MULTI-SIDED SHAPED ABRASIVE SANDING AID

Abstract

A hand tool comprising at least a single member having a top surface, a bottom surface, and opposing edges; and a fastener system disposed on the underside of the at least one member that is adapted to adhere an abrasive media, wherein the at least one member is bent at an angle upward from horizontal.

Description

FIELD OF THE DISCLOSURE

The present invention relates to hand tools and methods of using them.

BACKGROUND

To sand a surface, a backup pad or sanding block is commonly used with a coated abrasive. Sanding blocks have been shaped in order to sand particularly shaped workpieces or workpiece surfaces, such as corners. However, current methods of attaching abrasives to sanding blocks, such as by the use of clips positioned on the top of a sanding block, result in problems, including issues with maintaining the proper tension of the abrasive to the block. Further, the method and position of most current attachment systems contributes to a bulkiness of the sanding block that prohibits efficient and easy sanding in narrow spaces and thin openings.

Additionally, when sanding by conventional methods, in order to obtain a desired surface smoothness, more than one type of abrasive must be used. For example, initial rough sanding is accomplished with a large grit size abrasive, which is then followed by successive sanding with a fine grit size abrasive. Thus conventional blocks and sanding methods usually stopping work to switch types of abrasive media. Further, the need to switch abrasives can be compounded when faced with the challenge of sanding surfaces composed of more than one type of material, or that have various types of coatings and finishes. Even further, there may be concerns that some portions of a work piece surface can be contaminated by being exposed to the swarf produced during the sanding of another portion of the workpiece.

As such, there exists a need for tool that aids in efficient and easy hand sanding, or grinding, of work piece having challengingly shaped and hard to reach areas, as well as that provides for rapid and easy transition between types of abrasive media.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure may be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings.

FIG. 1 is a perspective view of an embodiment of a hand tool in accordance with the invention.

FIG. 2a is a top view of an embodiment of a hand tool in accordance with the invention.

FIG. 2b is a bottom view of an embodiment of a hand tool in accordance with the invention illustrating the perimeter shapes of portions of the bottom surface of the hand tool.

FIG. 3 is a side view of an embodiment of hand tool in accordance with the invention that illustrates angles alpha (α) and beta (β). is a cross-sectional view of an embodiment of hand tool in accordance with the invention.

FIG. 4a is a side view of an embodiment of a hand tool in accordance with the invention with a first portion of the bottom surface of a base member in contact with a work surface.

FIG. 4b is a side view of an embodiment of a hand tool in accordance with the invention with a second portion of a bottom surface of a base member in contact with a work surface.

FIG. 5 is a cross-sectional view of an embodiment of a hand tool in accordance with the invention.

FIG. 6 is a perspective view of an embodiment of a hand tool in accordance with the invention.

FIG. 7a is a top view of an embodiment of a hand tool in accordance with the invention.

FIG. 7b is a bottom view of an embodiment of a hand tool in accordance with the invention illustrating the perimeter shapes of portions of the bottom surface of the hand tool.

FIG. 8 is a side view of an embodiment of hand tool in accordance with the invention that illustrates angles alpha (α) and beta (β). is a cross-sectional view of an embodiment of hand tool in accordance with the invention.

FIG. 9a is a side view of an embodiment of a hand tool in accordance with the invention with a first portion of the bottom surface of a base member in contact with a work surface.

FIG. 9b is a side view of an embodiment of a hand tool in accordance with the invention with a second portion of a bottom surface of a base member in contact with a work surface.

FIG. 10 is a cross-sectional view of an embodiment of a hand tool in accordance with the invention.

FIG. 11 is a front view of an embodiment of a hand tool in accordance with the invention tilted so that the forward portion is in a horizontal position.

FIG. 12a to FIG. 12d are perspective views of embodiments of hand tools in accordance with the invention that have varying types of handles.

FIG. 13a is a side view of an embodiment of a hand tool in accordance with the invention with abrasive media attached to the bottom surface of the tool.

FIG. 13b is a side view of an embodiment of a hand tool in accordance with the invention with abrasive media attached to the bottom surface of the tool and to the top surface of the forward portion of the base member.

FIG. 14a and FIG. 14b illustrate of an embodiment of a hand tool in accordance with the invention in use.

FIG. 15a and FIG. 15b illustrate of an embodiment of a hand tool in accordance with the invention in a second use.

The use of the same reference symbols in different drawings indicates similar or identical items.

DETAILED DESCRIPTION

In a particular embodiment, a hand tool for aiding in sanding or grinding operations includes a base member and a fastener system to adhere an abrasive media to the bottom surface of the base member. The base member comprises a top surface, a bottom surface, a forward end, a back end, and opposing side edges. The bottom surface includes a first portion and a second portion adjoining the first portion such that when the first portion is horizontal, the second portion is bent upwards from horizontal at an angle.

In another embodiment, a hand tool includes a first member, a second member, and a fastener system to adhere an abrasive media to the underside of the first member and the second member. Each member includes a top surface and a bottom surface. The first member and second member are joined such that when the first member is horizontal, the second member extends from the first member at an exterior angle between 180° and 225° measured from the bottom surface of each member.

As used herein, a hand tool for aiding in sanding or grinding operations includes manually-operated hand tools and powered hand tools.

As illustrated in FIG. 1, a hand tool 100 comprises a base member 103. The base member 103 may have a top surface, a bottom surface, a forward end, a back end, and opposing side edges. The bottom surface may comprise a first portion 107 and a second portion 105. The first portion 107 may have an irregularly shaped or a regularly shaped perimeter, including a geometrically shaped perimeter. Suitable geometric perimeter shapes may include triangular, trapezoidal, circular, ovoid, elliptical, rectangular, or square shapes. As shown in FIG. 2b, in a preferred embodiment, the first portion 107 has a rectangular perimeter shape, p₁.

As shown in FIG. 2a, first portion 107 may have a width W₁. The width may be selected depending on the particular application of the hand tool, while still taking into account that the tool should not be so large or bulky that the tool becomes unwieldy for a user. For example, the width W₁ may be at least about 0.5 inch (12.7 mm), such as at least about 1 inch (25.4 mm), at least about 1.8 inch (45 mm), at least about 2 inch (50.8 mm), or even at least about 2.8 inch (70 mm). In another example, the width W₁ may be not greater than about 12 inch (304.8 mm), such as not greater than about 10 inch (254 mm), such as not greater than 8 inch (203.2 mm), such as not greater than about 6 inch (152.4 mm), such as not greater than about 5 inch (127 mm), such as not greater than about 4.5 inch (114.3 mm), or even not greater than about 3 inch (76.2 mm). W₁ may be at least about 0.5 inch (12.7 mm) and not greater than about 12 inch (304.8 mm), such as at least about 1 inch (25.4 mm) and not greater than about 10 inch (254 mm). It will be appreciated that the width W₁ of the first portion 107 may be within a range comprising any pair of the previous upper and lower limits. As shown in FIG. 2a, in a preferred embodiment, the first portion 107 has a width W1 in the range of about 1.57 inch (40 mm) and about 3.94 inch (100 mm).

The second portion 105 may have an irregularly shaped or a regularly shaped perimeter, including a geometrically shaped perimeter. In an embodiment, the shape of the perimeter of the second portion 105 may be the same as the shape of the perimeter of the first portion 107. In another embodiment, the shape of the perimeter of the second portion may be different from the shape of the perimeter of the first portion. Suitable geometric perimeter shapes for the second portion 105 may include triangular, trapezoidal, circular, ovoid, elliptical, rectangular, or square shapes. In a particular embodiment, the second portion 105 may have a substantially triangular perimeter shape, such as an isosceles triangle perimeter shape. In an example, the sides of the triangular perimeter shape may be substantially straight. In another example, the sides of the triangular perimeter shape may be curved. For example, the sides of the triangular perimeter shape may be convex. In another example, the sides of the triangular perimeter shape may be concave. In a further example, one side of the triangular perimeter may be concave and a second side may be convex, forming a partial arc shape. As shown in FIG. 2b, in a preferred embodiment, the perimeter shape p₂ of the second portion 105 is triangular with two convex sides.

As shown in FIG. 2a, second portion 105 may have a width W₂. In an example, the width W₂ may be substantially the same as the width W₁ of the first portion 107. For example, the width W₂ of the second portion 105 may be at least about 0.5 inch (12.7 mm), such as at least about 1 inch (25.4 mm), at least about 1.8 inch (45 mm), at least about 2 inch (50.8 mm), or even at least about 2.8 inch (70 mm). In another example, the width W₂ may be not greater than about 12 inch (304.8 mm), such as not greater than about 10 inch (254 mm), such as not greater than 8 inch (203.2 mm), such as not greater than about 6 inch (152.4 mm), such as not greater than about 5 inch (127 mm), such as not greater than about 4.5 inch (114.3 mm), or even not greater than about 3 inch (76.2 mm). It will be appreciated that the width W₂ of the second portion 105 may be within a range comprising any pair of the previous upper and lower limits. The shape of the second portion 105 may have a tapering shape, such that one end of the second portion has a width W₂, while the end of the second portion opposite width W₂ has a width W₃, which may be substantially smaller than W₂. For example, width W₃ may be at least about 0.04 inch (1 mm), such as at least about 0.12 inch (3 mm), at least about 0.2 inch (5 mm), or even at least about 0.28 inch (7 mm). In another example, W₃ may be not greater than about 0.6 inch (15 mm), such as not greater than about 0.47 inch (12 mm), not greater than about 0.4 inch (10 mm), or even not greater than about 0.3 inch (8 mm). In a further example, W₃ may be at least about 0.12 inch (3 mm) and not greater than about 0.6 inch (15 mm), such as at least about 0.2 inch (5 mm) and not greater than about 0.3 inch (8 mm). It will be appreciated that the width W₃ of the second portion 105 may be within a range comprising any pair of the previous upper and lower limits. It will also be appreciated that width W₃ may be so small as to be less than 0.04 inch (1 mm) in width, i.e., the perimeter shape of the second portion 105 tapers to a point. As shown in FIG. 2a, in a preferred embodiment, the second portion 105 has a width W₂ in the range of about 1.57 inch (40 mm) and about 3.94 inch (100 mm) and has a width W₃ that comes to a point (is less than 1 mm).

In an embodiment, the first portion 107 and the second portion 105 may be joined to form a base member 103 such that the first portion and the second portion are contiguous. The method of joining the first portion and the second portion may be selected based upon the material of composition of the first portion and the second portion and the intended use of the hand tool, and may include, but is not limited to, welding, soldering, brazing, fusion bonding, solvent bonding, adhesive bonding, such as with an epoxy, a glue, or a cement, and mechanical fastening, such as with screws, bolts, nails, dowels, rivets, pins, and any combination thereof. In another embodiment, the base member may be a unitary piece. It will be appreciated that the term unitary refers to a single, undivided element or part which does not require joining between pieces to form a whole. In a preferred embodiment, the base member is a unitary piece. A preferred method of forming a unitary base member is injection molding.

The second portion 105 may be joined relative to the first portion 107 such that the shape of the perimeter of the second portion tapers as it extends away from the first portion. As shown in FIGS. 2a and 2b, in a preferred embodiment, the first portion 107 and second portion 105 are joined together and the shape of the second portion tapers as it extends away from the first portion.

As illustrated in FIG. 3, the second portion 105 and the first portion 107 of the base member 103 are joined such that when the first portion is level with horizontal 301, the second portion is bent upwards from horizontal at an angle α, as measured from the horizontal up to the second portion 105 of the bottom surface of the base member. The angle α may be selected such that when the tool is tilted so that the second portion is horizontal, as illustrated in FIGS. 4b and FIG. 7, the wrist of the operator is positioned at a comfortable angle. For example, the angle α may be at least about 1°, such as at least about 10°, at least about 13°, at least about 17°, or even at least about 25°. In another example, the angle α may be not greater than about 45°, such as not greater than about 40°, not greater than about 35°, not greater than about 30°, or even not greater than about 28°. In a further example, the angle α may be at least about 1° and not greater than about 45°, such as at least about 10° and not greater than about 35°, or even at least about 13° and not greater than about 30°. It will be appreciated that the angle α may be within a range comprising any pair of the previous upper and lower limits. In a preferred embodiment, the angle α is in a range of 10° to 17°.

As illustrated in FIG. 3, the second portion 105 may be joined to the first portion 107 such that when the first portion is horizontal, the bottom surface of the second portion forms an exterior angle β with the bottom surface of the first portion. The angle β may be at least about 181°, such as at least about 185°, such as at least about 187°, such as at least about 190°, or even at least about 193°. The angle β may be not greater than about 230°, such as not greater than about 225°, not greater than about 210°, or even not greater than about 200°. Angle β may be at least about 181° and not greater than about 230°, such as at least about 185° and not greater than about 225°. It will be appreciated that angle β may be within a range comprising any pair of the previous upper and lower limits. In a preferred embodiment, the angle β is in the range of 185° to 195°.

As illustrated in FIG. 5, base member 103 may have a planar cross-sectional shape with a thickness t₁ and a length L₁ that correspond with the first portion 107. The cross-sectional shape may be irregular or regular, including rectangular shapes, square shapes, or trapezoidal shapes. In a preferred embodiment, the cross-sectional shape of the base member corresponding with the first portion has a regular rectangular shape.

The first portion length L₁ may be selected according to the desired application of the hand tool, while still taking into account that the tool should not be so large or bulky that the tool becomes unwieldy for a user. The length L₁ may be at least about 1 inch (25.4 mm), such as at least about 2 inch (50.8 mm), such as at least about 3 inch (76.2 mm), at least about 4 inch (101.6 mm), at least about 4.5 inch (114.3 mm), or even at least about 5 inch (127 mm). The length L₁ may be not greater than about 12 inch (304.8 mm), such as not greater than about 10 inch (254 mm), such as not greater than about 8 inch (203.2 mm), such as not greater than about 7.5 inch (190.5 mm), not greater than about 6.5 inch (165.1 mm), or even not greater than about 6 inch (152.4 mm). The length L₁ may be at least about 1 inch (25.4 mm) and not greater than 12 inch (304.8 mm), such as at least about 3 inch (76.2 mm) and not greater than about 8 inch (203.2 mm), such as at least about 5 inch (127 mm) and not greater than about 10 inch (254 mm). It will be appreciated that the length L₁ may be within a range comprising any pair of the previous upper and lower limits. In a preferred embodiment, the length L₁ is in the range of 4 inch (101.6 mm) to 5 inch (127 mm).

The thickness t₁ of the base member corresponding to first portion 107 may be a uniform thickness selected in accordance with the desired application of the hand tool, while still taking into account that the tool should not be so large or bulky that the tool becomes unwieldy for a user. For example, the thickness t₁ may be at least about 0.04 inch (1 mm), at least about 0.47 inch (12 mm), or even at least about 0.79 inch (20 mm). In another example, the thickness t₁ may be not greater than about 5 inch (127 mm), such as not greater than about 4.5 inch (114.3 mm), or even not greater than about 3.54 inch (90 mm). The thickness t₁ may be at least about 0.04 inch (1 mm) and not greater than about 5 inch (127 mm), such as at least about 0.47 inch (12 mm) and not greater than about 4.5 inch (114 mm). It will be appreciated that the thickness t₁ may be within a range comprising any pair of the previous upper and lower limits. In a preferred embodiment, the thickness t₁ of the base member is substantially uniform across the length L₁ corresponding to the first portion 107 and in the range of about 0.20 inch (5 mm) to about 0.79 inch (20 mm).

In another embodiment, the thickness t₁ may be non-uniform, such that the first portion has a trapezoidal cross-sectional shape or a tapering cross sectional shape.

As illustrated in FIG. 5, base member 103 may have a planar cross-sectional shape with a thickness t₂ and a length L₂ that correspond with the second portion 105. The cross-sectional shape may be irregular or regular, including rectangular, square, triangular, or trapezoidal shapes. In another embodiment, the cross-sectional shape of the second portion may be a truncated circular, truncated ovoid, or truncated elliptical shape. In a preferred embodiment, the cross-sectional shape of the base member corresponding with the second portion has a rectangular shape. In an alternate preferred embodiment, the cross-sectional shape of the base member corresponding with the second portion has a triangular shape.

The length L₂ may be selected based upon the intended application of the hand tool, while still taking into account that the tool should not be so large or bulky that the tool becomes unwieldy for a user. For example, length L₂ may be at least about 0.5 inch (12.7 mm), such as at least 0.79 inch (20 mm), at least about 1.57 inch (40 mm), at least about 2 inch (50.8 mm), or even at least about 2.48 inch (63 mm). In another example, length L₂ may be not greater than about 12 inch (304.8 mm), such as not greater than 8 inch (203.2 mm), such as not greater than 6 inch (152.4 mm), such as not greater than 4.5 inch (114.3 mm), such as not greater than about 4 inch (101.6 mm), not greater than about 3.5 inch (88.9 mm), or even not greater than about 3 inch (76.2 mm). In a further example, length L₂ may be at least about 0.5 inch (12.7 mm) and not greater than about 12 inch (304.8 mm), such as at least about 0.79 inch (20 mm) and not greater than about 8 inch (203.2 mm), such as at least about 1.18 inch (30 mm) and not greater than 6 inch (152.4 mm). It will be appreciated that L₂ may be within a range comprising any pair of the previous upper and lower limits. In a preferred embodiment, the length L₂ is in the range of about 1.18 inch (30 mm) to about 6 inch (152.4 mm).

The cross-sectional thickness t₂ of base member 103 that corresponds with the second portion 105 may be uniform. For example, the thickness t₂ may be at least about 0.04 inch (1 mm), such as at least about 0.2 inch (5 mm), at least about 0.28 inch (7 mm), at least about 0.47 inch (12 mm), or even at least about 0.79 inch (20 mm). In another example, the thickness t₂ may be not greater than about 5 inch (127 mm), such as not greater than about 4.5 inch (114 mm), not greater than about 3.54 inch (90 mm), not greater than about 2.56 inch (65 mm), or even not greater than about 1.97 inch (50 mm). In a further example, the thickness t₂ may be at least about 0.04 inch (1 mm) and not greater than about 5 inch (127 mm). It will be appreciated that t₂ may be within a range comprising any pair of the previous upper and lower limits. In an example, thickness t₂ may be equal to thickness t₁. In another example, thickness t₂ may not be equal to thickness t₁, such that thickness t₂ may be less than thickness t₁ or such that thickness t₂ may be greater than thickness t₁. In a preferred embodiment, thickness t₂ of the base member is substantially equal to t₁ and in the range of about 0.20 inch (5 mm) to about 0.79 inch (20 mm).

In another embodiment, the base member may have a non-uniform thickness along the length corresponding to the second portion 105, such that the cross-section of the second portion may have a trapezoidal, triangular, truncated circular, truncated oval, or truncated elliptical shape. In a preferred embodiment, the thickness of the base member corresponding to the second portion tapers along the length L₂ toward the front of the tool (i.e., the terminus of the second portion of the base member farthest away from the first portion of the base member), which has a thickness t₃. Thickness t₃ may be at least about 0.04 inch (1 mm), such as at least about 0.12 inch (3 mm), at least about 0.2 inch (5 mm), or even at least about 0.28 inch (7 mm). Thickness t₃ may be not greater than about 1 inch (25.4 mm), such as not greater than about 0.79 inch (20 mm), such as not greater than about 0.39 inch (10 mm), such as not greater than about 0.2 inch (5 mm), or even not greater than about 0.04 inch (1 mm). Thickness t₃ may be at least about 0.04 inch (1 mm) and not greater than about 1 inch (25.4 mm), such as at least about 0.2 inch (5 mm) and not greater than about 0.79 inch (20 mm). It will be appreciated that thickness t₃ may be within a range comprising any pair of the previous upper and lower limits. In an embodiment, thickness t₃ is greater than t₂. In a preferred embodiment, thickness t₃ is less than thickness t₂ and is in the range of at least about 0.08 inch (2 mm) to not greater than about 0.39 inch (10 mm).

Embodiments of the tool may be described and understood in relation to ratios or percentages of the lengths and thicknesses of the portions of the base member to each other. The length L₁ of the first portion of the base member may be in a ratio to the length L₂ of the second portion of the base member. For example, the ratio of L₁ to L₂ may be at least about 1:1, such as at least about 2:1, or even at least about 3:1. In a preferred embodiment, the ratio of L₁ to L₂ is about 2.1:1.

The second portion of the base member may have a thickness t₂ which is at least about 0.5% of length L₂. For example, thickness t₂ may be at least about 1% of length L₂, such as at least about 5% of length L₂. In another example, thickness t₂ may be not greater than about 20% of length L₂, such as not greater than about 15% of length L₂, or even not greater than about 10% of length L₂. In a further example, thickness t₂ may be 0.5-20% of length L₂, such as 5-15% of length L₂. It will be appreciated that thickness t₂ may be within a range of a percentage of length L₂ comprising any pair of the previous upper and lower limits. In a preferred embodiment, the thickness t₂ is in a range of 0.5-20% of length L₂

As illustrated in FIG. 4, the base member 103 may have a length L_T, which is equal to the sum of L₁ plus L₂. Based on the above upper and lower limits for L₁ and L₂, length L_T will range in length from at least about 1.5 inch (38.1 mm) to not greater than about 24 inch (609.6 mm), from at least about 3 inch (76.2 mm) to not greater than about 12 inch (304.8 mm), from at least about 4 inch (101.6 mm) to not greater than about 10 inch (254 mm). It will be appreciated that length L_T may be within a range comprising any pair of the previous upper and lower limits. In a preferred embodiment, length L_{T is} at least about 4 inch (101.6 mm) to not greater than about 8 inch (103.2 mm).

The second portion 105 of base member 103 may have a thickness t₂ which is at least about 0.5% of total length L_T of the base member. For example, t₂ may be at least about 1.0% of L_T, at least about 5.0% of L_T, or even at least about 7.0% of L_T. In another example, t₂ may be not greater than about 20.0% of L_T, such as not greater than about 14.0% of L_T, not greater than about 13.0% of L_T, or even not greater than about 10.0% of L_T. In a further example, t₂ may be 0.5-20% of L_T, such as 0.5-14% of L_T. It will be appreciated that t₂ may be within a range of a percentage of the length L_T comprising any pair of the previous upper and lower limits.

As illustrated in FIG. 6, a hand tool 600 may comprise a first member 607 and a second base member 605. The base members 607 and 605 may each have a top surface, a bottom surface, a forward end, a back end, and opposing side edges. The first member 607 may have a geometric perimeter shape. Suitable geometric perimeter shapes may include triangular, trapezoidal, circular, ovoid, elliptical, rectangular, or square shapes. As shown in FIG. 7b, in a particular embodiment, the first member may have a rectangular perimeter shape, p_m1.

First member 607 may have a width W_m1. The width may be selected depending on the particular application of the hand tool, while still taking into account that the tool should not be so large or bulky that the tool becomes unwieldy for a user. For example, the width W_m1 may be at least about 0.5 inch (12.7 mm), such as at least about 1 inch (25.4 mm), at least about 1.8 inch (45 mm), at least about 2 inch (50.8 mm), or even at least about 2.8 inch (70 mm). In another example, the width W_m1 may be not greater than about 12 inch (304.8 mm), such as not greater than about 10 inch (254 mm), such as not greater than 8 inch (203.2 mm), such as not greater than about 6 inch (152.4 mm), such as not greater than about 5 inch (127 mm), such as not greater than about 4.5 inch (114.3 mm), or even not greater than about 3 inch (76.2 mm). W_m1 may be at least about 0.5 inch (12.7 mm) and not greater than about 12 inch (304.8 mm), such as at least about 1 inch (25.4 mm) and not greater than about 10 inch (254 mm). It will be appreciated that the width W_m1 of the first portion 107 may be within a range comprising any pair of the previous upper and lower limits. As shown in FIG. 7a, in a preferred embodiment, the first portion 107 has a width W_m1 in the range of about 1.57 inch (40 mm) and about 3.94 inch (100 mm).

The second member 605 may an irregularly shaped or a regularly shaped perimeter p_m2, including a geometrically shaped perimeter. In an embodiment, the shape of the perimeter of the second member may be the same as the shape of the perimeter of the first member. In another embodiment, the shape of the perimeter of the second member may be different from the shape of the perimeter of the first member. Suitable geometric perimeter shapes may include triangular, trapezoidal, circular, ovoid, elliptical, rectangular, or square shapes. In a particular embodiment, the second member 605 may have a substantially triangular perimeter shape. In an example, the side of the triangular perimeter shape may be substantially straight. In another example, the sides of the triangular perimeter shape may be curved. For example, the sides of the triangular perimeter shape may have a convex shape such that the second member 605 has a shape substantially that of a shovel. In another example, the sides of the triangular perimeter shape may have a concave shape. In a further example, the sides of the triangular perimeter shape may be curved, such that one side has a concave shape and a second side has a convex shape, forming a partial arc shape. As shown in FIG. 7b, in a particular example, the perimeter p_m2 of the second member is triangular with two convex sides.

The second member 605 may have a width W_m2 at one end. In an example, the width W_m2 may be substantially the same as the width Wm₁ of the first member 607. For example, the width W_m2 of the second member 605 may be at least about 0.5 inch (12.7 mm), such as at least about 1 inch (25.4 mm), at least about 1.8 inch (45 mm), at least about 2 inch (50.8 mm), or even at least about 2.8 inch (70 mm). In another example, the width W_m2 may be not greater than about 12 inch (304.8 mm), such as not greater than about 10 inch (254 mm), such as not greater than 8 inch (203.2 mm), such as not greater than about 6 inch (152.4 mm), such as not greater than about 5 inch (127 mm), such as not greater than about 4.5 inch (114.3 mm), or even not greater than about 3 inch (76.2 mm). It will be appreciated that the width W_m2 of the second member 605 may be within a range comprising any pair of the previous upper and lower limits. The shape of the second member 605 may have a tapering shape, such that the second member has a width W_m2 at one end, while at the opposite end has a width W_m3, which may be substantially the same as, or substantially smaller than W_m2. For example, width W_m3 may be at least about 0.04 inch (1 mm), such as at least about 0.12 inch (3 mm), at least about 0.2 inch (5 mm), or even at least about 0.28 inch (7 mm). In another example, W₃ may be not greater than about 0.6 inch (15 mm), such as not greater than about 0.47 inch (12 mm), not greater than about 0.4 inch (10 mm), or even not greater than about 0.3 inch (8 mm). In a further example, W_m3 may be at least about 0.12 inch (3 mm) and not greater than about 0.6 inch (15 mm), such as at least about 0.2 inch (5 mm) and not greater than about 0.3 inch (8 mm). It will be appreciated that the width W_m3 of the second member 605 may be within a range comprising any pair of the previous upper and lower limits. It will also be appreciated that width W_m3 may be so small as to be less than 0.04 inch (1 mm) in width, i.e., the perimeter shape of the second member 605 tapers to a point. As shown in FIG. 7a, in a preferred embodiment, the second member 605 has a width W_m2 in the range of about 1.57 inch (40 mm) and about 3.94 inch (100 mm) and has a width W_m3 that comes to a point (is less than 1 mm).

In an embodiment, the first member 607 and the second member 605 may be joined. The method of joining the first member and the second member may be selected based on the material composition of the first member and the second member, which may be composed of the same or different materials, and the intended use of the hand tool and may include, but is not limited to, welding, soldering, brazing, fusion bonding, solvent bonding, adhesive bonding, such as with an epoxy, a glue, or a cement, and mechanical fastening, such as with hinges, latches, detents, joining plates, brackets, screws, bolts, nails, dowels, rivets, pins, and any combination thereof.

The second member 605 may be joined relative to the first member 607 such that the shape of the perimeter p_m2 of the second member tapers as it extends away from the first member. As shown in FIG. 7b, in a preferred embodiment, the first member 607 and second member 605 are joined together and the shape of the second member tapers as it extends away from the first member.

As illustrated in FIG. 8, the second member 605 may be joined to the first member 605 such that when the first member is horizontal, the second member may be bent upwards from horizontal at an angle α. The angle α may be selected such that when the tool is tilted such that the second member is horizontal, the wrist of the operator is positioned at a comfortable angle. For example, the angle α may be at least about 1°, such as at least about 10°, at least about 13°, at least about 17°, or even at least about 25°. In another example, the angle α may be not greater than about 45°, such as not greater than about 40°, not greater than about 35°, not greater than about 30°, or even not greater than about 28°. In a further example, the angle α may be at least about 1° and not greater than about 45°, such as at least about 10° and not greater than about 35°, or even at least about 13° and not greater than about 30°. It will be appreciated that the angle α may be within a range comprising any pair of the previous upper and lower limits. In a preferred embodiment, the angle α is in a range of 10° to 17°.

As illustrated in FIG. 8, the second member 605 may be joined to the first member 607 such that when the first member is horizontal, the bottom surface of the second member forms an exterior angle β with the bottom surface of the first member. The angle β may be at least about 175°, such as at least about 180°, at least about 187°, or even at least about 195°. The angle β may be not greater than about 230°, such as not greater than about 225°, not greater than about 210°, or even not greater than about 200°. Angle β may be at least about 175° and not greater than about 230°, such as at least about 180° and not greater than about 225°. It will be appreciated that angle β may be within a range comprising any pair of the previous upper and lower limits. In a preferred embodiment, the angle β is in the range of 185° to 195°.

As illustrated in FIG. 10, the first member 607 may have a planar cross-sectional shape. The cross-sectional shape may be a rectangular shape, a square shape, or a trapezoidal shape. In a preferred embodiment, the cross-sectional shape of the first member is a regular rectangular shape.

The first member may have a length L_m1 that may be selected according to the desired application of the hand tool, while still taking into account that the tool should not be so large or bulky that the tool becomes unwieldy for a user. The length L_m1 may be at least about 1 inch (25.4 mm), such as at least about 2 inch (50.8 mm), such as at least about 3 inch (76.2 mm), at least about 4 inch (101.6 mm), at least about 4.5 inch (114.3 mm), or even at least about 5 inch (127 mm). The length L₁ may be not greater than about 12 inch (304.8 mm), such as not greater than about 10 inch (254 mm), such as not greater than about 8 inch (203.2 mm), such as not greater than about 7.5 inch (190.5 mm), not greater than about 6.5 inch (165.1 mm), or even not greater than about 6 inch (152.4 mm). The length L₁ may be at least about 1 inch (25.4 mm) and not greater than 12 inch (304.8 mm), such as at least about 3 inch (76.2 mm) and not greater than about 8 inch (203.2 mm), such as at least about 5 inch (127 mm) and not greater than about 10 inch (254 mm). It will be appreciated that the length L₁ may be within a range comprising any pair of the previous upper and lower limits. In a preferred embodiment, the length L_m1 is in the range of 4 inch (101.6 mm) to 5 inch (127 mm).

The first member 607 may have a uniform thickness t_m1, which may be selected in accordance with the desired application of the hand tool, while still taking into account that the tool should not be so large or bulky that the tool becomes unwieldy for a user. For example, the thickness t_m1 may be at least about 0.04 inch (1 mm), at least about 0.47 inch (12 mm), or even at least about 0.79 inch (20 mm). In another example, the thickness t₁ may be not greater than about 5 inch (127 mm), such as not greater than about 4.5 inch (114.3 mm), or even not greater than about 3.54 inch (90 mm). The thickness t_m1 may be at least about 0.04 inch (1 mm) and not greater than about 5 inch (127 mm), such as at least about 0.47 inch (12 mm) and not greater than about 4.5 inch (114 mm). It will be appreciated that the thickness t_m1 may be within a range comprising any pair of the previous upper and lower limits. In a preferred embodiment, the thickness t_m1 of the first member is substantially uniform across the length L_m1 of first member 607 and is in the range of about 0.20 inch (5 mm) to about 0.79 inch (20 mm).

In another embodiment, the thickness t_m1 may be non-uniform, such that the first member has a trapezoidal cross-sectional shape.

As illustrated in FIG. 10, the second member 605 may have a cross-sectional shape with a thickness t_m2 and a length L_m2. In an embodiment, the cross-sectional shape of the second member may be a planar shape, such as a rectangular, square, triangular, or trapezoidal shape. In another embodiment, the cross-sectional shape of the second member may be a truncated circular, truncated oval, or truncated elliptical shape. In a preferred embodiment, the cross-sectional shape of the second member is a rectangular shape. In an alternate preferred embodiment, the cross-sectional shape of the second member is a triangular shape.

The second member may have a length L_m2, which may be selected based upon the intended application of the hand tool, while still taking into account that the tool should not be so large or bulky that the tool becomes unwieldy for a user. For example, length L_m2 may be at least about 0.5 inch (12.7 mm), such as at least 0.79 inch (20 mm), at least about 1.57 inch (40 mm), at least about 2 inch (50.8 mm), or even at least about 2.48 inch (63 mm). In another example, length L₂ may be not greater than about 12 inch (304.8 mm), such as not greater than 8 inch (203.2 mm), such as not greater than 6 inch (152.4 mm), such as not greater than 4.5 inch (114.3 mm), such as not greater than about 4 inch (101.6 mm), not greater than about 3.5 inch (88.9 mm), or even not greater than about 3 inch (76.2 mm). In a further example, length L_m2 may be at least about 0.5 inch (12.7 mm) and not greater than about 12 inch (304.8 mm), such as at least about 0.79 inch (20 mm) and not greater than about 8 inch (203.2 mm), such as at least about 1.18 inch (30 mm) and not greater than 6 inch (152.4 mm). It will be appreciated that L₂ may be within a range comprising any pair of the previous upper and lower limits. In a preferred embodiment, the length L_m2 is in the range of about 1.18 inch (30 mm) to about 6 inch (152.4 mm).

In an embodiment, the second member 605 may have a uniform thickness t_m2. For example, the thickness t_m2 may be at least about 0.04 inch (1 mm), such as at least about 0.2 inch (5 mm), at least about 0.28 inch (7 mm), at least about 0.47 inch (12 mm), or even at least about 0.79 inch (20 mm). In another example, the thickness t_m2 may be not greater than about 5 inch (127 mm), such as not greater than about 4.5 inch (114 mm), such as not greater than about 3.54 inch (90 mm), such as not greater than about 2.56 inch (65 mm), or even not greater than about 1.97 inch (50 mm). In a further example, the thickness t_m2 may be at least about 0.04 inch (1 mm) and not greater than about 5 inch (127 mm). It will be appreciated that t₂ may be within a range comprising any pair of the previous upper and lower limits. In an example, thickness t_m2 may be equal to thickness t_m1. In another example, thickness t_m2 may not be equal to thickness t_m1, such that thickness t_m2 may be less than thickness t_m1 or such that thickness t_m2 may be greater than thickness t_m1. In a preferred embodiment, thickness t_m2 of the base member is substantially equal to t_m1 and in the range of about 0.20 inch (5 mm) to about 0.79 inch (20 mm).

In another embodiment, the second member 605 may have a non-uniform thickness, selected in accordance with the desired application of the hand tool, such that the second member has a trapezoidal, triangular, truncated circular, truncated oval, or truncated elliptical shape. In a preferred embodiment, the thickness of the second member tapers toward the front of the tool (i.e., the end of the second member that is farthest away from the first member). In an example, where the second member adjoins the first member may have a thickness t_m2 which may be substantially the same, or different than, thickness t_m1, and the end of the second member opposite the first member may have a thickness t_m3, which may be the same or differ from the thickness t_m2. For example, the thickness t_m3 may be less than the thickness t_m2. Thickness t_m3 may be at least about 0.04 inch (1 mm), such as at least about 0.12 inch (3 mm), at least about 0.2 inch (5 mm), or even at least about 0.28 inch (7 mm). Thickness t_m3 may be not greater than about 1 inch (25.4 mm), such as not greater than about 0.79 inch (20 mm), such not greater than about 0.39 inch (10 mm), such not greater than about 0.2 inch (5 mm), or even not greater than about 0.04 inch (1 mm). The thickness t_m3 may be at least about 0.04 inch (1 mm) and not greater than about 1 inch (25.4 mm), such as at least about 0.2 inch (5 mm) and not greater than about 0.79 inch (20 mm). It will be appreciated that the thickness t_m3 may be within a range comprising any pair of the previous upper and lower limits. In a preferred embodiment, thickness t_m3 is less than thickness t_m2 and is in the range of at least about 0.08 inch (2 mm) to not greater than about 0.39 inch (10 mm).

Embodiments of the tool may be described and understood in relation to ratios or percentages of the lengths and thicknesses of the members to each other. For example, length L_m1 of the first member may be in a ratio to the length L_m2 of the second member. For example, the ratio of L_m1 to L_m2 may be at least 1:1, such as at least 2:1, or even at least 3:1. In a preferred embodiment, the ratio of L_m1 to L_m2 is about 2.1:1.

The second member may have a thickness t_m2 which is at least about 0.5% of length L_m2. For example, thickness t_m2 may be at least about 1% of length L_m2, such as at least about 5% of length L_m2. In another example, thickness t_m2 may be not greater than about 20% of length L_m2, such as not greater than about 15% of length L_m2, or even not greater than about 10% of length L_m2. In a further example, thickness t_m2 may be 0.5-20% of length L_m2, such as 5-15% of length L_m2. It will be appreciated that thickness t_m2 may be within a range of a percentage of length L_m2 comprising any pair of the previous upper and lower limits. In a preferred embodiment, the thickness t_m2 is in a range of 0.5-20% of length L_m2.

As illustrated in FIG. 10, the total horizontal length L_mTot of the tool, as measured when the first member is horizontal, is equal to the sum of the length L_m1 plus L. Based on the above upper and lower limits for L_m1 and L_m2, length L_mTot will range in length from at least about 1.5 inch (38.1 mm) to not greater than about 24 inch (609.6 mm), from at least about 3 inch (76.2 mm) to not greater than about 12 inch (304.8 mm), from at least about 4 inch (101.6 mm) to not greater than about 10 inch (254 mm). It will be appreciated that length L_mTot may be within a range comprising any pair of the previous upper and lower limits. In a preferred embodiment, length L_mcT is at least about 4 inch (101.6 mm) to not greater than about 8 inch (103.2 mm).

The second member 605 may have a thickness t_m2 which is at least about 0.5% of length L_mTot. For example, t_m2 may be at least about 1.0% of L_mTot, at least about 5.0% of L_mTot, or even at least about 7.0% of L_mTot. In another example, t_m2 may be not greater than about 20.0% of L_mcT, such as not greater than about 14.0% of L_mTot, not greater than about 13.0% of L_mTot, or even not greater than about 10.0% of L_mTot. In a further example, t_m2 may be 0.5-20% of L_mcT, such as 0.5-14% of L_mTot. It will be appreciated that t_m2 may be within a range of a percentage of length L_mTot comprising any pair of the previous upper and lower limits.

The hand tool may include a third member (not shown). The optional third member may be joined to the first member at the end opposite the second member. The optional third member may comprise the same features already described herein as relating to the second member.

The hand tool may include a handle. As shown in FIG. 1, the handle 101 may be attached to the top surface of base member 103. In another embodiment, as illustrated in FIG. 6, the handle 601 is attached to the top surface of first member 607 and second member 605. In an alternate embodiment, as shown in FIG. 12a, the handle 155 may be designed to attach to the top surface of a base member 103 at a single attachment point 151 and extend upward at an angle from the attachment along an elongated portion that defines a gripping portion 153. The attachment point of the handle may be placed anywhere along the top surface, for example, such as at the center of the top surface of the first portion (not shown). In another example, as shown in FIG. 12a, the handle 155 may attach to the base member 103 at a point where the first portion 107 and second portion 105 of the base member are contiguous.

In another embodiment, the handle may attach to the top surface of a base member at more than one point, such as at least two points, and the handle may include a gripping portion that extends between the attachment points. In an example, as shown in FIG. 12b, the handle 101 may attach at two attachment points 151 on the top surface of the first portion 107 of the base member 103, such as at either end of the first portion. In another example, illustrated in FIG. 12c, the handle 159 may attach to the top surface of base member 103 at two attachment points, each located on the first portion 107 and the second portion 105, such as at the center of the top surface of the first portion and the center of the top surface of the second portion.

As shown in FIG. 5, the second portion 105 of the base member 103 may extend forward fully or partly beyond the attachment point of the handle 101 that is located closest to the second portion of the base member. For example, as measured along a horizontal axis when the first portion is horizontal, at least about 35% of the length L₂ of the second portion may extend beyond the attachment point of the handle, such as at least about 50% of the length of the second portion, or even at least about 56% of the length of the second portion. In another example, not greater than about 100% of the length L₂ of the second portion may extend beyond the attachment point of the handle, such as not greater than about 75% of the length of the second portion, or even not greater than about 63% of the length of the second portion. In a further example, at least about 35% to not greater than about 100% of the length L₂ of the second portion, such as at least about 50% to not greater than about 100% of the length of the second portion, may extend forward beyond the attachment point of the handle that is closest to the second portion. As shown in FIG. 5, in a preferred embodiment 100% of the length L₂ of the second portion extends forward beyond the attachment point of the handle closest to the second portion.

As shown in FIGS. 12a-12c, the distance that the second portion 105 extends forward horizontally beyond attachment point 151 of the handle that is closest to the second portion, as measured along a horizontal axis when the first portion 107 is horizontal, may be identified as a length E. In an example, length E may be at least about 0.79 inch (20 mm), such as at least about 1.18 inch (30 mm), such as at least about 2.44 inch (62 mm), or even at least about 2.95 inch (75 mm). In another example, length E may be not greater than about 5.91 inch (150 mm), such as not greater than about 4.72 inch (120 mm), such as not greater than about 3.86 (98 mm), or even not greater than about 3.15 inch (80 mm). In a further example, length E may be at least about 1.18 inch (30 mm) and not greater than about 5.91 inch (150 mm), such as at least about 2.44 inch (62 mm) and not greater than about 4.72 inch (120 mm). It will be appreciated that length E may be within a range comprising any pair of the previous upper and lower limits. In a preferred embodiment, the length E is in the range of about 1.18 inch (30 mm) to about 6 inch (152.4 mm).

In an embodiment, the handle may be removably coupled to the base member such that the handle may be removed from the base member. In another embodiment, the handle may be fixedly attached to the base member such that the handle may not be removed from the base member. For example, the handle may be attached to the base member by welding, soldering, brazing, fusion bonding, solvent bonding, the use of adhesives, by mechanical fastening, such as with hinges, latches, detents, joining plates, brackets, screws, bolts, nails, dowels, rivets, pins, and any combination thereof. In a further embodiment, the handle may be unitary with the base member. In a preferred embodiment, the handle is unitary with the base member.

In an embodiment, the gripping portion of the handle may be smooth (not shown). In another example, as shown in FIGS. 12a-12d, the gripping portion 153 of the handle may be contoured to the shape of a human hand in order to increase operator comfort. The gripping portion of the handle may extend parallel to the top surface of the base member. In another embodiment, the gripping portion of the handle may extend at an angle relative to the top surface of the base member. For example, the handle may extend such that the front of the gripping portion of the handle is positioned at a height above the top surface of the base member that is less than the height at which the back end of the gripping portion of the handle is positioned relative to the top surface of the base member. In another example, the height above the base member at which the front of the gripping portion of the handle is positioned is greater than the height above the base member at which the back of the gripping portion of the handle is positioned. In a further embodiment, the handle may be a block, such as a curved block. In an example, the handle may include indentations for finger placement in order to improve the handle grippability. In another example, the handle may include a groove extending around the handle in order to improve handle grippability. In a further example, the handle may be formed of a compressible material and include no indentations for finger placement. In a preferred embodiment, the gripping portion of the handle is contoured to the shape of a human hand and extends parallel to the top of the base member.

As shown in FIG. 5, the bottom surface of the gripping portion of the handle may extend at a height h₂ above the top surface of a base member 103. For example, the height h₂ may be at least about 0.59 inch (15 mm), such as at least about 0.79 inch (20 mm), or even at least about 1.06 (27 mm). In another example, the height h₂ may be not greater than about 3.94 inch (100 mm), such as not greater than about 3.54 inch (90 mm), such as not greater than about 2.95 inch (75 mm), or even not greater than about 2.09 inch (53 mm). In another example, the height h may be at least about 0.59 inch (15 mm) and not greater than about 3.94 inch (100 mm), such as at least about 1.06 inch (27 mm) and not greater than about 2.09 (53 mm). It will be appreciated that h may be in a range comprising any pair of the previous upper and lower limits. In a preferred embodiment, h₂ is in the range of 0.79 inch (20 mm) to 1.18 inch (30 mm).

As shown in FIG. 5, the hand tool may have a height h₁ measured from the bottom surface of the hand tool to the top of the gripping portion of the handle. The height h₁ may be at least about 1.89 inch (48 mm), such as at least about 2.32 inch (59 mm), or even at least about 3.15 inch (80 mm). The height h₁ may be not greater than about 10.83 inch (275 mm), such as not greater than about 7.83 inch (199 mm), or even not greater than about 5.91 inch (150 mm). Height h₁ may be at least about 1.89 inch (48 mm) and not greater than about 10.83 inch (275 mm), such as at least about 2.32 inch (59 mm) and not greater than about 5.91 inch (150 mm). It will be appreciated that h₁ may be in a range comprising any pair of the previous upper and lower limits. In a preferred embodiment, h₁ is in the range of 1.18 inch (30 mm) to 3.54 inch (90 mm).

The hand tool may include a fastener system for fastening an abrasive media to the hand tool. The fastener system may be positioned or disposed on a base member such that the abrasive media is attached only to the bottom surface of the hand tool. For example, the fastener system may be positioned so that the attached abrasive media does not overlap the sides of the hand tool or overlap onto the top surface of the hand tool. In an alternate embodiment, the fastener system may be positioned such that the abrasive media attaches to only the bottom surface of the hand tool as well as the top surface of the second portion of the base member. As shown in FIG. 13, in a preferred embodiment, the abrasive media 161 is attached to the first 107 and second 105 portions of the bottom surface of base member 103, and the abrasive media does not overlap onto the sides or top portion of the base member. As shown in FIG. 13a, in an alternate preferred embodiment, the abrasive media 161 is attached to the first 107 and second 105 portions of the bottom surface of base member 103, and also to the top surface of the second portion of the base member, but does not overlap onto the sides of the base member.

Acceptable fastener systems may include hook and loop, releasable film, adhesive, clips, screws, pins, flanges, suction, magnetics, electrical surface charge, and a combination thereof. The fastener system may extend across the entire bottom surface of the hand tool, or the fastener system may be positioned in discrete locations on the bottom surface of the hand tool. In a preferred embodiment, the fastener system is a hook and loop system or a releasable film.

In order to change or control the pressure exerted by the tool onto the abrasive, a layer of resilient material may be disposed at the interface between the bottom surface of the hand tool and the attachment surface of the abrasive media. In an embodiment, the resilient material may be disposed between the bottom surface of the hand tool and the fastener system, in an embodiment. In another embodiment, the resilient layer may be disposed between the fastener system and the abrasive media. In a particular embodiment, the resilient material is a foam material. The resilient material can be selected to have a desired resilience by changing the type of material, the density of the material, the size of the foam cells, and whether the foam cells are open or closed. This resilient layer is not limited to foam material and can be other materials which would essentially cause a modification in the pressure exerted by the tool onto the abrasive. Materials suitable for use as a resilient layer include synthetic or natural materials, woven, non-woven, bonded or formed materials which can be used to change resiliency including foam, rubber, felt, and combinations thereof.

Abrasive media attachable by a fastener system may include coated abrasives, bonded abrasives, woven abrasives, or non-woven abrasives. In a particular embodiment, the abrasive media may include coated abrasives, such as flexible sheets of abrasive. In an embodiment, the abrasive media may be applied to a resilient layer. In another embodiment, the abrasive media may include a matrix composed of a resilient material. In an example, the abrasive media may have a standard shape, such as a rectangular shape. In another example, the abrasive media may be shaped to match the perimeter shape of the bottom surface of the base member. The abrasive media may further include a fastener system on the surface opposite the grinding surface of the abrasive media. For example, the abrasive media may include part of a hook and loop fastener or an adhesive on the surface opposite the grinding surface of the abrasive media.

In an embodiment, the abrasive media 161 may comprise a single piece of abrasive media. In an example, the abrasive media may extend across the entire bottom surface of the base member. In another example, the abrasive media may be positioned only on the first portion of the base member or only on the second portion of the base member. In another embodiment, the abrasive media may comprise more than one piece of abrasive media, such as at least two pieces of abrasive media. For example, the abrasive media may comprise one piece of abrasive media shaped to match and attached to the first portion of the base member and a second piece of abrasive media shaped to match and attached to the second portion of the base member. In a further example, the abrasive media may comprise one piece of abrasive media having a standard shape, such as a rectangle, attached to the first portion of the base member and a second piece of abrasive media having a standard shape, such as a triangle, attached to the second portion of the base member. In another embodiment, the abrasive media may include one piece of abrasive media attached to the first portion of the base member and a second piece of abrasive media attached to the second portion of the base member, each piece of abrasive media having a standard shape, such as a square or a rectangle. In a preferred embodiment, the abrasive media is matched to the shape of the portion of the base member to which it is attached.

In a particular embodiment, the abrasive media 171 may comprise two pieces of abrasive media. In an example, one piece of abrasive media may be attached to the first portion of the base member and may have a first grit size of abrasive particles and a second piece of abrasive media may be attached to the second portion of the base member and have a second grit size of abrasive particles. In a particular instance, the first piece of abrasive media may have a grit size which is equal to the grit size of the second piece of abrasive media. In another particular instance, the first piece of abrasive media may have a grit size which is larger than the grit size of the second piece of abrasive media. In a further particular instance, the first piece of abrasive media may have a grit size which is smaller than the grit size of the second piece of abrasive media. In a preferred embodiment, both the first and second portions of the bottom surface of the base member have a piece of an abrasive media attached and the grit size of the piece attached to the first portion is larger (i.e., the abrasive media is rougher) than the grit size of the abrasive media attached to the second portion.

The abrasive media may include abrasive particles and a bonding material. Abrasive particles can include inorganic materials, such as oxides, carbides, nitrides, borides, oxynitrides, oxycarbides, and a combination thereof. In one particular instance, abrasive particles can include alumina, silica carbide, silica, ceria, and a combination thereof. In an example, the abrasive particles may include a conventional abrasive. Suitable conventional abrasives include, but are not limited to, aluminum oxide, microcrystalline alumina (MCA), silicon carbide, emery, pumice, sand, steel abrasive, and combinations thereof. In another example, the abrasive particles can include a superabrasive material. Suitable abrasives may include diamond, cubic boron nitride (cBN), and a combination thereof.

In an example, the bonding material may include an inorganic material. Suitable inorganic materials may include ceramics, such as vitreous materials, metals, metal alloys, and a combination thereof. In another example, the bonding material may include an organic material. Suitable organic materials may include polymers such as glycol, resin, dextrin, glue, polyethylene, ethylene, propylene, polyvinyl alcohol, and combinations thereof. In a further example, the bonding material may comprise a composite material, such as a combination of organic and inorganic materials.

In a particular embodiment, the abrasive media may comprise a first piece of abrasive media attached to the first portion of the base member and a second piece of abrasive media attached to the second portion of the base member. In a particular instance, the type of abrasive particles of the first piece of abrasive media may be the same as the type of abrasive particles of the second piece of abrasive media. For example, the abrasive particles of the first piece of abrasive media and of the second piece of abrasive media may be conventional abrasives or may be superabrasive materials. In another particular instance, the type of abrasive particles of the first piece of abrasive media may be different from the type of abrasive particles of the second piece of abrasive media. For example, the first piece of abrasive media may include conventional abrasives and the second piece of abrasive media may include superabrasive particles, or vice versa. In a further instance, the type of abrasive particles of the first piece of abrasive media may be the same as the second piece of abrasive media, but the abrasive particles of the first piece of abrasive media may be different from the abrasive particles of the second piece of abrasive media, within the same type of abrasive particles. For example, the first piece of abrasive media may include silicon carbide abrasive particles and the second piece of abrasive media may include microcrystalline alumina (MCA) abrasive particles. In yet another instance, the abrasive particles of the first piece of abrasive media may be the same as the second piece of abrasive media. For example, the first piece of abrasive media and second piece of abrasive media may both comprise diamond abrasive particles.

A hand tool may be formed of a flexible material, a rigid material, or a combination thereof. Suitable rigid materials may include metals, metal alloys, ceramics, wood, and combinations thereof. Suitable flexible materials may include polymers, such as elastomers, rubbers, plasticized PVC, polystyrene, and a combination thereof. In a particular instance, the base material and the handle may be made of the same material. In another particular instance, the base material and the handle may be made of different materials. For example, the base material may be made of a rigid material and the handle may be made of a flexible material. In another instance, the base material and the handle may be made of the same material, such as a rigid material, and the handle may then be coated with another material, such as a flexible material, in order to increase comfort for the operator.

A hand tool may be formed by conventional forming processes, in accordance with the composition of the hand tool. Suitable forming processes may include molding, such as injection molding, stamping, die cutting, and combinations thereof. In a preferred embodiment, the hand tool is formed by injection molding.

A hand tool may be formed as a single, unitary piece. For example, a hand tool may be formed by injection molding a mold shaped to the final hand tool shape with a polymer. In another embodiment, the base member and handle may be formed separately and then coupled together. In a further embodiment, the first and second portions of the base member and the handle may all be formed separately and then joined together.

A hand tool may be used with an abrasive media in conventional manual grinding processes. In an example, the hand tool may be gripped by an operator and the surface of the grinding media attached to the hand tool placed against the surface to be ground. Force may then be applied by the operator to move the sanding block back and forth, side to side, in circles, and any combination thereof in order to grind the surface to be ground.

Hand tools 170 as described herein are particularly suited for grinding traditionally hard to sand areas, such as narrow spaces, as illustrated in FIGS. 14a-b and corners, as illustrated in FIG. 15a-b. Exemplary, narrow spaces suitable for grinding by the hand tools described herein include, but are not limited to, the space between louvers 171 of window shutters 170 and shades (not shown) and the spaces beneath built-in furniture such as cabinets and radiators. In addition, operators may use the hand tool to grind both easy to reach surfaces and difficult to reach surfaces, simply by tilting the wrist. For example, an operator may grind a floor with the first portion of the base member held horizontal to the floor and then grind a corner with the second portion of the base member simply by tilting the wrist such that the second portion is then horizontal to the floor and the first portion of the base member extends upward at an angle from horizontal.

Hand tools as described herein are also particularly suited for grinding two different surfaces without cross-contaminating said surfaces with swarf, or other waste produced by the abrading process, and without having to stop and change abrasives between surfaces. Hand tools as described herein also allow for grinding a surface with different abrasive grits without having to stop and change abrasives. For example, an operator may rough finish a surface and then fine finish a surface simply by tilting the wrist.

In the foregoing specification, the concepts have been described with reference to specific embodiments. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the invention.

As used herein, the terms “comprises”, “comprising”, “includes”, “including”, “has”, “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

Also, the use of “a” or “an” are employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.

Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.

After reading the specification, skilled artisans will appreciate that certain features are, for clarity, described herein in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination. Further, references to values stated in ranges include each and every value within that range.

Claims

1. A hand tool comprising;

a base member having a top surface, a bottom surface, a forward end, a back end, and opposing side edges, wherein the bottom surface comprises a first portion and a second portion, the first and second portions are contiguous and configured such that when the first portion is horizontal, the second portion is bent upwards from horizontal at an angle α; and

a fastener system adapted to adhere an abrasive media that is disposed directly onto the first and second portions of the bottom surface of the base member.

2. A hand tool comprising:

a base member having a topside and an underside, the base member being divided into a first portion and a second portion, the first and second portion adjoining, such that when the first portion is horizontal, the second portion is bent upwards and away from the first portion at an exterior angle β ranging from 180° to 225° as measured from the underside of the first portion to the underside of the second portion,

a fastener system disposed on the underside of the first portion and the second portion of the base member that is adapted to adhere an abrasive media.

3. The hand tool of claim 1, wherein the first portion, when horizontal and viewed from the bottom, has a perimeter shape selected from the group consisting of triangular, trapezoidal, rectangular, square, ovoid, circular, and elliptical; and the second portion, when horizontal and viewed from the bottom, has a perimeter shape selected from the group consisting of triangular, trapezoidal, rectangular, square, ovoid, circular, and elliptical.

4.-8. (canceled)

9. The hand tool of claim 3, wherein the width of the second portion tapers as it extends away from the first portion.

10. The hand tool of claim 1, wherein the first portion and the second portion are of substantially uniform and equal thickness.

11. (canceled)

12. The hand tool of claim 1, wherein the first portion has a first substantially uniform thickness, and the second portion has a second substantially uniform thickness.

13.-16. (canceled)

17. The hand tool of claim 1, wherein the cross section of the second portion is triangular.

18. The hand tool of claim 1, wherein the cross section of the second portion tapers as it extends away from the first portion.

19. (canceled)

20. The hand tool of claim 12, wherein the second portion has a thickness in the range of about 1-20% of the length of the second portion.

21. The hand tool of claim 1, wherein the length of the first portion and the second portion are in a ratio of about 2:1 to about 3:1 as measured along a horizontal axis when the first portion is in a horizontal position.

22. The hand tool of claim 1, wherein the length of the first portion is in the range of about 50-203 mm and the length of the second portion has a length in the range of about 20-114 mm as measured along a horizontal axis when the first portion is in a horizontal position.

23. The hand tool of claim 1, wherein the first portion is planar.

24. The hand tool of claim 1, wherein the second portion is planar.

25. The hand tool of claim 1, wherein a handle is attached to the base member.

26.-28. (canceled)

29. The hand tool of claim 25, wherein a handle has at least a single attachment point on the top surface of the base member located over the edge where the first and second portions are contiguous.

30. The hand tool of claim 25, wherein the second portion protrudes forward in front of the handle.

31.-33. (canceled)

34. The hand tool of claim 1, wherein a resilient layer is disposed between the bottom surface of the base member and an attachment surface of the abrasive media.

35. The hand tool of claim 1, wherein a resilient layer is disposed between the bottom surface of the base member and the fastener system.

36. The hand tool of claim 1, wherein a resilient layer is disposed between the fastener system and the abrasive media.

37.-40. (canceled)

41. A hand tool comprising:

a first member having a top surface and a bottom surface,

a second member having a top surface and a bottom surface, and

a fastener system disposed on the underside of the first member and second member adapted to adhere an abrasive media,

wherein the first and second member are joined such that when the first member is horizontal, the second member extends away from the first member at an exterior angle β ranging from greater than 180° but less than 225° as measured from the bottom surface of the first member to the bottom surface of the second member.

42.-77. (canceled)