Abstract:
A kit includes a collection of sanding blocks of various dimension and geometric shape for use in fine sanding exterior surfaces of an automobile body or marine craft during a body painting process. Each block is provided with one or more pressure application areas which are uniquely configured for sanding a particular surface contour in a manner which maintains uniform contact between the surface and a fine grade sandpaper overlying the pressure application area of the block. Use of the various blocks in the kit enables even sanding of all surface areas, including difficult to reach areas, without damaging the painted surface.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1.Field of the Invention  
           [0002]    The present invention relates to sanding blocks for applying pressure to sandpaper while sanding a surface and, more particularly, to a kit containing a plurality of sanding blocks of various dimension and configuration for fine sanding exterior surfaces of an automobile body or marine craft.  
           [0003]    2.Discussion of the Related Art  
           [0004]    The process of painting the body of an automobile or boat usually involves the use of a handheld paint spray gun which releases paint, under pressure, in an evenly dispersed pattern upon movement of a trigger or other actuator mechanism. In order to apply a uniform coat of paint to the painted surfaces of the vehicle, it is necessary to move the nozzle in a smooth or uninterrupted motion as paint is continuously released from the nozzle. Unfortunately, it is difficult to maintain an even application of paint, despite the level of skill of the painter, due to uneven surfaces of the automobile body. Specifically, the distance from the nozzle to the surface varies, due to the contour of the automobile body, and, therefore, the amount of paint deposited throughout the exterior surface may vary. Even the most skilled body painter will sometimes encounter imperfections such as paint runs, sags, or dust specs in the paint. When this happens, it is necessary to remove the imperfection without damaging the painted surface. In order to accomplish this, auto body painters in the industry are known to use various methods. Some painters use a metal file to remove paint build up and other imperfections. However, use of a metal file scratches the painted surface requiring subsequent sanding with find grade wet sandpaper to finish the painted surface. Other painters use a rotary sander to remove imperfections. Similar to use of a metal file, the rotary sander often causes excessive scratching of the painted surface, particularly if a grain of dirt or sand becomes captured between the rotating sandpaper and the painted surface. Also, both use of a metal file and a rotary sander results in removal of a larger area of paint than is necessary. Often, imperfections are small (e.g., smaller than the size of a pencil eraser) and sanding of a larger area of paint results in added labor to finish the surface. Specifically, after use of a rotary sander or metal file, it is sometimes necessary to wet sand the area to remove fine scratches. Also, it is necessary to polish and buff the sanded surface to bring the painted surface to a finished shine.  
           [0005]    To avoid many of the problems associated with the use of metal files, rotary sanders, and other tools which are sometimes used to remove imperfections of painted surfaces, many auto body painters use fine grade wet sandpaper and sometimes a razor blade to shave off excessive paint build up such as sags and runs and, while the use of wet sandpaper is preferable to dry sanding methods, particularly when removing soft areas of paint build up which have not completely cured, it can be difficult to maintain even pressure between the sandpaper and the painted surface. Because the imperfections are typically very small areas, as mentioned above, many painters simply use their hand to hold the wet sandpaper and apply pressure while sanding the surface to remove the imperfection. More specifically, pressure is usually applied with one or two fingertips by pressing against the back side of the sandpaper while moving the fine grade abrasive side of the sandpaper against the painted surface. And, while this method is generally less problematic than use of a metal file, rotary sander, or other tool, use of the fingertips to apply pressure is not the ideal method in that it is impossible to apply even pressure due to the shape of the fingertips. As a result, the sanding of the area where the imperfection is located is sometimes excessive and/or not uniform.  
           [0006]    In view of the foregoing problems associated with fine finishing of painted surfaces of automobile bodies, boats, and the like, in order to remove imperfections when painting, there still remains an urgent need for an instrument or a collection of instruments which are adapted to apply uniform pressure to painted areas in order to remove imperfections. More specifically, there is an urgent need for a collection of sanding blocks of various dimension and geometric shape for use in fine sanding exterior surfaces of an automobile, marine craft, or the like, during the painting process, in order to remove imperfections with the use of fine grade wet sandpaper.  
         SUMMARY OF THE INVENTION  
         [0007]    The present invention is directed to a kit including a collection of sanding blocks of various dimension and geometric shape for use in fine sanding exterior surfaces of an automobile body or marine craft during a body painting process. Each block is provided with one or more pressure application areas which are uniquely configured for sanding a particular surface contour in a manner which maintains uniform contact between the surface and a fine grade sandpaper overlying the pressure application area of the block. Use of the various blocks in the kit enables even sanding of all surface areas, including difficult to reach areas, without damaging the painted surface.  
           [0008]    In use, a strip of fine grade wet sandpaper, of a selected grade ranging between 1,000-2,000 grit, is wrapped about a selected one of the blocks so that there are multiple overlapping layers of the wet sandpaper covering the one or more pressure application areas of the block. The pressure application area(s) provides a firm backing for the sandpaper against the painted surface, while grasping the sides of the blocking and moving the block in a reciprocating, sanding motion. Once the outer layer of sandpaper has become worn, a segment of the strip of sandpaper is peeled and torn away from the block to expose a next successive unused layer of sandpaper.  
           [0009]    The particular sanding blocks are selected according to the size of the imperfection and the location and shape of the exterior body surface where the imperfection is located. More particularly, a sanding block is selected having a the pressure application area which is most suited for applying uniform pressure of the wet sanding paper against the painted surface in a manner which avoids gouging and/or uneven removal of the imperfection.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]    For a fuller understanding of the nature of the present invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings, in which:  
         [0011]    [0011]FIG. 1 is a top plan view of a first sanding block of the sanding block kit of the present invention;  
         [0012]    [0012]FIG. 2 is a side elevation of the sanding block of FIG. 1;  
         [0013]    [0013]FIG. 3 is an end elevational view of a second sanding block of the sanding block kit;  
         [0014]    [0014]FIG. 4 is an end elevational view of a third sanding block of the sanding blocking kit;  
         [0015]    [0015]FIG. 5 is a top plan view of a fourth sanding block of the sanding block kit; and  
         [0016]    [0016]FIG. 6 is a side elevational view of the sanding block of FIG. 4.  
         [0017]    Like reference numerals refer to like parts throughout the several views of the drawings. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0018]    The kit of the present invention includes a collection of sanding blocks of various dimension and geometric shape for use in fine sanding exterior surfaces of an automobile body or marine craft in order to remove surface imperfections when painting the exterior body.  
         [0019]    In a preferred embodiment, the kit includes four different sanding blocks, as seen in FIGS.  1 - 6 . A first one of the blocks is shown in FIGS. 1 and 2 and is generally indicated as  20 . The block  20  may be either square or rectangular in shape. Specifically, the length of the block  20  is preferably between 1-{fraction (1/4)}″ and 1{fraction (3/4)}”. Likewise, the width of the block  20  is between 1-{fraction (1/4)}″ and 1-{fraction (3/4)}″. In the preferred embodiment, as seen in FIG. 1, the block  20  is rectangular in shape, with a length of 1-{fraction (3/4)}″ and a width of 1-{fraction (1/4)}″. The thickness of the block  20  is preferably {fraction (1/4)}″. As seen in FIG. 1, the corners of the block  20  are provided with a radius to thereby eliminate a sharp pointed corner which may scratch the paint of the automobile body when sanding the painted surface. The opposite sides  22 ,  24  of the block  20  serve as pressure application areas, for applying pressure against the painted surface when sanding. Specifically, fine grade sandpaper is wrapped about the block  20 , preferably about the width of the block, to provide multiple layers. Upon sanding, the pressure applied downwardly, on either of the sides  22 ,  24 , forces the sandpaper against the painted surface, thereby applying uniform pressure while sanding to remove imperfections on the painted surface.  
         [0020]    [0020]FIG. 3 shows a second block of the kit which is generally indicated as  30 . The block  30  includes a rounded surface  32 , defining the pressure application area, and a flat bottom surface  34 . The radius of the rounded surface  34  is indicated as R 1 . In use, the fine grade sandpaper is wrapped about the rounded surface  32  and the flat bottom surface  34 , to provide multiple layers about the block  30 . The rounded pressure application surface  32  is applied against the painted surface of the automobile body having a rounded contour, thereby applying even pressure of the sandpaper on the pressure application area  32  against the painted surface of the automobile body, to remove imperfections. As the fine grade sandpapers wears at areas covering the pressure application surface  32 , a layer of sandpaper is peeled away and removed to expose the next underlying layer covering the pressure application surface  32 . In use, pressure is applied by grasping the opposite side edges  36 ,  38  between the thumb and the index and/or middle fingers. When sanding, pressure can also be applied downwardly against the bottom surface  34  to thereby press the pressure application area  32  and covering fine grade sandpaper against the painted surface. In the preferred embodiment, the block  30  has a width of approximately 1-{fraction (3/8)}″ and a height of {fraction (3/4)}″. The length is preferably 1-{fraction (3/4)}″.  
         [0021]    Referring to FIG. 4, a third sanding block of the present invention is shown and generally indicated as  40 . The block  40  includes a rounded pressure application area  42  of a particular radius indicated as R 2 , which may be provided in different sizes. In the embodiment shown in FIG. 4, the radius of the rounded pressure application surface  42  is approximately {fraction (1/4)}″ and is less than the radius R 1  of the sanding block  30 . The block  40  further includes opposite flat sides  44 ,  46  which taper down to an edge  48  opposite of the rounded pressure application  42 . The fine grade sandpaper is wrapped about the opposite sides  44 ,  46  and rounded pressure application area  42 , as well as the edge  48 . In use, block  40 , with sandpaper wrapped thereabout, is grasped on the opposite sides  44 ,  46  between the thumb and one or more fingers. The rounded pressure application area  42  is used to apply pressure on fine grade sandpaper against tight radius areas of contour on the automobile body having a tight radius generally less than {fraction (1/2)}″. The opposite edge  48  may be used to sand in tight crevices, such as around window frames and door handle frames. In the preferred embodiment, the block  40  has a width of approximately 1-{fraction (3/4)}″ and a height ranging between {fraction (1/32)}″ at the edge  48  and {fraction (1/2)}″ at the rounded pressure application area  42 . The length of the block  40  is preferably 1-{fraction (3/4)}″.  
         [0022]    Referring to FIGS. 5 and 6, a fourth sanding block of the present invention is shown and is generally indicated as  50 . The block  50  is rectangular in configuration and is similar to the block  20  of FIGS. 1 and 2, with the exception of the length being significantly longer. Specifically, the block  50  includes opposite pressure application areas  52 ,  54 . Similar to the block of FIGS. 1 and 2, the corners are provided with a radius to eliminate sharp edges. In the preferred embodiment, the length of the block  50  is 7-{fraction (1/4)}″. Further, the width of the block  50  is preferably 1-{fraction (1/4)}″ and the thickness is {fraction (1/4)}″.  
         [0023]    The blocks of the kit, shown throughout FIGS.  1 - 6 , are preferably made of a moldable material, such as plastic or Lucite. More specifically, it is preferable to manufacture the blocks from a material which can be used in either an extrusion molding process or injection molding process. It is also important that the material be significantly hard when it cures. In the preferred embodiment, the blocks are manufactured of a Lucite material which is transparent or translucent. The blocks may further be manufactured in varying colors, such as neon colors for marketing purposes.  
         [0024]    While the instant invention has been shown and described in connection with the preferred embodiments thereof, it is recognized that departures from the instant disclosure are contemplated within the spirit and scope of the present invention.