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.

What is claimed is: 
     
         1 . 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 improvement comprising:
 at least one aperture extending from the first major surface to the second major surface; and   at least one first channel having a cross-sectional area, with the channel formed in one of the first major surface, and with the first channel extending from one side surface to the aperture whereby the first channel is in communication with the aperture.   
     
     
         2 . The improved resilient sanding block of  claim 1 , wherein the second major surface further comprises a second layer of abrasive material. 
     
     
         3 . The improved resilient sanding block of  claim 2 , wherein the second major surface has at least one second channel formed in the second major surface, and with the second channel extending from one of the side surfaces to the aperture whereby the second channel is in communication with the aperture. 
     
     
         4 . The improved resilient sanding block of  claim 1  further comprising a second aperture extending from the first major surface to the second major surface, wherein the second aperture is spaced from and generally parallel with the first aperture. 
     
     
         5 . The improved resilient sanding block of either  claim 1  or  3  wherein the channel is generally linear. 
     
     
         6 . The improved resilient sanding block of either  claim 1  or  3  wherein the channel has a width in the range of about 1 to about 5 mm. 
     
     
         7 . The improved resilient sanding block of either  claim 1  or  3  wherein the channel has a depth in the range of about 1 to about 5 mm. 
     
     
         8 . The improved resilient sanding block of  claim 1 , wherein the aperture is generally circular and has a diameter that is larger than the cross-sectional area of the channel. 
     
     
         9 . The improved resilient sanding block of  claim 1 , wherein the core is generally rectangular and has a thickness defined by the first and second major surfaces, and wherein the thickness is in the range of about 2 to about 3 cm. 
     
     
         10 . The improved resilient sanding block of  claim 1 , wherein the core comprises resilient foam material. 
     
     
         11 . The improved resilient sanding block of  claim 1 , wherein the resilient sanding block is configured and arranged to be operatively connect to a suction device. 
     
     
         12 . The improved resilient sanding block of  claim 1 , wherein the first and second major surfaces are generally parallel with respect to each other. 
     
     
         13 . A method of forming a 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, a plurality of side surfaces and a plurality of end surfaces; with the first major surface, having a layer of abrasive material disposed thereon, the method comprising the steps of:
 a. providing a resilient block having a core and a plurality of exterior surfaces and having a layer of abrasive material disposed thereon; and   b. forming an aperture through the core between the first and second major surfaces.   
     
     
         14 . The method of  claim 13 , further comprising the step of:
 c. forming a channel having a cross-sectional area in the first major surface, such that the channel is in communication with one of the side surfaces and the aperture.   
     
     
         15 . The method of  claim 13 , further comprising the step of:
 c. forming a second aperture through the core between the first and second major surfaces.   
     
     
         16 . A method of forming a 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, a plurality of side surfaces and a plurality of end surfaces; with the first major surface, having a layer of abrasive material disposed thereon, the method comprising the steps of:
 a. providing a resilient block having a core and a plurality of exterior surfaces and having a layer of abrasive material disposed thereon; and   b. forming a channel having a cross-sectional area in the first major surface, such that the channel is in communication with one of the side surfaces.   
     
     
         17 . The method of  claim 16 , further comprising the step of:
 c. forming an aperture through the core between the first and second major surfaces and in communication with the channel.   
     
     
         18 . A method of forming a resilient sanding block, the method comprising the steps of:
 a. providing a resilient block having of the type comprising a core having a plurality of exterior surfaces, including a first major surface and a second major surface, a plurality of side surfaces and a plurality of end surfaces; with the first major surface, having a layer of abrasive material disposed thereon; and   b. forming an aperture through the core between the first and second major surfaces.   
     
     
         19 . The method of  claim 18  further comprising the step of:
 c. forming a plurality of channels having a cross-sectional area in the first and second major surfaces, such that at least one of the channels is in communication with one of the side surfaces and the aperture. 
 
     
     
         20 . A sanding system comprising:
 a resilient sanding block comprising a resilient core having a plurality of exterior surfaces, including a first major surface and a second major surface, a plurality of side surfaces and a plurality of end surfaces, the block having a depth defined by the first and second major surfaces, and with the block having a layer of abrasive material disposed thereon; and   a holder comprising a first shell and a second shell, with the first shell having a plurality of side walls and a first top wall, and with the second shell having a plurality of side walls and a second top wall, with the second top wall having an aperture therethrough, with the first shell configured and arranged to substantially reside within the second shell in a generally nesting relation, and with the first shell connected to the second shell such that a passageway is formed between the walls of the first and second shells and to the aperture in the second top wall.   
     
     
         21 . The system of  claim 20 , wherein the passageway connects the aperture, which may operatively be connected to a suction device. 
     
     
         22 . The system of  claim 20 , wherein the holder further comprises a handle. 
     
     
         23 . A resilient sanding block in combination with a holder, the resilient sanding block comprising:
 a first major surface, a second major surface, a plurality of side surfaces and a plurality of end surfaces, within the first and second major surfaces defining a depth, and with the block having an aperture extending from the first major surface to the second major surface; and   a holder comprising a plate having a front end and a rear end, with the front end of the plate comprising a downwardly extending tube, and the plate further comprising means for retaining the resilient sanding block to the holder such that one of the major surfaces is maintained in close proximity to the plate.   
     
     
         24 . The combination of  claim 23 , wherein the front end of the plate further comprises a second means for retaining the resilient sanding block to the holder such that one of the major surfaces is maintained in close proximity to the plate. 
     
     
         25 . The combination of either  claim 23  or  24  wherein the means for retaining is a downwardly extending flange and at least one tooth, with the tooth extending in a general direction toward the downwardly extending tube, and wherein the tooth is configured and arranged to engage one of the end surfaces of the resilient sanding block. 
     
     
         26 . The combination of either  claim 23  or  24  further comprising a handle. 
     
     
         27 . A holder for a resilient sanding block, the holder comprising:
 a first shell and a second shell, with the first shell having a plurality of side walls and a first top wall, and with the second shell having a plurality of side walls and a second top wall, with the second top wall having an aperture therethrough, with the first shell configured and arranged to substantially reside within the second shell in a generally nesting relation, and with the first shell connected to the second shell such that a passageway is formed between the walls of the first and second shells and the aperture in the second top wall.   
     
     
         28 . The holder of  claim 27  further comprising a handle, wherein the handle is operatively connected to the aperture in the second top wall of the second shell and wherein the handle may be operatively connected to a suction device. 
     
     
         29 . The holder of  claim 27  wherein one of the side walls of the second shell further comprises at least one aperture that extends therethrough, such that the aperture is in communication with the passageway. 
     
     
         30 . An improved resilient sanding block of the type comprising a resilient core having a plurality of exterior surfaces, including a first major surface and a second major surface, a plurality of side surfaces and a plurality of end surfaces, the improvement comprising:
 an abrasive member removably attached to either the first or second major surface.   
     
     
         31 . The improved resilient sanding block of  claim 30  further comprising at least one aperture extending from the first major surface to the second major surface. 
     
     
         32 . The improved resilient sanding block of  claim 30 , wherein the abrasive member is a flexible sheet. 
     
     
         33 . The improved resilient sanding block of  claim 32 , wherein the flexible sheet is a sanding screen. 
     
     
         34 . The improved resilient sanding block of  claim 30  further comprising complementary shaped fasteners configured and arranged to releasably attach the sanding screen to either the first or second major surfaces. 
     
     
         35 . The improved resilient sanding block of  claim 34 , wherein the complementary shaped fasteners are hooks and loops. 
     
     
         36 . The improved resilient sanding block of  claim 34 , wherein the complimentary shaped fasteners are substantially coextensive with the flexible sheet.