Vacuum Sander Having a Porous Pad

Abstract

A sander with a face plate, a porous abrasive pad coupled with the face plate for sanding a surface, and a vacuum coupled with at least a portion of the pad. The pad has a thickness or storage capacity sufficient to temporarily retain at least a portion of particles removed from the surface. The vacuum is configured to suck at least a portion of the particles removed from the surface.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to sanding mechanisms, and, is more particularly directed to a sander with an attached vacuum.

2. Description of Related Art

Drywall is currently the most popular material for finishing interior walls and ceilings. Drywall is typically sold in panels having predetermined dimensions. Because these dimensions do not usually correspond with the dimensions of a wall to be finished, a plurality of panels may be necessary to finish a wall. Joint compound is typically applied to the seam between two drywall panels in order to hide the seam. The joint compound is typically applied over the seam with a trowel and allowed to dry. The excess joint compound is then removed by sanding to create a smooth wall surface. Various types of sanding materials have been used for removing excess joint compound including sandpaper and screens. These materials may be employed with manual devices such as on sanding blocks or used in conjunction with automated sanding mechanisms.

While sanding the joint compound is obviously necessary to produce a smooth wall surface, it produces a significant amount of dust. Joint compound becomes a fine airborne dust when sanded and travels throughout the structure being finished. This dust is undesirable, especially for someone remodeling their home, because it becomes embedded in furniture, clothing and bedding, and it creates a mess in the home. Cleanup of the dust is time consuming, messy, and costly. The dust may also create or exacerbate health conditions, such as respiratory, skin and eye conditions. Further, after sanding the excess joint compound, dust remaining on the drywall must be removed before painting.

In an effort to control the amount of dust, automated drywall vacuum sanders have been developed utilizing a sander attached to a vacuum. One type of vacuum sander known in the art utilizes sandpaper attached to a rotating plate. A housing with a larger diameter than the plate surrounds one side of the plate such that there is a gap between the peripheral edge of the plate and the peripheral edge of the housing. A vacuum is coupled to the housing at the gap for capturing joint compound particles removed by the sander.

Another type of vacuum sander utilizes a sanding screen affixed to a plate having grooves. A vacuum coupled with the grooves draws removed joint compound through the screen. Yet another type of vacuum sander has a rotating plate with holes passing through the plate. A vacuum is coupled with the holes. The sander is used with sandpaper that has holes aligning with the holes in the plate. The sandpaper mounts on the plate opposite the vacuum.

While all of the vacuum sanders developed to date are useful, a significant amount of the particles removed by the sandpaper or screen are not captured by the vacuum because the particles are not aligned directly with the holes or gaps in the sander device and the holes constitute a small percentage of the total sanding area. In addition, the sandpaper or screen material may damage the underlying wall by creating swirls or other indentations in the wall. Lastly, it is sometimes difficult to mount the sandpaper or screen on the plate to align with the holes or gaps. Thus, a need remains in the art for an improved vacuum sander that captures a significant portion of the particles removed by the sander, avoids damage to the surface being sanded, is easy to use, and results in much less dust and consequent cleanup.

BRIEF SUMMARY OF THE INVENTION

The present invention is directed toward a vacuum sander comprising a porous pad coupled with a face plate and a vacuum. A vacuum is coupled with at least a portion of the pad. The pad is moved over a surface to be sanded to remove particles from the surface. The vacuum is configured to suck at least a portion of the particles removed from the surface. The pad comprises a thickness sufficient to temporarily retain at least a portion of particles removed from the surface within the pad. Thus, the sander captures the vast majority of the particles removed from the surface sanded so as to substantially reduce dust relative to conventional vacuum sanders.

In another embodiment, the present invention is directed toward a vacuum sander comprising a porous pad removably affixed to a face plate. The pad covers one or more openings in the face plate and a vacuum is coupled with the opening on the opposite side of the face plate from the pad. The vacuum sucks particles removed from a surface to be sanded into the pad and through the opening(s) in the face plate. The pad has a thickness sufficient to temporarily retain at least a portion of the particles removed from the surface before they are sucked through the opening(s) by the vacuum. The one or more openings in the face plate preferably have a surface area of at least 1%, preferably at least 10%, of the surface area of the pad overlying the openings so as to enhance the vacuum action through the pad.

In a preferred embodiment, the pad comprises a core of entangled fibers with pores located between the fibers. Particles removed from the surface being sanded are temporarily retained or stored within the pores of the pad. The pad is preferably removably affixed to a face plate with hook and loop fasteners or pressure sensitive adhesive. The vacuum sucks particles retained within the pores into a receptacle. A prime mover (e.g. motor) is coupled with the face plate for moving the face plate. In the preferred embodiment, the apparatus is adapted for use in sanding excess joint compound from drywall, but the apparatus may be used to sand other materials.

The pad of the present invention is preferably constructed of entangled fibers which do not damage the drywall being sanded. Hook and loop fasteners or pressure sensitive adhesive preferably used to affix the pad to the faceplate facilitate the quick replacement of a worn pad. One advantage of the present invention is that the porous nature of the pad combined with the thickness of the pad creates storage capacity for removed particles. The storage capacity ensures that particles are retained within the pad until they are sucked into the attached vacuum, thus substantially reducing dust. The present invention is also directed to a method of sanding utilizing a porous abrasive pad in conjunction with a vacuum.

Additional aspects of the invention, together with the advantages and novel features appurtenant thereto, will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned from the practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevational view of a sander according to the present invention shown partially in cross-section;

FIG. 2 is a top plan view of a pad of the sander of FIG. 1;

FIG. 3 is a bottom plan view of a face plate of the sander of FIG. 1;

FIG. 4 is a cross-sectional view of an alternative embodiment of a sander according to the present invention;

FIG. 5 is a top plan view of a pad of the sander of FIG. 4;

FIG. 6 is a cross-sectional view of an alternative embodiment of a sander according to the present invention; and

FIG. 7 is a bottom plan view of an intermediate pad of the sander of FIG. 6.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

An apparatus in accordance with one embodiment according to the present invention is denoted generally by 10 in FIG. 1. Apparatus 10 is a sanding machine having a housing 12, a motor 14, a shaft 16, a face plate 18, an exhaust manifold 20, a vacuum 22, a receptacle 24 and a porous abrasive pad 26 removably coupled with face plate 18 for sanding material from a surface.

FIG. 3 shows eight openings 28 in face plate 18. Openings 28 are in fluid flow communication with exhaust manifold 20, as shown in FIG. 1. Exhaust manifold 20 is coupled with vacuum 22 outside of housing 12. Vacuum 22 is coupled with receptacle 24. Vacuum 22 is adapted to suck material through openings 28 and exhaust manifold 20 and deposit the material in receptacle 24.

Shaft 16 couples face plate 18 with motor 14 for rotating face plate 18. While FIG. 1 shows the face plate coupled to a motor with a shaft, it is within the scope of the invention for the face plate to be coupled to any type of prime mover for moving the face plate, or for the face plate to be operated manually. Also, the face plate movement is not limited to rotary motion, the face plate may have any type of motion including, but not limited to, orbital, longitudinal, lateral or random motion. Further, the face plate may be adapted to vibrate. It is also within the scope of the invention for a single prime mover to drive both the face plate and the vacuum.

FIG. 1 shows the apparatus 10 positioned over a surface 30, such that pad 26 is in contact with surface 30. Particles 32 removed from surface 30 are shown within openings 28 of face plate 18 and within exhaust manifold 20. Surface 30 preferably comprises a wall with drywall joint compound thereon, but it is within the scope of the invention for the surface to be any material needing polishing or sanding.

FIG. 1 shows pad 26 with a bottom surface 33, a top surface 34, and a side surface 36 defined by a core of entangled fibers 38. Pores are located between the fibers for retaining dust or material removed from surface 30. Pad 26 has a thickness or storage capacity allowing particles 32 removed from surface 30 to be stored or retained within the pores of pad 26. This thickness also provides a cushion so as to minimize damage to the surface being sanded. Preferably, the pad has a thickness of between 1/16 inch to 3/4 inch, and more preferably a thickness of between ⅛ inch to 3/8 inch. Preferably, the entangled fibers 38 are polyamide fibers coated with an abrasive such as aluminum oxide or silicon carbide. Preferably, a binding agent binds the abrasive to the fibers. The binding agent may be phenol, epoxy, urethane, polyester, or any other suitable binder. Although a preferred construction for the porous pad is described herein, it is within the scope of the invention for the pad to be constructed from other materials so long as the pad is porous and abrasive in nature. One suitable material that may be used to construct the pad is sold under the trademark Mirlon™ by KWH Mirka Ltd., a company headquartered in Finland.

While pad 26 is described above as constructed from entangled fibers coated with an abrasive, the pad may have any type of construction. For example, the pad may be constructed from woven or knit fibers. Additionally, the pad may be constructed of fibers integrated into a non-woven structure by needle punching, through-air bonding, hydro entangling, spun-bonding, chemical bonding or mechanical processing. The pad may be constructed of a polymeric material, or natural or synthetic fibers. A non-exhaustive list of suitable materials for the pad include polyolefin, polyester, polypropylene, polyvinyl chloride, vinylidene chloride, nylon, polytetrafluoroethylene, polycarbonate, polyacrylate, polyoxymethylene, polystyrene, ABS, polyetherester, polyamide, polycaprolactan, thermoplastic starch, polyvinyl alcohol, polylactic acid, polyphenylsulfide, polyvinylidenes, polyurethane, polyurea, cotton and rayon. The material that the pad is constructed from may be abrasive, or additionally, the pad may be coated with an abrasive material as described above.

Pad 26 is removably affixed to face plate 18 with hook and loop fasteners 40 and 42, as shown in FIG. 1. FIG. 3 shows hook fasteners 40 affixed around a peripheral edge of face plate 18. Preferably, the hook fasteners are laminated to the face plate with adhesive, but other connection means are within the scope of the invention. FIG. 2 shows a backing 44 affixed to pad 26 adjacent the peripheral edge of the pad. Preferably, backing 44 is adhered to pad 26 with adhesive, but other connection means are within the scope of the invention. Loop fasteners 42 extend outward from backing 44. Preferably, loop fasteners 42 are woven into backing 44, but it is within the scope of the invention for the loop fasteners to be adhered to the backing or affixed to the backing by any other connection means. It is also within the scope of the invention for the entangled fibers to be adapted to affix directly to hook fasteners. Additionally, loop fasteners may be woven into the entangled fibers around a peripheral edge of one or both sides of the pad for removably affixing the pad to hook fasteners. It is also within the scope of the invention for the hook and loop fasteners to be switched such that the hook fasteners are affixed to the pad and the loop fasteners are affixed to the face plate. Further, it is not an essential feature of the invention that the pad and face plate are removably affixed by hook and loop fasteners, the pad and face plate could be affixed by corresponding pin and slot structures, brackets, adhesive, pressure sensitive adhesive, or any other connection means known in the art.

Pad 26 is affixed to face plate 18 over openings 28, as shown in FIG. 1. This allows material removed from surface 30 to be sucked into porous pad 26 by vacuum 22. Backing 44 has an opening 46 which is sized such that the opening 46 aligns with openings 28 on face plate 18 when hook and loop fasteners 40 and 42 are joined, as shown in FIGS. 2 and 3. In this manner, particles may move freely from the pad 26 through the openings 46 and 28. Preferably, the total surface area of backing 44 is approximately 25 to 75% of the surface area of the total surface of pad 26. In addition, the total surface area of openings 28 comprise at least 1% of the surface area of opening 46 and most preferably at least 10% of opening 46 so as to enhance the vacuum action through the entirety of the pad. The pad 26 of the present invention may be used with many conventional sanders that have a face plate with at least one opening and a vacuum coupled with the opening.

As shown in FIG. 1, a control circuit 46 is positioned within housing 12 for controlling the operation of the sander. Control circuit 46 receives power 48 from a remote power source, such as an electrical cable or a battery. A rheostat 50 is in electrical communication with control circuit 46 for varying the speed of motor 14. An on/off switch 52 is also in electrical communication with control circuit 46. Control circuit 46 provides controlled power to motor 14 in accordance with the input signals provided by rheostat 50 and on/off switch 52. Vacuum 22 may be powered by power source 48 or by some other external power source.

Referring now to FIG. 4, an alternative embodiment of sander according to the present invention is indicated generally as 100. Sander 100 comprises a housing 102, a shaft 104 extending through an opening 106 in the housing, a face plate 108 joined with the shaft, an intermediate pad 110 coupled to the shaft, a porous pad 112 affixed to the intermediate pad, and a vacuum (not shown) coupled with an opening 114 in the housing via a hose 116. Housing 102 has a bottom surface 130 with a recess 132 formed into the bottom surface to receive face plate 108 and intermediate pad 110. An inner wall 134 extends upward from bottom surface 130 and surrounds recess 132. Inner wall 134 has a diameter that is slightly larger than the diameter of either the face plate 108 or the intermediate pad 110, thus forming a gap between the inner wall 134 and the peripheral edges of the face plate and intermediate pad. This gap is in fluid communication with second opening 114 and the vacuum joined therewith by hose 116.

A retainer 118 extends outward from shaft 104 for joining face plate 108 with the shaft. Face plate 108 has an opening 120 for receiving shaft 104. A slot in retainer 118 receives a portion of face plate 108 surrounding opening 120. The structure joining face plate 108 to shaft 104 is not essential to the invention and thus it is within the scope of the invention for the face plate to be joined with the shaft by any means known in the art.

Intermediate pad 110 has an inner opening 122 for receiving shaft 104. A nut 124 has threads that engage with threads on shaft 104. A washer 126 positioned between the nut 124 and pad 110 engages a portion of pad 110 surrounding opening 122 and presses the pad against face plate 108 when the nut is tightened on the shaft. Face plate 108 also preferably comprises an abrasive surface that engages the top surface of intermediate pad 110 for coupling the pad with the face plate and shaft. It is within the scope of the invention for the intermediate pad to be coupled with the face plate and shaft by any suitable method known in the art including hook and loop fasteners and pressure sensitive adhesive. The intermediate pad is preferably constructed from a compressible and resilient polymeric material, although it is within the scope of the invention to construct the intermediate pad from any material.

Intermediate pad 110 and porous pad 112 are preferably joined with adhesive, although it is within the scope of the invention for the pads to be joined by any means known in the art including hook and loop fasteners. The pads 110 and 112 may be joined using any of the methods described above to join face plate 18 and pad 26, shown in FIG. 1. Porous pad 112 extends below bottom surface 130 of housing 102 and is constructed from a material capable of sanding a surface. The porous pad 112 is preferably constructed from any of the materials described above for pad 26, shown in FIGS. 1 and 2. The porous pad 112 also preferably has a thickness that is sufficient to temporarily retain at least a portion of particles removed from a surface sanded by the pad, as described above in connection with sander 10 shown in FIG. 1.

As shown in FIG. 5, intermediate pad 110 has six wedge shaped openings 128a-f spaced around a peripheral edge of the pad such that the peripheral edge is discontinuous. As shown in FIG. 4, the face plate 108 and intermediate pad 110 are received by recess 132 in housing 102, and there is a gap between inner wall 134 and the peripheral edges of the face plate and intermediate pad. The vacuum coupled with hose 116 sucks at least a portion of particles removed from a surface being sanded either through or around pad 112. Particles sucked through porous pad 112 pass through one of the openings 128a-f in intermediate pad 110, through the gap between inner wall 134 and face plate 108, and then through opening 114. Particles passing around pad 112 are sucked through the gap between inner wall 134 and face plate 108 and then through opening 114.

Housing 102 is preferably pivotally joined to one end of an elongate tube (not shown), and a motor (not shown) for rotating shaft 104 is preferably joined to the other end of the tube. Sander 100 also preferably has a power supply, on/off switch and speed control as described above for sander 10 shown in FIG. 1. The motor and shaft of sander 100 preferably rotate face plate 108 and pad 112, however it is within the scope of the invention for the face plate and pad to move in any of the manners described above for face plate 18 and pad 26, shown in FIG. 1.

Referring now to FIG. 6, an alternative embodiment of sander according to the present invention is indicated generally as 200. Sander 200 is substantially similar to sander 100, shown in FIG. 4, except that there is no opening in the center of porous pad 202, and porous pad 202 is removably affixed to intermediate pad 204 with hook and loop fasteners 206 and 208. Hook fasteners 206 joined to the bottom of intermediate pad 204, shown in FIG. 7, engage with loop fasteners 208 joined to the top of porous pad 202. It is within the scope of the invention for the hook and loop fasteners to be interchanged, for the porous pad 202 to be joined with the intermediate pad 204 with pressure sensitive adhesive, or for the pads to be joined using any of the other methods described above in connection with sanders 10 and 100.

In use, pad 26 of sander 10, shown in FIGS. 1-3, is positioned over face plate 18 and loop material 42 is engaged with hook material 40. Thus, entangled fibers 38 of pad 26 cover the openings 28 in face plate 18. The sander is connected to a power source 48 and the on/off switch 52 is switched to the on position. Vacuum 22 is also turned on via a connection with power source 48 or another external power source. The desired speed of motor 14 is adjusted with rheostat 50. Motor 14 rotates shaft 16, face plate 18 and pad 26. Rotating pad 26 is positioned against a surface 30 to be sanded. The abrasive material on pad 26 removes particles 32 from surface 30. Vacuum 22 sucks particles 32 removed from the surface 30 into pad 26 where the particles are temporarily stored or retained within the pad's pores. Vacuum 22 sucks the particles 32 retained within the pores of pad 26 through the openings 28 in face plate 18 and through exhaust manifold 20. The particles are finally deposited in receptacle 24.

In use, pad 110 of sander 100, shown in FIGS. 4 and 5, is positioned over face plate 108 such that opening 122 receives shaft 104. Then, washer 126 is positioned over pad 110 and nut 124 is screwed on shaft 104 compressing pad 110 against face plate 108. The sander is then connected to a power source and the motor (not shown) is turned on. The motor rotates shaft 104, face plate 108, intermediate pad 110 and porous pad 112. Rotating pad 112 is positioned against a surface to be sanded. The abrasive material on pad 112 removes particles from the surface. The vacuum (not shown) coupled to hose 116 sucks at least a portion of the particles removed from the surface either through or around pad 112. Particles sucked through pad 112 pass through one of openings 128a-f in pad 110, shown in FIG. 5, through the gap between inner wall 134 and face plate 108, and through opening 114. Particles sucked around pad 112 pass through the gap between inner wall 134 and face plate 108 and through opening 114. Pad 112 also temporarily retains at least a portion of the particles removed from the surface. These particles are preferably sucked through pad 112 by the vacuum.

Sander 200, shown in FIGS. 6 and 7, operates in the same manner as sander 100 described above except that pad 202 may be detached from intermediate pad 204 using hook and loop fasteners 206 and 208. This allows a user to change porous pad 202 without unscrewing the nut pressing the intermediate pad against the face plate.

The sanders described above eliminate the airborne dust created when sanding drywall joint compound because they capture virtually all removed particles and deposit them in a receptacle. The storage capacity of the pads ensure that virtually no removed particles become airborne before they are sucked into the receptacle. The entangled fibers of the pads also do not damage the drywall or create undesirable swirls in the drywall.

From the foregoing it will be seen that this invention is one well adapted to attain all ends and objectives herein-above set forth, together with the other advantages which are obvious and which are inherent to the invention.

Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as illustrative, and not in a limiting sense.

While specific embodiments have been shown and discussed, various modifications may of course be made, and the invention is not limited to the specific forms or arrangement of parts and steps described herein, except insofar as such limitations are included in the following claims. Further, it will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.

Claims

1. A sander comprising:

a face plate;

a motor coupled with said face plate and configured to move said face plate;

a porous abrasive pad coupled with said face plate for sanding joint compound applied to a surface, said pad comprising entangled fibers, wherein said pad comprises a thickness sufficient to temporarily retain at least a portion of the joint compound particles removed from the surface within said pad; and

a vacuum coupled with at least a portion of said pad, wherein said vacuum is configured to suck at least a portion of the joint compound particles removed from the surface.

2. The sander of claim 1, further comprising an intermediate pad positioned between and coupled with said face plate and said porous abrasive pad.

3. The sander of claim 2, wherein said intermediate pad comprises openings, and wherein said vacuum is configured to suck at least a portion of the joint compound particles removed from the surface through said openings.

4. The sander of claim 3, wherein said intermediate pad comprises a peripheral edge and said openings extend to said peripheral edge such that said peripheral edge is discontinuous.

5. The sander of claim 2, wherein said intermediate pad and said porous abrasive pad are joined by a pressure sensitive adhesive.

6. The sander of claim 2, wherein said intermediate pad and said porous abrasive pad are joined by hook and loop fasteners.

7. The sander of claim 2, further comprising:

a housing comprising a first opening; and

a shaft extending through said first opening, wherein said shaft couples said motor to said face plate and said intermediate pad.

8. The sander of claim 7, wherein said housing comprises a second opening coupled with said vacuum.

9. The sander of claim 8, wherein said housing further comprises a recess that receives said face plate and an inner wall surrounding said recess, wherein there is a gap between said inner wall and a peripheral edge of said face plate, and wherein said vacuum is configured to suck at least a portion of the joint compound particles removed from the surface through said gap and said second opening.

10. The sander of claim 1, wherein said face plate comprises at least one opening, wherein said porous abrasive pad is removably affixed to said face plate over at least a portion of said opening for sanding joint compound applied to a surface, wherein said vacuum is coupled with said opening opposite said pad, and wherein said vacuum is configured to suck at least a portion of the joint compound particles removed from the surface into said pad and through said opening.

11. The sander of claim 10, wherein said pad is affixed to said face plate with hook and loop fasteners.

12. The sander of claim 10, wherein said pad is affixed to said face plate with pressure sensitive adhesive.

13. The sander of claim 10, further comprising a backing affixed to said pad adjacent a peripheral edge of said pad, wherein said backing is removably affixed to said face plate and said backing comprises an opening aligned with said opening in said face plate.

14. The sander of claim 13, wherein the surface area of said backing is approximately 25 to 75% of the surface area of said pad.

15. The sander of claim 1, wherein said porous abrasive pad comprises a top surface, a bottom surface and a side surface defined by a core of entangled fibers, wherein said pad comprises pores located between said fibers within said core, and wherein said pores are configured to temporarily retain the joint compound particles removed from the surface.

16. The sander of claim 15, further comprising a receptacle coupled with said vacuum, and wherein said vacuum is configured to suck at least a portion of the joint compound particles retained within said pores of said pad into said receptacle.

17. The sander of claim 1, wherein said entangled fibers comprise nonwoven polyamide fibers coated with an abrasive material selected from the group consisting of aluminum oxide and silicon carbide.

18. The sander of claim 17, wherein a binding agent binds said abrasive to said nonwoven polyamide fibers, said binding agent selected from the group consisting of phenol, epoxy, urethane, and polyester.

19. (canceled)

20. A method for sanding comprising:

providing a face plate comprising at least one opening, a vacuum coupled with said opening, and a motor coupled with said face plate and configured to move said face plate;

affixing a porous abrasive pad to said face plate over at least a portion of said opening opposite said vacuum such that the surface area of the opening underlying the pad is at least 1% of the surface area of the pad overlying the opening, said pad having a thickness of at least 1/16 inch and comprising entangled fibers;

positioning said pad against joint compound applied to a surface;

turning on said motor to move said face plate such that said pad sands said joint compound and at least a portion of joint compound particles removed from said surface are temporarily stored within said pad; and

activating said vacuum such that said vacuum sucks at least a portion of the joint compound particles removed from said surface into said pad and through said opening.

21. The method of claim 20, wherein said pad comprises a core of entangled fibers with pores located between said fibers, and wherein at least a portion of the joint compound particles removed from the surface are temporarily stored within the pores of said pad.

22. The method of claim 21, further comprising providing a receptacle coupled with said vacuum, and wherein said vacuum sucks at least a portion of the joint compound particles removed from the surface through said opening and into said receptacle.

23. The method of claim 20, wherein said entangled fibers comprise nonwoven polyamide fibers coated with an abrasive material selected from the group consisting of aluminum oxide and silicon carbide.

24. The method of claim 20, wherein said pad is affixed to said face plate with hook and loop fasteners.

25. The method of claim 20, wherein said pad is affixed to said face plate with adhesive.

26. A sander for sanding joint compound applied to a surface, said sander comprising:

a face plate;

a motor coupled with said face plate and configured to move said face plate;

a pad affixed to said face plate for sanding the joint compound, wherein said pad has a thickness of at least 1/16 inch and comprises entangled fibers;

a vacuum coupled with said pad, wherein said vacuum is configured to suck at least a portion of joint compound particles removed from the surface; and

a receptacle coupled with said vacuum and configured to receive the joint compound particles sucked by said vacuum.

27. The sander of claim 26, wherein said pad comprises a core of abrasive entangled fibers for sanding the joint compound, wherein pores are located between said fibers, and wherein said pores are configured to temporarily store at least a portion of the joint compound particles removed from the surface.

28. The sander of claim 27, wherein said pad is removably affixed to said face plate with hook and loop fasteners.

29. The sander of claim 26, wherein said face plate comprises an opening, wherein said pad is affixed to said face plate over at least a portion of said opening, wherein said vacuum is coupled with said opening opposite said pad, and wherein said vacuum is configured to suck at least a portion of the joint compound particles removed from the surface through said pad and said opening.