Patent Publication Number: US-2012040594-A1

Title: Sanding apparatus and method of manufacture

Description:
This application claims benefit to a provisional application No. 60/657,461 filed on Mar. 1, 2005 which is hereby incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to surface finishing tools. Particularly, the present invention relates to flexible sanding tools. More particularly, the present invention relates to resilient sanding blocks that can be used in conjunction with a holder to improve the user&#39;s grip and which can be used in conjunction with components of existing surface finishers to form a dustless sanding system. 
     2. Description of the Related Art 
     Dustless sanding tools and dustless sanding have been known and practiced in the construction trades for a number of years. Known dustless sanding tools comprise a handle that connects to a vacuum source, and a sanding element, such as a sanding screen, which attaches to the bottom surface of the tool by means of clamping mechanisms. Such bottom surfaces are provided with through holes or grooves that are in communication with the vacuum source, and over which the sanding screen is positioned. In operation, dust is ducked through apertures in the screen and the grooves or through holes and is deposited into a collection receptacle. 
     Such dustless sanding tools have many disadvantages. They are not useful for small jobs, or jobs that have a limited amount of space in which to operate. They are not economical, especially for small jobs, because the user must purchase a hand held tool as well as an abrasive sanding screen, which are not inexpensive. Additionally, existing dustless sanding tools are designed to work only in a reciprocating motion and often, the suction force developed by the vacuum causes the sander to be clamped to the surface being sanded. Another drawback is that the bottom surface is made from relatively rigid material such as plastic or hard rubber. This makes it difficult, if not impossible, to sand a curved or undulating surface. Further, the hard bottom commonly leaves relatively deep grooves in drywall that requires subsequent re-finishing. Moreover, these known dustless sanding tools are large, heavy and cumbersome. 
     There is a need for a sanding tool that has the abrasive material incorporated into the tool itself, rather than requiring an abrasive material be attached to a tool. There is a need for a sanding tool made of a resilient material so the tool that is able to conform to irregular surfaces. There is a need for a sanding tool that is inexpensive to manufacture and disposable. There is a need for a compact and lightweight dustless sanding tool. There is a need for a resilient sanding block that can be used with existing dustless sanding components. And, there is a need for a small, portable, dustless sanding system that can be easily transported about a job site. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to increase the utility of known sanding tools that may be optionally connected to a-vacuum device. The present invention achieves this objective by providing an existing resilient sanding block having a centrally located through hole or aperture and one or more channels located and formed on sanding surfaces of the block. The aperture may be directly connected to a vacuum source or it may be attached to a holder that directs a vacuum source to the sanding surface of the resilient sanding block. The block may be more than one aperture or through holes depending on the particular type of holder that will be used in conjunction with the block. 
     More specifically, the resilient sanding block has a plurality of surfaces including a first and second major surface. Abrasive material may be disposed on one or both of the major surfaces. The channels on the major surfaces may be formed in a variety of patterns and are generally in communication with the aperture. When a suction force is applied to the aperture, dirt and dust will travel through the channels and then up through the aperture. From there, the dirt and dust will be directed towards the vacuum source and into a collection receptacle. If the resilient block is attached to a holder, the dirt and dust will travel from the channel, through the aperture and into the holder, which will direct the debris toward the vacuum source and into the collection receptacle. 
     A resilient sanding block of the present invention may be manufactured by taking an existing block with an abrasive material disposed on at least one major surface and forming at least one through hole or aperture between the major surfaces of the block. Channels may then be formed to be in communication with the aperture(s). The resilient sanding block of the present invention may also be manufactured by first forming channels in the major surfaces of the block and then forming a though hole between the major surfaces of the block. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of one embodiment of the resilient sanding block of the present invention showing a first major material working surface; 
         FIG. 2  is side elevational view of the embodiment of  FIG. 1 ; 
         FIG. 3  is an inverted perspective view of the resilient sanding block of  FIG. 1  showing a second major material working surface; 
         FIG. 4  is a perspective view of another embodiment of the resilient sanding block of the present invention; 
         FIG. 5  is a partial side elevational, partial cross-sectional view of resilient sanding block of  FIG. 4 ; 
         FIG. 6  is an overhead perspective view of one embodiment of a sanding system comprising a resilient sanding block of the present invention in association with a holder; 
         FIG. 7  is a cross-sectional, side elevational view of the sanding system of  FIG. 6 ; 
         FIG. 8  is a cross-sectional view of another embodiment of a sanding system comprising a resilient sanding block of the present invention in association with an alternatively configured holder; 
         FIG. 9  is a top plan view of the embodiment of  FIG. 8 ; 
         FIG. 10   a  is a cross-sectional, side elevational view of another embodiment of a sanding system that is similar to the sanding system as shown in  FIG. 8 ; 
         FIG. 10   b  is a side elevational, cross-sectional, split view of alternative methods for attaching a resilient sanding block to a holder; 
         FIG. 11  is a partial bottom plan view of the sanding system of  FIG. 10   a  showing portion resilient sanding block in conjunction with the holder of  FIG. 10   a;    
         FIG. 12  is an overhead perspective view of an embodiment of a holder of the present invention; 
         FIG. 13  is a cross-sectional view of the holder of  FIG. 12 ; 
         FIG. 14  is an inverted, overhead, perspective, cut-away view of the holder of  FIGS. 12 and 13 ; 
         FIG. 15  is an exploded perspective view of a sanding system comprising a resilient sanding block, the holder of  FIGS. 12-14 , and a handle; 
         FIG. 16  is an overhead perspective view of another embodiment of a sanding system that is configured to be used with a job-specific resilient sanding block; 
         FIG. 17  is a side elevational, cross-sectional view of the sanding system of  FIG. 16 ; 
         FIG. 18  is a cross-sectional bottom plan view of the sanding system of  FIG. 16 ; 
         FIG. 19  is an overhead, perspective view of alternative embodiment of a sanding system comprising a resilient sanding block and a holder that functions as a handle; 
         FIG. 20  is a side elevational, cross-sectional view of the sanding system of  FIG. 19 ; 
         FIG. 21  is a bottom, cross-sectional plan view of the sanding system of  FIG. 19 ; 
         FIG. 22  is an exploded perspective view of another embodiment of a sanding system of the present invention in which an abrasive sheet is attached to a resilient block, and the resilient block us received within a reinforced holder; 
         FIG. 23  is side elevational view of an embodiment of a machine used to manufacture the resilient sanding block of the present invention; 
         FIG. 24  is a partial, side elevational end view of the machine of in  FIG. 23 ; and 
         FIG. 25  is a partial top view of the machine of  FIG. 23  with the upper blades removed for clarity. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The present invention is illustrated in  FIGS. 1-25 .  FIG. 1  shows a perspective view and  FIG. 2  shows and end view of the preferred embodiment of the present invention. Generally, the resilient sanding block  10  comprises a core  12 , major surfaces  24 ,  26 , side surfaces  16 ,  20 , and end surfaces  18 ,  22 . More specifically, a first major surface  24  is best shown in  FIG. 1  and the second major surface  26  is best shown in  FIG. 3 . The resilient sanding block  10  comprises a core  12  having primary channels  42   a ,  44   a ,  44   b ,  46   a ,  48   a ,  48   b ,  50   a ,  52   a ,  52   b ,  54   a ,  56   a , and  56   b  that are in communication with an aperture  80 . The core  12  further comprises secondary channels  60   a ,  60   b ,  62   a ,  62   b ,  64   a ,  64   b ,  66   a ,  66   b ,  68   a ,  68   b ,  70   a ,  70   b ,  72   a ,  72   b ,  74   a , and  74   b  that are in communication with the primary channels  42 - 56 . The core  12  is made of a resilient material, preferably polyurethane foam, foam rubber or sponge. However, it will be understood that other materials having similar properties may be used without departing from the sprit and scope of the invention. Preferably, the resilient sanding block  10  has have a height of about 1 to about 5 cm, more preferably about 2 to about 3 cm. In this embodiment, the resilient sanding block  10  has two layers of abrasive material  30   a ,  30   b  disposed on its first and second major surfaces  24 ,  26 , respectively. 
     In this present embodiment, an aperture or through hole  80  is formed in the resilient sanding block  10  so that it extends through the thickness of the core  12  from the first major surface  24  to the second major surface  26 . Preferably, the aperture  80  is generally located in the center of the resilient sanding block  10 . Preferably, the primary channels  42 - 56  (see also  FIG. 3 ) are in communication with the aperture  80 . A vacuum source (not shown) is operatively connected to the aperture  80  by means of a vacuum hose (not shown) having a nozzle or end that may be inserted into the aperture  80 . As will be understood, when the first or second major surface is in contact with a working surface, the working surface substantially covers the channels so as to form temporary conduits. It will be further understood that the vacuum force will be transferred into the temporary conduits. A vacuum force can also be directed to the aperture  80  by use of a holder (see, for example,  FIG. 5 ) or by attachment of the vacuum source (not shown) directly to the aperture  80 . 
     The channels  42 - 74  can be formed, molded or cut into the core  12  and are recessed just below the first major surface  24  or the second major surface  26  of the core  12  to allow air to be sucked into the channels  42 - 74  from outside the core  12  and into the aperture  80 . As better illustrated in  FIG. 8 , air, bringing the dust with it, then travels through the holder  202  and into the vacuum attachment  340  and then into a collection receptacle of a vacuum source (not shown). 
     Referring particularly now to  FIG. 1 , in this embodiment, the channels  42 - 74  form a pattern or grid. The secondary channels  60 - 74  outline the resilient block  10  while the primary channels  42 - 56  extend in a radial pattern from the aperture  80 . In this embodiment, the channel pattern allows all channels  42 - 74  to be interconnected with each other and with the aperture  80  thereby distributing the vacuum force to all the channels  42 - 74 . Although the arrangement of channels  42 - 74  described here is the preferred embodiment, the invention should not be limited to this channel configuration but could include any channel configuration or pattern that serves the purpose of collecting dust while abrading a surface and is similar in concept. Moreover, the particular configuration of the sanding block need not be limited to a rectangular shape. For example, the resilient sanding block could be circular or triangular. In such cases, it will be understood that the channels will be appropriately configured. 
     As seen in  FIG. 3 , a channel pattern can be made with fewer channels than the number of channels in the first major surface  24  as shown in  FIG. 1 , thereby providing more abrasive material  30   b  on the second major surface  26 , without sacrificing the efficiency of the dust channeling capability of the resilient sanding block  10 . Although not shown, the channel pattern can consist of any number of channels consisting of vertical, horizontal, diagonal or even curved or nonlinear channels that are formed in the major surfaces. 
     The channels should not be limited in shape and can have any number of cross-sectional profiles including a “v”-shaped groove, round or flat bottom, square or rectangular. A square or rectangular shaped channel is preferred. More preferably, the channels will have a depth and width of about 0.5 to about 7.0 mm, more preferably 1.0 to about 5.0 mm. It is preferred, although not necessary, that the resilient sanding block be provided with channels in the first major surface  24 , as well as the second major surface  24 ,  26  so that resilient sanding block may be inverted and the first and second major surface  26 . Additionally, it is preferred that the apertures have a diameter that is larger than the cross-sectional area of the channels. 
     The resilient sanding block  10  should also not be limited in the number of surfaces that are coated with abrasive material. For example, the first major surface  24 , the second major surface  26 , two end surfaces  18 ,  22 , and the side surfaces can be coated with abrasive material and a pattern of channels can be applied to only the first major surface  24 . It should be noted that any combination of sides with or without abrasive coating or with or without channels can be included in the scope of the invention and the present invention should not be limited in scope by leaving out any combination. Moreover, it is envisioned that the surfaces of the resilient sanding block may be provided with different grades of abrasive material. 
       FIGS. 4 and 5  depict another embodiment of the present invention, similar to that shown in  FIGS. 1-3 . Generally, the resilient sanding block  110  comprises a core  112 , major surfaces  124 ,  126 , side surfaces  116 ,  120 , and end surfaces  118 ,  122 . In this embodiment, the resilient block  110  has two apertures  180   a  and  180   b . Similarly, the resilient sanding block  110  comprises a core  112  having primary channels  142   a ,  142   b  (not shown),  144   a ,  144   b ,  146   a ,  146   b ,  148   a ,  148   b ,  150   a ,  150   b  (not shown),  152   a ,  152   b ,  154   a ,  154   b  (not shown),  156   a , and  156   b  that are in communication with an aperture  180   a . The core  112  further comprises secondary channels  160   a ,  160   b ,  162   a ,  162   b ,  164   a ,  164   b ,  166   a ,  166   b ,  168   a ,  168   b ,  170   a ,  170   b  (not shown),  172   a ,  172   b  (not shown),  174   a , and  174   b  (not shown) that are in communication with the primary channels  142   a ,  142   b ,  144   a ,  144   b ,  146   a ,  146   b ,  148   a ,  148   b ,  152   a ,  152   b ,  154   a , 154   b ,  156   a , and  156   b . Additionally, the core  112  has primary channels  142   c ,  142   d ,  144   c ,  144   d ,  146   c ,  146   d  (not shown),  148   c ,  148   d  (not shown),  150   c ,  150   d  (not shown),  152   c ,  152   d ,  154   c ,  154   d ,  156   c , and  156   d  that are in communication with an aperture  180   b  and secondary channels  160   c ,  160   d ,  162   c ,  162   d  (not shown),  164   c ,  164   d ,  166   c ,  166   d ,  168   c ,  168   d ,  170   c ,  170   d ,  172   c ,  172   d ,  174   c , and  174   d  that are in communication with the primary channels  142   c ,  142   d ,  144   c ,  144   d ,  146   c ,  146   d  (not shown),  148   c ,  148   d ,  150   c ,  150   d  (not shown),  152   c ,  152   d ,  154   c ,  154   d ,  156   c , and  156   d . Again, the channels are operatively connected to corresponding apertures in a manner similar to the channels shown and described in  FIG. 1 . Note, however, that some of the channels are in communication with more than one aperture. 
       FIGS. 6 and 7  depict a sanding system  200 , which is formed by a holder  202  that connects a vacuum source (not shown) and a resilient sanding block  210 . The holder  202  further comprises a shell  204  into which a resilient sanding block  210  can be substantially inserted and frictionally retained. The shell  204  has an aperture  207  that allows air to pass from the resilient sanding block  210  via channels and an aperture  280  to a passageway  206  when a vacuum source (not shown) is operatively connected to the sanding system  200  through a vacuum attachment  240  tube. The holder  202  may be of the type presently used with sanding tools. 
       FIGS. 8 and 9  show an alternate embodiment of a sanding system  300  comprising a holder  302  that connects to a vacuum source (not shown) and a resilient sanding block  310 . Here, the holder  302  comprises a passageway  306  defined by a holder  302  that is attached to a triangular plate  244  having a flange  346   a  with block grippers or teeth  348   a  that are angled with respect to the flange  346   a . A tube  308  is connected to the end of the plate  344 . An aperture  307  in the plate  344  allows air to flow between the passageway  306  into the tube  308 . The tube  308  is inserted into aperture  380  of the resilient sanding block  310 , which allows air to be drawn through channels on the first major surface  324  of the resilient sanding block  310  into the tube  308 , through the passageway  306  and into the vacuum source  340 . 
       FIGS. 10   a ,  10   b , and  11  depict alternate embodiments of a holder for a resilient sanding block. Here, the holder  302  comprises a plate  344  that has two downwardly extending flanges  346   a - b  and two sets of teeth  348   a - b  that extend towards each other in a direction that is generally parallel to the plate  344 , and, which serve as a means to retain the resilient sanding block  310  in close proximity to the plate  344 . Additionally, an optional handle  342  (not shown in  FIG. 11 ) is attached to the plate  344  to provide a better grip for the user. A tube  308  is attached to the holder  302  and extends down from an aperture  307  in the plate  344  and into an aperture  380  in the block  310 , with the aperture  380  in communication with channels as previously described. Note that the sanding block  310  does not have channels on both major surfaces. 
       FIG. 10   b  depicts alternative means for retaining a resilient sanding block in close proximity to the plate  344  of a holder  302 . As can be seen on the left side of the figure, hook  346   a ′ and loop fasteners  346   a ″ may be used. Whereas, on the right side of the figure, adhesives  346   b  may be used. 
       FIGS. 12-15  show an alternate embodiment of a sanding system  400  comprising a holder  402 , a resilient sanding block  410 , and a handle  442 . The holder  402  comprises a first shell  404   a  and a second shell  404   b . The first shell  404   a  comprises a top wall  405   a  and side walls  407   a  extending downwardly therefrom, and is configured to frictionally retain a resilient sanding block  410 . Note that the side walls  407   a  have wedge-shaped teeth  448   a - b  as to provide a firm grip on the block  410 . The second shell  404   b  comprises a top wall  405   b , a set of side walls  407   b , and two collars  446 . The first shell  404   a  is configured and arranged to substantially reside within the second shell  404   b  in a generally nesting relation, and with the first shell  404   a  connected to the second shell  404   b  such that a passageway  406  is formed between the walls of the first and second shells  405   a - b ,  407   a - b . Preferably, the first and second shells  404   a - b  are connected to each other by one or more spacers or ribs  450 . The passageway  406  allows air/dust to be drawn from around the periphery of the resilient sanding block  410  and to a dust collection receptacle (not shown). As shown, the second shell  404   b  is provided with two collars  446  that line up with the apertures  452  in a handle  442 . The collars  446  extend the passageway  406  so that air and dust can flow between the second shell  404   b  and the first shell  404   a  and then ultimately out of the sanding device  400  through the vacuum attachment  438  and in to a collection receptacle (not shown). The collars  446  may be fitted to apertures  452  in the base of the handle  442  to operatively connect the holder  402  to the handle  442 . The handle  442  may be of known types presently used in sanding tools and may be attached to the holder  402  with fasteners  444 . 
       FIGS. 16-18  show an alternate embodiment of a sanding system  500  comprising a holder  502  attached to a resilient sanding block  510  having a similar shape and angle as an angled sanding apparatus commonly used for sanding drywall corners. Generally, this system  500  is similar to the previously described system of  FIGS. 12-15  in that it comprises a holder  502  having a first shell  504   a  and a second shell  504   b . A passageway  506  is formed between the first shell  504   a  and the second shell  504   b  that allows for air/dust to be drawn from around the periphery of the resilient sanding block  510  to a dust collection receptacle (not shown) via a vacuum attachment  540 . The first shell  504   a  frictionally retains the resilient sanding block  510 . A passageway  506  is formed between the first and second shells  504   a ,  504   b  to facilitate air flow from around the resilient sanding block  510  into the passageway  506  and then into the vacuum attachment  538  and out of the sanding system  500 . Preferably, the shells  504   a - b  are connected to one another with spacers or ribs  550  that are positioned at intervals to provide for air to flow between the shells  504   a - b.    
     This system  500  differs, however, in that it is designed to work in conjunction with irregularly, job specific angled sanding blocks  510 . To that end, the walls of the second shell  504   b  on one side of the holder  502  are angled to reflect the configuration of the block  510 . This shifts the passageway  506  on the side of the shell  504   b  so that it is positioned to receive dust that rides up on the angled surface of the sanding block  510 . Apertures  508  are located on the side of the second shell  504   b  to allow air/dust to be drawn from around the resilient sanding block  510  into the passageway  506  and eventually out of the sanding system  500  via the vacuum attachment  538 . 
       FIGS. 19 ,  20  and  21  show an alternative embodiment of a sanding system  600 . This system is similar to the previously described system of  FIGS. 16-18  in that it comprises a holder  602  having a first shell  604   a  and a second shell  604   b . A passageway  606  is formed between the first shell  604   a  and the second shell  604   b  that allows for air/dust to be drawn in from around the periphery of the resilient sanding block  610  and directed to a dust collection receptacle (not shown) via a vacuum attachment tube  638 . The side walls of the first shell  604   a  may frictionally retain the resilient sanding block  610  whose dimensions may be slightly larger than the interior dimensions of the shell. A passageway  606  is formed between the first and second shells  604   a ,  604   b  to facilitate air flow from around the periphery of the resilient sanding block  610  into the passageway  606  and then into the vacuum attachment tube  638  and onto a collection receptacle (not shown). Preferably, the shells  604   a - b  are connected to one another with spacers or ribs  650  that are positioned at intervals to provide for air to flow between the shells  604   a - b.    
     Note that the holder  602  in  FIGS. 19-21  does not have the same type of handle as in the previous embodiment. Rather, with this embodiment, the holder  602  further functions as a handle that can be gripped by a user. As will be understood, the particular shape of the holder/handle  602  need not be limited to the particular shape depicted. For example, the handle portion  642  may extend vertically, relative to the longitudinal axis of the sanding block  610 . 
       FIG. 22  illustrates an alternate embodiment of a sanding system  700 , comprising a holder  702  and a resilient block  710 . The holder  702  is similar to the holder depicted in  FIGS. 6 and 7  in that it has a plurality of side walls that are connected to each other by a top wall. One of the side walls of the holder  702  has an exit port  740 . As with the holder of  FIGS. 6-7 , the holder  702  of this embodiment includes an upper chamber or passageway  706  that is in communication with the exit port  740 . This embodiment differs from the embodiment of  FIGS. 6-7  in that it is configured to be used with resilient blocks  710  having a plurality of apertures or through holes  780 . The holder  702  also comprises a skirt  704  (shown in phantom) that frictionally retains the resilient sanding block  710 . 
     The resilient sanding block  710  of this embodiment also has hook material  782  disposed on a first major surface  724  of the block  710 . The hook material  782  may be attached to the surface  724  by laminating a sheet of hook materiel  782  via adhesive to the first major surface  724  or any other portion of the resilient sanding block  710  in where hook material is desired. The hook material  782  corresponds to a loop material  784  that is attached to an abrasive sheet  760 . The abrasive sheet  760  is thereby removably attached to the resilient sanding block  710 . The abrasive sheet  760  may be a sanding screen and could be made of a plastic material having the characteristics of a grater. If a sanding screen is used, the sanding screen will preferably have a grit size from about 40 to about 400 grit. The resilient sanding block  710  can be frictionally maintained by a skirt  704  formed by the holder  702 . 
     Inside the holder  702  are support ribs or spacers  750  that serve to position the resilient block  710  away from the passageway  706  so that it partially closes the walls of the holder  702  creating a substantially enclosed passageway  706 . Each spacer  750  has an aperture  708  or slot  709  to allow air/dust to therebetween. In operation with an vacuum source, air and or dust will travel from through the abrasive sheet  760 , through apertures  780  in the resilient sanding block  710 , into the holder  702  and then out of the sanding device  700  through the exit port  740 . 
       FIGS. 23-24  depicts a profile view of a machine  800  designed for forming channels in a resilient sanding block  810 . The principle components of the machine  800  are a series of six saw blades  802   a - f , a chain conveyor system  804 , a machine frame  806 , a hopper  808 , and a slide plate  812 . A plurality of resilient sanding blocks  810  are automatically fed into the machine  800  by means of a conveyor system  804  and through a series of saw blades  802   a - f , three on top and three on bottom, which cut channels into both sides of the resilient sanding block  810  in a single operation. 
     The conveyor portion  804  of the machine  800  comprises four sprockets  818 , two chains  820 , and individual catches or tines  816 . The chain conveyor system  804  revolves in a clockwise motion around the sprockets  818  so that the catches or tines  816  are able to grab individual resilient sanding blocks  810  from a plurality of blocks  810  stacked in the hopper  808 . The resilient sanding blocks  810  fall due to gravity onto the chain conveyor system  804  in-between the tines  816 . The chain conveyor system  804  rides on two rails  832  positioned under the slide plate  812 . The slide plate  812  has three slots  824  cut into it so that the saw blades  802   a - f  may extend through the slots  824  and above the surface of the slide plate  812 , thereby allowing the saw blades  802   a - f  to form channels in the surface of the resilient sanding blocks  810 . The slide plate  812  also has two longitudinal slots  824 ,  826  that cut into the length of the resilient sanding block  810  so that the tines or catches  816  of the chain conveyor system  804  extend above the surface of the slide plate  810  so as to allow the tines  816  to catch or grab resilient sanding blocks  810  from the hopper  808  and push them through the saw blades  802   a - f . The chain  820 , moving clockwise, transports or pushes the resilient sanding blocks  810  through the saw blades  802   a - f . The saw blades  802   a - f  are set up with a series of three blades on top and three blades on the bottom. The top blades  802   a - c  turn clockwise and the bottom blades  802   d - f  turn counter-clockwise. As the resilient sanding blocks  810  are fed into the saw blades  802   a - f , a spring bar  814  applies pressure to the top of the resilient sanding block  810  pushing it down onto the slide plate  812  so as to provide enough pressure so the resilient sanding block  810  does not kick up while going through the saw blades  802   a - f . Adjustable side guides  822  serve to align the resilient sanding blocks  810  accurately through the saw blades  802   a - f  preventing them from wandering from side to side. In the preferred method, the resilient sanding blocks  810  are stacked into the hopper  808  in quantities of about 40 or 50 at a time and gravity fed onto the conveyor  804  and as the conveyor  804  turns the bottom most resilient sanding block  810  is pulled from the bottom of the stack of blocks  810  by the tines  816 , which catch the block  810  and push it along and through the saw blades  802   a - f . The next resilient sanding block  810  falls onto the chain conveyor system  804  on so on. After the resilient sanding blocks  810  are pushed through the saw blades  802   a - f  they will have a series of three saw kerfs or channels (See  FIG. 3 ) cut in one direction on both sides of the resilient sanding block  810 . 
     The set of intersecting channels are cut into the resilient sanding block  810  by the same machine  800  by adjusting the saw blades  802   a - f , the hopper  808  size and the side guides  822  accordingly and by turning the blocks  810  approximately 90 degrees and restacking them in the hopper  808 . Alternatively, the channels may be molded, incised, or heat formed in the resilient sanding block  810 . 
     It is envisioned that, it may be more efficient to have a separate machine of the same type as the machine  800  set up to cut the intersecting channels so the resilient sanding blocks  810  may be placed in hopper  808  of the second machine  800  after going through the first machine  800  without requiring any readjustments. It may also be possible to set up the two machines  800  (only one is shown) so that the chain conveyor system  804  automatically feeds the resilient sanding blocks onto the conveyor system of the second machine without the need to place the resilient sanding blocks  810  in the hopper of the second machine (not shown). It may be necessary to install a cooling system (not shown) to run water on the saw blades  802   a - f  so that they do not overheat from cutting the abrasive material on the resilient sanding blocks  810 . In a third operation, the resilient sanding blocks  810  would be taken to a punch machine (not shown) with single or multiple hole punches so that the aperture  80  or apertures (See  FIGS. 1 and 4 , for example) may be punched into the resilient sanding block by means of existing hole punch mechanisms or machines. 
       FIG. 25  shows a top view of the machine  800  in  FIGS. 23-24  illustrating the principle components of the machine  800  including three saw blades  802   d - f  located underneath the slide plate  812 . The blades are positioned on a rotatable shaft  828 . The slide plate  812  has three rectangular slots  824  that allow the saw blades  802   d - f  to extend up through the surface of the slide plate  812 . The slide plate  812  has two longitudinal slots  826  that allow the tines or catches  816  to extend above the surface of the slide plate  812  so that the tines  816  may grab the individual resilient sanding blocks  810  and push them through the saw blades  82   d - f . The side guides  822  align and guide the resilient sanding blocks  810  through the saw blades  802   d - f  accurately and prevent side to side movement of the resilient sanding blocks  810 . A pulley  830  is attached to the shaft  828  to provide a means of driving the saw blades  802   d - f  by motor and belt (not shown).  FIG. 25  does not depict the three saw blades  802   a - c  located above the slide table  812  as shown in  FIG. 23  for ease in depicting the principle components of the machine  800 . 
     Although the preferred embodiments and methods of the present invention have been described herein, the above description is merely illustrative. Further modification of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the invention as defined by the appended claims.