FLEXIBLE SANDING APPARATUS

Abstract

As an example, a hand-held sanding apparatus has flexibility to enable a user to sand relatively straight surfaces as well as curved surfaces. A flexible base is attached to a lower surface of a flexible handle and includes a smooth bottom surface configured for attachment to an abrasive material, such as sandpaper or another similar material. The flexible base may comprise a polycarbonate material. The flexible handle may comprise a rubber-based material. A user applying pressure to opposite ends of the flexible handle is able to curve the hand-held sanding apparatus to enable the abrasive material to conform to a curvature of a surface that is to be sanded.

Claims

1. A sanding apparatus comprising: a flexible handle; and 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.

2. The sanding apparatus of claim 1, wherein: the flexible base comprises a polycarbonate material; and the flexible handle comprises the polycarbonate material.

3. The sanding apparatus of claim 2, wherein: the flexible base has a thickness that is within a range of between approximately inch to approximately 1/16 inch.

4. The sanding apparatus of claim 1, wherein: applying pressure to both ends of the handle cause the smooth bottom surface to curve to conform to a curved surface.

5. The sanding apparatus of claim 1, wherein the flexible handle comprises: a top surface including at least a flat middle section extending lengthwise.

6. The sanding apparatus of claim 1, wherein: the flexible base has a thickness in a range of approximately inch to 1/16 inch.

7. The sanding apparatus of claim 1, wherein: the flexible handle has a height of between approximately 1.25 to approximately 2.0 inches.

8. The sanding apparatus of claim 1, wherein: the flexible base has a width equal to or less than a standard width of commercially available standard sandpaper.

9. The sanding apparatus of claim 1, wherein: the flexible base has a length of between approximately 8 inches to approximately 24 inches.

10. A sanding apparatus comprising: a flexible handle; and a flexible base attached to a lower surface of the flexible handle, wherein the flexible base is a polycarbonate material.

11. The sanding apparatus of claim 8, the flexible base comprising: 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.

12. The sanding apparatus of claim 8, the flexible base comprising: 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, the gripping portion positioned between the top surface and the lower support portion.

13. The sanding apparatus of claim 8, wherein: the flexible base comprises a polycarbonate material; and the flexible handle comprises a rubber-based material.

14. The sanding apparatus of claim 8, wherein: the flexible base has a thickness of between approximately inch to approximately 1/32 inch; and the flexible handle has a height of approximately 1.25 to 2.0 inches.

15. A method of manufacturing a sanding apparatus, the method comprising: one or more processors; and one or more non-transitory computer-readable storage media to store instructions executable by the one or more processors to perform operations comprising: manufacturing a flexible handle by machining a polycarbonate block; manufacturing a flexible base by forming a thin sheet of polycarbonate material, wherein the thin sheet has a thickness of between approximately inch to approximately 1/32 inch; and attaching the flexible base to a lower surface of the flexible handle.

16. The method of claim 15, wherein: the flexible base is attached to the lower surface of the flexible handle using an adhesive, a heat process, or a combination of an adhesive and a heat process.

17. The method of claim 15, wherein: the flexible base and the flexible handle are machined from the polycarbonate block.

18. The method of claim 15, wherein: the flexible base is machined from a second polycarbonate block.

19. The method of claim 16, wherein: the flexible base has a thickness of approximately inch to 1/16 inch.

20. The method of claim 16, wherein: the flexible handle has a height of approximately 1.25 to 2.0 inches.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0004] A more complete understanding of the present disclosure may be obtained by reference to the following Detailed Description when taken in conjunction with the accompanying Drawings. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same reference numbers in different figures indicate similar or identical items.

[0005] FIG. 1 illustrates an exploded perspective view of exemplary embodiments of parts of a sanding apparatus with adjustable flexibility.

[0006] FIG. 2A illustrates a side perspective view of an exemplary embodiment of the sanding apparatus with adjustable flexibility.

[0007] FIG. 2B illustrates a perspective view of the lower surface of an exemplary embodiment of the sanding apparatus with adjustable flexibility.

[0008] FIG. 3 illustrates a side view of an exemplary embodiment of a first end of the sanding apparatus with adjustable flexibility.

[0009] FIG. 4A, 4B illustrate how an exemplary embodiment of the sanding apparatus can be used to sand a curved surface.

[0010] FIG. 5 illustrates a first process to manufacture a sanding apparatus.

[0011] FIG. 6 illustrates a second process to manufacture a sanding apparatus.

DETAILED DESCRIPTION

[0012] 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.

[0013] 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.

[0014] 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.

[0015] 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 inch to 1/16 inch and attaching the flexible base to a lower surface of the flexible handle.

[0016] 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.

[0017] 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 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.

[0018] 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.

[0019] 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.

[0020] FIG. 1 illustrates an exploded perspective view of exemplary embodiments of parts of a sanding apparatus 100 with adjustable flexibility. A flexible handle 110 includes an upper gripping portion 102 and a lower support portion 104. The upper gripping portion 102 is configured for grasping and exerting pressure manually on the sanding apparatus 100. The lower support portion 104 of the handle 110 includes a relatively flat, rectangular bottom 106 configured for attachment to a flexible base 150.

[0021] In some cases, a precision, smooth top surface 152 of the base 150 is attached to the bottom side 106 of the handle 110 using an adhesive 151, using a heat process, or a combination thereof. In other cases, the base 150 and handle 110 are manufactured as one piece. For example, the base 150 and handle 110 may be manufactured as one piece using a multi-shot injection molding process wherein a first material is injected into a mold to create the base 150 and a second material is injected into the mold to create the handle 110. As another example, the base 150 and handle 110 may be manufactured as one piece by taking a block of polycarbonate foam and using a computer numeric control (CNC) machine to shape the base 150 and the handle 110.

[0022] The base 150 includes a precise smooth lower surface 154 configured for attachment of an abrasive material 153. The abrasive material 153 includes an adhesive surface 190 and an abrasive surface 192. The abrasive material 153 is attached to the bottom surface 154 of the base 150 using the adhesive surface 190, while the abrasive surface 192 is left exposed. For example, the abrasive material 153 may be adhesive backed sandpaper, where a protective paper layer is peeled away to expose the adhesive surface 190 of the abrasive material 153.

[0023] The handle 110 extends lengthwise from a first end 160 of the handle 110 to a second end 162. In some cases, the handle 110 comprises 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 handle 110 may 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 handle 110 may 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 handle 110 while maintaining durability. The flexible material of the handle 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.

[0024] The flexible base 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 the base 150. The base 150 is flexible enough to conform to curved surfaces without deformity while also maintaining strength to apply pressure to protrusions in a sanding surface.

[0025] In some cases, the flexible base 150 and the flexible handle 110 are machined, using a CNC machine, from a single polycarbonate block. In other cases, the flexible base 150 may be machined, using a CNC machine, from a first polycarbonate block, the flexible handle 110 may be machined, using the CNC machine, from a second polycarbonate block, and the flexible handle 110 may be attached to the flexible base 150 using the adhesive 151, a heat process, or a combination of both.

[0026] The base 150, due to the flexibility of the polycarbonate material, may have a thickness in a range of approximately inch to 1/16 inch. This thickness of the base 150 provides strength while maintaining flexibility.

[0027] FIG. 2A illustrates a side perspective view of an exemplary embodiment of the sanding apparatus 100 with adjustable flexibility. The sanding apparatus has a height H.sub.SA between 1.5 inches to 2.0 inches. The base 150 may have a thickness or height H.sub.BM in a range of approximately inch to 1/16 inch or more particularly, 0.08 inches. This thickness provides strength but flexibility to the base. The handle 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.

[0028] FIG. 2B illustrates a perspective view of the lower surface of an exemplary embodiment of the sanding apparatus 100 with adjustable flexibility. The lower surface of the sanding apparatus 100 illustrated shows the lower or bottom surface 154 of the base 150. In one embodiment, the base 150 has a width W.sub.BM equal to or less than a standard width of commercially available standard sandpaper. For example, the base 150 has a width W.sub.BM between 2 inches to 3 inches wide, and more particularly 2.625 inches wide. Current standard sandpaper is approximately 3 inches wide. With the base 150 having a width W.sub.BM less than 3 inches, the standard-sized sandpaper may extend the width of the base 150 and include excess on the sides to fold or curl over the base 150 and/or handle 110. In other embodiments, the base 150 may have a width W.sub.BM of 3 inches to fit a standard sized 3 inch sandpaper without folding. The base 150 may thus fit within the width of commercially available sandpaper. However, the base 150 and/or the sanding apparatus 100 are not constrained to the widths described herein. Other widths of the sanding apparatus 100 and/or the base 150 may also be implemented depending on the application.

[0029] The length LBM of the base 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. The sanding apparatus 100, and/or the handle 110 and/or the base 150 are not constrained to the lengths described herein. Other lengths of the sanding apparatus 100 may also be implemented depending on the application.

[0030] FIG. 3 illustrates a side view of an exemplary embodiment of one end 160 of the sanding apparatus 100 with adjustable flexibility. The handle 110 includes two gripping portions 170a and 170b. The gripping portions 170a, 170b are between the top surface of the handle 110 and a lower support portion 104 of the handle 110. The gripping portions 170a, 170b include opposing lengthwise indentations on each side of the handle 110 for easier gripping and maneuvering of the sanding apparatus 100. The gripping portions 170a, 170b may extend lengthwise to a full length of the handle 110 as shown or to only a portion of the length of the handle 110.

[0031] In some cases, the handle 110 includes rounded top edges 180 lengthwise that extend from the indentations of the gripping portions 170a-b and meet at a relatively flat top surface 172 of the handle 110. For example, the side profiles of the handle 110 may have a rounded or contoured lengthwise top edges 180 that end with the relatively flat top surface 172 of the handle 110. The top surface 172 of the handle 110 includes at least a flat middle section W.sub.FT, extending lengthwise and parallel to the base 150. The flat middle section W.sub.FT may have a length extending from one end 160 of the handle 110 to the other end 162 of the handle 110, as shown in FIG. 3, or extend partially lengthwise. The flat middle section W.sub.FT may have a width of 1 inch to 2 inch, or more particularly 1.5 inches. The flat middle section W.sub.FT 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 W.sub.FT. In addition, the flat middle section W.sub.FT lowers a profile of the handle 110 for easier grasping by a user's fingers of the gripping portions 170a-b, especially for smaller hands. The height H.sub.GP of the handle 110 from the top surface 172 of the handle 110 to a start of the lower support 104 of the handle 110 may also be decreased from prior known blocks, e.g. to a height H.sub.GP of 1 inch-1.25 inches, to further ease grasping of the gripping portions 170a-b. This decreased height H.sub.GP helps a user to grip the handle and apply pressure to the sanding surface.

[0032] The side view of the sanding apparatus 100 also illustrates the lower support portion 104 of the handle 110. The support portion 104 is positioned between the gripping portions 170, 170b of the handle 110 and the base 150.

[0033] FIG. 4A 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 handle 110 to sand a relatively straight (non-curved) surface.

[0034] FIG. 4B 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 110 (as illustrated by the arrows in FIG. 4B, to cause the sanding apparatus 100 to bend, to enable the user to sand a curved surface. The amount of pressure applied to both ends of the handle 110 determines 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 handle 110 creates a relatively large amount of curvature while applying a relatively small amount of pressure to both ends of the handle 110 creates a relatively small amount of curvature. Thus, the user can, by varying the amount of pressure applied to both ends of the handle 110, cause the sanding apparatus to conform to a variety of curved surfaces.

[0035] FIG. 5 illustrates a process 500 to manufacture the sanding apparatus 100. At 502, a lower mold for a handle is obtained. At 504, an upper mold is positioned against the lower mold, e.g., using pressure exerted by screws, bolts, or other means. At 506, NBR material in a heated, liquid form is injected into the mold to form the handle 110. The NBR material of the handle 110 cools 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.

[0036] At 508, a thin sheet of polycarbonate is manufactured to form the base 150. This step may be performed at any time. For example, the base 150 may be prefabricated to the handle 110. At 510, the base 150 is attached to the handle 110, e.g., using an adhesive, heat, or a combination of both, or any other means of attachment.

[0037] The sanding apparatus 100 described herein enables both straight and curved surfaces to be sanded. The sanding apparatus 100 described herein has an improved profile to the handle 110 that provides for better and easier gripping. For example, a flat middle section W.sub.FT of the handle 110 applies a more uniform force to a sanding surface when a user's hand, e.g. palm, presses along the flat middle section W.sub.FT. In addition, the flat middle section W.sub.FT lowers a profile of the handle 110 for easier grasping by a user's fingers of the gripping portions 170a, 170b, especially for smaller hands. The height H.sub.GP of the handle 110 is also decreased to further ease grasping of the handle 110.

[0038] In some cases, the NBR material of the handle 110 may 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 side 106 of the handle 110 alleviates issues gripping the handle while increasing the elasticity of the handle 110. The sanding apparatus 100 described herein comprises two main parts, the handle 110 and the base 150 that are attached adhesively or manufactured as one piece though dual injection molding. The sanding apparatus 100 thus has relatively few parts and is less complicated manufacturing.

[0039] 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, the sanding 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.

[0040] FIG. 6 illustrates a second process 600 to manufacture a sanding apparatus. At 604 a polycarbonate block is shaped (machined) using a CNC machine to create a flexible handle. At 604, 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 604, that no a single polycarbonate block is not being used to create both the flexible handle and the flexible base, then, at 606, a second polycarbonate block is shaped (machined) using the CNC machine to create a flexible base. At 608, the flexible base is attached to the flexible handle using an adhesive, a heat process, or a combination of both. For example, in FIG. 1, a polycarbonate block is shaped (machined) using a CNC machine to create the flexible handle 110. 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 150. The flexible base 150 is attached to the flexible handle 110 using the adhesive 151, a heat process, or a combination of both.

[0041] If the process determines, at 604, that yes a single polycarbonate block is being used to create both the flexible handle and the flexible base, then, at 610, the polycarbonate block is shaped (machined) using the CNC machine to create a flexible base. For example, in FIG. 1, a polycarbonate block is shaped (machined) using a CNC machine to create the flexible handle 110. If a single polycarbonate block is being used to create both the flexible handle 110 and the flexible base 150 then the polycarbonate block is shaped (machined) using the CNC machine to create the flexible base 150. In this way, the flexible base 150 and the flexible handle 110 are machined out of a single polycarbonate block using CNC machine.

[0042] 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.

[0043] 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.

[0044] 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.

[0045] 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.

[0046] 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.

[0047] 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.

[0048] 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.