The present invention relates generally to mixing devices, and more particularly to mixing devices for joint compound, paint, ceramic tile thin set, or epoxy coatings.
Joint compound (also referred to as “drywall compound”) is typically a pre-mixed paste, a mud compound, or a white powder of primarily gypsum dust mixed with water. The mud is generally applied in conjunction with paper or fiber joint tape to seal joints between sheets of drywall to create a seamless base for painting a surface formed by the drywall sheets.
The joint compound often comprises a combination of many materials that need to be homogenized to ensure proper functioning of the joint compound once applied to a drywall joint. For example, the joint compound may comprise water, limestone, expanded perlite, ethylene-vinyl acetate polymer, attapulgite, and other ingredients.
Previously known joint compound mixers have been used to mix joint compound to homogenize the various materials of the joint compound. However, joint compound is generally carried in plastic buckets and is often highly viscous and dense, which has required previously known drywall heavy duty mixers to be made of strong materials, such as metal, to effectively mix joint compound.
A mixing device in accordance with the present invention includes a blade with radially outwardly extending arms and/or with a longitudinally extending wall with an elliptical cross-section. The elliptical cross-section may synergistically provide enhanced mixing and enhanced durability of the blade compared to previously known joint compound mixers. For example, the elliptical cross section may provide structural support to the radially outwardly extending arms and/or the longitudinally extending walls while allowing the radially outwardly extending arms and/or the longitudinally extending walls to cut through and spread joint compound.
The structural support may allow the blade to be made of a plastic material. For example, the blade may be made of acrylonitrile butadiene styrene (ABS). Making the blade out of plastic may reduce scratching and degradation of the container that holds the joint compound during mixing, compared to previously known drywall mixers made of metal. The plastic blade may reduce scratching of the surfaces of the container during mixing, compared to previously known drywall mixers.
The entire outer surface of the blade may have a smooth plastic finish, such as a smooth ABS. The smooth finish may allow the outer surface of the blade to repel joint compound for easier cleaning of the blade, compared to previously known drywall mixers.
According to one aspect of the invention, a mixing device includes a blade extending along a longitudinal axis, including: a first radially extending arm extending from a first radially central portion of the blade, wherein the first radially extending arm has an elliptical cross-section, and wherein the first radially extending arm includes a trailing edge, a leading edge, and a central portion between the trailing edge and the leading edge, a second radially extending arm extending from a second radially central portion of the blade that is axially spaced from the first radially central portion, wherein the second radially extending arm has an elliptical cross-section, and wherein the second radially extending arm includes a trailing edge, a leading edge, and a central portion between the trailing edge and the leading edge, a first axially extending wall extending from a radially outer end of the first radially extending arm to a radially outer end of the second radially extending arm, wherein the first axially extending wall has an elliptical cross-section, and wherein the first axially extending wall includes a trailing edge, a leading edge, and a central portion between the trailing edge and the leading edge, a third radially extending arm extending from the first radially central portion of the blade, wherein the third radially extending arm has an elliptical cross-section, and wherein the third radially extending arm includes a trailing edge, a leading edge, and a central portion between the trailing edge and the leading edge, a fourth radially extending arm extending from the second radially central portion of the blade, wherein the fourth radially extending arm has an elliptical cross-section, and wherein the fourth radially extending arm includes a trailing edge, a leading edge, and a central portion between the trailing edge and the leading edge, and a second axially extending wall extending from a radially outer end of the third radially extending arm to a radially outer end of the fourth radially extending arm, wherein the second axially extending wall has an elliptical cross-section, and wherein the second axially extending wall includes a trailing edge, a leading edge, and a central portion between the trailing edge and the leading edge, wherein each leading edge is able to cut through joint compound to be mixed, or any other fluid to be mixed, when the blade is rotated about the longitudinal axis in a first circumferential direction, and at least a portion of each leading edge is thinner than each adjacent central portion.
The foregoing and other features of the invention are hereinafter described in greater detail with reference to the accompanying drawings.
The principles of this present application have particular application to mixing joint compound, and thus will be described below chiefly in this context. It will of course be appreciated, and also understood, that principles of this invention may be applicable to other materials.
Referring now in detail to the drawings, and initially to
The shaft 24 may be concentric with the longitudinal axis A and may have a length along the longitudinal axis A that is greater than a length of the blade 22 along the longitudinal axis A. For example, drive end of the shaft 24 may extend through most of the blade 22 and a driven end of the shaft 24 opposite the drive end may extend away from the blade 22 more than three lengths of the blade 24 to allow a driver (not shown) to attach to the opposite end of the shaft 24 to drive the shaft 24. In an embodiment, the shaft may be any suitable length to allow the driver to driver the drive shaft.
The shaft 24 may have a hexagonal cross-section for engaging with any suitable driver (not shown), such as an electrically powered cordless drill, to drive the blade 22 via the shaft 24. In an embodiment, the shaft may have any suitable cross-section that is engageable with the driver. For example, an end of the shaft opposite the blade may have a cross-section that is square, round, octagonal, or any other suitable shape.
Turning now to
The second radially extending arm 32 and the fourth radially extending arm 36 may extend from a second radially central portion 52 of the blade 22—that is axially spaced from the first radially central portion 50—toward the corresponding axially extending wall 38 or 40. For example, the second radially extending arm 32 and the fourth radially extending arm 36 may extend radially outward along a second lateral axis L2 that is perpendicular to the longitudinal axis A and longitudinally offset from the first lateral axis L1.
The radially-central cylindrical support 42 may extend longitudinally from the first radially central portion 50 to the second radially central portion 52. For example, the radially-central cylindrical support 42 may be concentric with the longitudinal axis A for housing the drive end of the shaft 24 (shown in
The radially-central cylindrical support may have an opening 54 leading to a hole 56 (shown in dashed lines in
The hole 56 may extend through most of the radially-central cylindrical support 42 toward the second radially central portion 52. For example, the second radially central portion 52 may form a protective cover over an axial most end of the drive end of the shaft 24 to prevent the drive end from directly contacting of inner wall of a container while the blade 22 is inside the container.
The radially-central cylindrical support 42 may be fixed to the shaft 24 by any suitable connection, such as by an adhesive and/or by molding the radially-central cylindrical support 42 to the shaft 24. In an embodiment, the opening extends through the entire radially-central cylindrical support to provide maximum support for the shaft. For example, the first radially central portion, the second radially central portion and the radially-central cylindrical portion may together circumscribe the drive end the shaft. In another embodiment, the hole extends through less than half of the radially-central cylindrical support. For example, the first radially central portion and less than half of the radially-central cylindrical portion may together circumscribe the end the shaft.
The opening 54 may be adjacent the first radially central portion 50. For example, the opening 54 and the hole 56 may be concentric with the longitudinal axis A so that a center of the rotation of the shaft is adjacent a radially inward end of the radially extending arms 30-36. In an embodiment, the opening may be radially offset from the longitudinal axis.
Turning now to
The first radially extending arm 30 may include a trailing edge 30t, a leading edge 30l, and a central portion 30c between the trailing edge 30t and the leading edge 30l. For example, at least a portion of the leading edge 30l may be thinner than the adjacent central portion 30c and/or at least a portion of the trailing edge 30t may be thinner than the adjacent central portion 30c. The leading edge 30l may be able to cut through joint compound when the blade 22 is rotated about the longitudinal axis in a first circumferential direction C. Alternatively, the trailing edge 30t may be able to cut through the joint compound when the blade 22 is rotated about the longitudinal axis in direction opposite to the first circumferential direction C.
Similar to the first radially extending arm 30, the second radially extending arm 32 may include a trailing edge 32t, a leading edge 32l, and a central portion 32c between the trailing edge 32t and the leading edge 32l. The second radially extending arm 32 may be symmetrical with the first radially extending arm 30 relative to a plane transverse to the longitudinal axis A and extending through an axial center of the radially-central cylindrical support 42. For example, the second radially extending arm 32 may be circumferentially aligned with the first radially extending arm 30.
The first axially extending wall 38 may extend from a radially outer end of the first radially extending arm 30 to a radially outer end of the second radially extending arm 32. The first axially extending wall 38 may include a trailing edge 388t, a leading edge 38l, and a central portion 38c between the trailing edge 38t and the leading edge 38l. For example, the leading edge 38l of the first axially extending wall 38 may be radially offset radially outwardly from the adjacent central portion 38c such that rotation of the blade 22 in the first circumferential direction C would urge the joint compound radially inwardly.
At least a portion of the leading edge 38l may be thinner than the adjacent central portion 38c and/or at least a portion of the trailing edge 38t may be thinner than the adjacent central portion 38c. The leading edge 38l may be able to cut through the joint compound when the blade 22 is rotated about the longitudinal axis in a first circumferential direction C. Alternatively, the trailing edge 38t may be able to cut through the joint compound when the blade 22 is rotated about the longitudinal axis in direction opposite to the first circumferential direction C.
The adjacent central portion 38c may form a radially inward facing surface that extends between the leading edge 38l and the trailing edge 38t and faces slightly tangentially to a rotational path of the axially extending wall 38 about the longitudinal axis A. Facing the radially inward facing surface slightly tangential to the rotational path allows the radially inward facing surface to urge the joint compound in the first circumferential direction C when the radially-central cylindrical support 42 rotates in the first circumferential direction C.
The third radially extending arm 34, the fourth radially extending arm 36, and the second axially extending wall 40 may be a mirrored copy of the first radially extending arm 30, the second radially extending arm 32, and the first axially extending wall 38 across a plane extending parallel to the longitudinal axis A. For example, the radially extending arms 34 and 36 and the second axially extending wall 40 may be diametrically opposite the radially extending arms 30 and 32 and the first axially extending wall 38, respectively, relative to the longitudinal axis A.
Similar to the radially extending arms 30 and 32 and the first axially extending wall 38, the radially extending arms 34 and 36 and the second axially extending wall 40 may include a respective trailing edge 34t, 36t, or 40t, a respective leading edge 34l, 36l, or 40l, and a respective central portion 34c, 36c, or 40c.
Together, the first radially extending arm 30 and the third radially extending arm 34 may have a propeller shape. For example, the leading edge 30l and the trailing edge 30t may be tilted an angle θ relative to a normal axis Z that is centrally disposed between the dashed lines 30d and 32d and orthogonal to a plane formed by the longitudinal axis A and the lateral axis L1. The leading edge 30I and the trailing edge 30t may be longitudinally offset from one another such that the first radially extending arm 30 is tilted an angle θ (shown best in
The angle θ may affect the amount of power required to rotate the blade 22. The angle θ may be higher than 20°, which may result in the blade 22 having a relatively higher resistance to rotation. The higher resistance to rotation may require more power to rotate the blade 22 during use. Alternatively, the angle θ may be lower, which may result in the blade 22 having a relatively lower resistance to rotation. The lower resistance to rotation may require more power to rotate the blade 22 during use.
Offsetting the leading edge 30l of the first radially extending arm 30 from the adjacent central portion 30c and/or the trailing edge 30t in a first axial direction A1 allows the first radially extending arm 30 to urge the joint compound in the second axial direction A2 when the blade 22 is rotated. For example, the first radially extending arm 30 may form a surface that extends between the leading edge 30l and the trailing edge 30t and faces partially in the second axial direction A2 such that rotation of the blade 22 in the first circumferential direction C urges the joint compound in the second axial direction A2.
Similar to the first radially extending arm 30, the third radially extending arm 34 may be tilted an angle −θ relative to an axis orthogonal to a plane formed by the longitudinal axis A and the lateral axis L1 and that is centrally disposed between the radially extending arms 34 and 36. For example, the third radially extending arm 34 may mirror the first radially extending arm 30 across the plane extending parallel to the longitudinal axis A. In an embodiment, the third radially extending arm may be tilted an angle other than −θ, such as any angle between 5° and 45°.
The second radially extending arm 32 and the fourth radially extending arm 36 may similar form a propeller blade shape identical to the propeller blade shape of the first radially extending arm 30 and the third radially extending arm 34. For example, the first radially extending arm 30 and the second radially extending arm 32 may be parallel to one another such the corresponding leading edges 30l and 32l are axially offset from one another a distance equal to an axial offset of the corresponding trailing edges 30t and 32t. The third radially extending arm 34 and the fourth radially extending arm 36 may be parallel to one another such the corresponding leading edges 34l and 36l are longitudinally offset from one another a distance equal to a longitudinal offset of the corresponding trailing edges 34t and 36t.
In an embodiment, the second radially extending arm is tilted at an angle different than first radially extending arm and/or the fourth radially extending arm is tilted at an angle different than third radially extending arm.
The blade 22 may be entirely made of plastic, such as Acrylonitrile butadiene styrene (ABS). Making the blade 22 of plastic may reduce wear and tear of containers that hold joint compound while being mixed, compared to previously known joint compound mixers made of metal. For example, when the blade 22 rotates within a container with joint compound (not shown) to mix the joint compound, the blade 22 may rub and/or grind against inner walls of the container. The plastic of the blade 22 may wear away significantly less container material compared to previously known metal joint compound mixers. In an embodiment, the blade may be made of any other suitable material.
When the blade 22 and end of the shaft 24 (shown in
While the blade 22 rotates in the joint compound, the joint compound rotation of the blade 22, which may result in mechanical stresses within the blade 22. The elliptical cross section of the radially extending arms 30-36 (shown best in
The radially extending arms 30-36 and the axially extending walls 38 and 40 may together urge the joint compound in the direction of rotation of the blade 22. For example, when the blade 22 is rotated in the first circumferential direction C the joint compound may be urged in the first circumferential direction C and radially inward. When the blade 22 is driven in a second circumferential direction D opposite the first circumferential direction C, the joint compound may be urged in the second circumferential direction D and radially outward.
The radially extending arms 30-36 may together urge the joint compound axially. For example, when the blade 22 is rotated in the first circumferential direction C the joint compound may be urged in the second axial direction A2 away from the driven end of the shaft 24. When the blade 22 is driven in the second circumferential direction D, the joint compound may be urged in the first axial direction A1 opposite the second axial direction A2 toward the driven end of the shaft 24.
Although the invention has been shown and described with respect to a certain embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described elements (components, assemblies, devices, compositions, etc.), the terms (including a reference to a “means”) used to describe such elements are intended to correspond, unless otherwise indicated, to any element which performs the specified function of the described element (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiment or embodiments of the invention. In addition, while a particular feature of the invention may have been described above with respect to only one or more of several illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application.
This application claims the benefit of U.S. Provisional Application No. 62/150,582 filed Apr. 21, 2015, which is hereby incorporated herein by reference.
Number | Date | Country | |
---|---|---|---|
62150582 | Apr 2015 | US |