This invention relates generally to a drywall compound dispensing system for applying mastic material, drywall compound or similar material over tape joints between adjacent pieces of wallboard. More particularly, the present invention is directed to control structure for improving the efficiency and versatility of drywall compound application during a finishing operation.
Drywall has become a dominant material in the production of interior building partitions. In particular, interior building partitions generally comprise a vertical stud wall which is used as a support for pre-formed drywall panels that are attached to the stud wall. Joints between adjacent panels of drywall are usually taped, and finished with joint or drywall compound. One type of apparatus or tool for applying joint compound is disclosed in U.S. Pat. No. 2,815,142 issued Dec. 3, 1957. This apparatus mechanically applies tape and joint compound contemporaneously. After the tape and the first coat of joint compound has been applied over the joint, it is typical to apply multiple coats of joint compound. The multiple coats are typically applied using finishing tools such as a corner head, a coater, a flat box or other box tool.
A traditional box tool is constructed with a slotted orifice in the bottom surface which acts as an outlet through which the drywall compound is dispensed as well as refilled. A movable pressure plate on the box tool has springs attached to bias it to an open position. A handle pivotably affixed to the pressure plate allows an operator to apply inward pressure to the pressure plate to force drywall in the box tool through the outlet slot and onto a joint or the like. The expelled drywall compound is then spread and smoothed by a blade-like projection on the box tool as the box tool is moved along a joint. A cable is controlled by a brake lever on the handle to selectively lock the box tool on the handle and prevent relative pivotal motion thereof. One glaring inefficiency associated with use of traditional box tools in finishing is the frequent requirement of refilling the relatively small box tool which requires a lot of additional time and is labor intensive adding to the cost of the job.
More recently, box tools have been supplied with a source of pressurized drywall which is continuously fed by a supply line into and through the handle from a pump supply device for dispersion into the box tool so as to make the dispensing system more efficient and eliminate the costly downtime problem noted above. One known finishing tool system includes a handle equipped with a brake lever as well as an on/off switch and a volumetric control to regulate the continuous flow of pressurized drywall compound to the box tool. This system allows an operator to continuously feed drywall compound to the box tool and simultaneously control locking the box tool. However, this system is not designed to provide a separate optional manual control to vary the flow of pressurized drywall compound. In addition, such system does not provide relief valve protection in the event of excessive pressure buildup of drywall compound. The absence of these features detracts from the productivity, usefulness and ease of operating the box tool dispenser.
Accordingly, it is desirable to provide a system for applying drywall compound to wallboard joints with an improved control arrangement which will overcome the deficiencies of the prior art and enhance the operability, speed, efficiency and versatility of a drywall finishing operation.
It is one object of the present invention to provide a drywall compound dispensing system providing automatic, continuous or manual variable flow of drywall compound from a source of pressurized drywall compound to a dispensing head while simultaneously allowing selective locking of the pivoting dispensing head in a manner accessible to one hand of an operator.
It is also an object of the present invention to provide a finishing system in which a movable biased plate arrangement is provided to selectively lock and unlock pivotal movement of a dispensing head on a drywall compound delivery tube.
It is another object of the present invention to provide a box tool dispensing system wherein the drywall compound delivery tube is constructed with a relief valve which will expel drywall compound therefrom in the presence in excessive pressure.
In one aspect of the invention, a drywall compound dispensing system is provided for applying drywall compound to a wallboard. The system includes a delivery tube for delivering drywall compound entirely therethrough. The delivery tube has a supply end connected to a source of pressurized drywall compound, and a dispenser end opposite the supply end connected for pivotal movement with a drywall compound dispensing head. A control arrangement is located at the supply end of the delivery tube and is provided with a first movable lever spaced from a second movable lever. Both the first and second movable levers are grasped and selectively operated by fingers of one hand of a user. The first lever has an unlocked position for manually controlling flow of drywall compound into the delivery tube, and a locked position for enabling an automatic, continuous flow of drywall compound into the delivery tube. The second movable lever provides manual control for selectively allowing and preventing pivotal movement of the dispensing head at the dispensing end of the delivery tube.
The delivery tube includes a pressure regulator for controlling volume of flow of drywall compound. The delivery tube also includes a relief valve for allowing the expulsion of drywall compound out of the delivery tube in the presence of excessive pressure in the delivery tube. The relief valve includes a venting hole formed in the outer wall of the delivery tube, and an expandable and retractable shrink sleeve surrounding the delivery tube and normally covering the venting hole. A deflector collar is spaced from and surrounds the shrink sleeve and the delivery tube. The deflector has an open end for expelling drywall therefrom. The delivery tube includes a knurled tubular hand grip aligned with the first and second levers at the supply end. The dispenser end of the delivery tube includes a ball dispenser enabling the pivotal movement with the drywall compound dispensing head. The ball dispenser includes a shaft permitting pivotal movement of the drywall compound dispenser head about a horizontal axis only. A back wall of the drywall compound dispensing head is provided with a movable biased plate arrangement for receiving the ball dispenser in a socket formed therein. The movable bias plate arrangement is connected by a cable to the second movable lever. The drywall compound dispenser head normally pivots upon the ball dispenser and actuation of the second movable lever causes the cable to move the plate arrangement such that the ball dispenser is locked into frictional engagement so that there is no pivotal movement of the dispenser head relative to the ball dispenser. In the preferred embodiment, the drywall compound dispenser head is a dispenser box movable along a wallboard.
The movable biased plate arrangement includes a first plate connected to the back wall of the dispensing head and having a first opening. A second plate is connected to the first plate and has a second opening. A third plate is connected in spaced biased relationship to the second plate. A fourth plate is connected to the third plate and has an opening for retaining the cable. The socket and the first, second and third openings are all in alignment with each other and receive the ball dispenser. The second lever in the cable is actuated to pull the second and third plates together and frictionally lock the ball dispenser. The control arrangement includes a rotatable locking device for placing the first movable lever in the locked and unlocked positions. The first lever and the second lever are pivotable about a first pivot axis and a second pivot axis, respectively, which are parallel to each other.
In another aspect of the invention, a drywall compound dispensing system is provided for applying drywall compound to a wallboard of the type having a delivery tube for delivering drywall compound entirely therethrough provided with a supply end connected to a source of pressurized drywall compound, and a dispenser end opposite to the supply end connected for pivotal movement with a drywall compound dispensing end. The invention is improved by a tandem control lever arrangement located at the supply end of the delivery tube and engaged by one hand of a user for optionally providing manual and automatic, continuous flow of drywall compound through the delivery tube, and disabling pivotal movement of the dispensing head. The tandem control lever arrangement is located within a handle framework. A movable biased plate arrangement is connected to the dispensing head for allowing and preventing pivotal movement of the dispensing head relative to the dispenser end. A relief valve is positioned in the delivery tube between the supply end and the dispensing end for allowing the expulsion of drywall compound out of the delivery tube in the presence of successive pressure of drywall compound in the delivery tube.
Other objects, features and advantages of the invention will be made apparent from the following description taken together with the drawings.
The drawings illustrate the best mode presently contemplated of carrying out the invention.
In the drawings:
a and 8b are enlarged views of a control arrangement for the system; and
Referring now to the drawings,
In the preferred embodiment, the dispensing head 15 is shown as a box tool commonly known in the finishing industry as a flat box which may be variously sized and configured. The flat box 15 includes a front plate 18 with a front lip 20, a back plate 22, a bottom plate 24 and a pair of side plates 26,28. As seen in
A movable pressure plate 48 extends completely across the entire area of the flat box 15 from side to side and from front to back, and has a pivot edge 50 (
In accordance with one feature of the invention, the pressure plate 48 carries a movable biased plate arrangement 70 used in conjunction with the control arrangement 17 to selectively allow and prevent pivotal movement of the flat box 15 relative to the delivery tube 16. Referring to
The delivery tube 16 is designed to transport drywall compound 12 entirely therethrough from a supply end 102 connected to a source 104 of pressurized drywall compound 12 to a dispensing end 106 movably connected to the flat box 15. The dispensing end 106 includes a spherical or ball dispenser 83 connected to a curved arm tube 108 and a coupling 110. The ball dispenser 83 is provided with an outlet hole 112 (
In accordance with another feature of the invention, a relief valve 124 is provided on the main supply conduit 120 allowing the expulsion of drywall compound 12 out of the delivery tube 16 in the presence of excessive back pressure therein. As best seen in
A pressure regulator 134 is included in the main supply conduit 120 and has a rotatable adjustment disk 136 for selectively altering the volume of the drywall compound 12 flowing through the delivery tube 16. Following a further coupling 138, the main supply conduit 120 includes an angled branch 140 which passes through a knurled, tubular hand grip 142 and terminates in an inlet 144 at the supply end 102 which is connected such as by supply hose 145 (
In accordance with a further feature of the invention, the control arrangement 17 in the form of a tandem control lever arrangement is located at the supply end 102 of the delivery tube 116. The control arrangement 17 is engaged by one hand of the user for optionally providing manual or automatic continuous flow of drywall compound 12 through the delivery tube 16, and substantially disabling pivotal movement of the dispensing head 15 relative to the delivery tube 16.
As seen in
The control arrangement 17 also includes a second movable lever 152 (
In use during a finishing operation, pressurized drywall compound 12 supplied from compound supply 102 to inlet 144 can be delivered through delivery tube 16 to fill the flat box 15 by setting the pressure regulator 134 as desired and using the first lever 146 in either a manual or an automatic continuous flow mode. This is accomplished by placing the locking device 148 in either the unlocked position of
The user's other hand is able to completely control the system 10 by wrapping his/her hand around the hand grip 142 and simultaneously placing some fingers 172 (
In the event that excessive back pressure builds up within the delivery tube 16, such as caused by matter plugging the ball dispenser outlet 112 or a problem with flow from the box 15, the relief valve 124 can be relied up to signal to the user the existence of a problem by a slight leakage of drywall compound 12 from the delivery tube 16. As depicted in
The present invention thus provides a system 10 for eliminating the need to repeatedly rebuild a dispenser box 15 during drywall finishing. The operation, speed, efficiency and versatility of finishing is markedly improved by the provision of the control arrangement 17 which creates convenient one handed control for supplying drywall compound 12 either manually or automatically and continuously while enabling simultaneous control for locking dispenser box 15 when desired in conjunction with a unique, movable, biased plate arrangement 70. A relief valve 124 is incorporated into the delivery tube 16 to facilitate early warning and enable quicker resolution of excessive pressure problems which may occur.
While the invention has been described with reference to a preferred embodiment, those skilled in the art will appreciate that certain substitutions, alterations and omissions may be made without departing from the spirit thereof. Accordingly, the foregoing description is meant to be exemplary only and should not be deemed limitative on the scope of the invention set forth with the following claims.
This application relates to and claims priority from Provisional Application U.S. Ser. No. 60/719,308 filed Sep. 21, 2005.
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Number | Date | Country | |
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