Sanding apparatus and method of manufacture

Abstract

An improved resilient sanding block of the type comprising a core having a plurality of exterior surfaces, including a first major surface and a second major surface and side surfaces, and having a layer of abrasive material disposed thereon. The resilient sanding block may have one or more apertures or through holes extending from one major surface to the other major surface and channels formed in at least one of the major surfaces, with the channels in communication with the aperture. When a vacuum source is operatively connected to the aperture, the dust created by sanding will be substantially removed into the vacuum source via the channels and the aperture. A holder for a resilient sanding block is also disclosed, as well as a handle for the holder, which together form a sanding system.

1 - 36 . (canceled) 
   
   
       37 . A sanding system comprising:
 a sanding block having a flexible resilient core, a plurality of exterior surfaces, including an abrasive first major surface and a second major surface and side surfaces and abrasive material coated onto at least the abrasive first major surface;   apertures that extend from the abrasive first major surface to the second major surface, wherein the flexible resilient core is configured and arranged to be operatively connected to a suction device; and   a holder configured and arranged to hold the flexible resilient core, the holder being configured and arranged to be operatively connected to a suction device.   
   
   
       38 . The system of  claim 37 , further comprising a flexible hose that operatively connects the suction device to the flexible resilient core. 
   
   
       39 . The system of  claim 37 , further comprising a dust collection receptacle operatively connected to the suction device. 
   
   
       40 . The system of  claim 37 , further comprising a handle, the handle attached to the holder. 
   
   
       41 . The system of  claim 37 , wherein the holder comprises a grip. 
   
   
       42 . The system of  claim 37 , wherein said sanding block further comprises apertures that are generally circular. 
   
   
       43 . The system of  claim 37 , wherein said sanding block further comprises a flexible core that is generally rectangular and has a thickness defined by the first and second major surfaces. 
   
   
       44 . The system of  claim 37 , wherein said sanding block comprises first and second major surfaces that are generally parallel with respect to each other. 
   
   
       45 . The system of  claim 37  wherein the flexible resilient core comprises resilient foam material. 
   
   
       46 . The system of  claim 37 , wherein said holder further comprises an upper chamber having spacers positioned within said upper chamber, wherein said spacers position the sanding block away from said chamber, and a skirt that frictionally retains said sanding block within the holder. 
   
   
       47 . An improved sanding block comprising:
 one flexible resilient core having a plurality of exterior surfaces, including one abrasive first major surface and one second major surface and side surfaces and abrasive material coated onto at least the one abrasive first major surface; and   apertures that extend from the one abrasive first major surface to the one second major surface.   
   
   
       48 . The improved sanding block of  claim 47 , further comprising apertures that are generally circular. 
   
   
       49 . The improved sanding block of  claim 47 , further comprising the one resilient flexible core that is generally rectangular and has a thickness defined by the one abrasive first major surface and the one second major surface. 
   
   
       50 . The improved sanding block of  claim 47  further comprising the one abrasive first major surface and the one second major surface being generally parallel with respect to each other. 
   
   
       51 . The improved sanding block of  claim 47 , further comprising the one abrasive first major surface and the one second major surface being generally flat. 
   
   
       52 . The improved sanding block of  claim 47 , wherein the one flexible resilient core comprises resilient foam material. 
   
   
       53 . The improved sanding block of  claim 47 , wherein the one abrasive first major surface and the one second major surface are abrasive surfaces. 
   
   
       54 . The improved sanding block of  claim 47 , having hook and loop fastening material attached to the one second major surface. 
   
   
       55 . A method of forming a sanding block, comprising:
 providing a flexible resilient core having a plurality of exterior surfaces, including an abrasive first major surface and a second major surface and side surfaces;   coating abrasive material onto at least the abrasive first major surface; and   extending apertures from the abrasive first major surface to the second major surface.   
   
   
       56 . The method of  claim 55 , further comprising providing a resilient flexible core is generally rectangular and has a thickness defined by the first and second major surfaces.