application Ser. No. 11/286,975 PAINT BUCKET 2005 NOV. 28
Not Applicable
Not Applicable
This invention relates to receptacles with container attachment or adjunct. More specifically, to receptacles (paint buckets) including edge for removing excess material (i.e. scraper) with tool or brush holder.
Paint buckets up till now have almost always been needed/used in some fashion for brush dipping, brush wiping, and brush holding. It is desirous to comfortably hold or support a bucket while in use; to have an easy-to-dip-into bucket; to have a means to keep a paint implement out of the paint; to have a means to keep the rim clean and paint from dripping out of the bucket; to compactly stack buckets to reduce shipping costs and shelf space; and to have the bucket to be easily cleanable. Additionally pouring from and sealing a bucket would be benefits. It is a crowded art, yet prior art buckets have not yet fulfilled all these basic needs with a single bucket.
Round (at lip and base) buckets are common prior art. Perhaps most buckets were round because metal-formed cans and buckets were easiest to make round, perhaps many expect them to be round. However, round-lipped containers limit the dipping area of paint brushes, which are flat-sided. This problem is most obvious when one tries to dip a 4″ wide brush in a 1 gallon paint can that averages a 5.5″ inside diameter, like that shown in Prior Art FIG. X3 (a 4″ brush in use on a 1 gal can of paint, front perspective view (correct proportions drawn from a photograph)(can walls are cylindrical, no taper like injection mold buckets)): The brush virtually has to be dipped straight down from the top of such a can, which likely requires sitting a can down. Often when painting, sitting a can down on a stable surface while painting is not an option. One can tilt the can gripping the wire handle-and-cans-side, but this is only bearable if the can is mostly empty. Wiping a flat-sided brush on a round rim leaves the brush with an uneven load of paint. Often one tries to wipe nearly horizontal to more evenly wipe paint, but this often leaves paint in the sealing groove. Laying the brush on a cans top lip drips paint out of the can, leaves the lip groove full of paint, gets the handle messy with paint, spills paint out of the can, and is not always a secure place for the brush. Cleaning the groove for a good can seal is very time-consuming.
Noted is U.S. Pat. No. 3,595,431 by Francis L. Bird, granted Jul. 27, 1971, entitled DRIPLESS PAINT CONTAINER, which shows a circular-lipped container. In his abstract he states, “molded plastic paint container” with “two snap-on wire rods in diametrically opposed parallel relation to serve as wipers for the brushes enabling drainage of excess paint therefrom without any spillage. These rods also serve as shelves on which to rest the brush or brushes when not in use.” P. 1, lines 2-3, he states; “its principal object . . . low cost”.
Wire rods in his plastic bucket requires additional labor and expense beyond a basic bucket. Such rods (if not made of expensive stainless steel) can eventually rust (with latex paint) even if galvanized, as wiping is surface-abrasive. Also, a latex paint manufacturer could not sell their product in such a bucket because of the rustable rods. Because the container has a substantially round lip and base, the inside rods further restrict the usable dipping area. Though Francis does not state size, his drawing
A greater problem arises if his rods are used as a brush shelves. This is depicted in my redrawing of his
U.S. Pat. No. 4,927,046 by Robert E. Armstrong, granted May. 23, 1990, entitled HOLDING VESSEL WITH SUPPORTIVE HANDLE has a ledge to hold brush bristles and has oppositely-positioned center spout notch to hold brush neck. It's pentagonal shape likely an effort to elongate the container to hold a brush from handle ledge to handle. But the pentagonal shape makes brush wiping on a lip difficult, because a user is comfortable wiping straight in, where his
Though paint brushes are rectangular, and a rectangular container would more easily avail paint for use, both Armstrong and Bird teach away from that shape, perhaps because round shaped containers have almost always been used for painting with brushes. (A pentagonal shape is substantially round compared to a rectangular shape). Prior art rectangular-lipped molded plastic containers include plastic food containers, and some bathroom wastebaskets. Rectangular-lipped food containers with rounded corners allow for a secure seal with a lid.
Most importantly, Bird and Armstrong's containers cannot be stacked sufficiently one-inside another to reduce space. That is, buckets are low ticket items, so large quantities must take up a minimal amount of space when shipped and shelved in stores. Bird's bucket, even if rods were shipped separately, cannot be stacked one closely inside another because of the rod supports. Armstrong's handle prevents stacking of his container.
Large plastic totes, like Sterilite's 18 gal tote model 603171BL have opposite-side indentations (that interiorly look like round mounds) that are for handles. Another tote with indentations is seen at globalindustrial.com is 744171 which is size 16.3″ L×11.5 W×5.8″ H. Utility of indentations is for a user to cup their fingers of each hand under opposite side indentations such that the tote can be carried between the user's arms. Because of the large size and weight of the totes, and somewhat because of the shape of the indentations) the tote cannot be lifted easily by grasping just one side of the tote under the handle. The handle/ledges are positioned up high on the tote for the second benefit of mating with the opposite-side lid handles. The tote is of a size that a 9″ roller would roll horizontally in the tote. And some (9″ rollers have extension handles that might extend the 16″ horizontal width of the tote/box. However the interior side of a handle/mounds is not wide/flat enough into the bucket enough to support the cylinder of the roller on it, and it is too long to support a brush handle on the opposite side of the handle.
Prior art paint brushes (2″ to 4″ wide) are of average 9″ to 11″ brush tip to handle end. 3″ and 4″ wide (2″ diameter) roller handles average 10″ to 11.5″ from roller barrel to handle tip. Prior art 9″ (2″ diameter) roller handles average 12″ to much longer extended handles from roller barrel to handle tip.
U.S. Pat. No. 5,8110,196 by Michael J. Lundy, granted Sep. 22, 1998, entitled PAINT BUCKET, and U.S. Pat. No. 4,164,299 by Patti S. Fuhr, granted Aug. 14, 1979, entitled TRAY FOR PAINT AND BRUSHES show a separate compartment to stand a brush upright while not in use. Sur-line pail # 12300, a 5 qt. bucket, also shows a separate compartment to hold a brush. Shur-line's has roller grid up one side of the bucket that slants into the bucket, and bottom extensions beneath it. All the pail's compartments and corners make for difficulty cleaning. As pressure must be placed on the grid side of the pail when rolling a roller on it, the bucket would easily tip, so one substantially needs to use a second hand to secure the pail, so painting standing up requires bending over to hold the pail. Brush painting (versus 9″ roller painting) is usually done with the pail close to the user. So a user must lift the brush into a vertical position to put it in the second compartment. The non-compartment side of the paint pail is usable when closest to the user, so a user must reach over and vertically place the brush in with every stopped use. There is a hole where the roller handle can sit to keep roller out of paint so roller won't soak therein drip. For the roller to be hung inside the pail but not in the paint, the pail must be about ⅔ empty. Because the bucket is tall and deep, a brush painters hand is more likely to get paint on it, especially if roller and brush used alternately.
Lundy's bucket could have the effect of Bird's rod in holding brush bristles (but for the bucket being way too long). However having a pouring spout where the handle would lay is where paint would be, which would make the handle gooey with paint. The depth of his brush holding compartment makes the distance even longer and absurdly impossible.
Other prior art brush holding means include magnets, where the brush needs positioned just so and the bucket is to be held to pull the brush off to not spill paint. Also, paint can get on the ferrule, which is unpleasant at best. Paint on ferrule and magnet side also reduces magnet effectiveness.
This invention is an injection-moldable, substantially rectangular lipped paint bucket, with opposite-side, substantially parallel-edged ledges, ledges formed from the walls beneath the rectangles opposite-side narrower sides. In one embodiment, the first ledge is substantially 0.5 to 0.7″ down from the bucket lip. the second ledge is substantially 2″ down from the bucket lip. These ledges are formed substantially as upside-down L-shaped indentations in the bucket's narrower sides. Each ledge edge protrudes substantially 1″ into the bucket, and is substantially 6″ wide. The first ledge is for brush wiping below the bucket lip. The second ledge, along with the bucket lip rim on the opposite side, is for brush support. The second ledge doubles as a handle.
The first ledge lets a painter wipe a brush slightly down and away from the lip, to keep the lip clean for a lid or brush handle. The ledge is wide enough to wipe even a 4″ brush without paying much attention. The ledge tilts to allow paint to drip back in the bucket. One can pour paint from that side's corners.
The second ledge is wide and deep enough to easily lay flat even 4″ wide brushes. It is down about 1.75″ to 2″ to lay a brush bristles in the bucket without dripping paint outside the bucket. (Brush handle lays on opposite-side bucket lip rim.) The second ledge is either flat or declines away from the buckets center to help keep the brush from slipping off.
The buckets rectangular shaped lip and body easily allows a wide (like 4″) brush to be dipped while holding the buckets handle. The bucket can also be tilted (to get the last of the paint) by grabbing under the second ledge and above the same-side lip, like a handle. An average bucket can hold a gallon of paint below the lowest ledge (so it is always useable). Ledges formed as upside-down L-shaped indentations in a bucket are as easy to injection mold as common prior art plastic buckets. Because there are no extra parts (like metal rods), a paint manufacturer could sell their product in the bucket. The wiping/resting ledges average 6.25″ wide, so one doesn't have to maneuver a brush to wipe it, like if the ledge were only the exact width of the brush.
Holding a bucket by prior-art style metal handle is the most stress-free way of holding a bucket. With my bucket there's lots of room to dip a brush while hanging from the handle (because any bucket handle must lay substantially against the bucket side when not in use). This buckets handle is taller and flatter at the top than prior art buckets. A longer handle makes the buckets dipping area larger. Holding the flat handle is easier. [In contrast, prior art bucket openings are smaller/restrictive, and they often must be tilted to dip inside, which is strenuous on the wrist.] A 4″ painting grid can fit in my bucket because of the square lip and close-to-the-top first ledge. The rectangular shape is best for rollers, which are wide. The bucket is as easy to use by both left-handed and right-handed users (just turn the bucket around). The bucket can be stacked one inside another closely as prior art plain round buckets, which is a most important factor in reducing shipping costs and shelf space. Laying a brush down on/in the bucket is a more convenient position to leave a brush, as it requires no wrist twisting like second-compartment brush supports. Adding a roller grid versus making the grid part of the bucket allows for stable weight balance in the bucket and for more paint to be filled in the bucket. Laying a brush from right rim to left ledge is most advantageous because first ledge keeps the right rim clean and exact brush positioning is not required. That is, the first ledge and second ledge work together: keeping paint off a brush handle when brush bristles are positioned on the second ledge. A bucket design that allows for a sealing lid lets a painter go to lunch or come back the next day and continue painting without emptying and cleaning the bucket. The bucket has a single open area for paint, which makes cleaning the bucket easier.
PRIOR ART FIG. X1 is Bird's bucket in use, front view.
PRIOR ART FIG. X2 is Bird's bucket in use as a ledge, top view.
PRIOR ART FIG. X3 is a 4″ brush on a 1 gal can, front perspective view.
1 is a detail of the embodiment shown in
2 is an alternative lip embodiment, same view as
The embodiment has opposite-side (wider) front and back side walls 5F and 5B, each positioned beneath opposite-side lip rim longer portions. The bucket has opposite-side (narrower) left and right side walls 6L and 6R, each positioned beneath opposite-side lip shorter portions.
The bucket has two opposite side ledges 7L and 7R. The ledges each have a substantially straight horizontal edge (edge 8L and 8R) positioned inside the bucket. The ledges each substantially position beneath and substantially parallel with the shorter sides of the lip (best seen in
A substantial portion of each ledge edge protrudes at least ¾ inch horizontally centrally into the bucket from a corresponding lip shorter side. In this embodiment, each ledge protrudes about 1.2″ horizontally centrally into the bucket. The ledges are substantially integrally formed from the buckets narrower side walls, appearing as substantially horizontally-elongated upside-down L-shaped indentations in the narrower side walls (best seen in
The bucket has circumferentially enclosing side walls 5F, 5B, 6L, and 6R. The bucket has bottom 9 fixedly attached to substantially the bottom edges of all the side walls. The side walls together integrally form circumferentially enclosing side walls. All the side walls have bottom edges. Bottom 9 is fixedly attached substantially to all side wall bottom edges. So together, the bottom and side walls integrally form a container. The side walls are shown (best seen in
The bucket lip has a rim 10, which is the top-most portion of lip 1. In this embodiment, the lip is flat on top. The ledges are right hand side first ledge 7R and a left-hand side second ledge 7L. [Best seen in
The lips longer sides each have a horizontal middle (middle 1FM and 1BM). In use, the bucket should include a pair of prior art integrally-formed handle supports, like handle supports 11F and 11B. The supports position slightly beneath/directly beneath the lip at corresponding opposite-side horizontal middles 1FM and 1BM. Attached thereto is prior art wire metal handle, like handle 12. The supports are each of a size and shape to support one of two sides of a prior art style wire handle.
The bucket has a downwardly tapered form to be easily removable from a molding tool. A 5° total grade (includes both sides) is average for buckets that stack within each other. The bucket is of a downwardly tapered form to be stackable one said bucket substantially inside an identical bucket.
The bucket may be injection, vacuum-, blow-, or roto-molded. Or other. Though demonstrated for paint, my buckets utility is of benefit for liquids like wallpaper paste, as well as more viscous materials. In example, a smaller bucket of the same shape could be used for spackle (smaller bucket so spackle knife fits across from the second ledge to the opposite-side lip). The bucket can be used by right or left handed users by just turning the bucket around. Materials to make the invention include, but are not limited to be made from polypropylene, HDPE, or other plastics or resins. The lip is the area near the top of the bucket from the rim down. It may include the top portions of the side walls of a size and shape to mate with a lid. Often the lip can be the top quarter inch of the bucket.
All embodiments show a circumferentially-continuous lip rim. The second ledge is of a size and shape to support bush bristles flat side when brush bristles are placed on the second ledge and brush handle is placed on said right rim portion. The first ledge edge of a size and shape to wipe a brush flat-side and is for wiping a brush inside said bucket, for keeping paint off the right lip rim portion, and for keeping paint off a brush handle. The second ledge is horizontal to sloping upward medially, the first ledge is horizontal to sloping downward medially. The distance between upper portion of left side wall and the right side lip rim is less than the total length of a prior art paint brush, which is most often a distance less than 11″
The cross-section shows 6LD lower portion of the left side, which is below the second ledge. The second ledge is sloping/inclining upward medially, for keeping brush bristles or a roller from moving off the ledge. Specification describing the second ledge as upside-down L-shaped includes the description of the lower portion of the left side because it is integral to forming (by injection mould) and supporting the ledge, whereas the upper portion is not. The upper portion of both ledges has other utilities, like for sealing a lid on, keeping the lip clean, and keeping the paint implement on the second ledge from moving off to the left.
The cross-section shows 6RU upper portion of the right side, which is above the first ledge. This right side upper portion is only as tall as what is needed to seal a lid away from the paint, a height of which can be 0.25″ tall. The first ledge is sloping/declining downward medially for allowing paint to drip back into the bucket. The cross-section shows 6RD lower portion of the right side, which is below the first ledge. Specification describing the first ledge as upside-down L-shaped includes the description of the lower portion of the right side.
The invention provides a second ledge for holding a brush, a first ledge for brush wiping, and a rectangular, therein enlarged, area for brush dipping. The bucket can be a one-piece moldable from a 2-part tool. Buckets can be closely stacked, for saving shipping and shelf space. No other buckets, alone or in combination, recognize the ledge, clean rim, dipping benefits or that L-shaped ledges would allow buckets to be easily made and stacked.
Number | Date | Country | |
---|---|---|---|
Parent | 11286975 | Nov 2005 | US |
Child | 11906985 | Oct 2007 | US |