Patent Publication Number: US-7901275-B2

Title: Sanding apparatus

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     Embodiments of the present invention generally relate to a sanding apparatus. More specifically, embodiments of the present invention relate to an improved sanding apparatus for minimizing scoring of drywall and other sensitive finishes. 
     2. Description of the Related Art 
     Sanding sponges are used extensively in a variety of different applications, including drywalling, woodworking, and metalworking. Standard sanding sponges are generally a substantially rectangular block of material covered on either four or all six sides with an abrasive aggregate composition. An exemplary prior art sanding sponge is shown in  FIG. 1 . As shown in the Figure, a sanding sponge  100  generally comprises a rectangular block having a core material covered on all four sides with an abrasive material. Optionally, the ends of the rectangular block may also have abrasive material disposed thereon. These standard sanding sponges have a high compressive force resistance, and are thus very rigid, leading to unwanted scoring of drywall or other working surfaces, as well as numerous injuries to hands, fingers, and other sensitive parts of the body. 
     Well known problems exist with standard sanding sponges when used in corners (i.e., between two perpendicular walls or between a wall and a ceiling). Specifically, abrasive scoring occurs along the outer edge of the sanding sponge, i.e., along the wall. Thus, it is very difficult to achieve an adequately sanded wall or surface using only a standard sanding sponge without resanding the side walls which were scored. 
     Attempts have been made to create corner sanding sponges, which are designed for overcoming the problems associated with standard sanding sponges when sanding corners. Exemplary corner sanding sponges can be found in United States Patent Application Publication No. 2004/0038634, published Feb. 26, 2004, as well as U.S. Pat. No. 6,439,988, issued Aug. 27, 2002. In each of these references, the sanding sponges disclosed are designed for corner sanding, and adapted for holding and gripping the sponge for performing the same. 
     However, while these references disclose advantageous corner sanding properties, each of the exemplary embodiments disclosed therein would not be suitable or desirable for flat sanding (i.e., sanding a portion of a wall distal from a corner). Particularly, the very limited surface area on any one given face of the respective sanding sponge would make flat sanding burdensome and time consuming. Furthermore, at times the opposing faces of these existing sanding sponges are not aligned with one another (i.e., one face is offset from its opposing face), such that when pressure is applied in the center of one side of the sanding sponge, it may not applied to the center of its opposite side causing uneven force about the flat surface. Thus, a person would be required to carry corner sanding sponges and standard sanding sponges in order to efficiently and satisfactorily finish sanding projects. 
     Therefore, there is a need in the industry for an improved sanding apparatus designed for both flat and corner sanding while overcoming the deficiencies extant in the prior art. 
     SUMMARY OF THE INVENTION 
     Embodiments of the present invention generally relate to an improved sanding apparatus for minimizing scoring of drywall and other sensitive finishes. In one embodiment of the present invention, a sanding apparatus comprises a flexible, resilient core having a top and bottom sanding surface, a first and second side sanding surface, and a first and second non-sanding surface, each disposed at an angle with respect to the top sanding surface and bottom sanding surface, respectively, and an abrasive aggregate composition disposed on the top sanding surface, bottom sanding surface and the first and second side sanding surfaces, wherein each of the first and second non-sanding surfaces are free of an abrasive aggregate composition. 
     In another embodiment of the present invention, a sanding apparatus comprises a flexible, resilient core having a top and bottom sanding surface, a first and second side sanding surface, and a first and second non-sanding surface, disposed at an angle with respect to the top sanding surface and bottom sanding surface, respectively, whereby each non-sanding surface is free of an abrasive aggregate composition, and an abrasive aggregate composition disposed on the top sanding surface, bottom sanding surface and the first and second side sanding surfaces, comprising at least one of garnet, emery, aluminum oxide, silicon carbide, alumina-zirconia, chromium oxide, calcium carbonate, diamond dust, pumice dust, novaculite, sand, silica, iron oxide, ceramic, or borazon, wherein the angle of the first non-sanding surface is between about 35° to about 70° with respect to the top sanding surface, and wherein the angle of the second non-sanding surface is between about 35° to about 70° with respect to the bottom sanding surface. 
     In yet another embodiment, a method of sanding a wall comprises providing a sanding apparatus having a flexible, resilient core having a top and bottom sanding surface, a first and second side sanding surface, and a first and second non-sanding surface, each disposed at an angle with respect to the top sanding surface and bottom sanding surface, respectively, and an abrasive aggregate composition disposed on the top sanding surface, bottom sanding surface and the first and second side sanding surfaces, wherein each of the first and second non-sanding surfaces are free of an abrasive aggregate composition; applying a compressing force on at least one of the top or bottom sanding surface; and moving the sanding apparatus across a surface of the wall, while applying the compressive force thereon. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       So the manner in which the above recited features of the present invention can be understood in detail, a more particular description of embodiments of the present invention, briefly summarized above, may be had by reference to embodiments, which are illustrated in the appended drawings. It is to be noted, however, the appended drawings illustrate only typical embodiments of embodiments encompassed within the scope of the present invention, and, therefore, are not to be considered limiting, for the present invention may admit to other equally effective embodiments, wherein: 
         FIG. 1  depicts a perspective view of an exemplary prior art sanding sponge; 
         FIG. 2  depicts a perspective view of a sanding apparatus in accordance with one embodiment of the present invention; and 
         FIG. 3  depicts a cross-sectional view of the sanding apparatus of  FIG. 2 . 
     
    
    
     The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims. As used throughout this application, the word “may” is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include”, “including”, and “includes” mean including but not limited to. To facilitate understanding, like reference numerals have been used, where possible, to designate like elements common to the figures. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Embodiments of the present invention generally relate to a sanding apparatus. More specifically, embodiments of the present invention relate to a sanding apparatus having two opposing edges removed and free of aggregate to minimize scoring of drywall and other sensitive finishes. 
       FIG. 2  depicts a perspective view of a sanding apparatus in accordance with one embodiment of the present invention, a cross-section of which is depicted in  FIG. 3 . Generally, a sanding apparatus  200  comprises at least a flexible, resilient core  202 , having a top sanding surface  204 , a first side sanding surface  206 , and a first non-sanding surface  208 . In many embodiments, the sanding apparatus additionally comprises a second bottom sanding surface  214 , a second side sanding surface  216 , and a second non-sanding surface  218 , all of which are mirrored about a diagonal plane passing through the entire length of the sanding apparatus  200 , as shown in  FIG. 3 , as axis d-d. The sanding apparatus  200  also comprises a first end and a second end, generally defined by a plane of the flexible, resilient core substantially perpendicular to each of surfaces of the sanding apparatus. It is understood by embodiments of the present invention, any reference to a single surface may apply to the single surface, its mirrored surface, or both. 
     The core  202  generally comprises a flexible, resilient material, capable of conforming slightly to the hand of a user. The core  202  is also generally able to withstand moderate compressive forces, such as those experienced by the sanding apparatus during drywalling and woodworking applications. In one embodiment of the present invention, the core  202  comprises either open-celled or closed-celled foamed polymeric material, for example, open-celled urethane-based foam, or the like. The sanding apparatus  200  also comprises a first end and a second end. The ends of the sanding apparatus 
     Each of the top sanding surfaces  204  and side sanding surfaces  206  generally comprise an abrasive aggregate disposed on the respective surfaces by way of adhesive or other means for attachment. In one embodiment, the abrasive aggregate comprise at least one of garnet, emery, aluminum oxide, silicon carbide, alumina-zirconia, chromium oxide, calcium carbonate, diamond dust, pumice dust, novaculite, sand, silica, iron oxide, ceramic, borazon, or the like. In alternative embodiments, the abrasive aggregate comprises at least one of the abrasive particles disclosed by U.S. Pat. No. 6,059,850, the disclosure of which is incorporated by reference herein. 
     The abrasive aggregate may be applied to any surface, in particular, the top sanding surface  204  and side sanding surface  206 , by any means suitable for embodiments of the present invention. In one embodiment, the abrasive aggregate is applied by applying a liquid adhesive over a surface, coating the liquid adhesive layer with the abrasive aggregate composition, and then drying the adhesive. In many embodiments, where open-celled polymers are utilized as the core  202 , the liquid adhesive may be substantially wicked into the core  202 , leaving only a thin adhesive meniscus around the abrasive aggregate particles, resulting in a more abrasive surface roughness. 
     The abrasive aggregate generally comprises any suitable abrasive particles having a median particle diameter from about 1 micron to about 600 microns (2000 to 30 grit). In one embodiment of the present invention, the top sanding surface  204  and side sanding surface  206  of the sanding apparatus  200  comprise abrasive aggregate particles of substantially uniform size. Optionally, in such an embodiment, the second sanding surface and second side sanding surface may comprise abrasive aggregate particles of either the same uniform size, or of a different size (and resulting grit), so as to differentiate between a fine grit pair of surfaces and a coarse grit pair of surfaces. 
       FIG. 3  depicts a cross-sectional view of the sanding apparatus of  FIG. 2 . In one embodiment of the present invention, a sanding apparatus  200  comprises a six-sided structure, cross-sectionally mirrored about an axis d-d, passing through two ninety degree edges  210 ,  220 . In such an embodiment, the first non-sanding surface  208  and the second non-sanding surface  218  are disposed at an angle α with respect to the top sanding surface  204  and bottom sanding surface  214 , respectively. In alternative embodiments of the present invention, the angle of the first non-sanding surface and second non-sanding surface may be different from one another. 
     In many embodiments of the present invention, the angle α is between about 35° and about 70°. In other embodiments, the angle α is between about 40° and about 50°, and in another embodiment, the angle α is about 45°. 
     The sanding apparatus  200  may be dimensions suitable for embodiments of the present invention. In accordance with many embodiments, the size of the first and second non-sanding surfaces  208  and  218  is dependent upon the angle α, as discussed supra, as well as the height of side sanding surfaces  206  and  216 , respectively. In one exemplary embodiment, the sanding apparatus  200  may have a width (from side sanding surface  206  to side sanding surface  216 ) of about 3 inches, a length (from first end to second end) of about 4 inches, and a thickness or height (from top sanding surface  204  to bottom sanding surface  214 ) of about one inch. In such an exemplary embodiment, the height of side sanding surfaces  206  and  216  may range from between about 1/32 inch (about 0.03125 inch) to about 31/32 inch (about 0.96875). In another exemplary embodiment, the height of side sanding surfaces  206  and  216  may range from between about ¼ inch (about 0.25 inch) to about ¾ inch (about 0.75). Some alternative embodiments of the present invention provide although the overall dimensions of the sanding apparatus  200  may vary as necessary, the general size ratios between respective surfaces is generally maintained. 
     In use, embodiments of the present invention may be utilized to ideally sand a surface, as well as corners, without causing undesirable scoring. In one embodiment, in order to sand a corner, the ninety degree edge  220  is positioned along the corner (i.e., positioned against the intersection of two walls, or wall and ceiling). A compressive force is placed on the top sanding surface  204 . At the same time, the sanding apparatus  200  is moved in a direction along the corner such that the ninety degree edge  220  remains aligned against the corner throughout the process. Upon completion, the resulting corner is smoothly sanded, and the adjacent surface remains unscored. 
     Furthermore, the sanding apparatus  200  may be utilized to advantageously sand a general surface (i.e., the center portion of a wall). In one embodiment, the bottom sanding surface  214  is placed against the surface to be sanded as a compressive force is placed on the top sanding surface. The sanding apparatus  200  is then moved along the surface, either in rotational, vertical, horizontal, or random direction, in order to smoothly sand the surface without causing undesirable scoring. 
     While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof.