Note: Descriptions are shown in the official language in which they were submitted.
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MANUAL SANDER
FIELD OF THE INVENTION
[0001] The present invention relates to sanding. More particularly, the
present invention
relates to a manual sander.
BACKGROUND OF THE INVENTION
[0002] 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.
[0003] 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.
[0004] 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
[0005] 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
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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.
[0006] 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.
[0007] 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.
[0008] 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.
[0009] 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.
[0010] 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.
[0011] 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.
[0012] 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.
[0013] 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.
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[0014] 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.
[0015] 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.
[0016] 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.
[0017] 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.
[0018] 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.
[0019] 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.
[0020] Furthermore, in accordance with an embodiment of the present invention,
the
handle includes a socket to enable attachment of an extension handle.
[0021] Furthermore, in accordance with an embodiment of the present invention,
the
extension handle includes an eccentric knob.
[0022] 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.
[0023] Furthermore, in accordance with an embodiment of the present invention,
the
hinge includes a groove.
[0024] 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
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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
[0025] 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.
[0026] Fig. lA schematically illustrates a manual sanding device in accordance
with an
embodiment of the present invention.
[0027] Fig. 1B schematically illustrates the manual sanding device shown in
Fig. 1A,
with the sanding surface visible.
[0028] Fig. 2A schematically illustrates the manual sanding device shown in
Fig. 1A
when locked in an open configuration.
[0029] Fig. 2B schematically illustrates the unlocking of the manual sanding
device
shown in Fig. 1A.
[0030] Fig. 2C schematically illustrates the manual sanding device shown in
Fig. 1B
when folded.
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[0031] Fig. 3 schematically illustrates an extension handle for the manual
sanding
device shown in Fig. 1A.
[0032] Fig. 4 schematically illustrates components for assembly into the
manual
sanding device shown in Fig. 1A.
[0033] 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.
[0034] Fig. 5B schematically illustrates a folded configuration of the manual
sander for
smoothing an inside corner.
[0035] Fig. 5C schematically illustrates preparation of the manual sander
shown in Fig.
lA for smoothing an outer corner.
[0036] Fig. 5D schematically illustrates preparation of the manual sander
shown in Fig.
lA for smoothing a convexly curved surface.
DETAILED DESCRIPTION OF THE INVENTION
[0037] 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.
[0038] 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).
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[0039] 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.
[0040] 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 VelcroTm).
[0041] 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.
[0042] 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,
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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.
[0043] 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.
[0044] 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).
[0045] 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).
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[0046] 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.
[0047] 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).
[0048] 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.
[0049] 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).
[0050] 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
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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.
[0051] 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.
[0052] Fig. lA 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.
[0053] 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.
[0054] 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. lA
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).
[0055] 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
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(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.
[0056] 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.
[0057] 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.
[0058] 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.,
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adhesive, welding, soldering, screws, bolts, rivets, or otherwise) to foldable
section 18,
fixed section 16, or both.
[0059] 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.
[0060] 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.
[0061] 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.
[0062] 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.
[0063] 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.
[0064] In some cases, an extension handle may enable manipulation of manual
sander
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
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inaccessible when handheld). An extension handle may be telescoping or
bendable in
order to facilitate access to the work surface.
[0065] 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.
[0066] 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.
[0067] 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.
[0068] 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.
[0069] 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
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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.
[0070] 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.
[0071] 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.
[0072] 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.
[0073] 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.
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[0074] 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).
[0075] 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.
[0076] Fig. 2A schematically illustrates the manual sanding device shown in
Fig. 1A
when locked in an open configuration.
[0077] 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
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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.
[0078] 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.
[0079] 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).
[0080] 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).
[0081] 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
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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.
[0082] In some situations, manual sander 10 may be unlocked from the open
configuration to enable inward folding of one or foldable sections 18.
[0083] Fig. 2B schematically illustrates the unlocking of the manual sanding
device
shown in Fig. 1A.
[0084] 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.
[0085] Further backward lateral rotation of handle 11 may enable free inward
folding of
foldable sections 18.
[0086] Fig. 2C schematically illustrates the manual sanding device shown in
Fig. 1B
when folded.
[0087] 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.
[0088] Retaining foldable section 18b in a fully folded configuration may
facilitate use
of manual sander 10 in a fully folded configuration.
[0089] 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
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section 18a may be engaged by the corresponding handle retaining structure 26
on
handle 11.
[0090] 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).
[0091] 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.
[0092] 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.
[0093] Fig. 3 schematically illustrates an extension handle for the manual
sanding
device shown in Fig. 1A.
[0094] 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
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smoothed, handedness of the user, or otherwise. Thus, eccentric extension
handle 40
may enable ergonomic gripping and manipulation of manual sander 10.
[0095] 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.
[0096] 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.
[0097] 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
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33 having corresponding polygonal cross sections, or other guiding structure)
may be
provided.
[0098] 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.
[0099] Fig. 4 schematically illustrates components for assembly into the
manual
sanding device shown in Fig. 1A.
[00100] 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.
[00101] 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.
[00102] 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
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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.
[00103]
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.
[00104] 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.
[00105] 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.
[00106] 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.
[00107] 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.
[00108] Fig. 5B
schematically illustrates a folded configuration of the manual
sander for smoothing an inside corner.
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[00109] 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.
[00110] 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).
[00111] 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).
[00112] Fig. 5C
schematically illustrates preparation of the manual sander shown
in Fig. lA for smoothing an outer corner.
[00113] 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.
[00114] 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
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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".
[00115] Fig. 5D
schematically illustrates preparation of the manual sander shown
in Fig. lA for smoothing a convexly curved surface.
[00116] 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.
[00117] 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".
[00118]
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
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are intended to cover all such modifications and changes as fall within the
true spirit of
the invention.
[00119] 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.
23
