MANUAL SANDER

Abstract

A manual sander includes a handle and a fixed abrasion surface to which the handle is attached. At least one foldable abrasion surface is connected to the fixed abrasion surface by a hinge. The handle is manipulable to maintain the fixed abrasion surface and the foldable abrasion surfaces in an open configuration in which the fixed abrasion surface and the foldable abrasion surfaces are substantially coplanar. The handle is also manipulable to enable the foldable abrasion surface to fold about the hinge to form a folded configuration in which the fixed abrasion surface and the foldable abrasion surface form a bent surface.

Description

FIELD OF THE INVENTION

The present invention relates to sanding. More particularly, the present invention relates to a manual sander.

BACKGROUND OF THE INVENTION

Various types of sanding devices are available to enable smoothing of a surface by motion of an abrasive surface. Typically, the abrasive surface includes a preformed piece of grit-covered sandpaper that is attached to a permanent surface of the sanding device. Thus, a worn piece of sandpaper may be replaced with a fresh piece, or sandpaper with one grit sized may be replaced with sandpaper of another (e.g., finer or coarser) grit size.

For example, a manual sander or sanding block may include a handle and a flat, typically rectangular, surface to which a similarly shaped piece of sandpaper may be attached. When holding the device by the handle, a user may rub the sandpaper surface over the surface to be smoothed.

A power sander includes a motorized or pneumatically operated mechanism that may be operated to move the sandpaper with a predetermined motion. For example, the motion may be circular (e.g., as with a disk sander or flap sander), linear (e.g., as with a belt, drum, or straight-line sander), or otherwise (e.g., orbital, with a combination of motions, or otherwise). The sandpaper pieces may be circular, rectangular, triangular, or otherwise shaped.

SUMMARY OF THE INVENTION

There is thus provided, in accordance with an embodiment of the present invention, a manual sander including: a handle; a fixed abrasion surface to which the handle is attached; and at least one foldable abrasion surface that is connected to the fixed abrasion surface by a hinge, wherein the handle is manipulable to maintain the fixed abrasion surface and the at least one foldable abrasion surface in an open configuration in which the fixed abrasion surface and the at least one foldable abrasion surface are substantially coplanar, and is manipulable to enable the at least one foldable abrasion surface to fold about the hinge to form a folded configuration in which the fixed abrasion surface and the at least one foldable abrasion surface form a bent surface.

Furthermore, in accordance with an embodiment of the present invention, the handle includes an axis that is attached to the fixed abrasion surface to enable lateral rotation of the handle relative to the fixed abrasion surface.

Furthermore, in accordance with an embodiment of the present invention, the handle is configured to be laterally rotated in a forward direction to maintain the open configuration, and in a backward direction that is opposite the forward direction to enable the folded configuration.

Furthermore, in accordance with an embodiment of the present invention, the rotation in the forward direction causes an end of the handle to extend beyond the hinge.

Furthermore, in accordance with an embodiment of the present invention, the handle includes a locking structure that is configured to engage cooperating structure to lock the handle to maintain the fixed abrasion surface and the at least one foldable abrasion surface in the open configuration.

Furthermore, in accordance with an embodiment of the present invention, the cooperating structure is located on a foldable abrasion surface of the at least one foldable abrasion surface.

Furthermore, in accordance with an embodiment of the present invention, the locking structure is at an end of the handle and the cooperating structure is located at an edge of the at least one foldable abrasion surface that is furthermost from the hinge to which that foldable abrasion surface is connected.

Furthermore, in accordance with an embodiment of the present invention, the locking structure and the cooperating structure are configured to lock the handle when a longitudinal axis of the handle is substantially perpendicular to the hinge.

Furthermore, in accordance with an embodiment of the present invention, the locking structure includes an indentation in a base of the handle, and the cooperating structure includes a locking tab on the at least one foldable abrasion surface.

Furthermore, in accordance with an embodiment of the present invention, the fixed abrasion surface and the at least one foldable abrasion surface form a substantially circular abrasion surface when in the open configuration.

Furthermore, in accordance with an embodiment of the present invention, the sander includes a retaining mechanism that is configured to retain the fixed abrasion surface and the at least one foldable abrasion surface in a folded configuration.

Furthermore, in accordance with an embodiment of the present invention, the retaining mechanism includes a retaining structure on the handle, and cooperating retaining structure that is located on a foldable abrasion surface of the at least one foldable abrasion surface.

Furthermore, in accordance with an embodiment of the present invention, the retaining structure includes a ferromagnetic plate and the cooperating retaining structure includes a magnet.

Furthermore, in accordance with an embodiment of the present invention, the cooperating retaining structure is located on a locking tab of the at least one foldable abrasion surface.

Furthermore, in accordance with an embodiment of the present invention, the retaining mechanism is configured to retain the at least one foldable abrasion surface substantially perpendicular to the fixed abrasion surface.

Furthermore, in accordance with an embodiment of the present invention, the handle includes a socket to enable attachment of an extension handle.

Furthermore, in accordance with an embodiment of the present invention, the extension handle includes an eccentric knob.

Furthermore, in accordance with an embodiment of the present invention, an attachment stem of the extension handle and the socket include cooperating guiding structure to maintain an orientation of the extension handle relative to the socket.

Furthermore, in accordance with an embodiment of the present invention, the hinge includes a groove.

There is further provided, in accordance with an embodiment of the present invention, method for preparing a manual sander for smoothing a work surface, the method including: providing the manual sander, the sander including an abrasion surface that includes a fixed abrasion surface and at least one foldable abrasion surface that is connected to the fixed abrasion surface by a hinge; and manipulating a handle that is connected to the fixed abrasion surface to maintain attached the fixed abrasion surface and the at least one foldable abrasion surface in an open configuration in which the fixed abrasion surface and the at least one foldable abrasion surface are substantially coplanar, and attaching a piece of sandpaper to the substantially coplanar surfaces; or manipulating the handle to enable the at least one foldable abrasion surface to fold about the hinge to form a folded configuration in which the fixed abrasion surface and the at least one foldable abrasion surface form a bent surface; placing the piece of sandpaper on the work surface such that the piece of sandpaper is bent to match a contour of the work surface; and placing the abrasion surface on the sandpaper while folding the at least one foldable abrasion surface to form a bent abrasion surface that is attached to the bent piece of sandpaper.

BRIEF DESCRIPTION OF THE DRAWINGS

In order for the present invention, to be better understood and for its practical applications to be appreciated, the following Figures are provided and referenced hereafter. It should be noted that the Figures are given as examples only and in no way limit the scope of the invention. Like components are denoted by like reference numerals.

FIG. 1A schematically illustrates a manual sanding device in accordance with an embodiment of the present invention.

FIG. 1B schematically illustrates the manual sanding device shown in FIG. 1A, with the sanding surface visible.

FIG. 2A schematically illustrates the manual sanding device shown in FIG. 1A when locked in an open configuration.

FIG. 2B schematically illustrates the unlocking of the manual sanding device shown in FIG. 1A.

FIG. 2C schematically illustrates the manual sanding device shown in FIG. 1B when folded.

FIG. 3 schematically illustrates an extension handle for the manual sanding device shown in FIG. 1A.

FIG. 4 schematically illustrates components for assembly into the manual sanding device shown in FIG. 1A.

FIG. 5A schematically illustrates a side view of attaching a piece of sandpaper to the manual sander shown in FIG. 2A when in an open configuration.

FIG. 5B schematically illustrates a folded configuration of the manual sander for smoothing an inside corner.

FIG. 5C schematically illustrates preparation of the manual sander shown in FIG. 1A for smoothing an outer corner.

FIG. 5D schematically illustrates preparation of the manual sander shown in FIG. 1A for smoothing a convexly curved surface.

DETAILED DESCRIPTION OF THE INVENTION

In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be understood by those of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well-known methods, procedures, components, modules, units and/or circuits have not been described in detail so as not to obscure the invention.

Although embodiments of the invention are not limited in this regard, the terms “plurality” and “a plurality” as used herein may include, for example, “multiple” or “two or more”. The terms “plurality” or “a plurality” may be used throughout the specification to describe two or more components, devices, elements, units, parameters, or the like. Unless explicitly stated, the method embodiments described herein are not constrained to a particular order or sequence. Additionally, some of the described method embodiments or elements thereof can occur or be performed simultaneously, at the same point in time, or concurrently. Unless otherwise indicated, the conjunction “or” as used herein is to be understood as inclusive (any or all of the stated options).

In accordance with an embodiment of the present invention, a manual sander is convertible to an open configuration that is suitable for smoothing a substantially flat work surface, or to a folded configuration that is suitable for smoothing a joint or corner between two substantially flat work surfaces. For example, an abrasion surface of the manual sander may include one or more foldable sections or wings that enable the abrasion surface to be configured to form a single substantially flat and coplanar abrasion surface, or to form a bent abrasion surface.

The manual sander includes a handle and the abrasion surface. The sander may be manipulated by a user who is holding the handle to rub the abrasion surface over a work surface (e.g., wood, drywall, or another type of work surface) that is to be smoothed. For example, the abrasion surface may be inherently abrasive (e.g., roughened or coated with an abrasive grit or other abrasive material, or may incorporate a metal rasp or similar surface), or may be configured to hold a piece of sandpaper substantially flat against a mounting surface. As used herein, sandpaper may refer to any type of replaceable or disposable sheet-like abrasive material. The sandpaper may be held to the mounting surface by one or more clips or other holding structure, or may be held by an adhesive. The adhesive may include an adhesive material (e.g., adhesive tape, glue, or other sticky or tacky surface), or may include a mechanical adhesive surface (e.g., a hook-and-loop fastener such as Velcro™)

The abrasion surface includes a fixed section and one or more foldable sections. For example, the foldable sections may be connected to the fixed section by a hinge. As used herein, a hinge refers to any substantially straight connection between two sections or surfaces that enables relative folding or rotation of the sections or surfaces about the axis of the hinge. The hinge may include a groove, scoring, or other modification in an otherwise continuous piece of material (e.g., a plastic disk) that facilitates folding relative to one another of two regions on opposite sides of the hinge. Alternatively or in addition, a hinge structure may enable folding of two pieces of a rigid material (e.g., metal, wood, or another rigid material) relative to one another.

The handle is attached to the fixed section of the abrasion surface in a manner that allows for manipulation of the handle relative to the fixed section. The attachment may enable rotation or translation of the handle relative to the fixed section. However, the attachment may be such that the handle cannot be readily removed from the fixed section without disassembling, breaking, bending, or distorting the fixed section, the handle, or both. For example, an axis of the handle may be attached to the fixed section in a manner that enables rotation of the handle relative to the fixed section while not enabling ready removal the handle from the fixed section. As another example, a tab or extension of the handle may extend into a slot of the fixed section, or a tab or projection from the fixed section may extend into a slot of the handle, in a manner that enables sliding or translation of the handle relative to the fixed section but not ready removal of the handle from the fixed section.

The handle may be manipulated to lock or hold the abrasion surface such that the abrasion surface is maintained in an open configuration. For example, the handle may be mounted on or attached to the fixed section of the abrasion surface. The handle may be configured to rotate relative to the fixed section, or to translate or slide relative to the fixed section. When the handle is in one rotation or translation configuration, locking structure of the handle may engage cooperating structure on a foldable section of the abrasion surface. When the cooperating structure is engaged, one or more of the foldable sections may be fixed in an open configuration. For example, a rigid structure of the handle may block any folding of the foldable section. Alternatively or in addition, the motion of the handle may activate or trigger a mechanical or actuated locking mechanism, e.g., on the fixed section, to engage cooperating structure, e.g., on a foldable section.

When in the open configuration, the fixed and foldable sections of the abrasion surface are substantially coplanar configuration to form a substantially flat abrasion surface. For example, a flat abrasion surface may be used to smooth a substantially flat or gently curved surface (e.g., a surface whose curvature is sufficiently small so as to enable the substantially flat abrasion surface to be manipulated and rubbed over so as to smooth the gently curved surface).

The handle may be manipulated to enable a folded configuration of the abrasion surface. For example, the handle may be rotated or translated so as to disengage the locking structure from the cooperating structure (or to cause or enable a locking mechanism to disengage from cooperating structure).

When the configuration of the abrasion surface is unlocked, one or more foldable sections of the abrasion surface may be folded inward. As used herein, inward folding refers to folding a foldable section in a direction that is away from the abrasive surface of the section. When inwardly folded, the abrasion surface may take the form of two or more sections that present a convex fold or bend. When the convex fold of the abrasion surface is aligned parallel to a concave junction between two surfaces (e.g., at an internal corner where two flat walls meet) and inserted into the concave junction, the convex abrasive surface may be rubbed (e.g., parallel to the junction, or otherwise) to smooth the surfaces at the concave junction.

As another example, the foldable sections of the abrasion surface may be folded outward (opposite the inward folding, e.g., in the direction of the abrasive surface of the foldable section). When folded outward, the surface may conform at least approximately to the form of a convex surface (e.g., the outer surface of a cylindrical workpiece).

The manual sander may include retaining mechanism structure that is configured to retain the abrasion surface in one or more folded configurations. For example, the retaining mechanism may include retaining structure that is located on the handle. The retaining structure on the handle may be configured to engage cooperating retaining structure on one or more of the foldable sections. For example, the retaining structure and the cooperating retaining structure may include parts of a snap fastener, a magnet and a ferromagnetic plate, hook-and-loop fasteners, clips, or other retaining structure.

The retaining structure may be configured to retain a fold between two sections of the abrasion surface at a hinge in a particular configuration. For example, the retaining structure may maintain the fold at a right angle, or at another fixed angle. Alternatively or in addition, the retaining structure may be configured (e.g., with two or more stops or other structure) to maintain the fold at two or more predetermined fixed angles. Alternatively or in addition, the retaining structure may be configured (e.g., with a clamp or other structure) to enable a user to fix the fold at an arbitrarily selected angle (e.g., within a predetermined range of angles).

In order to lock the abrasion surface in an open configuration, any folded sections may be unfolded until all sections of the abrasion surface are substantially coplanar. Any retaining structure that is retaining any of the sections in a folded configuration may be caused to release the folded sections. For example, the retaining structure (e.g., in the form of a magnet, snap fastener, hook-and-loop fasteners, or other types of fastening structure) may be configured to release when an unfolding force or torque is applied to the folded sections. In some cases, the retaining structure (e.g., in the form of a clip, latch, or other type of fastening structure) may be released prior to unfolding the folded sections. When all sections of the abrasion surface are unfolded so as to be substantially coplanar, the handle may be manipulated (e.g., rotated or translated) to lock the sections in a flat configuration.

The handle may include a grip that is configured to facilitate grasping and manipulation of the handle, manual sander, or both, by a user. The handle may include structure to enable attachment of an extension handle. For example, the handle may include one or more sockets into which an extension handle may be inserted. The extension handle may be of fixed length and shape, may be telescoping, may be bendable, or may have another form.

FIG. 1A schematically illustrates a manual sanding device in accordance with an embodiment of the present invention. FIG. 1B schematically illustrates the manual sanding device shown in FIG. 1A, with the sanding surface visible.

Manual sander 10 is shown in an unlocked configuration. Manual sander 10 includes abrasion base 12. In the example, shown, abrasion base 12 is in the form of a disk with a fixed section 16 and two foldable sections 18. In other examples, an abrasion base may include a single foldable section, or three or more foldable sections.

Fixed section 16 includes fixed abrasion surface 22. Each foldable section 18 includes a foldable abrasion surface 24. In the configuration that is shown in FIGS. 1A and 1B, fixed abrasion surface 22 and foldable abrasion surfaces 24 are coplanar, so as to function as a single flat abrasion surface 13. In the example shown, flat abrasion surface 13 is circular. In other examples, abrasion base 12 and flat abrasion surface 13 may have other shapes (e.g., rectangular, polygonal, oval, or another shape).

Fixed abrasion surface 22 and each foldable abrasion surface 24 may be at least partially covered with a hook-and-loop fastener surface. The hook-and-loop fastener surface may enable attachment of a piece of sandpaper or other abrasive material (whose rear surface is similarly provided with a cooperating hook-and-loop fastener surface) to fixed abrasion surface 22 and foldable abrasion surfaces 24. For example, a disk-shaped piece of sandpaper may be attached to a circular flat abrasion surface 13, as in the example shown. Alternatively or in addition, separate pieces of sandpaper, e.g., each shaped to cover fixed abrasion surface 22 or foldable abrasion surface 24, may be attached to the correspondingly shaped fixed abrasion surface 22 or foldable abrasion surface 24.

Alternatively or in addition, fixed abrasion surface 22 and foldable abrasion surface 24 may be provided with other structure for holding a piece of sandpaper. For example, part or all of one or both of fixed abrasion surface 22 or foldable abrasion surface 24 may be covered with an adhesive coating. Alternatively or in addition, abrasion base 12 may include one or more clips, straps, suction cups, or other structure for holding a piece of sandpaper to flat abrasion surface 13.

Each foldable section 18 of abrasion base 12 is connected to fixed section 16 at a hinge 20. Each hinge 20 enables its connected foldable section 18 to fold in at least one direction relative to fixed section 16.

In the example shown, hinge 20 includes a linear groove in a piece of plastic from which abrasion base 12 is formed (e.g., by a molding or machining process). For example, hinge 20 in the form of a groove may have a V-shaped cross section. The V-shape of the cross section of the groove may be configured to enable inward folding (toward sander handle 11, and away from foldable abrasion surface 24) of the connected foldable section 18 toward fixed section 16 (e.g., so as to close the walls of the groove inward to close the V-shape). The extent of inward folding may be limited by the shape of the groove, by grip 14, or both. Hinge 20 in the form of a groove may also enable outward folding of foldable section 18, such that fixed abrasion surface 22 and foldable abrasion surface 24 form a concave surface (e.g., for smoothing a convex surface such as a cylindrical, spherical, spheroid, exterior corner between two flat sides, or other convex surface). Alternatively or in addition, hinge 20 may include another type of jointed or flexible structure that connects foldable section 18 to fixed section 16. For example, the jointed or flexible structure may be mechanically attached (e.g., using an adhesive, welding, soldering, screws, bolts, rivets, or otherwise) to foldable section 18, fixed section 16, or both.

Manual sander 10 includes handle 11. Handle 11 includes grip 14 and handle base 21. In the example shown, grip 14 is shorter than handle base 21. In other examples, grip 14 and handle base 21 may have substantially similar length.

Handle 11 may be configured to facilitate grasping and manipulation of manual sander 10. For example, grip 14 may be shaped in a manner (e.g., an arched shape, as shown, or another shape) that facilitates firm and comfortable grasping of handle 11. Grip 14 may include surfaces that are covered with a non-slip material that facilitates gripping of handle 11. For example, grip 14 may include side panels 19 and one or more finger grooves 17. One or more side panels 19 and finger grooves 17 may be covered or coated with a non-slip material.

Handle 11 may be configured so as to facilitate grasping and manipulation of manual sander 10 when manual sander 10 is in different configurations. For example, in the open configuration (e.g., as shown in FIGS. 1A, 1B and 2A), handle 11 may be grasped primarily using side panels 19 of grip 14. When manual sander 10 is in a folded configuration (e.g., as shown in FIGS. 2C), handle 11 may be grasped primarily using finger grooves 17 of grip 14.

Handle 11 may include an extension handle socket 33, shown covered by socket cap 34. Extension handle socket 33 may be configured to attach to an end of an extension handle. For example, extension handle socket 33 may include internal threading, projections, sockets, or other structure to enable firm attachment of an extension handle to extension handle socket 33.

An extension handle (e.g., eccentric extension handle 40, as shown in FIG. 3) may be ergonomically designed for convenient handling of manual sander 10.

In some cases, an extension handle may enable manipulation of manual sander 10 when holding grip 14 by hand is difficult, inconvenient, or not possible. For example, an extension handle may be used to manipulate manual sander 10 to smooth a work surface that would otherwise be inaccessible (e.g., more distant than the length of the user's arm, recessed within a narrow space or cavity, around a corner, or otherwise inaccessible when handheld). An extension handle may be telescoping or bendable in order to facilitate access to the work surface.

Manual sander 10 may include one or more structures to facilitate storage of manual sander 10. For example, manual sander 10 may include hanger 32 to enable hanging on a hook or peg. In the example shown, hanger 32 may be foldable inward when manual sander 10 is in use so as to reduce or eliminate interference with manipulation of manual sander 10. For example, when hanger 32 is folded inward, hanger 32 may engage hanger latch 31 (visible in FIGS. 2A and 2B) to retain hanger 32 in its folded state. Alternatively or in addition, hanger 32 may be slidable or retractable into an appropriate cavity of manual sander 10. Alternatively or in addition, other structure to enable storage of manual sander 10 may be included. Such other storage structure may include one or more hooks, magnets, holes, or other structure to facilitate storage.

Handle 11 may be manipulated to lock manual sander 10 in an open configuration (where fixed abrasion surface 22 and foldable abrasion surfaces 24 are substantially coplanar), or to enable inward folding of one or more foldable sections 18.

In the example shown, handle 11 may be rotated about handle axis 15. Handle axis 15 may enable lateral rotation (e.g., parallel to fixed abrasion surface 22) of handle 11 relative to fixed section 16 of abrasion base 12. In the configuration shown in FIG. 1A, handle 11 is oriented so as not to impede inward folding of either foldable section 18 about its connected hinge 20.

When handle 11 is rotated from the parallel configuration shown in FIG. 1A through at least a minimum angle (e.g., to the configuration shown in FIG. 2B), part of handle base 21 of handle 11 may extend beyond hinge 20. When part of handle base 21 extends beyond hinge 20, the part of handle base 21 that extends beyond hinge 20 may impede or prevent inward folding of either foldable section 18 about its connected hinge 20.

In the example shown in FIG. 1A, handle 11 may be laterally rotated in a forward direction (clockwise in the example shown) in order to lock abrasion base 12 in an open configuration. Forward lateral rotation of handle 11 about handle axis 15 when foldable sections 18 are unfolded (as shown in FIG. 1A) may cause locking structure in the form of a locking indentation 30 at an end (along the longitudinal axis) of handle base 21 of handle 11 to engage cooperating locking structure in the form of locking tab 28 on foldable section 18. In the example shown, locking indentation 30 includes an indentation at either end of handle base 21 and each foldable section 18 includes a locking tab 28.

Other configurations of locking structure and cooperating structure may be used. For example, the locking structure may include a tab and the cooperating structure may include a latch or indentation. The locking structure, cooperating structure, or both, may include a magnet, a latch, or other type of structure.

When locking indentation 30 engages locking tab 28, inward folding of foldable section 18 about hinge 20 may be prevented. For example, locking indentation 30, locking tab 28, or both may be elastic (e.g., made of a resilient plastic that may temporarily distort or bend when subjected to a force), spring loaded, or otherwise resiliently bendable or distortable such that exertion of torque (e.g., in the clockwise direction in the example shown) will locking tab 28 to insert into locking indentation 30. The elasticity or resilience may prevent locking tab 28 from disengaging from locking indentation 30 in the absence of exertion of an opposite (e.g., counterclockwise) torque. Alternatively or in addition, handle 11, foldable section 18, or both may have other structure that may operate to impede or prevent inward folding of foldable section 18.

Engagement of locking indentation 30 by locking tab 28 may also prevent outward folding of foldable section 18 about hinge 20. For example, locking tab 28 may be shaped (e.g., with an enlarged distal end, or otherwise) such that engagement of locking indentation 30 by locking tab 28 does not allow locking tab 28 to slide relative to locking indentation 30. Alternatively or in addition, friction between locking indentation 30 and locking tab 28 may prevent sliding of locking tab 28 relative to locking indentation 30.

Alternatively or in addition, locking structure on the handle may be configured to engage cooperating structure on fixed section 16. For example, the locking structure on the handle may be located at a part of the handle that is proximal to the ends of the handle, e.g., near a rotation axis of the handle.

Retaining structure may be provided to retain abrasion base 12 in a folded configuration. For example, handle 11, e.g., grip 14 of handle 11, may include handle retaining structure 26. When a foldable section 18 is folded inward toward handle 11, handle retaining structure 26 may engage foldable section retaining structure 29. Foldable section retaining structure 29 may be located on a locking tab 28, or elsewhere on foldable section 18. For example, one of handle retaining structure 26 and foldable section retaining structure 29 may include a magnet, while the other includes a ferromagnetic plate, tab, or other structure. Alternatively or in addition, both handle retaining structure 26 and foldable section retaining structure 29 may include magnets (e.g., with appropriate polarity to enable retention). Alternatively or in addition, handle retaining structure 26 and foldable section retaining structure 29 may include cooperating mechanical retaining structure (e.g., male and female parts of a snap connector, a latch and structure that may be engaged by the latch, hook-and-loop fastener surfaces, adhesive surfaces, or other mechanical retaining structure).

Alternatively or in addition to rotation of handle 11, a handle may be configured to be moved or slid translationally in order to prevent inward folding of foldable sections 18. For example, an end of a translatable handle may be configured in the form of a wedge that may be inserted into cooperating structure (e.g., a wedge-like slot or indentation) on one or more foldable sections. Locking structure may be provided to prevent unintended sliding away from the configuration that prevents inward folding of foldable sections 18.

FIG. 2A schematically illustrates the manual sanding device shown in FIG. 1A when locked in an open configuration.

In the example shown, when manual sander 10 is locked in an open configuration, a longitudinal axis of handle 11 (e.g., the longitudinal axis of handle 11 representing an axis along the longest lateral dimension of handle 11, e.g., extending between both locking structures 30 on handle 11) is oriented substantially perpendicular to (the folding axis of each of) hinges 20. The length of handle base 21 of handle 11 extends beyond the width of fixed section 16 of abrasion base 12 to cover the width of each foldable section 18. Thus, in this orientation, handle base 21 overlaps each foldable section 18 and prevents inward folding of foldable section 18 about its connected hinge 20. In the example, shown, the length of handle base 21 is sufficiently close to the radius of abrasion base 12 so as to cover most of the width of each foldable section 18.

When the longitudinal axis of handle 11 is rotated to a locking angle, locking indentation 30 on handle base 21 of handle 11 may engage locking tab 28 of foldable section 18. Thus, the orientation of handle 11 relative to abrasion base 12 may be locked. For example, engagement of locking tab 28 by locking indentation 30 may prevent further forward lateral rotation of handle 11 (e.g., clockwise in the example shown) relative to abrasion base 12 beyond the locked orientation. Engagement of locking tab 28 by locking indentation 30 may impede or prevent unintentional backward lateral rotation of handle 11 away from the locked orientation (e.g., counterclockwise in the example shown). For example, backward lateral rotation of handle 11 may require deliberate application of torque to handle 11 relative to abrasion base 12. In order to enable the backward rotation of handle 11, the applied torque may be sufficient so as to disengage locking indentation 30 from locking tab 28.

In the example, shown, handle 11 is rotated to the locking angle when the longitudinal axis of handle 11 is oriented substantially perpendicular to hinge 20. Locking indentation 30 is located on either end of handle base 21, and locking tab 28 is located at the furthermost edge of foldable section 18 from its hinge 20 (e.g., as measured by perpendicular distance from hinge 20).

Alternatively or in addition, locking structure on handle 11 may be configured to engage structure (e.g., similar to locking tab 28) on foldable section 18 when the longitudinal axis of handle 11 is oriented at a non-perpendicular oblique angle to hinge 20. The rotation of handle 11 to the oblique locking angle may be require rotation of handle 11 through an angle that is less than 90° (an acute angle), or through an angle that is greater than 90° (an obtuse angle).

When locked in an open configuration, fixed abrasion surface 22 and foldable abrasion surfaces 24 form a substantially coplanar and contiguous flat abrasion surface 13. The area of the contiguous flat abrasion surface 13 may enable efficient smoothing of a flat (or gently curving) work surface. For example, the full area of a disk-shaped piece of sandpaper that is attached to flat abrasion surface 13 may be exposed as a single contiguous surface. A user may grasp grip 14 of handle 11 (e.g., by one or more of side panels 19 and finger grooves 17, or otherwise) and manipulate manual sander 10 to smooth a work surface. Engagement of locking tabs 28 by locking indentation 30 may impede or prevent unintentional folding of foldable sections 18.

In some situations, manual sander 10 may be unlocked from the open configuration to enable inward folding of one or foldable sections 18.

FIG. 2B schematically illustrates the unlocking of the manual sanding device shown in FIG. 1A.

In the configuration shown, handle 11 has been laterally rotated backward (e.g., counterclockwise in the example shown) to disengage each locking indentation 30 from its corresponding locking tab 28. For example, a backward torque may have been applied to handle 11 relative to abrasion base 12. Since the ends of handle base 21 if handle 11 continue to extend beyond each hinge 20 to its attached foldable section 18, inward folding of foldable section 18 is impeded.

Further backward lateral rotation of handle 11 may enable free inward folding of foldable sections 18.

FIG. 2C schematically illustrates the manual sanding device shown in FIG. 1B when folded.

In the example, shown, foldable section 18b is partially folded inward about hinge 20b. As a result of the inward folding, foldable abrasion surface 24b is not coplanar with fixed abrasion surface 22. Continued inward folding of foldable section 18b about hinge 20b, e.g., until foldable section 18 is completely folded inward toward handle 11, may bring foldable section retaining structure 29 adjacent to handle retaining structure 26. Foldable section retaining structure 29 may then engage handle retaining structure 26 to retain foldable section 18b in a fully folded configuration.

Retaining foldable section 18b in a fully folded configuration may facilitate use of manual sander 10 in a fully folded configuration.

In the example shown, foldable section 18a is fully folded inward about hinge 20a such that foldable abrasion surface 24a is substantially perpendicular to fixed abrasion surface 22. For example, foldable section retaining structure 29 of foldable section 18a may be engaged by the corresponding handle retaining structure 26 on handle 11.

Fixed abrasion surface 22 together with foldable abrasion surfaces 24a and 24b form a convexly bent abrasion surface 13′. Alternatively, one or both of foldable abrasion surfaces 24a and 24b may be folded outward to form a concavely bent abrasion surface, or bent partly concavely (e.g., at one hinge 20) and partly convexly (e.g., at another hinge 20).

Thus, manual sander 10 may be used to smooth work surfaces at a corner. In the example, shown, hinge 20a may be inserted into a corner where two substantially perpendicular work surfaces, e.g., two walls of a room or of another enclosure, meet. Application of pressure to manual sander 10 while moving manual sander 10 parallel to hinge 20a within the corner may concurrently smooth the sections of both of the work surfaces where they meet at the corner.

For example, socket cap 34 may be opened and an extension handle may be inserted into the exposed extension handle socket 33. For example, structure on the extension handle (e.g., one or more of external threading, tabs, sockets, or other structure) may engage cooperating structure (e.g., internal threading, sockets, tabs, or other cooperating structure) within extension handle socket 33. The extension handle may then be used to manipulate manual sander 10 in a folded configuration. Alternatively or in addition, handle 11 of manual sander 10 may be grasped (e.g., at finger grooves 17 on grip 14, or elsewhere) in order to manipulate manual sander 10 in a folded configuration.

FIG. 3 schematically illustrates an extension handle for the manual sanding device shown in FIG. 1A.

Eccentric extension handle 40 includes eccentric knob 42. Eccentric knob 42 is asymmetrically distributed about the point of attachment, e.g., attachment stem 46, of eccentric extension handle 40 to extension handle socket 33. Eccentric extension handle 40 may be configured to enable a user of manual sander 10 to select an orientation of eccentric extension handle 40 relative to handle 11 and grip 14. For example, the user may select the handle on the basis of, comfort, the position of work surface to be smoothed, handedness of the user, or otherwise. Thus, eccentric extension handle 40 may enable ergonomic gripping and manipulation of manual sander 10.

Eccentric extension handle 40 may be disassembled into a knob section 41 that includes eccentric knob 42 and attachment stem 46, and a knob cover 44. Knob cover 44 may be attached to knob section 41 to form eccentric extension handle 40. For example, knob section 41 and knob cover 44 may be made of plastic and separately formed by a molding process, or otherwise. In some cases, eccentric handle 40 may be made a single integral part.

Attachment stem 46 may be inserted into extension handle socket 33 of handle 11. The outer diameter or other outer dimension of attachment stem 46 may be selected to be approximately equal to the inner diameter, or other corresponding dimension, of extension handle socket 33. Thus, a pushing force may be applied to attachment stem 46 in order to insert attachment stem 46 into extension handle socket 33. As a result, friction forces may prevent unintentional withdrawal of attachment stem 46 from extension handle socket 33 until a pulling force is applied to withdraw attachment stem 46 from extension handle socket 33.

Attachment stem 46 and extension handle socket 33 may be provided with guiding structure. For example, guiding structure on attachment stem 46 may include a plurality of stem grooves 47 that are oriented longitudinally along (e.g., substantially parallel to an axis of) attachment stem 46. Stem grooves 47 may be distributed approximately uniformly around the diameter of attachment stem 46, or may be otherwise distributed. Extension handle socket 33 may include guiding structure in the form of one or more socket tabs 48. For example, extension handle socket 33 may include two socket tabs 48 one opposite sides of extension handle socket 33. Each socket tab 48 is configured with a size, orientation, and shape to engage (e.g., insert into) a stem groove 47 of attachment stem 46 when attachment stem 46 is inserted into extension handle socket 33. Alternatively, extension handle socket 33 may include a plurality of distributed socket tabs 48 while attachment stem 46 includes one or more stem grooves 47. Alternatively or in addition, attachment stem 46 may be provided with one or more tabs while extension handle socket 33 is provided with one or more grooves. Other guiding structure (e.g., attachment stem 46 and extension handle socket 33 having corresponding polygonal cross sections, or other guiding structure) may be provided.

Thus, the guiding structure (e.g., stem grooves 47 and socket tab 48, or other guiding structure) may limit the orientation of eccentric extension handle 40 relative to handle 11 to a limited number of orientations. The guiding structure may maintain an orientation of eccentric extension handle 40 relative to extension handle socket 33 and handle 11 during use of manual sander 10 by preventing unintentional rotation of eccentric extension handle 40 relative to handle 11 and manual sander 10. The guiding structure may increase friction between attachment stem 46 and extension handle socket 33 so as to further prevent unintentional withdrawal of attachment stem 46 from extension handle socket 33.

FIG. 4 schematically illustrates components for assembly into the manual sanding device shown in FIG. 1A.

Socket cap 34 may be inserted into extension handle socket 33 of grip 14 when no extension handle is inserted into extension handle socket 33. Insertion of socket cap 34 into extension handle socket 33 may facilitate comfortable gripping of grip 14 when no extension handle. For example, when socket cap 34 is inserted into extension handle socket 33, a user who is gripping grip 14 may feel a smooth surface, rather than an opening that may chafe or otherwise cause discomfort to the user.

In the example shown, each handle retaining structure 26 may include a ferromagnetic plate (e.g., made of stainless steel or another ferromagnetic material) that is inserted into and held by a plate slot 27 on grip 14. Each handle retaining structure 26 may include a magnet that may be inserted into each magnet socket 49 and into each locking tab 28 in each foldable section 18 of abrasion base 12.

Flat abrasion surface 13 may be covered with (e.g., with an appropriate glue or other adhesive) with sandpaper attachment surface 50. Sandpaper attachment surface 50 may enable attachment of sandpaper or another type of sheet-like abrasive material to flat abrasion surface 13. For example, sandpaper attachment surface 50 may include a surface of a hook-and-loop fastener that is configured to attach to a cooperating hook-and-loop fastener on the sandpaper. In the example shown, the sandpaper may include a typical commercially available sandpaper disk for attachment to a disk sander. The rear surface of such a sandpaper disk may be covered with a loop surface of the hook-and-loop fastener. In this case, a front surface of sandpaper attachment surface 50 (e.g., the surface that is configured to face the work surface and away from abrasion base 12) may be covered with a hook surface of the hook-and-loop fastener.

Sandpaper attachment surface 50 may include a single piece that is shaped (circular in the example shown, or otherwise shaped) to cover substantially all of flat abrasion surface 13. Alternatively or in addition, sandpaper attachment surface 50 may include separate sections that are each shaped to cover part of flat abrasion surface 13. For example, central sheet section 52 of sandpaper attachment surface 50 may be shaped so as to cover fixed abrasion surface 22 Similarly, each end sheet section 54 of sandpaper attachment surface 50 may be shaped to cover a foldable abrasion surface 24. A sandpaper attachment surface 50 may be otherwise divided into sections.

In order to use manual sander 10 to smooth a work surface, a user may execute a method for preparing manual sander 10 for use.

FIG. 5A schematically illustrates a side view of attaching a piece of sandpaper to the manual sander shown in FIG. 2A when in an open configuration.

When preparing to smooth a flat work surface 64 or gently curving work surface 66 (e.g., a convex work surface as shown, or, in some cases, a concave work surface with a radius of curvature that is much larger than the diameter of flat abrasion surface 13), handle 11 (represented by grip 14) may be manipulated to the open configuration shown in FIG. 2A. Sandpaper 60 (e.g., a sandpaper disk or otherwise shaped piece of sandpaper) may be attached to the resulting coplanar, flat abrasion surface 13, as indicated by sandpaper attachment motion 62. Manual sander 10 may then be manipulated (e.g., by gripping grip 14 or otherwise) to sand flat work surface 64 or gently curving work surface 66.

In some cases, the work surface may include a concavely bent work surface, such as an inside corner along an inside edge where two flat or gently curved surfaces meet.

FIG. 5B schematically illustrates a folded configuration of the manual sander for smoothing an inside corner.

When a concavely bent work surface is to be smoothed, such as inside corner surface 68, handle 11 may be manipulated to enable foldable abrasion surface 24 to fold about hinge 20, with sandpaper 60 attached, to form a folded configuration in which fixed abrasion surface 22 and foldable abrasion surfaces 24 form a convexly bent abrasion surface 13′. Manual sander 10 with convexly bent abrasion surface 13′ may then be manipulated to smooth inside corner surface 68.

In the example shown, inside corner surface 68 is in the form of a right angle. In this case, handle retaining structure 26 and foldable section retaining structure 29 may retain bent abrasion surface 13′ so as to form a right angle. In some cases, the sides that meet to form an inside corner surface may meet at an obtuse angle. In that case, a foldable section 18 may be partially folded inward (e.g., similar to foldable section 18b in FIG. 2C).

In some cases, sandpaper 60 may be placed on the work surface prior to attachment to bent abrasion surface 13′. For example, the front surface (e.g., the abrasive surface) of a piece of sandpaper may be inserted into inside corner surface 68, or placed over a convexly bent or curved surface. An appropriately shaped abrasion surface of manual sander 10 may then be pressed onto the rear side of the piece of sandpaper to attach the piece of sandpaper to the abrasion surface (e.g., via a hook-and-loop fastener, an adhesive, or otherwise, and in a manner similar to attachment of outwardly bent abrasion surface 13″ to sandpaper 60 as described below).

FIG. 5C schematically illustrates preparation of the manual sander shown in FIG. 1A for smoothing an outer corner.

In the example shown, outside corner surface 70 forms a right angle. In other cases, outside corner surface 70 may form an acute or obtuse angle. Sandpaper 60 may be placed over outside corner surface 70, with the front (abrasive) side of sandpaper 60 facing outside corner surface 70.

Manual sander 10 may be moved toward sandpaper 60 with sander attachment motion 72. Concurrently, one or more of foldable sections 18 may be folded outwardly from manual sander 10 with outward folding 73 to form an outwardly bent abrasion surface 13″ whose contour substantially matches the form of sandpaper 60 on outside corner surface 70. In this manner, outwardly bent abrasion surface 13″ may attach to sandpaper 60. Typically, sandpaper 60 is not appreciably elastic (e.g., cannot be stretched to an extent that would be detectible by the unaided eye). Therefore, if the bond between sandpaper 60 and outwardly bent abrasion surface 13″ is sufficiently strong, sandpaper 60 may function to preserve the form of outwardly bent abrasion surface 13″.

FIG. 5D schematically illustrates preparation of the manual sander shown in FIG. 1A for smoothing a convexly curved surface.

In the example shown, convexly curved surface 74 is circular (cylindrical). In other cases, convexly curved surface 74 may be elliptical or otherwise curved, or may be in the form of a corrugation. Sandpaper 60 may be placed over convexly curved surface 74, with the front side of sandpaper 60 facing convexly curved surface 74.

Manual sander 10 may be moved toward sandpaper 60 with sander attachment motion 76. Concurrently, one or more of foldable sections 18 may be folded outwardly from manual sander 10 with outward folding 77 to form an outwardly bent abrasion surface 13″ whose contour substantially matches (e.g., partially circumscribes) the form of sandpaper 60 on convexly curved surface 74 (e.g., at lines or points where outwardly bent abrasion surface 13″ is tangent to sandpaper 60 on convexly curved surface 74). In this manner, outwardly bent abrasion surface 13″ may attach to sandpaper 60. Typically, when sandpaper 60 is not appreciably elastic and the bond between sandpaper 60 and outwardly bent abrasion surface 13″ is sufficiently strong, sandpaper 60 may function to preserve the form of outwardly bent abrasion surface 13″.

Different embodiments are disclosed herein. Features of certain embodiments may be combined with features of other embodiments; thus certain embodiments may be combinations of features of multiple embodiments. The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. It should be appreciated by persons skilled in the art that many modifications, variations, substitutions, changes, and equivalents are possible in light of the above teaching. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.

While certain features of the invention have been illustrated and described herein, many modifications, substitutions, changes, and equivalents will now occur to those of ordinary skill in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.

Claims

1. A manual sander comprising: wherein the handle is manipulable to maintain the fixed abrasion surface and said at least one foldable abrasion surface in an open configuration in which the fixed abrasion surface and said at least one foldable abrasion surface are substantially coplanar, and is manipulable to enable said at least one foldable abrasion surface to fold about the hinge to form a folded configuration in which the fixed abrasion surface and said at least one foldable abrasion surface form a bent surface.

a handle;

a fixed abrasion surface to which the handle is attached; and

at least one foldable abrasion surface that is connected to the fixed abrasion surface by a hinge,

2. The sander of claim 1, wherein the handle comprises an axis that is attached to the fixed abrasion surface to enable lateral rotation of the handle relative to the fixed abrasion surface.

3. The sander of claim 2, wherein the handle is configured to be laterally rotated in a forward direction to maintain the open configuration, and in a backward direction that is opposite the forward direction to enable the folded configuration.

4. The sander of claim 3, wherein the rotation in the forward direction causes an end of the handle to extend beyond the hinge.

5. The sander of claim 4, wherein the handle comprises a locking structure that is configured to engage cooperating structure to lock the handle to maintain the fixed abrasion surface and said at least one foldable abrasion surface in the open configuration.

6. The sander of claim 5, wherein the cooperating structure is located on a foldable abrasion surface of said at least one foldable abrasion surface.

7. The sander of claim 6, wherein the locking structure is at an end of the handle and the cooperating structure is located at an edge of said at least one foldable abrasion surface that is furthermost from the hinge to which that foldable abrasion surface is connected.

8. The sander of claim 5, wherein the locking structure and the cooperating structure are configured to lock the handle when a longitudinal axis of the handle is substantially perpendicular to the hinge.

9. The sander of claim 5, wherein the locking structure comprises an indentation in a base of the handle, and the cooperating structure comprises a locking tab on said at least one foldable abrasion surface.

10. The sander of claim 1, wherein the fixed abrasion surface and said at least one foldable abrasion surface form a substantially circular abrasion surface when in the open configuration.

11. The sander of claim 1, further comprising a retaining mechanism that is configured to retain the fixed abrasion surface and said at least one foldable abrasion surface in a folded configuration.

12. The sander of claim 11, wherein the retaining mechanism comprises a retaining structure on the handle, and cooperating retaining structure that is located on a foldable abrasion surface of said at least one foldable abrasion surface.

13. The sander of claim 12, wherein the retaining structure comprises a ferromagnetic plate and the cooperating retaining structure comprises a magnet.

14. The sander of claim 12, wherein the cooperating retaining structure is located on a locking tab of said at least one foldable abrasion surface.

15. The sander of claim 11, wherein the retaining mechanism is configured to retain said at least one foldable abrasion surface substantially perpendicular to the fixed abrasion surface.

16. The sander of claim 1, wherein the handle comprises a socket to enable attachment of an extension handle.

17. The sander of claim 16, wherein the extension handle comprises an eccentric knob.

18. The sander of claim 17, wherein an attachment stem of the extension handle and the socket comprise cooperating guiding structure to maintain an orientation of the extension handle relative to the socket.

19. The sander of claim 1, wherein the hinge comprises a groove.

20. A method for preparing a manual sander for smoothing a work surface, the method comprising:

providing the manual sander, the sander including an abrasion surface that includes a fixed abrasion surface and at least one foldable abrasion surface that is connected to the fixed abrasion surface by a hinge; and manipulating a handle that is connected to the fixed abrasion surface to maintain attached the fixed abrasion surface and said at least one foldable abrasion surface in an open configuration in which the fixed abrasion surface and said at least one foldable abrasion surface are substantially coplanar, and attaching a piece of sandpaper to the substantially coplanar surfaces; or manipulating the handle to enable said at least one foldable abrasion surface to fold about the hinge to form a folded configuration in which the fixed abrasion surface and said at least one foldable abrasion surface form a bent surface; placing the piece of sandpaper on the work surface such that the piece of sandpaper is bent to match a contour of the work surface; and placing the abrasion surface on the sandpaper while folding said at least one foldable abrasion surface to form a bent abrasion surface that is attached to the bent piece of sandpaper.