Abrasive flap wheel with custom profiles

Abstract

A flap sander is disclosed for use with a workpiece having a nonlinear profile. The flap sander comprises a cylindrical rotary head including a central hub concentric with an axis of rotation of the rotary head, and an inclined surface extending radially outward from the central hub. A plurality of abrasive flaps are detachably secured to the inclined surface of the rotary head and are aligned in a radial array radiating outward from central hub to the periphery of the rotary head. Each of the abrasive flaps comprises an unsecured working edge having a nonlinear profile that substantially matches the profile of the workpiece to provide an even sanding distribution across the workpiece profile independent of the shape of the profile.

1 . A sanding apparatus for use with a workpiece to be finished, said workpiece having a substantially nonlinear profile, comprising:
 a rotary head;   a plurality of abrasive flaps secured to the rotary head;   wherein the plurality of abrasive flaps are aligned in a radial array radiating outward from an axis of rotation of the rotary head;   wherein each of the plurality of abrasive flaps comprises an unsecured working edge;   wherein the working edge comprises a nonlinear profile that substantially matches the profile of the workpiece.   
     
     
         2 . An apparatus as recited in  claim 1 , further comprising:
 a plurality of support members secured to the rotary head;   wherein each support member is positioned radially adjacent and parallel to a corresponding abrasive flap;   wherein each support member comprises an unsecured end substantially matching the working end of the abrasive flap.   
     
     
         3 . An apparatus as recited in  claim 1 , wherein the working edge of the flap is uninterrupted across the length of the flap. 
     
     
         4 . An apparatus as recited in  claim 3 , wherein the working edge of the flap is configured to evenly distribute pressure across the length of the workpiece profile. 
     
     
         5 . An apparatus as recited in  claim 1 , wherein the abrasive flaps are releasably mounted to the rotary head. 
     
     
         6 . An apparatus as recited in  claim 5 , wherein each abrasive flap slideably engages a radial slot in the rotary head. 
     
     
         7 . An apparatus as recited in  claim 1 , wherein:
 the working edge profile comprises a first segment having a first path and a second segment having a second path; and   wherein the path of the first segment is different from the path of the second segment.   
     
     
         8 . An apparatus as recited in  claim 7 , wherein one or more of the first and second paths is curvilinear. 
     
     
         9 . An apparatus as recited in  claim 7 , wherein the path of the first segment has a different slope from the path of the second segment. 
     
     
         10 . An apparatus as recited in  claim 7 , wherein the paths of the first and second segments correspond to features of the workpiece profile. 
     
     
         11 . A flap sander for use with a workpiece to be finished, said workpiece having a substantially nonlinear profile, comprising:
 a cylindrical rotary head;   the rotary head comprising a central hub concentric with an axis of rotation of the rotary head, and an inclined surface extending radially outward from the central hub.   a plurality of abrasive flaps secured to the inclined surface of the rotary head;   wherein the plurality of abrasive flaps are aligned in a radial array radiating outward from central hub to the periphery of the rotary head;   wherein each of the plurality of abrasive flaps comprises an unsecured working edge;   wherein the working edge comprises a nonlinear profile that substantially matches the profile of the workpiece.   
     
     
         12 . A flap sander as recited in  claim 11 , further comprising:
 a plurality of support members secured to the rotary head;   wherein each support member is positioned radially adjacent and parallel to a corresponding abrasive flap;   wherein each support member comprises an unsecured end substantially matching the working end of the abrasive flap.   
     
     
         13 . A flap sander as recited in  claim 11 , wherein the working edge of the flap is uninterrupted across the length of the flap. 
     
     
         14 . A flap sander as recited in  claim 13 , wherein the working edge of the flap is configured to evenly distribute pressure across the length of the workpiece profile. 
     
     
         15 . A flap sander as recited in  claim 11 , wherein the abrasive flaps are releasably mounted to the rotary head. 
     
     
         16 . A flap sander as recited in  claim 15 , wherein each abrasive flap slideably engages a radial aligned slot in the rotary head. 
     
     
         17 . A flap sander as recited in  claim 11 , wherein:
 the working edge profile comprises a first segment having a first path and a second segment having a second path; and   wherein the path of the first segment is different from the path of the second segment.   
     
     
         18 . A flap sander as recited in  claim 17 , wherein one or more of the first and second paths is curvilinear. 
     
     
         19 . A flap sander as recited in  claim 17 , wherein the path of the first segment has a different slope from the path of the second segment. 
     
     
         20 . A flap sander as recited in  claim 17 , wherein the paths of the first and second segments correspond to features of the workpiece profile. 
     
     
         21 . A flap sander as recited in  claim 17 :
 wherein the inclined surface forms a conical surface radiating outward from the central hub; and   wherein the hub extends in a cylinder a specified length beyond the conical surface.   
     
     
         22 . A method of sanding a workpiece, comprising:
 providing a rotary head having a plurality of abrasive flaps;   wherein each of the plurality of abrasive flaps comprises an unsecured working edge;   wherein the working edge comprises a nonlinear profile that substantially matches the profile of the workpiece;   positioning a rotary head adjacent the workpiece such that at least one of the abrasive flaps substantially lines up with the workpiece profile; and   rotating the rotary head to sand the profile with substantially even pressure across the profile.   
     
     
         23 . A method as recited in  claim 22 :
 wherein the plurality of abrasive flaps are aligned in a radial array radiating outward from an axis of rotation of the rotary head;   wherein a plurality of support members secured to the rotary head;   wherein each support member is positioned radially adjacent and parallel to a corresponding abrasive flap;   wherein each support member comprises an unsecured end substantially matching the working end of the abrasive flap to support the abrasive flap as the flap is applied to the workpiece.   
     
     
         24 . A method as recited in  claim 23 , wherein the unsecured end of the abrasive flap curves over the support member when applied to the workpiece to form a curvilinear sanding work surface in contact with the workpiece.