Manual operated detail sander

Abstract

A manually operated detail sander comprises a first plate, a second plate and a sheet of sanding material. The first plate has uniform thickness and includes first and second sides that define a sculpting profile. The second plate has the thickness of the first plate and has an ergonomic profile including an elongate fastening edge extending at least partially across and joined to the first side of the first plate. The sheet of sanding material extends across the second side of the first plate.

Description

BACKGROUND

[0001] The present invention is directed to abrading devices and, more particularly, to manually operated detail sanders.

[0002] Many devices have been developed over the years to produce fine finishes on surfaces, such as on automobile panels or furniture facades. Many such devices comprise handheld platforms for stiffening sheets or strips of sandpaper. Some of these devices comprise thick rectangular or square blocks have protruding handles. These sanders provide large, rigid surfaces that are well-suited for sanding large planar work areas. As such, the handles are typically thick and bulky to provide strength for repeated, heavy usage. Other similar sanding devices have been developed for producing detail finishes. These devices, too, often include thick handles or large heads that inhibit application of the sander to all surfaces. For example, thick handles, such as those disclosed in U.S. Pat. Nos. D612,222 to Ali et al. and 5,054,248 to Thayer, prevent delicate handling of the devices with fingers, thus inhibiting precise sanding. U.S. Pat. Nos. 4,730,430 to Petrovich and 3,699,729 to Garvey et al. disclose devices that provide elongate heads suitable for insertion into small areas, but provide no gripping means to facilitate manipulation. U.S. Pat. Nos. 4,694,618 to Eberhardt et al. and 4,977,712 to Fisher et al. disclose devices having elongate sanding surfaces comprising strips of sanding paper in tension. These sanding surfaces are, however, flexible such that they inhibit delicate sanding. Although each of these devices provides a manually operated sander for particular applications, none provides a device having dimensions suitable for detail sanding of hard to reach or irregularly shaped surfaces while also being comfortable to manipulate.

SUMMARY

[0003] The present invention is directed to a manually operated detail sander for abrading surfaces. The detail sander comprises a first plate, a second plate and a sheet of sanding material. The first plate has uniform thickness and includes first and second sides that define a sculpting profile. The second plate has the thickness of the first plate and has an ergonomic profile including an elongate fastening edge extending at least partially across and joined to the first side of the first plate. The sheet of sanding material extends across the second side of the first plate.

BRIEF DESCRIPTION OF THE DRAWINGS

[0004] FIG. 1 shows a perspective view of a manually operated detail sander of the present invention having a head and a handle.

[0005] FIG. 2 shows a top view of the manually operated detail sander of FIG. 1.

[0006] FIG. 3 shows a side view of the manually operated detail sander of FIG. 1.

[0007] FIG. 4 shows a front end view of the manually operated detail sander of FIG. 1.

[0008] FIG. 5 shows a close up view of callout 5 of FIG. 4 showing finishing material adhered to the head by hook and loop fastener material.

[0009] FIG. 6 shows a side perspective view of an embodiment of a manually operated detail sander having a handle that extends parallel beyond a perimeter of a sanding head.

[0010] FIG. 7 shows a side perspective view of an embodiment of a manually operated detail sander having a handle positioned within a perimeter of a sanding head.

[0011] FIG. 8 shows a top perspective view of an embodiment of a manually operated detail sander having an ovaloid sanding head.

[0012] FIG. 9 shows a top perspective view of an embodiment of a manually operated detail sander having a triangular sanding head.

[0013] FIGS. 10A and 10B show top perspective views of left-hand and right-hand configurations of manually operated detail sanders having trapezoidal sanding heads with offset handles.

DETAILED DESCRIPTION

[0014] FIG. 1 shows a perspective view of manually operated detail sander 10 of the present invention. Detail sander 10 includes head 12, handle 14 and finishing material 16. Head 12 includes handle side 18, planar side 20 and head edge perimeter region 22. Handle 14 includes gripping surface 24A, gripping surface 24B (FIG. 2), and handle edge perimeter region 26. Detail sander 10 comprises a device that is shaped to be easily gripped and precisely manipulated by a hand or fingers, while providing a finishing surface that can be easily inserted into small areas. Sander 10 has an overall low profile and elongate and narrow shape to accomplish these ends. In the embodiment shown if FIGS. 1-5, head 12 is rectangular, while handle 14 extends at an angle from handle side 18. Also, finishing material 16 is shown adhered to planar side 20 by hook and loop fastener material. Other embodiments with variations of the head and handle are shown if FIGS. 6-10B.

[0015] FIG. 2 shows a top view of detail sander 10 of FIG. 1. Detail sander 10 includes head 12 and handle 14. In the embodiment shown, head 12 includes handle side 18, which forms a rectangular profile having front side 28, rear side 30, right side 32 and left side 34. Planar side 20 (FIG. 1) has an identical rectangular profile to that of handle side 18. Edge perimeter region 22 extends between handle side 18 and planar side 20. Edge perimeter region 22 can be flat or rounded to facilitate manufacture of head 12. Constructed as such, head 12 comprises a thin, plate-like structure.

[0016] From the side, handle 14 has thickness t₁, which produces a narrow shape of sander 10. In one embodiment, thickness t₁ is approximately 0.25 inches [in] (˜0.64 centimeters [cm]) thick. Head 12 also has a width W₁, which produces a narrow shape of sander 10. Width W₁ extends in the direction of the minor axis of head 12. In one embodiment, width W₁ is 1.5 in (˜3.8 cm). Head 12 has length L₁, which produces an elongate shape of sander 10. Length L₁ extends in the direction of the major axes of head 12 and handle 14. In one embodiment, length L₁ is approximately 10 in (˜25.4 cm). These dimensions give sander 10 a geometry that facilitates manipulation and insertion into small areas. In particular, sander 10 has a high overall length to width ratio and a high overall length to handle-thickness ratio. For example, embodiments of sander 10 have a length to width ratio of approximately 6.5:1, and a length to handle-thickness ratio of approximately 40:1 or greater.

[0017] Handle 14 is completely within the outline or profile of edge perimeter region 22. Handle 14 extends completely across length L₁ of head 12 such that planar side 20 and finishing material 16 (FIG. 1) are fully supported. In the embodiment shown, handle 14 extends across a middle of width W₁ of head 12. In other embodiments, handle 14 may extend along an edge of head 12, such as right side 32 or left side 34. As is better seen in FIG. 3, handle 14 extends generally longitudinally from handle side 18 of head 12.

[0018] FIG. 3 shows a side view of detail sander 10 of FIG. 1. Detail sander 10 includes head 12, handle 14 and finishing material 16. In the embodiment shown, handle 14 includes gripping surface 24A, which forms a profile having grip 36, forward support 38, rear support 40 and contour 42. Gripping surface 24B (not shown) comprises an identical profile to that of gripping surface 24A. Edge perimeter region 26 extends between gripping surfaces 24A and 24B. Edge perimeter region 26 can be flat or rounded to facilitate manufacture of handle 14. Constructed as such, handle 14 comprises a thin, plate-like structure. Edge perimeter region 26 includes planar fastening region 43.

[0019] Head 12 has thickness t₂, which produces a low height of sander 10. In one embodiment, thickness t₂ is approximately 0.25 in (˜0.635 cm) thick. Head 12 has length L₁, which, as discussed above, is approximately 10 in (˜25.4 cm). Thus, the length to head-thickness ratio of sander 10 for the embodiment shown is approximately 40:1. The thinness of head 12 allows the fingers of an operator of sander 10 to come close to the surface to be sanded, allowing for a better feel of the sanding operation.

[0020] Grip 36 of handle 14 extends from handle side 18 of head 12 at angle α₁. In the embodiment shown, angle α₁ is approximately forty degrees. Grip 36 extends along the minor axis of handle 14. Grip 36 is buttressed by forward support 38 and rear support 40, which comprise flared regions of grip 36 near head 12. For example, forward support 38 is flared from grip 36 at approximately twenty degrees. As such in one embodiment angle α₂ is approximately one-hundred-sixty degrees. Similarly, support 40 flares rearward to the back of head 12. Supports 38 and 40 extend the width of grip 36 across head 12 without unduly increasing the height of sander 10 across its entire length.

[0021] Handle 14 extends at such angles to provide an ergonomic lever for operators of sander 10. Extension of grip 36 allows a tip portion of head 12 away from grip 36 to be easily inserted into a small orifice or other such cramped area. Other angles that extend the tip of head 12 away from grip 36 can be used. Contour 42 provides ergonomic shaping to grip 36 to provide comfort to operators of sander 10. The combination of angled grip 36 and contour 42 allow sander 10 to be easily manipulated with a hand or with only the fingers of a hand.

[0022] Grip 36, support 38 and support 40 form planar fastening region 43 of edge perimeter region 26. Fastening region 43 extends across the entire length of head 12 to add rigidity. As such fastening region 43 extends in the direction of the major axis of handle 14. Fastening region 43 prevents head 12 from flexing so that sander 10 more readily keeps finishing material 16 in contact with a surface to be sanded.

[0023] FIG. 4 shows a front end view of manually operated detail sander 10 of FIG. 1. Handle 12 extends straight out from head 14 such that right angles are formed between handle side 18 of head 12 and gripping surfaces 24A and 24B of handle 14. Handle 14 has height H₁. Height H₁ extends along the minor axis of handle 14. In one embodiment, height H₁ is approximately 5 in (˜12.7 cm). The height of handle 14 is selected to facilitate manipulation of head 12. For example, the taller handle 14 is, or the larger angle α₁ is, the easier it becomes to tilt head 12, thus making adjustment of sander 10 easier.

[0024] Finishing material 16 is affixed to planar side 20 of head 12. Planar side 20 is flat to allow finishing material 16 to flushly contact the surface to be sanded. As discussed above, handle 14 stiffens head 12 such that finishing material 16 remains in contact with the surface to be sanded during operation. Accordingly, finishing material 16 is rigidly adhered to planar side 20 of head 12 to resist deformation. In one embodiment, finishing material 16 is glued or otherwise secured with adhesive to planar side 20. In other embodiments, finishing material 16 is secured to planar side 20 using fastener material, as discussed with reference to FIG. 5. In other embodiments, a layer of foam can be positioned between finishing material 16 and planar side 20.

[0025] FIG. 5 shows a close up view of callout 5 of FIG. 4 showing finishing material 16 adhered to head 12 by interaction of hook and loop fastener material. The hook and loop fastener material includes hook material 44 and loop material 46. Finishing material 16 includes backing 48 and abrasive material 50. Loop material 46 is bonded to planar surface 30 such as with an adhesive. Likewise, hook material 44 is bonded to backing 48 of finishing material 16. Additionally, abrasive material 50 is bonded to backing 48 via a bonding agent. Abrasive material 50 comprises sand or other granules typically used to abrade material. Backing 48 and abrasive material 50 comprise typical sand paper or other such similar products. Hook material 44 and loop material 46 comprise typical fabric hook and loop fastener material, such as Velcro®, which is a registered trademark of Velcro Industries.

[0026] FIG. 6 shows a side perspective view of manually operated detail sander 52 having handle 54 that extends parallel beyond a perimeter of sanding head 56. Head 56 comprises a rectangular head similar to the head described with respect to FIGS. 1-5, including a layer of finishing material and edge perimeter region 57. Handle 54 comprises grip 58 and support 60. Handle 54 and head 56 comprise plate-like structures joined along a flat fastening region of edge perimeter region 57. In one embodiment, each plate is approximately 0.25 in (˜0.635 cm) thick.

[0027] Grip 58 comprises an elongate handle-member having a generally trapezoidal shape. First end 62 of grip 58 is positioned near mid-point 64 of head 56, while second end 66 of grip 58 extends beyond edge perimeter region 57 of head 56. Grip 58 extends along a major axis of handle 54, generally parallel to the major axis of head 56. Support 60 extends from the first end of grip 58 toward the edge of head 56 at first end 62. As such, handle 54 extends across the entire length of head 56. Thus, handle 54 can be used to press the entirety of head 56 into the surface to be sanded while keeping head 56 rigid. However, support 60 is tapered such that the height of first end 62 is reduced to facilitate insertion of sander 52 into tight areas. In the embodiment shown, head 56 has a length of approximately 8 in (˜20.3 cm) from first end 62 to second end 66, the length of handle 54 has a length in the same direction of approximately 12 in (˜40.6 cm), and the width of head 56 is approximately 1.5 in (˜3.8 cm).

[0028] FIG. 7 shows a side perspective view of manually operated detail sander 68 having handle 70 positioned within a perimeter of sanding head 72. Head 72 comprises a rectangular head similar to the head described with respect to FIGS. 1-5, including a layer of finishing material and edge perimeter region 74. Handle 70 comprises grip 76 and contours 78A and 78B. Handle 54 and head 56 comprise plate-like structures joined along a flat fastening region of edge perimeter region 74. In one embodiment, each plate is approximately 0.25 in (˜0.635 cm) thick.

[0029] Grip 76 comprises an elongate handle-member having a generally rectangular shape that extends across head 72 from first end 80 to second end 82. Grip 76 extends along a major axis of handle 70, generally parallel to the major axis of head 72. The height H₂ of handle 70 is short compared to length L₂ of head 72. In one embodiment, height H₂ is approximately 1.5 in (˜3.8 cm) and length L₂ is approximately 20 in (˜50.8 cm), giving rise to a length to width ratio of over approximately 13:1. Sander 68 also has a length to thickness ratio of approximately 80:1. The width of head 72 is approximately 1.5 in (˜3.8 cm). Contours 78A and 78B provide handle 70 with an ergonomic gripping shape. For example, contours 78A and 78B accommodate the palm of a hand when gripped by an operator.

[0030] FIG. 8 shows a top perspective view of manually operated detail sander 84 having ovaloid sanding head 86 and handle 88. Handle 88 includes center grip 90 and supports 92A and 92B. Head 86 includes center portion 94, first rounded end 96A, second rounded end 96B and edge perimeter region 98. Handle 88 and head 86 comprise plate-like structures joined along a flat fastening region of edge perimeter region 98. In one embodiment, each plate is approximately 0.25 in (˜0.635 cm) thick.

[0031] Handle 88 comprises an isosceles trapezoid-shaped plate having a first flat edge that runs along center grip 90 parallel to head 86, a second flat edge that runs along center grip 90 and supports 92A and 92B against head 86, and oblique edges that extend from the first flat edge to head 86 along supports 92A and 92B. Handle 88 extends a short distance straight out from head 86 at a right angle. In one embodiment, handle 88 is approximately 1.5 in (˜3.8 cm) tall. Thus, handle 88 provides grip for manipulating sander 84, but is tapered to facilitate working with rounded ends 96A and 96B of head 86.

[0032] Head 86 comprises an ovaloid-shaped plate having two straight edges that extend along center portion 94 and two rounded edges at rounded ends 96A and 96B, respectively, that connect the two straight edges. Head 86 has an overall length L₃. In one embodiment, L₃ is approximately 6 in (˜15.2 cm) such that the length to thickness ratio of sander 8 is approximately 24:1. The radii R of rounded ends 96A and 96B are approximately half of width W₃ of head 86. In one embodiment, W₃ is approximately 1.5 in (˜3.8 cm) such that R is approximately 0.75 in (˜1.9 cm).

[0033] FIG. 9 shows a top perspective view of manually operated detail sander 100 having triangular sanding head 102 and handle 104. Head 102 and handle 104 comprise plate-like structures similar to those of other embodiments, each being approximately 0.25 in (˜0.635 cm) thick. Edge perimeter region 106 of head 102 comprises a triangle, having vertex 108 and base 110. Edge perimeter region 112 of handle 104 comprises a right-angled trapezoid having parallel base sides 114 (of which only one is shown in FIG. 9), an oblique-angled side extending across head 102 and a right-angled side connecting parallel sides 114. The oblique-angled side of handle 104 extends from vertex 108 of the triangle to a center point of base 110 of the triangle. As such, parallel base sides 114 of handle 104 extend away from head 102 at an angle. Thus, handle 104 allows vertex 108 of head 102 to be easily inserted into tight areas. In the embodiment shown, head 102 is approximately 6 in (˜15.2 cm) long and approximately 1.5 in (˜3.8 cm) wide at base 110, and handle 104 is approximately 1.5 in (˜3.8 cm) tall and approximately 8 in (˜20.3 cm) long from the oblique-angled side to the right-angled side.

[0034] FIGS. 10A and 10B show top perspective views of manually operated detail sanders 116A and 116B having left-hand and right-hand configurations, respectively, of trapezoidal sanding heads with offset handles. Detail sander 116A includes head 118A and handle 120A. Head 118A comprises a right-angled trapezoid having oblique-angled side 122A, right-angled side 124A and parallel base sides 126A and 128A. Similarly, handle 120A comprises a trapezoid having oblique-angled side 130A, end side 132A and parallel base sides 134A and 136A. Detail sander 116B includes analogous elements bearing the same reference numerals with the designation "B."

[0035] In one embodiment, right-angled side 124A of head 118A is approximately 1.5 in (˜3.8 cm), side 126A is approximately 6 in (˜15.2 cm), and side 126B is approximately 4.5 in (˜11.4 cm), while side 136A of handle 120A is approximately 12 in (˜30.5 cm), side 134A is approximately 8 in (˜20.3 cm), and side 130A is approximately 4.5 in (˜11.4 cm).

[0036] Oblique-angled side 130A of handle 120A is positioned across head 118A. Oblique-angled side 130A abuts right-angle side 124A and base side 128A of head 118A. Oblique-angled side 130A extends toward the intersection of base side 126A and oblique-angled side 122A at point 138A of head 118A at angle α₃. In one embodiment, angle α₃ is approximately ten degrees. Accordingly, angle α₄ shown in FIG. 10B is also approximately ten degrees. Oblique-angled side 122A of head 118A positions point 138A along base side 126A. Handle 120A is directed toward point 138A. Thus, an operator of sanders 10A and 10B have the benefit of having a pointed sanding head, similar to that of the triangular sanding head of FIG. 9, as well as the benefit of straight edge sanding head, similar to that of the rectangular sanding head of FIGS. 1-4. The orientation of handle 120A toward point 138A allows the operator feel the orientation of head 118A, while also providing a suitable feel for base side 126A.

[0037] The present invention provides a detail sander that can be fabricated with a variety of configurations. Each sander is comprised of two thin plates, e.g. "a smooth, flat, relatively thin, rigid body of uniform thickness" as plates are commonly defined by dictionaries. Although described as two separate plates that are joined together, each sander can be formed as a single piece. For example, each sander can be formed of wood material wherein the two plates are bonded together with a glue or adhesive, or each sander can be formed of a plastic material wherein the two plates are simultaneously formed during an injection molding process.

[0038] Additionally, the disclosed embodiments describe various sanding heads and handles having different configurations in specific combinations. Each sanding head has an edge perimeter region defining a sculpting profile, while each handle has an edge perimeter region defining an ergonomic profile. However, in other embodiments, the sanding head of one described embodiment may be used in combination with a handle of another described embodiment. For example, the triangular sanding head of FIG. 9 may be provided with an angled handle of FIG. 1 or a straight handle of FIG. 6. The various configurations have high overall length to thickness ratios, which permit the sanders to be inserted in small, confined spaces while giving operators improved feel of the sanding operation.

[0039] While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.

Claims

1. A manually operated detail sander comprising: a first plate of uniform thickness having first and second sides that define a sculpting profile; a second plate having the thickness of the first plate and having an ergonomic profile including an elongate fastening edge extending at least partially across and joined to the first side of the first plate; and a sheet of finishing material extending across the second side of the first plate.

2. The manually operated detail sander of claim 1 wherein the sheet of finishing material extends rigidly across the second side of the first plate.

3. The manually operated detail sander of claim 1 wherein the sheet of sanding material is secured to the second side of the first plate by hook and loop fastener material.

4. The manually operated detail sander of claim 1 wherein the sculpting profile defines a first major axis and a first minor axis extending along a length and width of the first plate, respectively, such that a ratio of the length to the width is approximately 5:1 or higher.

5. The manually operated detail sander of claim 4 wherein the ratio of the length of the first plate to the thickness of the first plate is approximately 20:1 or higher.

6. The manually operated detail sander of claim 4 wherein the fastening edge of the second plate extends across an entirety of the length of the first plate along a joined region.

7. The manually operated detail sander of claim 4 wherein the fastening edge of the second plate extends across an edge of the sculpting profile of the first plate.

8. The manually operated detail sander of claim 4 wherein the ergonomic profile of the second plate defines a second major axis and a second minor axis extending along a length and a width of the second plate, wherein the second major axis extends at an oblique angle to the first major axis.

9. The manually operated detail sander of claim 4 wherein the ergonomic profile of the second plate defines a second major axis and a second minor axis extending along a length and a width of the second plate, wherein the second minor axis extends at an oblique angle to the first major axis.

10. The manually operated detail sander of claim 4 wherein the ergonomic profile of the second plate defines a second major axis and a second minor axis extending along a length and a width of the second plate, wherein the second major axis extends parallel to the first major axis.

11. The manually operated detail sander of claim 4 wherein the sculpting profile defines a triangular region.

12. The manually operated detail sander of claim 4 wherein the sculpting profile defines an oval region.

13. The manually operated detail sander of claim 4 wherein the sculpting profile of the first plate surrounds the second plate.

14. A manually operated abrading tool comprising: a head comprising: an elongate planar finishing side; an elongate planar handle side, wherein the finishing side and the handle side have matching first profiles; and a first edge perimeter region extending between the finishing side and the handle to define a thickness; a handle comprising: a pair of elongate planar gripping surfaces having matching second profiles; a second edge perimeter region extending between the elongate planar gripping surfaces and having the thickness of the first edge perimeter region; and a planar fastening region along the second edge perimeter region secured to the elongate planar handle side of the head; and a strip of abrasive finishing material rigidly secured to the elongate planar finishing side of the head.

15. The manually operated abrading tool of claim 14 wherein the strip of abrasive finishing material is secured to the finishing side of the elongate planar head by hook and loop fastener material.

16. The manually operated abrading tool of claim 14 wherein the matching first profiles define a first major axis and a first minor axis extending along a length and width of the matching first profiles, respectively, such that a ratio of the length to the width is approximately 5:1 or higher.

17. The manually operated abrading tool of claim 16 wherein a ratio of the length of the matching first profiles to the thickness of the edge perimeter regions is approximately 20:1 or higher.

18. The manually operated abrading tool of claim 16 wherein the matching second profiles define a region having a second major axis and a second minor axis, wherein the second major axis extends at an oblique angle to the first major axis.

19. The manually operated abrading tool of claim 16 wherein the matching second profiles define a region having a second major axis and a second minor axis, wherein the second major axis extends parallel to the first major axis.

20. The manually operated abrading tool of claim 16 wherein the matching first profiles define a region having a shape selected from the group consisting of a triangular region and an oval region.

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