Aspects of this document relate generally to applicator devices and related methods used to apply drywall compound (drywall mud) to surfaces.
Drywall compound, otherwise known as drywall mud, can be applied to ceilings and walls of buildings during their construction or repair. For example, the walls and ceilings of buildings are often formed by securing drywall panels (sometimes called wallboard) to wooden or metal frame elements, such as with nails, screws, or staples. To ensure a flat and aesthetically appealing surface, drywall compound is often applied at the gaps between adjacent drywall panels (or otherwise where drywall panels meet) and/or at the locations where screws, nails, staples, or the like were driven through the drywall panels. Once the drywall compound is applied, it can be smoothed and extra compound removed, then allowed to dry. It can then be sanded to further ensure a flat and smooth surface. Various tools are used to apply drywall compound and/or plaster and/or spackling and/or to smooth and/or texture it, including hawks (such as for holding drywall compound while applying it using a separate applicator), texture sprayers, darbies (such as for example applying an undercoat layer when working with stucco or plaster), brushes and texture brushes, flat boxes (for applying even layers of drywall compound), knives, taping knives, joint knives, knock-down knives (to give wall and ceiling textures a flattened appearance), skimming blades (such as for example for smoothing out fresh drywall compound and/or for bedding and wiping down applied drywall tape), sanders, drywall sanders, sandpaper, and sanding sponges.
In some aspects, the techniques described herein relate to an applicator device, including: a back panel; one of: a pole attached to the back panel; and a coupler coupled with the back panel and configured for receiving a pole; and an applicator panel having four sides each of which at least partially defines a rectangular perimeter, the applicator panel including a plurality of openings; and at least one spacer coupled between the applicator panel and the back panel, the at least one spacer facilitating a gap between the applicator panel and the back panel; wherein the applicator panel includes a flat top surface and is configured for applying a layer of wet drywall compound to one of a wall and a ceiling.
In some aspects, the techniques described herein relate to an applicator device, wherein the back panel has four sides each of which at least partially defines a rectangular perimeter.
In some aspects, the techniques described herein relate to an applicator device, wherein the rectangular perimeter at least partially defined by the back panel is substantially equivalent in shape and size to the rectangular perimeter at least partially defined by the applicator panel.
In some aspects, the techniques described herein relate to an applicator device, wherein some of the plurality of openings are not fully circumscribed by the applicator panel.
In some aspects, the techniques described herein relate to an applicator device, wherein some of the plurality of openings are fully circumscribed by the applicator panel.
In some aspects, the techniques described herein relate to an applicator device, wherein the at least one spacer includes a plurality of spacers, each of the plurality of spacers including a substantially identical height so that the gap between the applicator panel and the back panel is substantially equal proximate each spacer.
In some aspects, the techniques described herein relate to an applicator device, wherein the at least one spacer is hollow, and wherein the applicator panel is coupled with the back panel using a fastener which passes through the at least one spacer.
In some aspects, the techniques described herein relate to an applicator device, wherein the fastener which passes through the at least one spacer includes one of a bolt and a screw.
In some aspects, the techniques describe herein relate to an applicator device, wherein the applicator panel is substantially black to provide visual contrast with the wet drywall compound.
In some aspects, the techniques described herein relate to an applicator device, wherein the four sides of the applicator panel at least partially define a square perimeter.
In some aspects, the techniques described herein relate to an applicator device, wherein the applicator device includes the coupler coupled with the back panel, and wherein the coupler is a threaded coupler.
In some aspects, the techniques described herein relate to an applicator device, wherein the back panel includes a plurality of openings, and wherein the threaded coupler is coupled with the back panel using fasteners that pass through the openings.
In some aspects, the techniques described herein relate to an applicator device, wherein the fasteners that pass through the openings include threaded fasteners.
In some aspects, the techniques described herein relate to an applicator device, wherein the applicator device includes the pole, and wherein the pole is a threaded pole configured for attaching to the threaded coupler.
In some aspects, the techniques described herein relate to an applicator device, wherein the back panel is formed of one of a metal and a polymer, and wherein the applicator panel is formed of one of a metal and a polymer.
In some aspects, the techniques described herein relate to an applicator device, including: a back panel; one of: a pole attached to the back panel; and a coupler coupled with the back panel and configured for receiving a pole; an applicator panel including a plurality of openings; and a plurality of spacers coupled between the applicator panel and the back panel, the spacers facilitating a gap between the applicator panel and the back panel; wherein at least one of the spacers is hollow, and wherein the applicator panel is coupled with the back panel using a threaded fastener which passes through the hollow spacer; and wherein the applicator panel includes a flat top surface and is configured for applying a layer of wet drywall compound to one of a wall and a ceiling.
In some aspects, the techniques described herein relate to an applicator device, wherein the applicator panel has four sides each of which at least partially defines a rectangular perimeter.
In some aspects, the techniques described herein relate to an applicator device, wherein each of the spacers is hollow, and wherein the applicator panel is coupled with the back panel using a plurality of threaded fasteners passing through the spacers.
In some aspects, the techniques described herein relate to an applicator device, including: a back panel having four sides each of which at least partially defines a first rectangular perimeter; a threaded coupler coupled with the back panel and configured for receiving a threaded pole; an applicator panel having four sides each of which at least partially defines a second rectangular perimeter, the applicator panel including a plurality of openings; a plurality of spacers coupled between the applicator panel and the back panel, each of the spacers having a substantially identical height, the spacers facilitating a gap between the applicator panel and the back panel, wherein each of the spacers is hollow; and a plurality of threaded fasteners, each threaded fastener coupling the applicator panel with the back panel through one of the spacers; wherein the applicator panel includes a flat top surface and is configured for applying a layer of wet drywall compound, in a repeating pattern, to one of a wall and a ceiling.
In some aspects, the techniques described herein relate to an applicator device, wherein the first rectangular perimeter is substantially equivalent in shape and size to the second rectangular perimeter.
In some aspects, the techniques described herein relate to an applicator device, wherein some of the plurality of openings are not fully circumscribed by the applicator panel, wherein the first rectangular perimeter includes a square, and wherein the second rectangular perimeter includes a square.
General details of the above-described implementations, and other implementations, are given below in the DESCRIPTION, the DRAWINGS, the CLAIMS and the ABSTRACT.
Implementations will be discussed hereafter using reference to the included drawings, briefly described below, wherein like designations refer to like elements. The drawings are not necessarily drawn to scale.
Implementations/embodiments disclosed herein (including those not expressly discussed in detail) are not limited to the particular components or procedures described herein. Additional or alternative components, assembly procedures, and/or methods of use consistent with the intended applicator devices and related methods may be utilized in any implementation. This may include any materials, components, sub-components, methods, sub-methods, steps, and so forth.
With regards to the drawings, it is pointed out that, for simplicity and for ease of viewing the elements shown, some elements are excluded in some of the views (for example in
Referring now to
The HDPE is black, which helps the drywall compound to be easily seen on it, there being a high contrast between the drywall compound and the HDPE. In other implementations other rigid polymers could be used such as polyvinyl chloride (PVC), polypropylene (PP), and so forth. Metallic materials could be used, but the use of polymers helps the back panel to be lightweight (along with the applicator panel, discussed hereafter), which is useful to reduce fatigue from a user while using the applicator device. In implementations the back panel could be formed of a composite material.
The back panel has openings (which may be bolt holes) for threaded fasteners, such as by non-limiting example bolts 108 and 116. In the drawings these bolt holes are not visible because of the bolts and corresponding nuts 110/118. A threaded coupler 106 is attached to the back panel using bolts 108 and corresponding nuts 110 (the bolt and nut positions/locations could be reversed, if desired). In the drawings the threaded coupler is formed of metal, such as a steel or aluminum, though in other implementations it could be formed of a rigid polymer or composite material. The threaded coupler includes female threads (not shown in the drawings) for receiving male threads (not shown in the drawings) of a pole 104. The pole in the drawings is accordingly a threaded pole and is formed of a metal, such as a steel or aluminum, though in other implementations it could be formed of a rigid polymer, wood or a composite material (though the male threads could be formed of metal and coupled with a portion of the pole even if the pole itself is not metal, or the threads could be integrally formed with a non-metal pole material). The pole is seen to be orthogonal to the plane of the back panel, and allows a user to directly press the applicator device upwards when applying drywall compound to a ceiling (as seen in
An applicator panel 112 is coupled with the back panel but is spaced therefrom using spacers 120. The applicator panel may be formed of any materials disclosed above for the back panel. In the drawings the applicator panel is made of the same material and color as the back panel, and having the same thickness and other dimensions, except that the applicator panel has been laser cut to form openings 114 therein to form a design. Other cutting or material removal techniques could be used to form the openings, or the applicator panel could be integrally formed with the openings therein, such as using a mold which inherently forms the openings during molding. Additionally, the back panel and applicator panel could have thicknesses other than one-fourth inch, such as between one-eighth inch and one-half inch, or any other size, though a one-fourth inch thickness creates sufficient rigidity for drywall compound application and also keeps material costs low. Additionally, the panels could have sizes other than twenty-two inches by twenty-two inches, and could have a shape other than a square (such as a rectangle or circle or any other regular or irregular shape), though the twenty-two inch by twenty-two inch size, and the square shape, is a useful to keep the applicator device lightweight and also apply drywall compound in a step-wise approach without wasting material or time and without overlapping drywall compound (as can be envisioned from
The applicator panel includes bolt holes for receiving bolts 116, though the bolt holes are not visible in the drawings. Bolts 116 are passed through the bolt holes of the applicator panel and through hollow centers of spacers 120 and then through bolt holes of the back panel, and corresponding nuts 118 are secured to the bolts 116, to secure the back panel and applicator panel in fixed positions relative to one another and spaced apart using the spacers. The spacers in the drawings are formed of one inch long hollow copper tubes or copper bushings (for example cut from a longer tube or otherwise formed originally or later cut/sized to the one inch size), though in other implementations they could be formed of any other metal, or even a rigid polymer or composite. The spacers help to create a space between the panels. This allows excess drywall compound to drip down to the back panel so as to not negatively affect the design applied to a ceiling. The back panel helps prevent excess drywall compound which falls through the openings 114 from falling onto the user or onto the floor. The positions/locations of bolts 116 and nuts 118 could be reversed. Additionally, anything other than bolts/nuts could be used to secure the panels in the spaced position. For example in some implementations the spacers and panels could be integrally formed without requiring bolts and nuts at all. Other configurations are possible. In implementations the space between the panels makes it easier to clean the device after use. The space between panels is one inch in the drawings, but in other implementations it could be any other size such as between one-half inch and two inches, or any other desired size. The size of one inch allows sufficient space for a decent amount of excess drywall compound to fall between the panels and onto the back panel and also sufficient space to easily clean the applicator device after use by removing all drywall compound. Screws or friction fit elements or other coupling mechanisms could be used instead of any of the bolts/nuts described herein, in implementations.
In
As shown in
In other implementations there may be more or fewer than three applications per dip, depending on the consistency of the drywall compound and on the desired texture thickness for the design. During dipping, the user may in implementations dip the applicator panel into the drywall compound about one-half inch, though in other implementations the user may dip only one-fourth inch or less into the drywall compound each time, or just enough into the drywall compound to get the drywall compound on the face/surface of the applicator panel.
Although the user does not generally need to overlap each square (or other shape) of application, if it turns out the user has had one or more applications that did not apply much drywall compound, the user can simply make another application at that location (either trying to maintain the same position of the applicator panel so as to not change the overall design at that location, or not, as desired) to add more drywall compound at that location.
Once the user has finished applying the pattern or design in the manner shown in
In implementations the smoothing/flattening procedure needs to be done relatively quickly after the pattern is initially applied, such as within several minutes (in some implementations within fifteen minutes), so that the drywall compound does not harden. If the drywall compound were to harden then it would form pointy projections downward from the ceiling and/or pieces would break off if smoothing/flattening were thereafter attempted. In implementations where pointy projections are desired the user could simply not do a flattening/smoothing procedure. Where pointy projections are not desired, a smoothing flattening procedures is done.
In implementations the drywall compound applied to the ceiling by the applicator device is the last drywall compound applied to the ceiling, and after the smoothing/flattening procedure the drywall compound is left to dry for about a day or at least for several hours. Thereafter, a light sanding (such as using a light sanding pole) may be done, then the ceiling may be painted.
The devices and methods disclosed herein may be used to apply texture to ceilings, or to walls or other surfaces, using any design formed into or formed by an applicator panel. In implementations the drywall compound 122 and drywall compound 128 are the same material, though in implementations they may be different materials and/or different consistencies as desired by the user, based on using different amounts of water or different products, or so forth. In implementations the material for the panels 102/112 comes in four foot by eight foot sheets and is cut into twenty-two inch by twenty-two inch squares and then some of these squares are laser cut (or otherwise cut or material is otherwise removed) to form the openings 114 and, accordingly, the design in the applicator panels.
If the ceiling has areas or items such as recessed lighting, or curvature, specially shaped applicator panels may have non-square shapes (such as having round cutouts of the size/shape of common recessed lighting to apply the design around the recessed lighting but not at the location of the recessed lighting), or curved surfaces to apply texture to curved ceilings/walls, or the user may otherwise use careful application techniques to go around areas where it is not desirable to apply the design or to apply the design to curved areas.
Although the applicator panels could have non-square or non-rectangular shapes, such shapes would be harder to apply the design to an entire ceiling or wall quickly and without overlapping. Square or rectangular shapes allow the design to be very quickly applied to the ceiling or wall, by not overlapping the applications and by it visually being very easy to quickly determine where to make each next application in sequence, and this helps to not only reduce the time applying the design but also ensures that the applied drywall compound does not dry too much before the described smoothing/flattening process is done using the knockdown knife (because faster application means less drying before the smoothing/flattening). Additionally, for aesthetic purposes it may be desirable to not overlap the applications. In implementations the knockdown knife is not pressed hard against the ceiling during the smoothing/flattening process but only a light pressure is used so that the applied design/texture is not flattened too much. Although the example in the drawings results in a thickness of about one-sixteenth inch, other thicknesses, greater or less than one-sixteenth inch, may be achieved as desired by the user by applying more or less drywall compound during application or by applying different pressures during the smoothing/flattening process with the knockdown knife.
As can be seen in the drawings, in implementations the applicator panel has four sides, each of which at least partially defines a rectangular (in the drawings, square) perimeter. The back panel also has four sides, each of which at least partially defines a rectangular (in the drawings, square) perimeter. In implementations these perimeters are substantially equal or are equal in size and/or shape. As used herein, substantially means having at least 90% identicality or similarity in size, shape, or other features as dictated by the context in which it is used. The applicator panel in the drawings at least partially defines a square perimeter because a square perimeter can be identified or defined which would contact each side of the applicator panel in at least one location (indeed, in the drawings, three of the sides of the applicator panel would contact such a perimeter in four locations and one of the sides would contact the perimeter in five locations). Further, each corner of the applicator panel has sides that would contact two corresponding square perimeter sides. For at least one or more of these reasons, and possibly for other reasons, it is accurate to say that the applicator panel (and, for similar reasons, the back panel) at least partially defines a rectangular, and indeed a square, perimeter.
The number of spacers may be modified for any applicator device. It is seen in the figures that the spacers facilitating a gap between the applicator panel and back panel, and that since the spacers are in some cases substantially similar in size (or having equal or substantially equal heights) the respective panels are accordingly parallel, so that the gap between the applicator panel and the back panel is substantially equal proximate each spacer.
The figures show that some of the openings 114 are fully circumscribed in the applicator panel (for example the bottommost marked openings 114 of
In
The pattern on the ceiling in
The applicator panel may form thick lines or thin lines, depending on the thickness of the material of the panel between the openings, as desired.
The bolt and nut configurations of the various drawings are not all exactly matching and may look different from figure to figure. For example in
In places where the phrase “one of A and B” is used herein, including in the claims, wherein A and B are elements, the phrase shall have the meaning “A and/or B.” This shall be extrapolated to as many elements as are recited in this manner, for example the phrase “one of A, B, and C” shall mean “A, B, and/or C,” and so forth. To further clarify, the phrase “one of A, B, and C” would include implementations having: A only; B only; C only; A and B but not C; A and C but not B; B and C but not A; and A and B and C.
In places where the description above refers to specific implementations of applicator devices and related methods, one or more or many modifications may be made without departing from the spirit and scope thereof. Details of any specific implementation/embodiment described herein may, wherever possible, be applied to any other specific implementation/embodiment described herein. The appended claims are to encompass within their scope all such changes and modifications as are within the true spirit and scope of this disclosure.
Furthermore, in the claims, if a specific number of an element is intended, such will be explicitly recited, and in the absence of such explicit recitation no such limitation exists. For example, the claims may include phrases such as “at least one” and “one or more” to introduce claim elements. The use of such phrases should not be construed to imply that the introduction of any other claim element by the indefinite article “a” or “an” limits that claim to only one such element, and the same holds true for the use in the claims of definite articles.
Additionally, in places where a claim below uses the term “first” as applied to an element, this does not imply that the claim requires a second (or more) of that element—if the claim does not explicitly recite a “second” of that element, the claim does not require a “second” of that element. Furthermore, in some cases a claim may recite a “second” or “third” or “fourth” (or so on) of an element, and this does not necessarily imply that the claim requires a first (or so on) of that element—if the claim does not explicitly recite a “first” (or so on) of that element (or an element with the same name, such as “a widget” and “a second widget”), then the claim does not require a “first” (or so on) of that element.
Method steps disclosed anywhere herein, including in the claims, may be performed in any feasible/possible order. Recitation of method steps in any given order in the claims or elsewhere does not imply that the steps must be performed in that order—such claims and descriptions are intended to cover the steps performed in any order except any orders which are technically impossible or not feasible. However, in some implementations method steps may be performed in the order(s) in which the steps are presented herein, including any order(s) presented in the claims.
This document claims the benefit of the filing date of U.S. Provisional Patent Application No. 63/365,479, entitled “Applicator Devices and Related Methods,” naming as first inventor John L. Stubbs, which was filed on May 27, 2022, the disclosure of which is hereby incorporated entirely herein by reference.
Number | Date | Country | |
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63365479 | May 2022 | US |