfaces 164 and 166, respectively is manipulatable such that abrasive removal of excess drywall compound 186 from second side adjacent 184 of interior corner 180 occurs. In this way the present invention may be used on either first side adjacent 182 or second side adjacent 184 independently or first side adjacent 182 and second side adjacent 184 in combination with interior corner 180.
When used properly (ensuring both aggregated surfaces 164 and 166 are manipulated to be substantially parallel to and evenly flat upon first side adjacent 182 and second side adjacent 184 in interior corner 180), drywall corner sanding assembly 110 is manipulatable such that simultaneous abrasive removal of excess drywall compound 186 from interior corner 180 does not cause gouging in either of first side adjacent and second side adjacent (182 and 184, respectively) of interior corner 180. In this way the present invention saves time by reducing operations over prior inventions and thus provides cost-effective use for its users. Interior corner 180 as described herein comprises a ninety degree angle, as shown. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as user preferences, design preference, structural requirements, marketing preferences, cost, available materials, technological advances, etc., other interior corner angles such as, for example, angles less than 90 degrees, angles more than 90 degrees, and/or may be used on outside/exterior angles, may be used on flat wall surfaces, etc., may be sufficient.
Referring now to FIGS. 2 and 3, a perspective rear view illustrating perpendicularly-angled mounting beam 120 and manipulator securer 130 of drywall corner sanding assembly 110 in relation to a replacement abrasive pad 160 and another perspective view illustrating replacement abrasive pad 160 having an indivisible one-piece L-construction 168 both according to an embodiment of the present invention of FIG. 1.
Drywall corner sanding assembly 110, within a preferred embodiment of the present invention comprises replacement abrasive pad 160 which in-turn comprises an indivisible one-piece L-construction 168. Replacement pad 160 preferably comprises ninety degree sponge 160 with two aggregated surfaces (164 and 166) being about 7 inches long and about ¾ inch thick. Aggregated surfaces (164 and 166) are preferably about 7 inches long so that they provide a relatively large footprint to expedite the amount of surface area that may be engaged at one time, yet not so large that the device is not easy to manipulate. Additionally it is advantageous that the larger footprint is employed because it tends to provide a smoother end-finish. Perpendicularly-angled mounting beam 120 is about 5¾ inches long (slightly shorter) and about ⅞ inch wide, thereby providing a suitably durable, yet light-weight construction suitable for longevity in service. Perpendicularly-angled mounting beam 120 is designed to receive replacement abrasive pad 160 parallel to its front surface(s), perpendicularly-angled mounting beam 120 providing a rigid flat on two sides, backing support surface for sanding operations. This convenient non-permanent fastening means is accomplished preferably using at least one fastener 170 which may comprise at least one adhesive; hook and loop fasteners or other. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as user preferences, design preference, structural requirements, marketing preferences, cost, available materials, technological advances, etc., other fastening arrangements such as, for example, clips, snaps, etc., may be sufficient.
Ninety degree sponge 162 with two aggregated surfaces 164 and 166 preferably comprises flexible porous interior 158 and/or semi-flexible exterior 156. In this way the present invention is able to bend-flex and create/follow contours, through increased flexibility throughout the width of flexible porous interior 158, yet be durable in use because of semi-flexible exterior 156, which constitutes a more rigid portion. Semi-flexible exterior 156 comprises abrasive suitable to remove drywall compound 186 when contacted in a friction-contact.
In certain embodiments as shown in FIGS. 2 and 4, drywall corner sanding assembly 110 further comprises at least one slider-biasing-clip 190 for engaging attachable manipulator pole 140. In other embodiments engaging means may comprise threading, clipping, snapping or integrally fastened means. It should be appreciated that other equivalent fastening means are to be considered within the scope of the invention as disclosed herein. Manipulator securer 130 may comprise wedge profile 134, as shown, an opposed-facing inner slider track 192 wherein slider-biasing-clip 190 can be moved to biasingly engage and/or disengage from attachable manipulator pole 140. In this way manipulator securer 130 removably secures attachable manipulator pole 140 to perpendicularly-angled mounting beam 120 thereby including attachable manipulator pole 140 within drywall corner sanding assembly 110, making it easier for a user to sand in difficult to reach locations.
Referring now to FIG. 4, a perspective view illustrating perpendicularly-angled mounting beam 120 as fitted with replacement abrasive pad 160 according to an embodiment of the present invention of FIGS. 1-3.
As disclosed herein, plastic drywall corner sanding assembly 110 and kit 104 for use on interior corners may comprise: a perpendicularly-angled mounting beam 120 having dimensions of about 6¾ inches long and about ⅞ inch wide and having two outer adjacent planar mounting surfaces 122. It should be appreciated that the inventor has found the disclosed dimensions to be favorable in use (in-use condition 150), however other dimensions may be used in other related applications when using speed sand 90 systems 100 and still be considered within the scope and spirit of the invention. The mentioned dimensions throughout the disclosure are intended to be exemplary, to assist the user in replicating the invention, and is not meant to be limiting in any way.
Manipulator securer 130 may or may not comprise universal ball joint 132 for ease of fluid movement when operating drywall corner sanding assembly 110 of speed sand 90 systems 100. As mentioned previously, manipulator securer 130 is preferably designed to receive at least one OEM corner flushing handle. Manipulator securer 130 further comprises a wedge profile 134 to provide a rigid support and force distribution means for back of perpendicularly-angled mounting beam 120. In this way force from sanding operations and following contours using pressure is suitably dissipated to prevent damage from stress occurring to drywall corner sanding assembly 110.
Referring now to the biasing means, opposed-facing inner slider track 192 is preferably used in conjunction with slider-biasing-clip 190 which can be moved to biasingly engage and/or disengage from an attachable manipulator pole 140 when distal end 142 of attachable manipulator pole 140 is inserted in aperture 136 in manipulator securer 130. In certain embodiments attachable manipulator pole 140 may be telescopic for reaching a greater vertical distance, or in alternate embodiments attachable manipulator pole 140 may be integral (built as a one-piece unit with drywall corner sanding assembly 110). The advantage of the present invention's design is that it may be easily disassembled or coupled with an appropriate length of attachable manipulator pole 140.
Replacement abrasive pad 160 preferably has an indivisible one-piece L-construction 168 forming a ninety degree sponge 162 with two aggregated surfaces (164 and 166) of sandpaper sponge (for wet or dry sanding use) or other such abrasive. Aggregated surfaces (164 and 166) comprise a length of about 7 inches and a thickness of about ¾ inch, as discussed previously. It is crucial that one-piece L-construction 168 be indivisible so as to provide sufficient rigidity, to prevent dust from sanded drywall compound 186 from entering behind ninety degree sponge 162 and to provide a smooth end-surface product by minimizing ‘catching edges’. As referred to previously, the above dimensions are merely exemplary and may be modifiable as such.
Drywall corner sanding assembly 110 as described above may be sold as kit 104 comprising the following parts: at least one perpendicularly-angled mounting beam 120; at least one manipulator securer 130; at least one (telescopic or non-telescopic) attachable manipulator pole 140; at least one replacement abrasive pad 160 (ninety degree sponge 162) of differing grits for different desired finishes; at least one sandpaper or other abrasive; and at least one set of user instructions. Drywall corner sanding assembly 110 of speed sand 90 systems 100 may be manufactured and provided for sale in a wide variety of sizes and shapes for a wide assortment of applications. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other kit contents or arrangements such as, for example, including more or less components, customized parts, parts may be sold separately, etc., may be sufficient.
Referring now to FIG. 11, a flowchart 550 illustrating a method for using 500 drywall corner sanding assembly 110 on interior corners 180 according to embodiments of the present invention of FIGS. 1-10.
Method of use 500 for drywall corner sanding assembly 110 of speed sand 90 systems 100 on interior corners 180 preferably comprises the steps of: step one 501 attaching a replacement abrasive pad 160 comprising an L-shaped sponge 168 via adhesive, hook and/or loop fasteners 170 to a surface of a perpendicularly-angled mounting beam 120 (adjacent planar mounting surface 122 and adjacent planar mounting surface 124 simultaneously) via fastener 170; step two 502 inserting attachable manipulator pole 140 into manipulator securer 130 located on a back portion of perpendicularly-angled mounting beam 120; step three 503 sliding slider-biasing-clip 190 in a track (at least herein embodying opposed-facing inner slider track 192) on manipulator securer 130 to biasingly engage to the attachable manipulator pole 140; and step 504 sanding an interior corner 180 of drywall such that simultaneous abrasive removal of excess drywall compound 186 from both a first side adjacent 182 and a second side adjacent 184 interior corner 180 occurs when device is used and does not cause gouging in either of the first side adjacent 182 and/or the second side adjacent 184 interior corner 180. Further, optionally step five 505 replacement abrasive pad 160 may be exchanged when ‘used up’ (abrasive worn down) for another new replacement abrasive pad 160. Additionally, attachable manipulator pole 140 may be switched out/exchanged for one of different length(s) or telescopically extended and drywall corner sanding assembly 110 may be disassembled for a storage period of non-use.
It should be noted that step 505 is an optional step and may not be implemented in all cases. Optional steps of method 500 are illustrated using dotted lines in FIG. 11 so as to distinguish them from the other steps of method 500.
It should be noted that the steps described in the method of use can be carried out in many different orders according to user preference. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other methods of use arrangements such as, for example, different orders within above-mentioned list, elimination or addition of certain steps, including or excluding certain maintenance steps, etc., may be sufficient.
The embodiments of the invention described herein are exemplary and numerous modifications, variations and rearrangements can be readily envisioned to achieve substantially equivalent results, all of which are intended to be embraced within the spirit and scope of the invention. Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientist, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application.

Claims

1. A drywall corner sanding assembly for use on interior corners comprising:

a perpendicularly-angled mounting beam having two adjacent planar mounting surfaces joined at a right angle to each other;

a manipulator securer having a universal ball joint;

an attachable manipulator pole for reaching a greater vertical distance; and

at least one replacement abrasive pad;

wherein said manipulator securer is center-back-mounted to said perpendicularly-angled mounting beam for removable attachment to said attachable manipulator pole;

wherein said replacement abrasive pad is removably mounted to said two adjacent planar mounting surfaces on said perpendicularly-angled mounting beam;

wherein said drywall corner sanding assembly is used to simultaneously abrasively remove excess drywall compound from both a first and second side adjacent said interior corner.

2. The drywall corner sanding assembly of claim 1 wherein said replacement abrasive pad comprises an indivisible one-piece L-construction.

3. The drywall corner sanding assembly of claim 2 wherein said replacement pad comprises a ninety degree sponge with two aggregated surfaces at about 7 inches long and about ¾ inch thick.

4. The drywall corner sanding assembly of claim 1 wherein said perpendicularly-angled mounting beam is about 6¾ inches long and about ⅞ inch wide.

5. The drywall corner sanding assembly of claim 1 wherein said drywall corner sanding assembly comprises plastic.

6. The drywall corner sanding assembly of claim 1 wherein said universal ball joint is designed to accept at least one OEM corner flushing handle.

7. The drywall corner sanding assembly of claim 1 wherein said perpendicularly-angled mounting beam receives said replacement abrasive pad using a fastener.

8. The drywall corner sanding assembly of claim 7 wherein said fastener comprises at least one adhesive.

9. The drywall corner sanding assembly of claim 7 wherein said fastener comprises hook and loop fasteners.

10. The drywall corner sanding assembly of claim 3 wherein said ninety degree sponge with two aggregated surfaces comprises a flexible porous interior.

11. The drywall corner sanding assembly of claim 3 wherein said ninety degree sponge with two aggregated surfaces comprises a semi-flexible exterior.

12. The drywall corner sanding assembly of claim 3 wherein said ninety degree sponge with two aggregated surfaces is manipulatable such that simultaneous abrasive removal of excess drywall compound from both said first side adjacent and said second side adjacent said interior corner occurs when used.

13. The drywall corner sanding assembly of claim 12 wherein said ninety degree sponge with two aggregated surfaces is manipulatable such that abrasive removal of said excess drywall compound from said first side adjacent of said interior corner occurs.

14. The drywall corner sanding assembly of claim 12 wherein said ninety degree sponge with two aggregated surfaces is manipulatable such that abrasive removal of said excess drywall compound from said second side adjacent of said interior corner occurs.

15. The drywall corner sanding assembly of claim 12 wherein said ninety degree sponge with two aggregated surfaces is manipulatable such that simultaneous abrasive removal of said excess drywall compound from said interior corner does not cause gouging in either of said first side adjacent and said second side adjacent said interior corner.

16. The drywall corner sanding assembly of claim 1 wherein said interior corner comprises a ninety degree angle.

17. The drywall corner sanding assembly of claim 1 further comprising a slider-biasing-clip for engaging said attachable manipulator pole.

18. The drywall corner sanding assembly of claim 1 wherein said manipulator securer comprises a wedge profile, an opposed-facing inner slider track wherein a slider-biasing-clip can be moved to biasingly engage and/or disengage from said attachable manipulator pole.

19. A drywall corner sanding assembly for use on interior corners comprising:

a modular beam having,

a first wing,

a second wing, and

a center portion;

a sponge approximately 7″ long, having as a width along an abrasive side of about 4″, and approximately ¾″ thick, said sponge angle forms a right angle one-piece L-construction, said abrasive forming a coating on an outside of said sponge and said abrasive is continuous;

wherein said first wing and said second wing slidingly removably attach to said center portion to form said modular beam;

wherein said modular beam has leading and trailing edges;

wherein said modular beam tapers from about 100 degrees to about 90 degrees along its length, defining said leading edge and said trailing edge such that sanding pressure is displaced through said first wing and said second wing and said center portion according to said sanding pressure applied on said leading edge and said trailing edges;

wherein said modular beam is designed to fit on a standard flusher handle;

wherein said modular beam provides a surface to support said sponge for use on interior corners during sanding activities.

20. A method for using a drywall corner sanding assembly on interior corners comprising the steps of:

attaching a replacement abrasive pad comprising an L-shaped sponge via a fastener to a surface of a perpendicularly-angled mounting beam via adhesive, and/or hook and loop fasteners;

inserting an attachable manipulator pole into a manipulator securer located on a back portion of said perpendicularly-angled mounting beam;

sliding a slider-biasing-clip in a track on said manipulator securer to biasingly engage to said attachable manipulator pole; and

sanding an interior corner of drywall such that simultaneous abrasive removal of excess drywall compound from both a first side adjacent and a second side adjacent said interior corner occurs when used and does not cause gouging in either of said first side adjacent and said second side adjacent said interior corner.