This invention relates to grouting and more particularly to machines for applying grout.
Grout is a construction material used to embed rebars in masonry walls, connect sections of pre-cast concrete, fill voids, and seal joints. For most individuals the latter represents their general exposure to grout as it is used to seal the joints between tiles in their homes such as within bathrooms, kitchens, and floors. Grout is generally a mixture of water, cement, and sand with often a colour tint added. Sometimes fine gravel is added if it is being used to fill the cores of concrete blocks. It is typically applied as a thick emulsion and hardens over time, much like its close relative mortar.
The main varieties include:
Tiling grout is often used to fill the spaces between tiles or mosaics, and to secure the tiles to the base they are being installed upon. There are several tools typically associated with applying grout such as:
When grouting joints narrow than 1/16″ (approximately 1.5 mm), typically on walls and countertops in most residential settings then a non-sanded grout may be employed. For grouting joints wider than 1/16″ (approximately 1.5 mm), typically on floors, then generally a sanded grout is employed which gives extra strength to keep it from cracking. Typically, a grouter will work in small areas. Once, mixed (when considering a sanded cement grout for example) then a grout float, generally padded for tiles, is used to spread the grout over the tiles and force it into the joints, see first image 150A in
Once, the area is finished, typically 3′ wide by 2′ deep (approximately 1 m by 0.7 m) then the grouter will hold the long edge of the float almost perpendicular to the floor and scrape the excess grout off the surface of the tiles. At this point it is important that they are sweeping diagonally to the joints so that the float is always running along the surface of the tiles and not accidentally digging the grout out of the joints.
Once this spread-smush-and-scrape phase is complete then judgment must be used about how long to continue working before going back to clean off the surface of the tiles as it needs to have time to harden but not so long that the residue on the surface of the tiles gets too hard to clean off. Typically, this is done by individuals by hand using a water and a soft, thick sponge for cleaning off the grout, see third image 150C in
Accordingly, today grouting even where it is for large areas such as commercial environments, offices, shopping malls, etc. is achieved using professionals who work through the entire process on their hands and knees. Generally, because of this larger areas being tiled tend to be tiled with larger tiles. Accordingly, it would be beneficial to provide building contractors, individuals, etc. with a machine to implement some or all of these steps thereby allowing a wider range of tiles and tile effects to be implemented when tiling large areas including employing smaller tiles, tiling mosaics, etc. without the costs of these visually effective and attractive designs being prohibitive. Such a machine would also beneficially reduce the amount of time the worker is working on their hands and knees.
Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.
It is an object of the present invention to mitigate limitations in the prior art relating to grouting and more particularly to machines for applying grout.
In accordance with an embodiment of the invention there is provided a device comprising:
In accordance with an embodiment of the invention there is provided a method of grouting a surface comprising a plurality of tiles or mosaics using a machine having a number of rotating grouter assemblies, each grouter assembly comprising a plurality of deformable floats that direct and force grout into the gaps between the plurality of tiles or mosaics.
In accordance with an embodiment of the invention there is provided a floor supported device for grouting a surface comprising a plurality of tiles or mosaics using a machine having a number of rotating grouter assemblies, each grouter assembly comprising a plurality of deformable floats that direct and force grout into the gaps between the plurality of tiles or mosaics.
In accordance with an embodiment of the invention there is provided a handheld device for grouting a surface comprising a plurality of tiles or mosaics using a machine having a number of rotating grouter assemblies, each grouter assembly comprising a plurality of deformable floats that direct and force grout into the gaps between the plurality of tiles or mosaics.
Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.
Embodiments of the present invention will now be described, by way of example only, with reference to the attached Figures, wherein:
The present invention is directed to grouting and more particularly to machines for applying grout.
The ensuing description provides exemplary embodiment(s) only, and is not intended to limit the scope, applicability or configuration of the disclosure. Rather, the ensuing description of the exemplary embodiment(s) will provide those skilled in the art with an enabling description for implementing an exemplary embodiment. It being understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope as set forth in the appended claims.
“Grout” as used herein and throughout this disclosure, refers to a material employed within various narrow cavities, as masonry joints, wall tile joints, mosaics, and floor tile joints for example, to fill them and consolidate the adjoining objects into a solid assembly. This includes, but is not limited to, mortar, sanded grout, unsanded gout, furan grout, urethane tiling grout, cement tiling grout, epoxy tiling grout, flooring grout, resin grout, non-shrink grout, structural grout, and thixotropic grout.
Referring to
Now referring to
Referring to
It would be evident to one skilled in the art that other designs of the handle assembly 300 may be provided without departing from the scope of the invention including, but not limited to, a single central bar with a handle attached at the top, auger motor activation switch and wiring as external or internal to the central bar of handle, etc. The materials for the handle assembly may include, but not be limited, one or more of steel, stainless steel, aluminum, fiber reinforced plastic, plastic, etc. according to the design of the overall grouting machine 100 as discussed below which may vary from a small handheld unit to medium floor units and large floor units for example. It would also be evident that according to the design of the other elements of the grouting machine 100 that the handle mounting assembly 2 and/or handle 31 may also be varied to adjust to variations in the design of the motor plate 1 or other elements of the grouting machine 100 to which the handle assembly 300 fits and may be permanently, removably and/or pivotally attached together using techniques known in the art.
Now referring to
Optionally, gearbox 19 and drive gear 18B may provide the operator of the grouting machine 100 with a predetermined set of gear ratios, a single gear ratio, or a continuously variable gear ratio according to embodiments of the invention determined in dependence upon desired rotation rate(s) of the grouter assemblies 500 and the operating speed range(s) of the motor (not shown for clarity). Optionally, each gear box 19 may also contain a clutch allowing the drive to be selectively coupled without starting/stopping the motor. It would be evident that drive assembly 400 schematic may be easily modified to provide three spinner assemblies 500 by providing the third grouter assembly 500 opposite the auger assembly. It would also be evident that a drive assembly 400 schematic with four grouter assemblies 500 and two auger assemblies feeding pairs of grouter assemblies 500 may be implemented by mirroring the depicted drive assembly 400 schematic with an additional gear assembly coupled to the motor shaft driving each drive assembly 400 schematic, Optionally, multiple grouter assemblies 500 may be coupled via a single gear box or in other embodiments of the invention according to the characteristics of the motor (not shown for clarity) coupled directly to the motor shaft 5.
Optionally, a gear box and/or clutch and/or potentiometer may also be provided on the auger drive assembly so that the speed of grout dispensing may be adjusted independent of the speed of the spinner assemblies 500. Now referring to
Referring to
Within embodiments of the invention the float 16 may demountably or permanently attached to the float bracket 15. For ease of assembly the float bracket 15 is shown attached via holes in the spinner plate 14 such that the screws/bolts or attachment means are inserted from the top of the spinner plate 14 through it and into the float bracket 15. Float bracket may optionally have threaded portions allowing direct mounting to a bolt although it would evident that other means of attaching the float brackets 15 and optional sponge may be employed, such as t-slots for example. Alternatively, the float bracket 15 may be attached to the spinner plate 14 from below via nut and bolt or the spinner assembly may incorporated thread portions to directly receive a bolt. A similar arrangement may be employed for the optional replaceable sponge.
Spinner plate 14 may be manufactured from a variety of materials which may include, but not be limited, one or more of steel, stainless steel, aluminum, fiber reinforced plastic, plastic, etc. according to the design of the overall grouting machine 100 as discussed below which may vary from a small handheld unit to medium floor units and large floor units for example. Similarly, float bracket 15 may be manufactured from a variety of materials which may include, but not be limited, one or more of steel, stainless steel, aluminum, fiber reinforced plastic, plastic, etc. Float 16 may be manufactured from a range of compliant materials including, but not limited to, rubber, neoprene, synthetic rubber, plastic, vinyl, polyethylene etc. In other embodiments of the invention the floats 16 may be formed from non-compliant materials may include, but not be limited, one or more of steel, stainless steel, aluminum, fiber reinforced plastic, plastic, etc. Optionally, a spinner assembly 500 may be provided as a disposable element or as an assembly allowing replacement of the different elements to account for use, damage, etc.
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Referring to
An opening within the auger housing 24 couples to hopper spout 28 through which grout flows from hopper 27 when a trap door 29 is opened or may feed directly into the auger housing in other embodiments of the invention. Alternatively, the auger assembly may be disposed within the hopper assembly in line such that grout is drawn from the hopper and driven to the dispensing portion of the auger assembly. Within an embodiment of the invention the dispensing portion of the auger assembly may simply be a single hole and/or nozzle whereas in other embodiments of the invention it may an inline or clustered array of holes and/or nozzles as depicted in first and second images 610 and 620 respectively.
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Within embodiments of the invention the motor 30, and an additional auger motor where employed, may be provided by, for example, an electric motor including, but not limited to, brushed DC motor, brushless DC motor, induction motor, synchronous motor, single phase AC motor, and multiple phase AC motor. In some embodiments of the invention an electric motor may be driven via a power cord connecting the motor to an electrical socket and therein electrical mains. In other embodiments of the invention a DC battery based design may be employed, such as those employed within cordless power tools for example exploiting 10.5V, 12V, 18V, 19.2V, 20V, 24V, 36V or 40V battery designs. In other embodiments of the invention combustion motors exploiting fuels such as gasoline, paraffin, liquid petroleum gas, compressed butane, natural gas, etc. may be employed.
Within the embodiments of the invention described supra in respect of
A grouting machine, such as that depicted and described with respect to grouting machine 100 in
The user must begin by mixing a desired amount of grout to fill the hopper 27. Once the hopper is full and the motor is plugged in, the machine can be started and the grouting process can begin. The user controls the trap door lever 3 to open the trap door 29, via cable 4, to allow the grout to fall into the auger housing 24 from the hopper 27 although in other embodiments of the invention the trap door 29 is removed and cable 4 provides control from a switch mounted to the handle to a separate auger motor that pushes/pulls the grout such that it is dispensed directly through an opening in the machine onto the floor. This allows the user to control the amount of grout landing on the floor, thus facilitating final cleanup. The grout in the auger housing is moved by an auger 23 to be pushed out of a hole directly on to the floor. As grout is dispensed, the grouter assemblies rotate, and the floats 16 press the grout between the tile crevices. With the assistance of the float keeping the grout mobilized between the spinner floats.
Grouter assemblies 500 are driven by the drive assembly 400 which works such that a bevel gear 5 is driven directly by the motor 30, which turns two bevel gears 8 opposite each other within grouting machine 100. Each bevel gear 8 drives one grouter assembly 800. Bevel gear 8 drives a shaft that in turn drives a worm gear set 18A/18B which drives spinner shaft 20 which is attached to the spinner plate 14. Three floats 16 are attached to each spinner plate 14 via float brackets 15 wherein these floats 16 press grout between tile crevices as they spin over the floor.
The worm gear setup is used to drive each spinner assembly opposite directions as well as to control speed, from the top view, the left assembly turns clockwise while the right turns counter-clockwise, therefore guiding the grout towards the center of the machine. This rotation may in other embodiments of the invention be reversed by the user, such as for example when the travel direction of the machine reverses during use. The auger assembly 800 is also driven by the motor 30. Bevel gear 26 is driven by bevel gear 5 and drives the auger 23 in some embodiments of the invention whereas in others the auger 23 may be driven by a separate auger motor in conjunction with an auger drive train. The auger 23 pushes grout dispensed from the hopper 27 to the floor. As depicted the grouter assemblies 500 and auger assembly 800 may be removed/dismantled allowing for clean-up whilst the hopper 27 may be flushed through with water. Similarly, the hopper assembly may also be demounted along with the auger housing to facilitate cleaning.
Within the process described in respect of
In the embodiment of the invention wherein four or more grouter assemblies 500 are coupled to the motor 30 these may be driven such that each pair of adjacent grouter assemblies 500 are rotating in opposite directions. This, for example, may be mounted onto a ride-on vehicle allowing for large areas to grouted.
The foregoing disclosure of the exemplary embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many variations and modifications of the embodiments described herein will be apparent to one of ordinary skill in the art in light of the above disclosure. The scope of the invention is to be defined only by the claims appended hereto, and by their equivalents.
Further, in describing representative embodiments of the present invention, the specification may have presented the method and/or process of the present invention as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims. In addition, the claims directed to the method and/or process of the present invention should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied and still remain within the spirit and scope of the present invention.
This patent application claims the benefit of U.S. Provisional Patent Application 62/008,670 filed Jun. 6, 2014 entitled “Methods and Devices relating to Grouting”, the entire contents of which are incorporated herein by reference.
Number | Name | Date | Kind |
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2556983 | Root | Jun 1951 | A |
5314100 | Deaver | May 1994 | A |
5372452 | Hodgson | Dec 1994 | A |
5449406 | Presti, Jr. | Sep 1995 | A |
6260743 | Mazzenga | Jul 2001 | B1 |
Number | Date | Country | |
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20190226216 A1 | Jul 2019 | US |
Number | Date | Country | |
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62008670 | Jun 2014 | US |