Patent Grant
9616456
The present invention pertains to methods and various apparatus for building and/or construction tools. For example, the invention involves various apparatus and methods for building tools for finishing various building surfaces which provide improved retention, function & durability.
Various tools have been known in the past for working with cements, concretes, mastics and/or muds to, for example, prepare, apply and finish a desired shape or smooth surface for various building surfaces. For example, some tools used for preparing the surface of, for example, concrete, include trowels. Another example are various tools used to prepare and finish, for example, mastics and mud for drywall, including, flat boxes, corner finishing boxes, corner finishing tools, and automatic taper (taping) machines. Some examples of various previously known corner finishing tools may be found in U.S. Pat. Nos. 2,824,443; 5,419,693; 5,423,666; 5,622,729; 6,155,809; and 7,114,869: among others. In any case, regardless of type, these tools are often hand tools that are used to apply substances to and/or smooth various building surfaces, such as walls, ceilings and floors, and often result in skilled craftsman working on a number of surfaces for long periods of time during the work day. As such, the weight of the tool, ease of use, and quality of quick results may contribute to its appeal to the skilled craftsman.
For many of these tools, one aspect of improving their usefulness during the working day includes a quick yet high integrity attachment, retaining, and releasing system, so that the tool can be utilized both with injected mud as an applying tool, and without injected mud, as a spreading tool. Similarly, a corner finishing tool may be used with, or without, a corner finisher applicator box. Proper functioning of the tool includes how it glides along the surfaces, for example, a corner joint of drywall. The mechanical durability is also an important aspect of various designs for such tools. One particular example of an attachment system, is the ball style attachment, retention, and releasing system for a corner finisher applicator and finishing tool 100, that is illustrated in
Referring to
Referring now to
However, these prior art embodiments have problems associated with high cost to produce and/or sharp edges which have been known to cut into the geometry of the ball end (e.g., 115 and 215) thereby shortening the life of the tools. In addition, all these prior art attachment, retaining, and releasing systems require additional effort by the user to actuate, for both attachment and release of the finishing tool to the applicator box or handle.
In another aspect of the prior art, these corner finisher tools operate in a manner such that the tools are moved along a corner of a room under construction while applying and or spreading “mud” or “mastic” materials intended to fill gaps and/or smooth the surface finish. The finished surface of the “mud” or “mastic” is made smooth by the wiping action of the “blades” in the finishing tool. One example of prior art for these corner finisher tool blades can be seen in
Generally, there are two types of blades in the known corner finisher tools. The main or working blades 420A and 420B are primarily responsible for leaving a nice finish in the mud as it flows out of the central region of the tool 405A and 405B and under the working blades 420A and 420B. These blades have an angled surface at one end 425A and 425B allowing the 2 blades to come together to form a point which relates to and defines the inner most geometry of the ‘corner’ of the wall and/or wall to ceiling interface. A second set of blades, running or width control blades 440A and 440B, are mounted in the tool frame 410A and 410B at right angles to the working blades 420A and 420B. These running or width control blades 440A and 440B control the width of the applied mud and glide along the wall and/or ceiling surface during use, ideally allowing little to no mud to pass under them. These blades are typically shorter than the working blades and have both ends squared off at 90 degree angles from their longitudinal sides (not pointed). Corner finisher tool sizes typically vary from 2″ to 4″ wide. For these size tools the running or width control blades are typically 2.5″ long, regardless of the tool size. The larger tools allow for a greater width of mud in each corner making blending of corner imperfections easier. However, motion of the tool along the corner can become less smooth especially as tool size increases, partially due to the shorter length of the running or width control blades relative to the working blades 420A and 420B. Some prior art corner finisher tools have included the added complexity of wheels in various locations to improve the tools motion along the corner. However, these wheals and related parts are know to increase the problems with tool cleaning, get stuck during operation, and wear out quickly in the abrasive “mud” or ‘mastic” environment.
The present invention is directed generally to tools that may, for example, be reduced in cost to manufacture and use, lightweight, high quality, corrosion resistant, durable, strong, easy to assemble and disassembly, and easy to clean. Various embodiments of the present invention may include various building tools that may be used, for example, to apply and/or smooth mastic or mud in the construction industry. For example, various embodiments may include a mastic applicator including a container or housing and/or a corner finishing tool. The mastic applicator and/or corner finishing tool may be made from multiple pieces or sections, wherein each piece or section may be made of, for example, metal, plastic, etc., and may be used for applying and/or smoothing mastic or mud to, for example, drywall board on walls and ceilings of buildings. The corner finishing tool may be attached to, for example, a cone and ball portion of the mastic applicator and/or a ball at the end of a handle so as to apply and/or smooth mastic or mud to a corner of a working surface to fill and smooth wall(s) and/or ceiling corner junction.
In various embodiments of the invention, the finishing tool may coupled to either a handle or applicator box using a ball and socket construction. This configuration allows for relatively free rotation in all directions in order for the tool to align itself against the corner forming walls regardless of the orientation of the handle. The coupling ball may also be either solid for use on a handle to remove excess mud from a corner, or hollow to allow mud to flow from an applicator box to the corner surfaces when it is desired to apply mud to the corner. A critical aspect of this is the way in which the ball coupling is locked to the tool so that it is securely attached while also being free to rotate through the desired range of motion. The corner finishing tool of the present invention may include a quick connect/disconnect system that may open and remain open for reloading in a single movement of a tab and/or pin release and hold.
During use of Corner finishing tools there is often need to use the tool on a handle to remove excess material from a corner after “mud” and tape have been applied, and to use it in conjunction with a mastic or mud applicator box. The mastic applicator box may include a multi-piece cone and ball output port. As a result of varying ceiling heights, there is often a need to use different length handles. Corner finishing tools can be expensive precision tools which results in the user often having only one corner finishing tool available. This results in the finishing tool being removed and reattached to various handle configurations during the course of completing one job. Therefore it is advantageous for the tool to be quickly and easily removed and quickly and easily re-attached to the different handles with a minimum of effort and movements, while being durable and effective at retaining coupling to each handle in a reliable way with no loss of function over extended usage of the product. The present invention may achieve this and other objectives in a cost effective and reliable way that requires little or minimal effort by the user. Various embodiments may include a single manual stroke design that may include a hinged latching mechanism and/or an opening, holding, and locking pin configuration for attaching and releasing a coupling or connecting ball.
In various embodiments, the corner finishing tool may include a quick connect/disconnect arrangement that may include a socket portion and a locking portion that can quickly and reliably allow for the removal and connection of the corner finishing tool to a mastic applicator and/or a handle having a ball connection end (i.e., a quick disconnect ball and socket arrangement). In various embodiments, the finishing tool quick connect/disconnect system or ball attachment system may be a pivoting or hinged door that automatically pivots and latches upon insertion of a coupling ball found on, for example, a applicator box or a handle. In various embodiments the finishing tool may include a finishing tool quick connect/disconnect system or ball attachment system that opens and remains open when a connection or coupling ball is removed in response to a single motion of an activation tab or pin, until pressure is applied by, for example, the same or another coupling or connecting ball being inserted, or pressure applied by a user. In various embodiments, the invention may include a connecting ball made of a two-piece cone output port coupled to an applicator box.
In various embodiments the finishing tool may include a finishing tool quick connect/disconnect system or ball attachment system that may open and close to release and/or hold a coupling or connection ball for a mastic applicator box and/or handle with a coupling or connecting ball. In various embodiments, the finishing tool may include a ball and socket construction that may include a door or ball retention member that may be in the shape of a “C” or “U” that may be attached to a center piece or post that connects to the finishing tool body so as to open outwardly and close inwardly. The connection may be achieved using, for example, a hinged configuration, and the hinged configuration may be achieved using a separate or integral pins that may be affixed to the center piece or post. Another end of the quick connect/disconnect system or ball attachment system hinge pins may be coupled to the body of the finishing tool. The quick connect/disconnect system or ball attachment system may be constructed to remain open when a connection or coupling ball is removed, so as to be in a position to quickly receive another connection or coupling ball. This may be achieved by including a spring loaded slide and pin arrangement, a ridge and spring tension ball arrangement, or a number of other mechanizations that allow the “C” or “U” shaped ball retention member to lock firmly in a closed position and release with user motion when desired to be opened to release a coupling or connection ball when desired. The mechanism may include a gripping or release tab and slide that may be spring loaded to allow it to release the “C” or “U” shaped ball retention member and/or lock the “C” or “U” shaped ball retention member in the closed and/or open position. The quick connect/disconnect system or ball attachment system may include an automatic close or couple mechanism that may be activated by inserting a connection or coupling ball into the socket portion of the corner finishing tool. The automatic close or couple mechanism may be a center post that may be contacted by the connection or coupling ball. The automatic close or couple mechanism may be formed in the shape of the socket, for example curved in a concaved arc that may mate closely to the shape of the connection or coupling ball. The quick connect/disconnect system or ball attachment system may open in response to a single motion of, for example, an activation tab or pin, until pressure is applied to the automatic close or couple mechanism by, for example, the same or another coupling or connecting ball being inserted, or pressure is applied by a user.
Various embodiments of the corner finishing tool of the present invention may have unique blade(s) and frame(s) designs. Various embodiments may also include using a ‘square’ geometry for all size tools and/or a reversible blade. In various embodiments, a blade and frame may be designed so that the blades may be reversible and/or interchangeable between a working blade and a running blade. In various embodiments, a working blade and a running blade geometrical shape and size may be made the same so that they may be used interchangeably and/or so as to provide a back-up blade for one another in case of wear or damage. The blades may have opposite elongated sides that are of different geometries, one elongated side may be shaped for use as a working blade and the other may be shaped as a running blade. As such, the same blade may be used as either a working blade or as a running blade. In various embodiments, the frame of the corner finishing tool may be made approximately equal in its length along the direction of motion and the direction of frame reach, or tool size, in all sizes of corner finishing tools including the larger size corner finishing tools (e.g., 3″×3″ tool, 3.5″×3.5″, and larger). With this geometry the larger tools may have a greater width along the direction of motion and improve the smooth movement along a working surface. Also, having approximately equal length on each of the working blade and running blade frame sides may enable the blades to be the same length for all sizes of the corner finishing tools. As a result of this unique frame & blade construction, the user always has the benefit of spare blades found directly on the tool in case one or more should be damaged in use. In doing so, the user may reverse the blades and expose new surfaces which were previously protected inside the frame channels. Further since all four blades on the corner finishing tool may be identical in shape and size, the blades can be switched form side to side as well, resulting in many combinations of defective surfaces being accommodated such that the tool can be set up as ‘new’ by, for example, placing the damaged surfaces inside the frame channels leaving undamaged surfaces available for proper tool function. In various embodiments, frame grooves may be cut in a novel geometry and/or the blades main surfaces may not be parallel. The frame groves may be cut so that the location where the running blades meet the working blades, a grove for the running blades is slightly deeper than that of the working blade so the edge of the running blade is slightly lower than and edge of the working blade. In this way the blades can be easily and correctly removed and replaced in the field.
Details on blade force system: multiple springs with different geometries and tension adjustment arms In various embodiments, the invention may include a blade force system that may include a plurality of tension springs. The tension springs may adjustably apply tension to a corner finishing tool frame and/or blade(s) so as to apply a desired amount of force of the blade(s) to a working surface (e.g., a wall or ceiling) so as to form a desired pattern, shape, or smoothness of, for example, wall and/or ceiling corner that is, for example, 90 degree interface of two working surfaces. The adjustable blade tension system may include one or more blade tension adjustment lever(s) or handle(s). There may be, for example, two springs for each side of the corner finishing tool frame associated with one set of working and running blades (i.e., four springs in total, two springs on each half frame). The two tension springs on one side or half of the frame may be made with different geometries from one another so as to enable one of the lever(s) or handle(s) to fit there between and slide so as to lift one of the two tensions springs off of the frame in a disengaged manner. In this way, the spring system tension may be adjust so that either one or two total spring forces may be applied to the frame and/or blades. The levers or handles may operate independently so that the spring tension on one half of the frame or blades may be different than the spring tension applied to another half of the frame or blades.
In various embodiments of the invention, a novel face plate construction may be employed at, for example, a top interface of the frame and/or working blade retention channels or grooves. The face plate structure may utilizes, for example, a two piece construction including the face plate and a bracket. The face plate may cover, for example, the front of the frame up to and abutting the front face of the blades. The face plate may have a lip or protrusion that wraps aroung the top corner or vertex of the frames where a left and right side frames interface (i.e., the outside 90 degree corner of the corner finishing tool). The face plate may be retained by a bracket, which may be fastened by a screw to the corner finishing tool body. This construction may provide improved tool cleaning capability and fills the gap that occurs between the blades (152) and the frames (151) at the corner or vertex of the tool
In various embodiments, the invention may include a connecting ball made of a two-piece cone output port coupled to an applicator box. Each piece of the two-piece cone output port may be made from different materials, one may be of lighter weight than the other. One piece of the two piece output port may be made cylindrical while the other may be an oblong shape or off-center cone shape. The two piece output port cone and connecting ball arrangement may be manufactured using, for example, and insert molding process. The connecting ball portion may include geometries to improve the coupling between the two pieces of the output port.
As will be seen in the figures and the detailed description of the present specification, the above discussion touches on some, but not all of the inventive aspects of the present invention. Thus, this Summary is not intended and does not limit the scope of the present invention, but is only meant to give the reader an overall idea of the invention with enough detail to understand the main aspects (but not all aspects) of the present invention. The reader is invited to read the following and review the figures so as to understand some of the exemplary embodiments of the present invention inn more detail.
Some of the objects, features and advantages of the present invention will become more readily apparent to those skilled in the art upon reading the following detailed description, in conjunction with the appended drawings, in which:
The present invention is directed generally to tools that may be, for example, reduced in cost to manufacture and use, lightweight, high quality, corrosion resistant, durable, strong, easy to assemble and disassembly, and easy to clean. Various embodiments of the present invention may include various tools that may be used in the building and/or construction industry. For example, various embodiments may include tools used for applying mastic or mud to a working surface, such as drywall wall and/or ceiling construction. The various embodiments of the present invention may include, for example, a mastic applicator including a container or housing and/or a corner finishing tool. The mastic applicator and/or corner finishing tool may be made from multiple parts, pieces or sections, wherein each part, piece or section may be made of, for example, metal, plastic, etc., and may be used for applying and/or smoothing mastic or mud to, for example, drywall board on walls and ceilings of buildings. The corner finishing tool may be attached to, for example, a cone and ball portion of the mastic applicator and/or a ball at the end of a handle so as to apply and/or smooth mastic or mud to a corner of a working surface to fill and smooth wall(s) and/or ceiling corner junction.
During use of a corner finishing tool, there is often need to use the tool on a handle to remove excess material from a corner after “mud” and tape have been applied, and to use the corner finishing tool in conjunction with a mud or mastic applicator box. In addition with varying ceiling heights, there is often a need to use different length handles. As such, the user (e.g., a construction worker) may either have multiple corner finishing tools attached in a dedicated manner to a variety of handles and/or mud applicator mechanisms (e.g., applicator box, mud or mastic feed handles, etc.), or one or few corner finishing tools that are interchanged as needed with various types of handles and/or mud applicator mechanisms. However, corner finishing tools are typically expensive precision tools which results in the user often having only one tool available. This results in tools being removed and reattached to various handle configurations during the course of completing one job. Therefore the present invention is advantageous designed so that a corner finishing tool may be easily removed and re-attached to the different handles and to be retained to each handle in a reliable way with no loss of function over extended usage of the product that may result from wear and tear by interchanging or use of a corner finishing tool over time. Furthermore, the present invention may include an attachment mechanism that may be quickly and reliably opened and closed to attach and release from a handle and/or applicator box using, for example, a connecting ball and socket arrangement.
In various embodiments of the invention, the finishing tool may be coupled to either a handle or applicator box using a swivel mechanization that allows the corner finishing tool to pivot freely in, for example, approximately a 30 to 180 degree radius about a mounting point with, for example, a handle and/or applicator box. One such swivel mechanization may be, for example, a ball and socket construction configuration. This ball and socket configuration may allow for relatively free rotation in all directions about a point (e.g., a circular swivel) in order for the tool to align itself against the corner forming walls regardless of the orientation of the handle and/or mud applicator box. The coupling ball may also be, for example, solid for use on a handle to remove excess mud from a corner, or hollow to allow mud to flow from an applicator box to the corner surfaces when it is desired to apply mud to the corner. One aspect of this design is the way in which the ball coupling is locked to the tool, an attachment and release system, so that it is securely attached while also being free to rotate about a point through the desired range of motion and a quick and easy means of releasing the corner finishing tool.
In various embodiments, the present invention may include a mud or mastic applicator box including a bi-material output port. One exemplary bi-material output port may be in the shape of an offset cone that may include an offset portion of one material and a conical shape of another material, as illustrated in co-pending U.S. provisional patent application Ser. No. 61/094,053 Titled Apparatus and Methods for Building or Drywall Tools filed on Sep. 3, 2008, hereby incorporated herein by reference in its entirety for all purposes. Mud or mastic being pushed out of a housing (e.g., and applicator box) may be transferred through a cone shaped feature, which may be at least partially a conical shape, to cause the material to flow out of a small opening. In various embodiments the cone may be designed so as to transfer the mud or mastic to the building surface without unduly raising the pressure required to move the mud out of the housing.
The cone shaped feature of the tool may include a nipple or ball shaped connection that the mud or mastic then flows through and that connects into a tool specifically design to distribute mud on the wall surface, for example, a corner finishing tool. The cone, which may be at least partially a conical shaped structure, may be instrumental in providing a channel from the mud storage tool housing or container to the mud applying tool, e.g., a corner finisher tool. In various embodiments of the invention the cone shaped or at least partially conical shaped, structure may be produced from two parts rather than one single part. The ball end or connection structure of the cone or at least partially conical shaped structure may be produced from, for example, a metal such as stainless steel, for its strength, wear and corrosion resistance. The ball end or connection structure may be combined with or molded with a cone or conical shaped wall structure using a material which may be light weight, low cost, strong and corrosion resistant, for example a plastic material. For example, the ball end or connection structure may be insert molded with a plastic type material so as to form a bi-material structure. The plastic material may be a rigid petroleum based or synthetic based material that has the desired structural and formability characteristics. The plastic material may include fiber. The output port of the cone may be offset from center, for example, may be shifted more closely to the front wall of the container or housing. The side walls of the resulting bi-material cone shaped or at least partially conical shaped structure may have a single angle pitch from a flange end to the ball end, or may include a plurality of angles on one or more sides as desired. The plurality of angles may improve manufacturability of the at least two piece structure, may improve the pivoting aspects of a corner finisher tool on the cone, and may help place the cone and ultimately the corner finisher tool attached thereto, closer to the front wall of the container or housing upon which the cone may be mounted. Further, the walls may be made thicker in the plastic portion than the metal portion, if desired, to provide better adhesion to one another and better strength. The resulting bi-material cone shaped or at least partially conical shaped structure including a nipple, formed of two different materials, may then be mounted to existing tools the same way traditional cones have been mounted or in alternative ways that may be more cost effective to manufacture and assemble. However, the new part may now be designed to meet the varying needs of each region of the part by utilizing the best material for that area. The lighter weight material section structure, for example plastic, may be molded over and/or through portions of the ball end section to ensure that the overall cone shaped or at least partially conical shaped structure including the ball end never separates under the stresses found on the job site for tools of this nature. In various embodiments, the stainless steel and plastic materials may be made of various different combinations of materials, for example, Stainless steel with aluminum, plastic with aluminum, plastic with zinc, etc., as long as the materials for each section meet the desired characteristics and may be manufactured.
Referring now to
The interior cornered side-wall plate(s) section may be formed to be at an angle that may be slightly less than approximately a right or 90 degree angle. In any case, the inside wall section or inter-face of sides 515A and 515B may be made to be a generally flat surface with movement limitation or retention tabs, e.g., 530A, 530B, 530C and 530D, that will stop the frame sections 505A, 505B, 510A and 510B, and their related working and running blades from moving beyond these tabs in the rearward direction and separating from the inside wall section. On the other hand, the outer face side of sides 515A and 515B may be formed to include cavities, valleys, or concave sections (not shown) that may help distribute and/or accumulate mud or mastic to be applied to or smoothed on a working surface (e.g., wall or ceiling). Further, the frame sections 505A and 505B may also include one or more movement limitation or retention tabs 535A and 535B, respectively, that may be connected to the frame sections using conventional connecting means (e.g., welding, screws, etc.) and act as a stop for the forward movement of the frame sections 505A and 505B relative to the interior cornered side-wall plate(s) section. As such, the movement of the frame sections and related blades is limited by the tabs or ears 530A, 530B, 530C, 530D, 535A and 535B, on the interior cornered side-wall plate(s) and frame(s), and can thus only move a short distance in either the forward or backward directions from the face of the slightly less than approximately 90 degree interior cornered side-wall plate(s) structure. The actual relative location and movement of the frame sections 505A, 505B, 510A and 510B (with working and running blades), may be controlled by the spring tension system that will be described in more detail below.
Various embodiments of the present invention may include a corner finishing tool handle and/or application box coupling system. For example, a ball and socket system female portion bracket 550 may be formed as an integral socket 555A and top lip 555B, as shown in this embodiment. The female portion bracket 555 may be coupled or connected to the interior side wall section. The socket 555A may be provided as a seat for a ball to be received in the female portion bracket 550. The top lip 555B may be formed integral with the female portion bracket 550, and may provide a means for gripping or retaining the ball to be received. The handle and/or application box coupling system may also include a hinged U or C shaped door 560 that may cooperate with top lip 555B. The door 560 may include a right side arm 560A with lip, a left side arm 560B with lip, and a rear arm or post 560C. The right side arm 560A with lip and left side arm 560B with lip may cooperate with top lip 555B to form an oval or circular structure that is smaller than at least the largest diameter of a ball end (of, for example, a handle or mud application box cone) so as to surround and retain the ball into the socket 555A. The rear arm or post 560C may form a portion of a hemispherical surface of the socket 555A when the door 560 is closed so as to retain a ball end, and may operate to automatically activate closure and/or locking of the door 560 when receiving a ball end. The door may include a locking hole 565. The handle and/or application box coupling system may also include a lock and release pin (not shown) and a lock and release pin handle or tab 570 that may be spring loaded such that when the door 560 is closed the pin may be force into the hole 565 via spring force (using a tensioning spring) and when the door is open the spring asserts pressure on the pin so as to hold the door 560 in an open position. To release the door (and thereby release a ball retained therein), a user may push down on handle or tab 570 (in the direction of the arrow) so as to remove the pin from hole 565 in door 560. The pin may then latch the door in the open position via the force applied to the pin by a tension spring (not shown). The door 560 may be closed and locked automatically by inserting a ball against the post 560C and into the socket area 555A, thereby releasing the pin an spring to insert itself into the hole 565 in the door 560. As such, the present invention provides a quick and easy ball and socket locking and release system. This function and operation will be described further below.
Further, various embodiments of the present invention may include a corner finishing tool spring tension system. The spring tension system may include one or more springs, e.g., springs 585A, 585B, 590A and 590B, associated with each side of the corner finishing tool frame for allowing the blades of the corner finishing tool to vary in their angular relationship to one another and a working surface(s). The springs 585A, 585B, 590A and 590B may be a leaf type spring structure and may be of varying geometry or bending relative to one another. For example, a first set of springs closest to and interfacing with the frame portions, e.g., springs 590A and 590B, may be formed so as to have a side profile that is relatively flat along it lateral length except for a very end that interfaces with a surface of the frame 510A and 510B. A second set of springs closest to and interfacing with the frame portions, e.g., springs 585A and 585B, may be formed so as to have a side profile that is bent or bowed outwardly along it lateral length and bent where it interfaces with a surface of the frame 510A and 510B or the other set of springs. As a result of the bend or outwardly bow, springs 585A and 585B may allow handles, wipers, or tension adjustment arms 580A and 580B to be moved under springs 585A and 585B so as to lift them up and disengage them so they may not apply spring tension to the frames 510A and 510B. In this way, the spring tension system is adjustable to apply more or less tension to one or both of frames 510A and 510B. Handles, wipers, or tension adjustment arms 580A and 580B may be coupled to the inter wall member via a screw 510A and MOB, respectively, so as to pivot thereabout. A pivot stop 582A and 582B, respectively, may also be provided so that the handle, wipers, or tension adjustment arms may not be moved outward beyond the end of springs 585A and 585B by the user during spring tension adjustment.
Referring now to
As illustrated, a first left side of a frame system may be coupled to surround the left side wall 605A, and may include a working blade side 620A, a running blade side 625A, and a lower frame side 630A (blades not shown). The frame system may also include a second right side that may be coupled to surround the right side wall 605B, and may include a working blade frame side 620B, a running blade frame side 625B, and a lower frame side 630B. Working blade frame side 620B may have a working blade 635A coupled therein, and may be retained therein using, for example, set screws 637A and 637B. Running blade frame side 625B may have a running blade 635B coupled therein, and may be retained therein using, for example, set screws 637C and 637D. A running blade height adjustment set screws 637E and 637F may also be provided in the running blade frame side 625B. It is noteworthy that the working blade 635A and running blade 635B may be face outward on the frame system and be of an approximately same or similar size and shape so as to be interchangeable with each other and the left side frame related blades, and that they may be inserted in the frame system with opposite sides inserted into, for example, a channel formed in the frame system and an angled end placed in opposite directions away from one another with right angle ends oriented in the frame so as to be adjacent one another. Similar blade arrangements, attachments, and adjustment mechanization may be arranged on the outside of the left side frame system. The frame system may be coupled to the interior wall section using, for example an interlocking tab arrangement (described with respect to
The corner finishing tool 600 may also include a handle and/or application box coupling system that may include a base section 675 having, for example, a hemispherical well or socket area, a coupling lip, and a mounting area for coupling a U shaped or C-shaped (not shown) ball locking and releasing door 677. A cover 670 may be provided for attaching the U shaped or C-shaped (not shown) ball locking and releasing door 677 by locking ends of two hinge pins on the door between the cover 670 and the base section 675. A locking and release pin 660 may be included and placed along with a spring 665 into a hole or channel formed in the lower end of the base section 675. One end of the pin 660 may interface with the door 677 to lock, release and/or hold open the door 677 during the introduction or removal of, for example, a ball, into the socket area of the base 675. The cover may also retain the pin 660 in the case a channel is formed in the base 675. In any case, a handle or tab 667 may be attached to an opposite end of the pin 660. As such, a user may open or release the door 677 by moving the handle or tab 667 downward against the force applied by spring 665 until the door 667 opens, and when the user lets go of the handle or tab 667 the spring 665 force may push the other end of pin 660 into an ear or indent on the door 677, so as to hold the door in an open position. Insertion of a ball end into the socket and door 677 may automatically close the door and allow the pin 660 to enter a hole in the base of the door 677, thereby automatically locking the door in a closed position.
Referring now to
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Referring now to
The ball coupling end of the handle or applicator box may rest in the hemispherical surface 820 of the ball joint 825A and 825B. This surface may interact with approximately ½ of the ball coupling. In various embodiments, the upper half of the ball coupling may only be partially engaged. This partial engagement may be accomplished by the door 830. The door 830 may cover over just enough of the ball end (not shown in this figure) to lock in or retain it into the ball joint 820, 825A and 825B. The door 830 may operates on a hinge and spring loaded arrangement. In order to lock the hinged door from operation and thereby retain a coupling ball, the door may be locked in place by, for example, a locking pin, post, or shaft 840. The locking pin, post, or shaft 840 may be biased into the door by, for example, a compression spring 850. In order to remove the locking pin, post, or shaft 840, thereby allowing the door to rotate open and release or receive a coupling ball, the user may pull the lock pin tab or handle 845 against the force of the compression spring 850.
Referring now to
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Referring now back to
As discussed above, various embodiments of the present invention may be designed to apply the mastic or mud to a building surface, such as wall or ceiling corners, in an efficient and effective manner that results in a desired pattern of mastic or mud on the wall so as to finish a corner where two sheets of wall board or drywall material meet. A desired pattern may include one or more layers of mastic or mud that when dry appears to be smooth, flat, and fill in, for example, a corner and preferably needs a minimal amount of work (e.g., sanding or further mastic or mud coating) to be considered complete. To obtain such performance, the frame and blade system for mastic or mud shaping and distribution along with the frame and blade spring tension system may be designed for interchangeability, adjustability, and performance.
Referring now to
The top view shown in
Referring now to
Referring now to
The abrasive aspects of the “mud”, the presence of screws or nails which may not be properly set in the wall surface, or dropping the tool may all adversely affect the blade 1500 and may cause it to be nicked, chipped, scratched, or broken. A blade 1500 with any of these defects will result in a corner finishing tool that will perform poorly and leave an uneven surface behind requiring further work by the builders (e.g., more filling and/or sanding). Further the tendency of the corner finishing tools, especially the larger dimension corner finishing tools, to move in a non-smooth manner along the wall can have similar results and cause additional work to even the corner surfaces. The non-smooth movement is typically caused by the width along the direction of motion (i.e., the running blade length) to be generally less than the length that the frames reach to (i.e., the working blade length), commonly known as the size of the tool. The equal dimensions of various embodiments of the corner finishing tool according to the present invention may help to solve these problems by using a ‘square’ geometry for all size corner finishing tools and a reversible blade that may be used as either/or a working blade or a running blade. As such, in various embodiment(s), the frame of the corner finishing tool may be roughly equal in its length along the direction of motion (height) and the direction of frame reach (width), or corner finishing tool size. For example, corner finishing tools of width sizes such as 9-10 cm may have a length of approximately 9-10 cm, and the same blade may be used for either a working blade and/or a running blade.
Referring now to
Referring now to
As a result of this unique approximately equal leg length frame and reversible universal blade construction, the user may have the benefit of spare blades found directly on the tool in case one or more working edges of the blade(s) should be damaged by chipping, nicking, denting, etc., during use. For example, if a working blade elongated side of a blade (e.g., 1715A or 1715B) hits a raised screw and chips when used in one of the working frame sides 1730A or 1730B, that blade (e.g., 1715A or 1715B) may be removed from the working blade frame side, turned over and reversed in orientation, and switched with one of the blades (e.g., 1710A or 1710B) in a running blade frame side 1725A or 1725B. In doing so, the user will flip over and reverse the blades so as to expose the opposite surface (preferably new and not previously used surfaces) which were previously inside and protected by one of the frame grooves or channels. The previously used and/or chipped surface may now likewise be hidden inside one of the frame channels where it does not affect tool performance and the resulting smoothness of a working surface (e.g., drywall corner surface smoothed with mastic or mud). Further since all four blades on every tool may now be identical in shape, the blades may be switched form side to side as well, resulting in many combinations of defective surfaces being accommodated such that the corner finishing tool may be set up as ‘new’ or almost as good as new, by placing imperfect or damaged surfaces inside the frame channels, leaving perfect or undamaged blade surfaces available for proper tool function or swapping blades from side to side so that a primary edge to interface the working surface is more close to being perfect or with fewer or no imperfection(s).
Another unique feature of the present invention is the design of the grooves or channels for the blades that are formed in the frames. In various embodiments of the present invention the grooves or channels in the frames for holding the blade may be formed so that the blades main surfaces may not be parallel to the frame, resulting in one or more blades being at a slight angle relative to the normal outer surface of the blades and thereby the working surface of, for example, a wall, ceiling, or floor.
Traditional corner finishing tools in this category require relatively high precision for the orientation of the blades in the frames in order to have the tool function properly. This is currently accomplished through the use of set screws projecting through the frames in both the working and running portions. Typical setup of the tool requires a trained technician and precision fixturing. The tool is set into a corner replicating fixture with the blades held loosely in the frame grooves. The blades are then biased such that they meet at the tool vertex and the running blades are biased such that they abut the working blade leaving no gap for mud to flow through where they blades meet at the outer corners of the tool. The set screws located at the top surface of the frames are then screwed into the frames until the blades are biased against the fixturing surface. The fixture surface sets both the height of the blades, their angle in the channels, and the relative height where they but against each other. Each of these geometry characteristics is important for proper tool function. Once positioned, a second set of set screws projecting through the side of the frame are tightened which locks the blade in place. The net result is that the blades are supported on set screws which have been set to a relatively precision depth and are then locked in place by a second set of retaining set screws. This setup is typically done at the factory or by trained technicians at specified repair locations.
On the other hand, the present invention significantly reduces the complexity of setting up the blades in the corner finishing tools with proper blade geometry and height, through the novel use of simple geometry. Referring now to
In any case, under typical manufacturing tolerances for the present invention, this may result in blade surfaces that are flush to only slightly lower on the running blade than the working blade. Referring now back to
Referring now to
In still further variations of the invention, a novel face plate construction may be employed.
Referring now to
Referring now to
Although particular embodiment(s) of the present invention has been shown and described, it will be understood that it is not intended to limit the invention to the preferred embodiment(s) and it will be obvious to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the present invention. Thus, the invention is intended to cover alternatives, modifications, and equivalents, which may be included within the spirit and scope of the invention as defined by the claims.
All publications, patents, and patent applications cited herein are hereby incorporated by reference in their entirety for all purposes.
This application claims priority to, and is a continuation of, U.S. patent application Ser. No. 12/717,127, filed on Mar. 3, 2010, now to issue as U.S. Pat. No. 8,628,318, which claims benefit of U.S. Provisional Patent Application No. 61/157,156, filed Mar. 3, 2009. These prior patent applications are hereby incorporated by reference for all purposes.
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| Number | Date | Country | |
|---|---|---|---|
| 61157156 | Mar 2009 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12717127 | Mar 2010 | US |
| Child | 14154107 | US |
