US20240001512A1 - Sanding apparatus with adjustable flexibility - Google Patents
Sanding apparatus with adjustable flexibility Download PDFInfo
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- US20240001512A1 US20240001512A1 US18/339,913 US202318339913A US2024001512A1 US 20240001512 A1 US20240001512 A1 US 20240001512A1 US 202318339913 A US202318339913 A US 202318339913A US 2024001512 A1 US2024001512 A1 US 2024001512A1
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- sanding apparatus
- handle
- base member
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- rod
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D15/00—Hand tools or other devices for non-rotary grinding, polishing, or stropping
- B24D15/04—Hand tools or other devices for non-rotary grinding, polishing, or stropping resilient; with resiliently-mounted operative surface
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
- B24D18/0009—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for using moulds or presses
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)
Abstract
A hand-held sanding apparatus has an adjustable flexibility. The sanding apparatus includes a flexible handle with a plurality of preformed rod channels. One or more rods are configured for insertion into the rod channels, wherein the one or more rods adjust a flexibility of the sanding apparatus. A flexible base member is attached to a lower surface of the flexible handle and includes a precisely smooth bottom surface configured for attachment to an abrasive material. The flexible base member may comprise a polycarbonate material, and the flexible handle may comprise a rubber material.
Description
- This application claims priority under 35 U.S.C. § 119 to U.S. Provisional Application No. 63/356,915 entitled, “SANDING APPARATUS WITH ADJUSTABLE FLEXIBILITY,” filed Jun. 29, 2022, and hereby expressly incorporated by reference herein.
- This application relates to an apparatus for sanding, and more particularly, to a hand-held sanding block with adjustable flexibility.
- Hand-held sanding blocks are commonly used for sanding various types of surfaces, such as vehicles, furniture, buildings, etc. In its simplest form, a sanding block has a flat side for attaching adhesive sanding material, such as sanding paper, and an opposing side for use as a handle. The sanding block helps distribute sanding pressure more evenly and maintain a flatter surface than sandpaper alone. The sanding block also provides for greater application of force to a surface. However, a problem arises when the surface to be sanded is curved, and the sanding block is not flexible to conform to the curve. In addition, different surfaces being sanded have varying degrees of curvature, from highly curved to nearly flat. A sanding block having flexibility increases its utility for sanding such curved surfaces. In addition, a sanding block that is not only flexible, but includes a means to adjust the flexibility, further increases its utility and reduces the need to have multiple variations of the tool. Various solutions have been proposed in the past but each has distinct disadvantages.
- In one particular example, U.S. Pat. No. 6,544,113 discloses a sanding apparatus with adjustable flexibility including a handle and a thin, stainless steel base member including two end attachment brackets on a top side of the base member for securing the base member to the handle. Stainless steel rod reception brackets are also attached to a top side of the base member including rod reception channels. The handle includes corresponding rod reception channels that are designed for alignment with the bracket rod reception channels when the base member brackets are inserted into the handle. Plastic rod reception tubes are positioned through the bracket rod reception channels and the aligned handle rod reception channels. Steel flexibility rods may then be inserted into the plastic rod reception tubes to adjust the flexibility of the sander. Abrasive, sanding material is attachable to a bottom side of the base member.
- However, the sanding apparatus described in this U.S. Pat. No. 6,544,113 has various disadvantages in practice. Thus, there is a need for an improved sanding apparatus with more utility, durability, and ease of use.
- In one aspect, a sanding apparatus includes a flexible handle including a plurality of rod channels, wherein the plurality of rod channels is formed into the flexible handle. The sanding apparatus also includes a flexible base member including a smooth top surface that is attached to a lower surface of the flexible handle and a smooth bottom surface configured for attachment to an abrasive material.
- In another aspect, a sanding apparatus includes a flexible handle including a plurality of rod channels, wherein the plurality of rod channels is preformed into the flexible handle, and a flexible base member attached to a lower surface of the flexible handle, wherein the flexible base member is a polycarbonate material. The sanding apparatus further includes one or more rods configured for insertion into one or more of the plurality of preformed rod channels, wherein the one or more rods adjust a flexibility of the sanding apparatus.
- In another aspect, a method of manufacturing a sanding apparatus includes manufacturing a flexible handle including a plurality of rod channels, wherein the plurality of rod channels is preformed into the flexible handle, by: in a lower mold, positioning a manufacturing rod on each one of a plurality of rows of pegs; attaching an upper mold to the lower mold; and injecting a heated nitrile butadiene rubber (NBR) material in liquid form into the attached upper and lower molds, wherein the plurality of manufacturing rods forms the plurality of rod channels. The method further includes manufacturing a flexible base member by forming a thin sheet of polycarbonate material, wherein the thin sheet has a thickness of approximately ⅛ inch to 1/16 inch and attaching the flexible base member to a lower surface of the flexible handle.
- In one or more of the above aspects, the flexible base member comprises a polycarbonate material and the flexible handle comprises a rubber material.
- In one or more of the above aspects, one or more inflexible rods are configured for insertion into one or more of the plurality of preformed rod channels, wherein the one or more inflexible rods adjust a flexibility of the sanding apparatus.
- In one or more of the above aspects, an elasticity of the rubber material of the flexible handle holds one or more rods in position within the one or more of the plurality of preformed rod channels.
- In one or more of the above aspects, the flexible handle is inflexible when the plurality of rods is inserted into the plurality of preformed rod channels.
- In one or more of the above aspects, the flexible handle comprises a top surface with at least a flat middle section WFT extending lengthwise, a lower support portion including the plurality of rod channels, and a gripping portion including two indentations on opposing sides of the handle, wherein the gripping portion is positioned between the top surface and the lower support portion.
- In one or more of the above aspects, the flexible base member has a thickness in the range of approximately ⅛ inch to 1/16 inch.
- In one or more of the above aspects, the flexible handle has a height of approximately 1.4 to 1.6 inches.
- In one or more of the above aspects, the base member has a width WBM equal to or less than the standard width of commercially available standard sanding paper.
- In one or more of the above aspects, the base member has a length LBM of approximately one of: 8 inches, 16 inches, or 24 inches.
- In one or more of the above aspects, the flexible base member includes a smooth top surface that is attached to the lower surface of the flexible handle, and a smooth bottom surface configured for attachment to an abrasive material.
- In one or more of the above aspects, the flexible handle includes a top surface including at least a flat middle section WFT extending lengthwise, a lower support portion including the plurality of rod channels, and a gripping portion including two indentations on opposing sides of the handle, wherein the gripping portion is positioned between the top surface and the lower support portion.
- In one or more of the above aspects, the plurality of rows of pegs in the lower mold of the flexible handle form a plurality of cavities on the lower surface of the flexible handle.
- In one or more of the above aspects, at least one rod is manufactured for each of the plurality of rod channels in the flexible handle.
- In one or more of the above aspects, the flexible base member is attached to the lower surface of the flexible handle using one of: an adhesive, a heat process, or a combination of an adhesive and a heat process.
- The foregoing summary, as well as the following detailed description of preferred embodiments of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings embodiments that are presently preferred. It should be understood, however, that the claims are not limited to the precise arrangements and instrumentalities shown.
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FIG. 1 illustrates an exploded perspective view of exemplary embodiments of parts of a sanding apparatus with adjustable flexibility. -
FIG. 2A illustrates a side perspective view of an exemplary embodiment of the sanding apparatus with adjustable flexibility. -
FIG. 2B illustrates a perspective view of the lower surface of an exemplary embodiment of the sanding apparatus with adjustable flexibility. -
FIG. 3 illustrates a side view of an exemplary embodiment of a first end of the sanding apparatus with adjustable flexibility. -
FIG. 4 illustrates a side view of an exemplary embodiment of a flexibility adjustment rod for use with the sanding apparatus. -
FIGS. 5A-C illustrate a perspective of example embodiments of varying rod ends for a plurality of rods. -
FIG. 6 illustrates a flexibility simulation for an embodiment of the sanding apparatus having a length of 8 inches. -
FIG. 7 illustrates a flexibility simulation for an embodiment of the sanding apparatus having a length of 16 inches. -
FIG. 8 illustrates a flexibility simulation for an embodiment of the sanding apparatus having a length of 24 inches. -
FIGS. 9A-C illustrate side perspective views of exemplary embodiments of the sanding apparatus with adjustable flexibility. -
FIG. 10A illustrates a schematic block diagram of an embodiment of the handle of the sanding apparatus. -
FIG. 10B illustrates a schematic block diagram of an embodiment of a mold to manufacture a plurality of handles. -
FIG. 11 illustrates an embodiment of a method for manufacturing an embodiment of the sanding apparatus. - The word “exemplary” or “embodiment” is used herein to mean “serving as an example, instance, or illustration.” Any implementation or aspect described herein as “exemplary” or as an “embodiment” is not necessarily to be construed as preferred or advantageous over other aspects of the disclosure. Likewise, the term “aspects” does not require that all aspects of the disclosure include the discussed feature, advantage, or mode of operation.
- Embodiments will now be described in detail with reference to the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the aspects described herein. It will be apparent, however, to one skilled in the art, that these and other aspects may be practiced without some or all of these specific details. In addition, well known steps in a method of a process may be omitted from flow diagrams presented herein in order not to obscure the aspects of the disclosure. Similarly, well known components in a device may be omitted from figures and descriptions thereof presented herein in order not to obscure the aspects of the disclosure.
- Through repeated and prolonged use and experimentation, various disadvantages were ascertained in current sanding apparatuses with adjustable flexibility, such as that in the above described U.S. Pat. No. 6,544,113. First, to obtain the desired flexibility and conform to curved surfaces, the current sanders have a thin stainless steel base member. However, this thin stainless steel base member is prone to deformations and breakage. These deformations make it difficult to attach the abrasive sanding material to the stainless steel base member. In addition, the thin stainless steel, especially after repeated use and wear, becomes too weak to exert sufficient force on rough surfaces. This reduces the utility of the tool in that the thin metal yields to imperfections in the surface being sanded. This undermines the purpose of the tool which is to cause the surface being sanded to yield to the sanding block, removing imperfections, and produce a flat, smooth surface. The thin metal can also lead to undue wear and tear and even failure.
- Second, in current sanding apparatuses with adjustable flexibility, the rod reception channels in the brackets must be aligned with the bracket rod reception channels in the handle. This alignment creates additional steps and increases difficulties in manufacture and assembly.
- Third, in current sanding apparatuses with adjustable flexibility, the stainless steel brackets on the base member are prone to bending and even breaking from the base member. This bending or breaking of the brackets causes misalignment between the rod reception channels in the brackets and the bracket rod reception channels in the handle. The misalignment creates difficulties in inserting the adjustment rods into the plastic rod reception tubes. It may also loosen the attachment of the steel base member from the handle causing more difficulty in generating a smooth sanded surface.
- In later renditions of these currently known sanding blocks, a plurality of cuts or indentations were positioned on a top gripping portion of the handle to enhance the flexibility of the handle portion. These cuts were prone to pinching a user and made it more difficult to apply pressure on the handle for sanding.
- To address these disadvantages in currently known hand-held sanding blocks with adjustable flexibility, an improved sanding block with adjustable flexibility is described herein.
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FIG. 1 illustrates an exploded perspective view of exemplary embodiments of parts of asanding apparatus 100 with adjustable flexibility. Aflexible handle 110 includes an uppergripping portion 102 and alower support portion 104. The uppergripping portion 102 is configured for grasping and exerting pressure manually on thesanding apparatus 100. Thelower support portion 104 of thehandle 110 includes a relatively flat, rectangularbottom side 106 configured for attachment to aflexible base member 150. In one embodiment, a precision, smoothtop surface 152 of thebase member 150 is attached to thebottom side 106 of thehandle 110 using an adhesive or using a heat process or a combination thereof. In another embodiment, thebase member 150 and handle 110 are manufactured as one piece, e.g. using a multi-shot injection molding process wherein a first material is injected into a mold to create thebase member 150 and a second material is injected into the mold to create thehandle 110. - The
base member 150 further includes a precise smoothlower surface 154 configured for attachment of an abrasive material, such as sanding paper. The abrasive material is attached to thesurface 154 of thebase member 150 using adhesive, such an adhesive backed sandpaper. - The
handle 110, and in specific, thelower support portion 104 of thehandle 110, includes a plurality of preformedrod channels 120 that extend lengthwise from afirst end 160 of thehandle 110 to asecond end 162 of thehandle 110. The plurality ofrod channels 120 is preformed within the material of thehandle 110 during manufacturing of thehandle 110, e.g., through injection molding or other types of manufacturing processes. Since the plurality ofrod channels 120 are preformed within thehandle 110, there is no need for thebase member 150 to include brackets or rod channels within the brackets as in prior configurations of sanding apparatuses. And thesanding apparatus 100 no longer has the problems with bending or breakage of the base member brackets. Furthermore, the difficulties of aligning the rod channels in the base member brackets to the rod channels in the handle are eliminated. - In an embodiment, the
handle 110 comprises a flexible material, such as rubber material, or more particularly a foam rubber material or nitrile butadiene rubber (NBR). For example, the flexible material of thehandle 110 may have a Shore A Hardness Scale in a range of 20 A to less than 40 A or more particularly, a Shore A Hardness Scale of approximately 30 A. The flexible material is thus categorized as soft to medium soft along the Shore A Hardness Scale. In another embodiment, the flexible material of thehandle 110 may have a Shore A Hardness in a range of 40 A to 60 A or more particularly, a Shore A Hardness in a range of 45 A to 55 A or more particularly, approximately 50 A. This generates flexibility in thehandle 110 while maintaining durability. The flexible material of thehandle 110 also provides chemical resistance, such as to residues from sanded surfaces and from paint, solvents and other chemicals typically present in an automotive body repair facility. - One or more
flexibility adjustment rods 130 may be inserted into one or more of the plurality ofrod channels 120 in thehandle 110 to adjust flexibility of thesanding apparatus 100. Therods 130 comprise a strong, inflexible material, such as steel, titanium, iron, or a metal alloy of one or more metals, or a polycarbonate or other polymer compound material, etc. Anelastic cap 140 is configured to fit snugly onto an end of eachrod 130 for protection of the rod and user from scraping. The elasticity of the cap exerts circumferential force against therod 130 to maintain thecap 140 securely onto therod 130. Theelastic cap 140 also provides guidance to indicate when therod 130 is fully inserted into arod channel 120. - When the
rod 130 is inserted into one of the plurality ofrod channels 120, the elasticity of the flexible material of thehandle 110 exerts circumferential force on therod 130 to hold therod 130 in position. Alternatively or additionally, in an embodiment, the fittedcap 140 may be configured to extend partially into the opening of therod channel 120 when the rod is inserted into therod channel 120, e.g. such that the fitted cap is at least partially wedged into the opening of therod channel 120. Due to the compression of therod channel 120 on the fittedcap 140, the elasticity of the fittedcap 140 generates a force against the inner circumference of therod channel 120 to hold therod 130 in place. - The
flexible base member 150 comprises a polycarbonate material. Polycarbonate has an ability to undergo significant deformation without cracking or breaking. It has an extremely high impact strength, e.g., compared to plexiglass or other acrylics. Polycarbonate is also highly resistant to acids and other chemicals with a low level of flammability. This combination of strength and flexibility in the material provides a unique advantage to thebase member 150. Thebase member 150 is flexible enough to conform to curved surfaces without deformity while also maintaining strength to apply pressure to protrusions in a sanding surface. - The
base member 150, due to the flexibility of the polycarbonate material, may have a thickness in a range of approximately ⅛ inch to 1/16 inch. This thickness of thebase member 150 is greater than stainless steel base members of currently known sanding apparatuses. Thus, thebase member 150 in this embodiment has a greater thickness and strength while maintaining flexibility. -
FIG. 2A illustrates a side perspective view of an exemplary embodiment of thesanding apparatus 100 with adjustable flexibility. The sanding apparatus has a height HSA between 1.5 inches to 2.0 inches. Thebase member 150 may have a thickness or height HBM in a range of approximately ⅛ inch to 1/16 inch or more particularly, 0.08 inches. This thickness provides strength but flexibility to the base member. Thehandle 110 has a height of approximately 1.4 to 1.6 inches, or more particularly 1.5 inches. This height makes it easier to grip the handle and apply pressure to the sanding surface. -
FIG. 2B illustrates a perspective view of the lower surface of an exemplary embodiment of thesanding apparatus 100 with adjustable flexibility. The lower surface of thesanding apparatus 100 illustrated shows the lower orbottom surface 154 of thebase member 150. In one embodiment, thebase member 150 has a width WBM equal to or less than a standard width of commercially available standard sanding paper. For example, thebase member 150 has a width WBM between 2 inches to 3 inches wide, and more particularly 2.625 inches wide. Current standard sanding paper is approximately 3 inches wide. With thebase member 150 having a width WBM less than 3 inches, the standard-sized sanding paper may extend the width of thebase member 150 and include excess on the sides to fold or curl over thebase member 150 and/or handle 110. In other embodiments, thebase member 150 may have a width WBM of 3 inches to fit a standard sized 3 inch sanding paper without folding. Thebase member 150 may thus fit within the width of commercially available sanding paper. However, thebase member 150 and/or thesanding apparatus 100 are not constrained to the widths described herein. Other widths of thesanding apparatus 100 and/or thebase member 150 may also be implemented depending on the application. - The length LBM of the
base member 150 is approximately 16 inches in this example, but other embodiments may include other lengths, such as 8 inches or 24 inches, which are appropriate for different sizes, locations and shapes of the vehicle panel or other object being sanded. Thesanding apparatus 100, and/or thehandle 110 and/or thebase member 150 are not constrained to the lengths described herein. Other lengths of thesanding apparatus 100 may also be implemented depending on the application. -
FIG. 3 illustrates a side view of an exemplary embodiment of afirst end 160 of thesanding apparatus 100 with adjustable flexibility. Thehandle 110 includes two gripping portions 170 a-b. The gripping portions 170 a-b are between the top surface of thehandle 110 and alower support portion 104 of thehandle 110. The gripping portions 170 a-b include opposing lengthwise indentations on each side of thehandle 110 for easier gripping and maneuvering of thesanding apparatus 100. The gripping portions 170 a-b may extend lengthwise to a full length of thehandle 110 as shown or to only a portion of the length of thehandle 110. - In an embodiment, the
handle 110 includes roundedtop edges 180 lengthwise that extend from the indentations of the gripping portions 170 a-b and meet at a relatively flattop surface 172 of thehandle 110. For example, the side profiles of thehandle 110 may have a rounded or contoured lengthwisetop edges 180 that end with the relatively flattop surface 172 of thehandle 110. Thetop surface 172 of thehandle 110 includes at least a flat middle section WFT, extending lengthwise and parallel to thebase member 150. The flat middle section WFT may have a length extending from oneend 160 of thehandle 110 to theother end 162 of thehandle 110, as shown inFIG. 3 , or extend partially lengthwise. The flat middle section WFT may have a width of 1 inch to 2 inch, or more particularly 1.5 inches. The flat middle section WFT generates a more uniform force to be applied to a sanding surface when a user's hand, e.g. palm, presses along the flat middle section WFT. In addition, the flat middle section WFT lowers a profile of thehandle 110 for easier grasping by a user's fingers of the gripping portions 170 a-b, especially for smaller hands. The height HGP of thehandle 110 from thetop surface 172 of thehandle 110 to a start of thelower support 104 of thehandle 110 may also be decreased from prior known blocks, e.g. to a height HGP of 1 inch −1.25 inches, to further ease grasping of the gripping portions 170 a-b. This decreased height HGP helps a user to grip the handle and apply pressure to the sanding surface. - The side view of the
sanding apparatus 100 also illustrates thelower support portion 104 of thehandle 110. Thesupport portion 104 is positioned between the gripping portions 170 a-b of thehandle 110 and thebase member 150. Thesupport portion 104 includes the plurality of preformedrod channels 120. A plurality ofrods 130 withend caps 140 are shown inserted into the plurality ofchannels 120. In this embodiment, thesupport portion 104 includes threerod channels 120. However, more orless rod channels 120 may be implemented in other applications. For example, tworod channels 120 may be employed for ashorter sanding apparatus 100, such as an 8 inchlength sanding apparatus 100. In another example,additional rod channels 120 may be implemented with wider sanding apparatus, e.g. a sanding apparatus having a width of 3 inches or more. -
FIG. 4 illustrates a side view of an exemplary embodiment of arod 130 for use with thesanding apparatus 100. Therod 130 is cylindrically shaped and sized for placement in at least one of the plurality ofrod channels 120. Therod 130 comprises a stainless steel, titanium, iron, or other relatively inflexible material in comparison to the material of thehandle 110. In one embodiment, therod 130 has a length L R equal to approximately 16 inches for a sanding apparatus of length LSA of 16 inches. In other embodiments, the length LR of therod 130 may be 8 or 24 inches for asanding apparatus 100 of length LSA of 8 or 24 inches, respectively. Thus, in an embodiment, the length L R of the rods for asanding apparatus 100 equals a length LSA of thesanding apparatus 100 or at least a length of thesupport portion 104 of thesanding apparatus 100. In other embodiments, the length L R of therod 130 is at least ⅔ of the length of thesupport portion 104 of thehandle 110. For example, therod 130 may be slightly shorter than thesupport portion 104 to fit within therod channels 120. In another example, therods 130 may be slightly longer than a length of thesupport portion 104 of thesanding apparatus 100, e.g. such that a portion of therod 130 extends outward from an opening of arod channel 120 for easy removal and insertion. Other lengths of thesanding apparatus 100 may also be implemented depending on the application. In this embodiment, therods 130 androd channels 120 are cylindrical but may have alternate shapes, such as rectangular or octagonal. -
FIGS. 5A-C illustrate a perspective of example embodiments of varying rod ends 132 for the plurality ofrods 130. In one embodiment, the plurality ofrods 130 have a same diameter DR, such as 0.188 inch as shown inFIG. 5A . The plurality ofrod channels 120 in thehandle 110 will then also have a same or similar diameter configured to fit therods 130. For example, the diameter DRC of each of the plurality of therod channels 120 may be 0.188 inch or in a range of 0.178 inch-0.198 inch diameter, to allow for insertion of therods 130. When therods 130 have a same diameter, each insertedrod 130 decreases or decrements the flexibility of thesanding apparatus 100 by an approximately same proportion. - In another embodiment, the plurality of
rods 130 have varying diameters to affect the flexibility of thesanding apparatus 100 by different proportions. For example, afirst rod 130 may have a diameter DR1 of 0.188 inches (+/−0.01 inches tolerance) as shown inFIG. 5A , a second rod may have a diameter DR2 of 0.094 inches (+/−0.01 inches tolerance) as shown inFIG. 5B , and a third rod may have a diameter DR3 of 0.36 inches (+/−0.01 inches tolerance) as shown inFIG. 5C . The plurality ofrod channels 120 may also have varying diameters configured to fit the rods, e.g. such as 0.188 inch diameter, 0.094 inch diameter and 0.36 inch diameter (each with at least +/−0.01 inches tolerance) to allow for insertion of therods 130 with varying diameters. Each insertedrod 130 then will decrease or decrement the flexibility of thesanding apparatus 100 by different proportions. Thesanding apparatus 100 may accommodate a plurality of rods with different diameters or two rods with a same diameter and a third with a different diameter or other combinations. The various diameters of the plurality ofrods 130 and the plurality ofrod channels 120 is exemplary, and other diameters may be implemented depending on the application. - In another embodiment, rod insertion tubes may be employed with
rods 130 and the plurality ofchannels 120. The rod insertion tubes may be installed in one or more of the plurality ofchannels 120. Therods 130 are then inserted into the rod insertion tubes. In an embodiment, the rod insertion tubes have a same outer diameter to snugly fit within the plurality ofrod channels 120. However, the rod insertion tubes have a varying inner diameter to fitrods 130 having varying diameters. The plurality ofrod channels 120 may thus have a same diameter but still accommodate rods of varying diameters. -
FIG. 6 illustrates a flexibility simulation for an embodiment of thesanding apparatus 100 including thehandle 110 andbase 150. In this embodiment, the sanding apparatus has a length of 8 inches. Thehandle 110 has the approximate dimensions of a height of 1.5 inches and a width of 2.25 inches. Thehandle 110 comprises an NBR material, as described herein, having an elastic modulus of approximately 4 megapascals (MPa) and approximately Shore A hardness 50. Thebase 150 is a polycarbonate material. - In this simulation, the plurality of
rod channels 120 are empty and do not include theinflexible rods 130. The simulation illustrates the resultant deformation of the sanding apparatus with an applied force of 10 pounds (lbs.) on a center,top portion 600 of thehandle 110 of thesanding apparatus 100 while theends sanding apparatus 100 are maintained at a same parallel level. The largest deformation shown at the center,top portion 600 of thehandle 110 is approximately 3.3 millimeters (mm) or 0.13 inches. -
FIG. 7 illustrates a graph of a flexibility simulation for another embodiment of thesanding apparatus 100 including thehandle 110 andbase 150. In this embodiment, thesanding apparatus 100 has a length of approximately 16 inches, and thehandle 110 has the approximate dimensions of a height of 1.5 inches and a width of 2.25 inches. Thehandle 110 comprises an NBR material, as described herein, having an elastic modulus of approximately 4 megapascals (MPa) and approximately Shore A hardness 50. Thebase 150 is a polycarbonate material. - In this simulation, the plurality of
rod channels 120 are empty and do not include therods 130. The simulation illustrates the resultant deformation of the sanding apparatus with an applied force of 10 lbs. on a center,top portion 610 of thehandle 110 of thesanding apparatus 100 while theends top portion 610 of thehandle 110 is approximately 15.5 millimeters (mm) or 0.61 inches. Thesanding apparatus 100 is thus flexible but the handle still retains its shape. - Preferably, in an embodiment, with the plurality of
rods 130 inserted into the plurality ofchannels 120, thesanding apparatus 100 does not bend or bends 1 mm or less with an applied force of 10 pounds (lbs.) on a center,top portion 600 of thehandle 110. Thesanding apparatus 100 is thus inflexible and resistant to bending with the insertion of acorresponding rod 130 in each of the plurality ofrod channels 120. One or tworods 130 may be inserted to obtain a flexibility between the flexible, approximately 15.5 mm bend of the block and the inflexible block with a bend of 1 mm or less. -
FIG. 8 illustrates a graph of a flexibility simulation for another embodiment of thesanding apparatus 100 including thehandle 110 andbase 150. In this embodiment, thesanding apparatus 100 has a length of approximately 24 inches, and thehandle 110 has the approximate dimensions of a height of 1.5 inches and a width of 2.25 inches. Thehandle 110 comprises an NBR material, as described herein, having an elastic modulus of approximately 4 megapascals (MPa) and approximately Shore A hardness 50 A. Thebase 150 is a plate of polycarbonate material. - In this simulation, the plurality of
rod channels 120 are empty and do not includerods 130. The simulation illustrates the resultant deformation of the sanding apparatus with an applied force of 10 pounds (lbs.) on a center,top portion 620 of thehandle 110 of thesanding apparatus 100 while theends top portion 610 of thehandle 110 is approximately 46.6 millimeters (mm) or 1.83 inches. Thesanding apparatus 100 is thus flexible but the handle still retains its shape. - Preferably, in an embodiment, with the plurality of
rods 130 inserted into the plurality ofchannels 120, thesanding apparatus 100 in this embodiment is inflexible and does not bend or bends 1.5 mm or less with an applied force of 10 pounds (lbs.) on thetop portion 600 of thehandle 110. One or tworods 130 may be inserted to obtain a flexibility between the approximately flexible 15.5 mm bend and the inflexible a bend of 1.5 mm or less. -
FIGS. 9A-C illustrates side perspective views of exemplary embodiments of thesanding apparatus 100 with adjustable flexibility. InFIG. 9A , thesanding apparatus 100 has a length LBM of 8 inches. In this example, thesanding apparatus 100 has threerod channels 120 a-c for insertion ofrods 130 a-c. Themiddle rod 130 b androd channel 120 b have a diameter of approximately 3/16 inch, and theend rods rod channels rods 130 a-c inserted, thesanding apparatus 100 with length LBM of 8 inches is inflexible and does not bend or bends 0.5 mm or less with an applied force of 10 lbs. on a center,top portion 600 of thehandle 110. - In
FIG. 9B , thesanding apparatus 100 has a length LBM of 16 inches. In this example, thesanding apparatus 100 has threerod channels 120 a-c for insertion ofrods 130 a-c, and each of the threerods 130 a-c androd channels 120 a-c have a diameter of approximately 3/16 inch. With theserods 130 a-c inserted, sandingapparatus 100 with length LBM of 16 inches is inflexible and does not bend or bends 1 mm or less with an applied force of 10 lbs. on a center,top portion 600 of thehandle 110. - In
FIG. 9C , thesanding apparatus 100 has a length LBM of 24 inches. In this example, thesanding apparatus 100 has threerod channels 120 a-c for insertion ofrods 130 a-c, and each of the threerods 130 a-c androd channels 120 a-c have a diameter of approximately ¼ inch. With theserods 130 a-c inserted, sandingapparatus 100 with length LBM of 24 inches is inflexible and does not bend or bends 1.5 mm or less with an applied force of 10 pounds (lbs.) on a center,top portion 600 of thehandle 110. - Though the
rod channels 120 a-c are described as having a same diameter as therods 130 a-c, therod channels 120 a-c may be formed with a slightly small diameter, e.g., such as 5%-10% smaller diameter. Therod channels 120 a-c hold therods 130 a-c through the elastic force of the NBR material of thehandle 110 pressing against therods 130 a-c. So therod channels 120 a-c must have a diameter sufficiently large to insert therods 130 a-c but also sufficiently small to hold therods 130 a-c in place. - As shown in
FIGS. 9 a-c , a diameter of one or more of therods 130 needs to increase as the length LBM of thesanding apparatus 100 increases to maintain the inflexibility of the sanding apparatus with therods 130 a-b inserted. Additionally and/or alternatively, the number ofrods 130 may be increased to maintain the inflexibility of the sanding apparatus with therods 130 a-b inserted. For example, thesanding apparatus 100 with the length LBM of 24 inches may include four or fiverods 130 a-c having a diameter of approximately 3/16 inch, e.g., rather than three rods having a diameter of approximately ¼ inch. In another example, asanding apparatus 100 with the length LBM of 30 inches may include four or fiverods 130 a-c having a diameter of approximately ¼ inch or may include three rods having a diameter of approximately ⅓ inch. The diameter of therods 130 may also vary depending on their material, such as steel, titanium, iron, or a metal alloy of one or more metals, etc. Thesanding apparatus 100 may thus have a different number and/or a different diameter ofrods 130 depending on a length LBM of the sanding apparatus and a material of therods 130 so that the plurality ofrods 130 maintain the inflexibility of thesanding apparatus 100 with therods 130 inserted. -
FIG. 10A illustrates a schematic block diagram of an embodiment of thehandle 110 of thesanding apparatus 100. In this embodiment, abottom surface 1010 of thehandle 110 includes a plurality ofcavities 1000 formed in thebottom side 1010 of thehandle 110 during manufacturing. In an embodiment, the plurality ofcavities 1000 are formed to a depth of therod channels 120 in thelower support portion 104 of thehandle 110. Thecavities 1000 may be formed along one or more rows parallel to one or more of the plurality ofrod channels 120. -
FIG. 10B illustrates a schematic block diagram of an embodiment of amold 1020 to manufacture a plurality ofhandles 110 of thesanding apparatus 100. In this embodiment, themold 1020 includes a plurality of individual handle molds 1030 a-d. Each of the handle molds 1030 a-d includes a plurality ofpegs 1022 that are formed in a number of rows 1024 a-c. In one example, thepegs 1022 have a height of no more than thelower support portion 104 of thehandle 110, e.g., 0.5 inch to 0.25 inch. More particularly, thepegs 1022 may have a height of no more than a height from thebase member 150 to therod channels 120, e.g. 0.25 inch to 0.125 inch. - In an embodiment, the number of rows 1024 a-c of the
pegs 1022 corresponds to the number ofrods 130. The rows 1024 extend lengthwise along thehandle 110 and are spaced equally distant apart along a width of thehandle 110. During manufacturing, a manufacturing rod is positioned on each of the rows 1024 ofpegs 1022, wherein a first end of the rod extends at least to a first end of the mold 1030 or overhangs the mold 1030 of thehandle 110. This position creates the opening of therod channel 120. A second end of the manufacturing rod is positioned within alast peg 1026 of a row 1024 and does not create an opening in a second end of the mold 1030. The manufacturing rods are sized in diameter equally to the plurality ofrods 130 for thesanding apparatus 100. In another embodiment, the manufacturing rods may be sized slightly larger or smaller than the diameter of the plurality ofrods 130. - The
pegs 1022 may include a slot for insertion of the manufacturing rod to hold the rod in place. Anend peg 1026 may include a concave slot with three sides to help form an end of therod channel 120. The NBR material is then injected into the mold 1030, and the manufacturing rods preform the plurality ofrod channels 120 in the material of thehandle 110. Therod channels 120 are thus preformed and sized to fit theinflexible rods 130. The manufacturing rods may comprise a metal or rubber and be repetitively used during the manufacturing process. - The
pegs 1022 form the plurality ofcavities 1000 in thebottom surface 1010 of thehandle 110 shown inFIG. 10A . The plurality ofcavities 1000 may help increase the flexibility of thesanding apparatus 100. Thehandle 110 may thus be made with a stiffer or stronger material, e.g., an NBR material with a higher Shore A hardness in a range of 45 A to 55 A or more particularly, approximately 50 A. This stronger and possibly more durable material may thus be used for thehandle 110 without sacrificing elasticity. - In addition, since the plurality of
cavities 1000 are formed on abottom surface 1010 of thehandle 110, there is no risk of pinching a user or impeding sanding by a user. In prior sanding apparatuses, cuts or slits were formed on a top or periphery surface of the sanding block. These slits could pinch a user and make it more difficult to apply force to the sanding apparatus, especially on curved surfaces when the slits or cuts would open wider. This present embodiment with the plurality ofcavities 1000 formed on the lower orbottom side 1010 of thehandle 110 of thesanding apparatus 100 alleviates these problems while still increasing the elasticity of thehandle 110. The base 150 may then be attached to thehandle 110 using, e.g., industrial adhesive or heat or a combination thereof. -
FIG. 11 illustrates an embodiment of amethod 1100 for manufacturing thesanding apparatus 100. Themethod 1100 atstep 1102 includes constructing a first mold for thehandle 110, wherein the lower mold includes one or more rows 1024 of a plurality ofpegs 1022. Each row 1024 of thepegs 1022 is configured to hold a manufacturing rod. Thepegs 1022 may include slits to hold the manufacturing rod or include other configurations. A manufacturing rod is positioned on each of the rows 1024 ofpegs 1022 atstep 1104. An upper mold is positioned against the lower mold, e.g., using pressure exerted by screws, bolts, or other means, atstep 1106. NBR material in a heated, liquid form is injected into the mold atstep 1108 to form thehandle 110 with the plurality ofrod channels 120. The NBR material of thehandle 110 cools and hardens to have, e.g., a Shore A Hardness in a range of 40 A to 60 A or more particularly, a Shore A Hardness in a range of 45 A to 55 A or more particularly, approximately 50 A. - At
step 1110, a thin sheet of polycarbonate is manufactured to form thebase 150. This step may be performed at any time, e.g., thebase 150 may be prefabricated to thehandle 110. Atstep 1112, thebase 150 is attached to thehandle 110, e.g., using an adhesive or heat or a combination thereof or other means. - The
sanding apparatus 100 described herein overcomes the various disadvantages identified in the prior known sanding apparatuses, such as the known sanding block described in the above referenced U.S. Pat. No. 6,544,113. First, thesanding apparatus 100 described herein includes athicker base member 150 comprised of polycarbonate. Thebase member 150 is still flexible and conforms to curved surfaces but is stronger than the thin stainless steel base member of the prior sanding apparatuses. Thebase member 150 herein is less prone to deformations and breakage and has strength to exert sufficient force on rough surfaces and protrusions to generate a smooth sanded surface. - Second, the
sanding apparatus 100 described herein hasrod channels 120 preformed in the rubber material of thehandle 110 during manufacture. There is no need for brackets with bracket rod reception channels attached to thehandle 110 as with the prior sanding apparatuses. There is no need for alignment between the brackets of the base member and the handle as in the prior sanding apparatus that creates additional steps and increases difficulties in manufacture and assembly. There is no bending or breaking of the brackets as in the prior sanding apparatus. Moreover, the elasticity of thehandle 110 holds therods 130 in position within therod channels 120 without need of the rod reception tubes as in the prior sanding apparatus. - Third, the
sanding apparatus 100 described herein has an improved profile to thehandle 110 that provides for better and easier gripping. For example, a flat middle section WFT of thehandle 110 applies a more uniform force to a sanding surface when a user's hand, e.g. palm, presses along the flat middle section WFT. In addition, the flat middle section WFT lowers a profile of thehandle 110 for easier grasping by a user's fingers of the gripping portions 170 a-b, especially for smaller hands. The height HGP of thehandle 110 is also decreased to further ease grasping of thehandle 110. - Further, in one embodiment, the
sanding apparatus 100 described herein includes a plurality ofcavities 1000 formed on abottom surface 106 of thehandle 110. Thesanding apparatus 100 may thus comprise a stiffer material in thehandle 110 and have an approximately similar overall elasticity when the plurality ofcavities 1000 is implemented, e.g., the NBR material of thehandle 110 may have a Shore A Hardness in a range of 40 A to 60 A rather than in a lower range of less than 40 A to 20 A. In prior sanding apparatuses, a plurality of cuts or indentations were positioned on a top gripping portion of the handle to enhance the flexibility of the handle portion. These cuts were prone to pinching a user and made it more difficult to apply pressure on the handle for sanding. The plurality ofcavities 1000 described herein formed on the lower orbottom side 106 of thehandle 110 alleviates these problems while still increasing the elasticity of thehandle 110. - The
sanding apparatus 100 described herein comprises two main parts, thehandle 110 and thebase member 150 that are attached adhesively or manufactured as one piece though dual injection molding. Thesanding apparatus 100 thus has less parts and less complicated manufacturing than the prior sanding apparatus. - The
sanding apparatus 100 may be used for paint removal and/or smoothing of panels or other surfaces of vehicles, such as automobiles, recreational vehicles, aircraft, boats, etc. In addition to vehicles, thesanding apparatus 100 may be used for sanding furniture, fences, or other objects. The sanding apparatus may be used for sanding metallic materials, wood, polycarbonate, ceramics, or other types of materials. - The
sanding apparatus 100 described herein thus has many advantages over prior known sanding apparatus. Additional and/or alternative advantages may be present in the embodiments described herein. For example, certain benefits, other advantages, and solutions to problems have been described above with regard to particular embodiments; however, any benefit, advantage, solution to a problem, or any element that may cause any particular benefit, advantage, or solution to occur or to become more pronounced are not to be construed as critical, required, or essential features or components of any or all the claims. - In the foregoing specification, certain representative aspects have been described with reference to specific examples. Various modifications and changes may be made, however, without departing from the scope of the present invention as set forth in the claims. The specification and figures are illustrative, rather than restrictive, and modifications are intended to be included within the scope of the present invention. Accordingly, the scope of the invention should be determined by the claims and their legal equivalents rather than by merely the examples described. For example, the components and/or elements recited in any apparatus claims may be assembled or otherwise operationally configured in a variety of permutations and are accordingly not limited to the specific configuration recited in the claims. As such, the present teachings can be readily applied to other types of apparatuses and many alternatives, modifications, and variations will be apparent to those skilled in the art.
- As may be used herein, the term “operable to” or “configurable to” indicates that an element includes one or more components, fasteners, or dimensions to perform one or more of the described or necessary corresponding functions and may further include inferred coupling to one or more other items to perform the described or necessary corresponding functions. As may also be used herein, the term(s) “coupled,” “coupled to,” “connected to” and/or “connecting” or “interconnecting” includes direct connection or and/or indirect connection through one or more other components. As may be used herein, the terms “substantially” and “approximately” provide an industry-accepted tolerance for its corresponding term and/or relativity between items.
- As used herein, the terms “comprise,” “comprises,” “comprising,” “having,” “including,” “includes” or any variation thereof, are intended to reference a nonexclusive inclusion, such that a process, method, article, composition or apparatus that comprises a list of elements does not include only those elements recited, but may also include other elements not expressly listed or inherent to such process, method, article, composition, or apparatus. Other combinations and/or modifications of the above-described structures, arrangements, applications, proportions, elements, materials, or components used in the practice of the present invention, in addition to those not specifically recited, may be varied, or otherwise particularly adapted to specific environments, manufacturing specifications, design parameters, or other operating requirements without departing from the general principles of the same.
- Moreover, reference to an element in the singular is not intended to mean “one and only one” unless specifically so stated, but rather “one or more.” Unless specifically stated otherwise, the term “some” refers to one or more. All structural and functional equivalents to the elements of the various aspects described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is intended to be construed under the provisions of 35 U.S.C. § 112(f) as a “means-plus-function” type element, unless the element is expressly recited using the phrase “means for” or, in the case of a method claim, the element is recited using the phrase “step for.”
Claims (20)
1. A sanding apparatus, comprising:
a flexible handle including a plurality of preformed rod channels, wherein the plurality of rod channels is preformed into the flexible handle; and
a flexible base member including:
a smooth top surface that is attached to a lower surface of the flexible handle; and
a smooth bottom surface configured for attachment to an abrasive material.
2. The sanding apparatus of claim 1 , wherein the flexible base member comprises a polycarbonate material and wherein the flexible handle comprises a rubber material.
3. The sanding apparatus of claim 1 , further comprising:
one or more inflexible rods configured for insertion into one or more of the plurality of preformed rod channels, wherein the one or more inflexible rods adjust a flexibility of the sanding apparatus.
4. The sanding apparatus of claim 3 , wherein an elasticity of the rubber material of the flexible handle holds the one or more inflexible rods in position within the one or more of the plurality of preformed rod channels.
5. The sanding apparatus of claim 4 , wherein the flexible handle is inflexible when at least one of the one or more inflexible rods is inserted in each of the plurality of preformed rod channels.
6. The sanding apparatus of claim 1 , wherein the flexible handle comprises:
a top surface including at least a flat middle section WFT extending lengthwise;
a lower support portion including the plurality of rod channels; and
a gripping portion including two indentations on opposing sides of the handle, wherein the gripping portion is positioned between the top surface and the lower support portion.
7. The sanding apparatus of claim 2 , wherein the flexible base member has a thickness in a range of approximately ⅛ inch to 1/16 inch.
8. The sanding apparatus of claim 1 , wherein the flexible handle has a height of approximately 1.4 to 1.6 inches.
9. The sanding apparatus of claim 1 , wherein the flexible base member has a width WBM equal to or less than a standard width of commercially available standard sanding paper.
10. The sanding apparatus of claim 1 , wherein the flexible base member has a length LBM of approximately one of: 8 inches, 16 inches, or 24 inches.
11. A sanding apparatus, comprising:
a flexible handle including a preformed plurality of rod channels, wherein the plurality of rod channels is preformed into the flexible handle;
a flexible base member attached to a lower surface of the flexible handle, wherein the flexible base member is a polycarbonate material; and
one or more rods configured for insertion into one or more of the plurality of preformed rod channels, wherein the one or more rods adjust a flexibility of the sanding apparatus.
12. The sanding apparatus of claim 11 , wherein the flexible base member comprises:
a smooth top surface that is attached to the lower surface of the flexible handle; and
a smooth bottom surface configured for attachment to an abrasive material.
13. The sanding apparatus of claim 11 , wherein the flexible handle comprises:
a top surface including at least a flat middle section WFT extending lengthwise;
a lower support portion including the plurality of rod channels; and
a gripping portion including two indentations on opposing sides of the handle, wherein the gripping portion is positioned between the top surface and the lower support portion.
14. The sanding apparatus of claim 11 , wherein the flexible base member comprises a polycarbonate material and wherein the flexible handle comprises a rubber material.
15. The sanding apparatus of claim 11 , wherein the flexible base member has a thickness of approximately ⅛ inch to 1/16 inch and wherein the flexible handle has a height of approximately 1.4 to 1.6 inches.
16. The sanding apparatus of claim 11 , wherein the flexible base member has a width WBM equal to or less than a standard width of commercially available standard sanding paper.
17. A method of manufacturing a sanding apparatus, comprising:
manufacturing a flexible handle including a plurality of rod channels, wherein the plurality of rod channels is preformed into the flexible handle, by:
in a lower mold, positioning one manufacturing rod of a plurality of manufacturing rods on each one of a plurality of rows of pegs;
attaching an upper mold to the lower mold; and
injecting a heated nitrile butadiene rubber (NBR) material in liquid form into the attached upper and lower molds, wherein the plurality of manufacturing rods forms the plurality of rod channels; and
manufacturing a flexible base member by forming a thin sheet of polycarbonate material, wherein the thin sheet has a thickness of approximately ⅛ inch to 1/16 inch; and
attaching the flexible base member to a lower surface of the flexible handle.
18. The method of claim 17 , wherein the plurality of rows of pegs forms a plurality of cavities on the lower surface of the flexible handle.
19. The method of claim 17 , further comprising:
manufacturing at least one inflexible rod for each of the plurality of rod channels in the flexible handle.
20. The method of claim 17 , wherein the flexible base member is attached to the lower surface of the flexible handle using one of: an adhesive, a heat process, or a combination of an adhesive and a heat process.
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US18/339,913 US20240001512A1 (en) | 2022-06-29 | 2023-06-22 | Sanding apparatus with adjustable flexibility |
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US202263356915P | 2022-06-29 | 2022-06-29 | |
US18/339,913 US20240001512A1 (en) | 2022-06-29 | 2023-06-22 | Sanding apparatus with adjustable flexibility |
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US20240001512A1 true US20240001512A1 (en) | 2024-01-04 |
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US18/339,913 Pending US20240001512A1 (en) | 2022-06-29 | 2023-06-22 | Sanding apparatus with adjustable flexibility |
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