Flexible Sanding Apparatus

The present non-provisional patent application is a continuation-in-part of U.S. Non-Provisional application Ser. No. 18/339,913 filed on Jun. 22, 2023 (US Patent Publication No. 2024/0001512), which claim the benefit of U.S. Provisional Application 63/356,915, filed on Jun. 29, 2022, both of which are incorporated herein by reference in their entirety and for all purposes as if completely and fully set forth herein.

This application relates to an apparatus for sanding, and more particularly, to a hand-held sanding block.

Hand-held sanding blocks are commonly used for sanding various types of surfaces, such as vehicles, furniture, buildings, etc. Typically, a sanding block has a flat side for attaching adhesive sanding material, such as sandpaper, 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 sanding block typically has six rectangular surfaces and is rigid (non-bendable). which makes sanding a curved surface difficult with a sanding block.

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 are described herein 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.

A sanding apparatus is described herein. The sanding apparatus includes a flexible handle. The sanding apparatus also includes a flexible base 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 (sandpaper). In some cases, the flexible base comprises a polycarbonate material.

A method of manufacturing a sanding apparatus is described herein and includes manufacturing a flexible handle, attaching an upper mold to a lower mold, and injecting a heated nitrile butadiene rubber (NBR) material in liquid form into the attached upper and lower molds. The method includes manufacturing a flexible base 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 to a lower surface of the flexible handle.

In some cases, the flexible base comprises a polycarbonate material and the flexible handle comprises a rubber-based material. In some cases, an elasticity of the rubber-based material of the flexible handle enables a user to exert pressure on either end of the flexible handle to enable the sanding device to curve to conform to a curve surface that is to be sanded. The flexible handle is straight (not curved) when pressure is not applied to either or both ends of the flexible handle.

In some cases, the flexible handle comprises a top surface with at least a flat middle section extending lengthwise, a lower support portion, 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 some cases, the flexible base has a thickness in the range of approximately ⅛ inch to 1/16 inch. In some cases, the flexible handle has a height of approximately 1.4 to 1.6 inches. In some cases, the base has a width equal to or less than the standard width of commercially available standard sandpaper. In cases, the base has a length between approximately 8 to 24 inches.

In some cases, the flexible base 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 some cases, the flexible handle includes a top surface including at least a flat middle section extending lengthwise, a lower support portion, and a gripping portion including two indentations on opposing sides of the handle, where the gripping portion is positioned between the top surface and the lower support portion. The flexible base 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.

In some cases, the flexible base and the flexible handle are machined, using a CNC machine, from a single polycarbonate block. In other cases, the flexible base may be machined, using a CNC machine, from a first polycarbonate block, the flexible handle may be machined, using the CNC machine, from a second polycarbonate block, and the flexible handle may be attached to flexible base using an adhesive, a heat process, or a combination of both.

illustrates an exploded perspective view of exemplary embodiments of parts of a sanding apparatuswith adjustable flexibility. A flexible handleincludes an upper gripping portionand a lower support portion. The upper gripping portionis configured for grasping and exerting pressure manually on the sanding apparatus. The lower support portionof the handleincludes a relatively flat, rectangular bottomconfigured for attachment to a flexible base.

In some cases, a precision, smooth top surfaceof the baseis attached to the bottom sideof the handleusing an adhesive, using a heat process, or a combination thereof. In other cases, the baseand handleare manufactured as one piece. For example, the baseand handlemay be manufactured as one piece using a multi-shot injection molding process wherein a first material is injected into a mold to create the baseand a second material is injected into the mold to create the handle. As another example, the baseand handlemay be manufactured as one piece by taking a block of polycarbonate foam and using a computer numeric control (CNC) machine to shape the baseand the handle.

The baseincludes a precise smooth lower surfaceconfigured for attachment of an abrasive material. The abrasive materialincludes an adhesive surfaceand an abrasive surface. The abrasive materialis attached to the bottom surfaceof the baseusing the adhesive surface, while the abrasive surfaceis left exposed. For example, the abrasive materialmay be adhesive backed sandpaper, where a protective paper layer is peeled away to expose the adhesive surfaceof the abrasive material.

The handleextends lengthwise from a first endof the handleto a second end. In some cases, the handlecomprises a flexible material, such as rubber-based material, or more particularly a foam rubber-based material or nitrile butadiene rubber (NBR). For example, the flexible material of the handlemay have a Shore A Hardness Scale in a range of 20A to less than 40A or more particularly, a Shore A Hardness Scale of approximately 30A. The flexible material may thus be categorized as soft to medium soft along the Shore A Hardness Scale. In other cases, the flexible material of the handlemay have a Shore A Hardness in a range of 40A to 60A or more particularly, a Shore A Hardness in a range of 45A to 55A or more particularly, approximately 50A. This generates flexibility in the handlewhile maintaining durability. The flexible material of the handlealso 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.

The flexible basecomprises 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 the base. The baseis flexible enough to conform to curved surfaces without deformity while also maintaining strength to apply pressure to protrusions in a sanding surface.

In some cases, the flexible baseand the flexible handleare machined, using a CNC machine, from a single polycarbonate block. In other cases, the flexible basemay be machined, using a CNC machine, from a first polycarbonate block, the flexible handlemay be machined, using the CNC machine, from a second polycarbonate block, and the flexible handlemay be attached to the flexible baseusing the adhesive, a heat process, or a combination of both.

The base, 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 the baseprovides strength while maintaining flexibility.

illustrates a side perspective view of an exemplary embodiment of the sanding apparatuswith adjustable flexibility. The sanding apparatus has a height Hbetween 1.5 inches to 2.0 inches. The basemay have a thickness or height Hin 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. The handlehas 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.

illustrates a perspective view of the lower surface of an exemplary embodiment of the sanding apparatuswith adjustable flexibility. The lower surface of the sanding apparatusillustrated shows the lower or bottom surfaceof the base. In one embodiment, the basehas a width Wequal to or less than a standard width of commercially available standard sandpaper. For example, the basehas a width Wbetween 2 inches to 3 inches wide, and more particularly 2.625 inches wide. Current standard sandpaper is approximately 3 inches wide. With the basehaving a width Wless than 3 inches, the standard-sized sandpaper may extend the width of the baseand include excess on the sides to fold or curl over the baseand/or handle. In other embodiments, the basemay have a width Wof 3 inches to fit a standard sized 3 inch sandpaper without folding. The basemay thus fit within the width of commercially available sandpaper. However, the baseand/or the sanding apparatusare not constrained to the widths described herein. Other widths of the sanding apparatusand/or the basemay also be implemented depending on the application.

The length LBM of the baseis 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. The sanding apparatus, and/or the handleand/or the baseare not constrained to the lengths described herein. Other lengths of the sanding apparatusmay also be implemented depending on the application.

illustrates a side view of an exemplary embodiment of one endof the sanding apparatuswith adjustable flexibility. The handleincludes two gripping portionsand. The gripping portions,are between the top surface of the handleand a lower support portionof the handle. The gripping portions,include opposing lengthwise indentations on each side of the handlefor easier gripping and maneuvering of the sanding apparatus. The gripping portions,may extend lengthwise to a full length of the handleas shown or to only a portion of the length of the handle.

In some cases, the handleincludes rounded top edgeslengthwise that extend from the indentations of the gripping portions-and meet at a relatively flat top surfaceof the handle. For example, the side profiles of the handlemay have a rounded or contoured lengthwise top edgesthat end with the relatively flat top surfaceof the handle. The top surfaceof the handleincludes at least a flat middle section W, extending lengthwise and parallel to the base. The flat middle section Wmay have a length extending from one endof the handleto the other endof the handle, as shown in, or extend partially lengthwise. The flat middle section Wmay have a width of 1 inch to 2 inch, or more particularly 1.5 inches. The flat middle section Wgenerates 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 W. In addition, the flat middle section Wlowers a profile of the handlefor easier grasping by a user's fingers of the gripping portions-, especially for smaller hands. The height Hof the handlefrom the top surfaceof the handleto a start of the lower supportof the handlemay also be decreased from prior known blocks, e.g. to a height Hof 1 inch-1.25 inches, to further ease grasping of the gripping portions-. This decreased height Hhelps a user to grip the handle and apply pressure to the sanding surface.

The side view of the sanding apparatusalso illustrates the lower support portionof the handle. The support portionis positioned between the gripping portions,of the handleand the base.

illustrates how an exemplary embodiment of the sanding apparatus can be used to sand a straight (non-curved) surface. A user may apply relatively even pressure along the top of the handleto sand a relatively straight (non-curved) surface.

illustrates how an exemplary embodiment of the sanding apparatus can be used to sand a curved surface. A user may apply pressure to both ends of the handle(as illustrated by the arrows in, to cause the sanding apparatusto bend, to enable the user to sand a curved surface. The amount of pressure applied to both ends of the handledetermines an amount of curvature of the sanding surface of the sanding apparatus. For example, applying a relatively large amount of pressure to both ends of the handlecreates a relatively large amount of curvature while applying a relatively small amount of pressure to both ends of the handlecreates a relatively small amount of curvature. Thus, the user can, by varying the amount of pressure applied to both ends of the handle, cause the sanding apparatus to conform to a variety of curved surfaces.

illustrates a processto manufacture the sanding apparatus. At, a lower mold for a handle is obtained. At, an upper mold is positioned against the lower mold, e.g., using pressure exerted by screws, bolts, or other means. At, NBR material in a heated, liquid form is injected into the mold to form the handle. The NBR material of the handlecools and hardens to have, e.g., a Shore A Hardness in a range of 40A to 60A or more particularly, a Shore A Hardness in a range of 45A to 55A or more particularly, approximately 50A.

At, a thin sheet of polycarbonate is manufactured to form the base. This step may be performed at any time. For example, the basemay be prefabricated to the handle. At, the baseis attached to the handle, e.g., using an adhesive, heat, or a combination of both, or any other means of attachment.

The sanding apparatusdescribed herein enables both straight and curved surfaces to be sanded. The sanding apparatusdescribed herein has an improved profile to the handlethat provides for better and easier gripping. For example, a flat middle section Wof the handleapplies a more uniform force to a sanding surface when a user's hand, e.g. palm, presses along the flat middle section W. In addition, the flat middle section Wlowers a profile of the handlefor easier grasping by a user's fingers of the gripping portions,, especially for smaller hands. The height Hof the handleis also decreased to further ease grasping of the handle.

In some cases, the NBR material of the handlemay have a Shore A Hardness in a range of 40A to 60A rather than in a lower range of less than 40A to 20A. The plurality of cavities described herein formed on the lower or bottom sideof the handlealleviates issues gripping the handle while increasing the elasticity of the handle. The sanding apparatusdescribed herein comprises two main parts, the handleand the basethat are attached adhesively or manufactured as one piece though dual injection molding. The sanding apparatusthus has relatively few parts and is less complicated manufacturing.

The sanding apparatusmay 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, the sanding apparatusmay 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.

illustrates a second processto manufacture a sanding apparatus. Ata polycarbonate block is shaped (machined) using a CNC machine to create a flexible handle. At, the process determines if a single polycarbonate block is being used to create both the flexible handle and the flexible base. If the process determines, at, that “no” a single polycarbonate block is not being used to create both the flexible handle and the flexible base, then, at, a second polycarbonate block is shaped (machined) using the CNC machine to create a flexible base. At, the flexible base is attached to the flexible handle using an adhesive, a heat process, or a combination of both. For example, in, a polycarbonate block is shaped (machined) using a CNC machine to create the flexible handle. If a single polycarbonate block is not being used to create both the flexible handle and the flexible base then a second polycarbonate block is shaped (machined) using the CNC machine to create a flexible base. The flexible baseis attached to the flexible handleusing the adhesive, a heat process, or a combination of both.

If the process determines, at, that “yes” a single polycarbonate block is being used to create both the flexible handle and the flexible base, then, at, the polycarbonate block is shaped (machined) using the CNC machine to create a flexible base. For example, in, a polycarbonate block is shaped (machined) using a CNC machine to create the flexible handle. If a single polycarbonate block is being used to create both the flexible handleand the flexible basethen the polycarbonate block is shaped (machined) using the CNC machine to create the flexible base. In this way, the flexible baseand the flexible handleare machined out of a single polycarbonate block using CNC machine.

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.”

This disclosure provides various example implementations, as described and as illustrated in the drawings. However, this disclosure is not limited to the implementations described and illustrated herein, but can extend to other implementations, as would be known or as would become known to those skilled in the art. Reference in the specification to “one implementation,” “this implementation,” “these implementations” or “some implementations” means that a particular feature, structure, or characteristic described is included in at least one implementation, and the appearances of these phrases in various places in the specification are not necessarily all referring to the same implementation.

Although the present invention has been described in connection with several embodiments, the invention is not intended to be limited to the specific forms set forth herein. On the contrary, it is intended to cover such alternatives, modifications, and equivalents as can be reasonably included within the scope of the invention as defined by the appended claims.