Sanding tool with molding interface pad

Abstract

A hand-held, manually-operated, sanding tool for use with a replaceable sheet-like abrasive material, such as sandpaper, includes a base member, a molded interface pad provided on the base member to define a working face against which the sheet-like abrasive material is arranged, and a retaining mechanism arranged to maintain the sheet-like abrasive material in operative relation with the interface pad. The base member is formed of a first material and the molded interface pad is formed of a second injection moldable material

1 . A hand-held, manually-operated, sanding tool for use with a replaceable sheet-like abrasive material, comprising: 
 (a) a base member;    (b) a molded interface pad provided on the base member to define a working face against which the sheet-like abrasive material is arranged; and    (c) a retaining mechanism arranged to maintain the sheet-like abrasive material in operative relation with the interface pad;    wherein the base member is formed of a first material and the molded interface pad is formed of a second, injection moldable, material.    
   
   
       2 . A sanding tool as defined in  claim 1 , wherein the first material has a Shore hardness that is greater than the Shore hardness of the second material.  
   
   
       3 . A sanding tool as defined in  claim 2 , wherein the second material has a Shore A hardness of less than about 95.  
   
   
       4 . A sanding tool as defined in  claim 3 , wherein the first material has a Shore D hardness of greater than about 30.  
   
   
       5 . A sanding tool as defined in  claim 1 , wherein the interface pad is a polymeric material.  
   
   
       6 . A sanding tool as defined in  claim 5 , wherein the interface pad is an elastomeric material.  
   
   
       7 . A sanding tool as defined in  claim 6 , wherein the interface pad is formed from at least one of a thermoplastic elastomer, a thermoplastic vulcanizate, and a thermoplastic rubber.  
   
   
       8 . A sanding tool as defined in  claim 1 , wherein the base member is formed of an injection moldable synthetic plastic material and the interface pad is formed of an injection moldable material that is softer than the material used to form the base member.  
   
   
       9 . A sanding tool as defined in  claim 1 , wherein the interface pad includes a textured surface.  
   
   
       10 . A sanding tool as defined in  claim 1 , wherein the interface pad working face includes a macroscopically three-dimensional surface topography.  
   
   
       11 . A sanding tool as defined in  claim 6 , wherein the surface topography comprises a regular non-random pattern defined by raised regions and recessed regions.  
   
   
       12 . A sanding tool as defined in  claim 1 , wherein the base member contains slots, and the interface pad includes extensions extending into the slots, thereby to form a secure connection between the base member and the interface pad.  
   
   
       13 . A method of making the sanding tool of  claim 1 , comprising the steps of: 
 (a) providing a sanding tool including a base member having a working face; and    (b) forming the interface pad on the base member by injection molding an elastomeric material over the working face.    
   
   
       14 . A sanding tool as defined in  claim 1 , wherein the retaining mechanism is configured to releasably retain the sheet-like abrasive material.  
   
   
       15 . A sanding tool as defined in  claim 1 , wherein the retaining mechanism comprises at least one clamping mechanism arranged to secure the sheet-like abrasive material to the sanding tool.  
   
   
       16 . A sanding tool as defined in  claim 1 , wherein the retaining mechanism comprises two clamping mechanisms pivotally connected on opposite ends of the base member to secure the sheet-like abrasive material to the sanding tool.  
   
   
       17 . A sanding tool as defined in  claim 1 , wherein the interface pad is molded to the base member.  
   
   
       18 . A sanding tool as defined in  claim 1 , wherein the sanding tool is user-powered without a motor.  
   
   
       19 . A sanding tool as defined in  claim 1 , characterized by an absence of adhesive between the base member and the interface pad.  
   
   
       20 . A sanding tool as defined in  claim 1 , wherein the interface pad is directly affixed to the base member.