Patent Application
20230304307
This application claims priority to Australia Patent Application No. 2022900784, filed Mar. 28, 2022, the disclosure of which is incorporated herein by reference in its entirety.
The present invention relates generally to finishing tools for use in plasterboard (a.k.a. drywall) construction, and more specifically to rollers, particularly (but not exclusively) corner rollers, for use in plasterboard finishing.
In plasterboard construction (a.k.a. drywall construction), so-called “plasterboard” panels or sheets (a.k.a. “drywall” panels) are secured to framing to create surfaces of interior walls, ceilings and the like. The individual plasterboard panels (sheets) themselves are typically supplied with dimensions in the order of 3000 mm×1200 mm×10 mm, although panels can of course be supplied in different sizes, and in any case, they are (where necessary) cut to the required size and shape prior to installation. The plasterboard (drywall) panels themselves are made from a layer of gypsum plaster (or similar material) sandwiched between two outer layers of heavy-duty paper (or similar outer surface material). Thus, the internal layer in the panel (which is what provides the panel's rigidity) is already dry/set when the panels are supplied, and before the panels are cut to size (if necessary) and secured to framing to form e.g. part of a wall or ceiling surface. As a result, plasterboard panels are easy to secure in place, typically by simply nailing or screwing them to the underlying wall or ceiling framing.
The fact that the plaster layer within each plasterboard panel is already dry/set (and therefore solid) at the time when the panel is supplied (and before the panel is attached to the framing to form part of the wall or ceiling surface) is also the reason why plasterboard panels are sometimes known by the other common name, “drywall” panels/sheets.
When adjacent plasterboard panels are installed at an angle to one another, that is, to create a corner (which may be either an internal corner or an external corner) where the edge of the plasterboard panel (or the edges of the plasterboard panels) on one side of the corner meets with the adjoining edge of the other plasterboard panel (or with the adjoining edges of the other plasterboard panels) on the other side of the corner, there is generally a gap (or at least a line or join) between the edges of the panels on either side of the corner.
This gap or line/join between the panels on respective sides of a corner, regardless of whether the corner is an internal corner or on external corner, needs to be “finished”. This “finishing” of the corner is important not only for cosmetic reasons (for example to ensure that any such gaps between panels on or in corners are filled and smoothed etc before being painted), but also because the finishing of such corner gaps and lines also has an important reinforcing purpose.
The finishing of the gaps and joints/lines between the panels on either side in an internal corner, as part of the finishing process, often involves applying a tape which is made of paper or a similar material. An example of such tape is visible in
The finishing of the gaps and joints/lines between the panels on either side on an external corner, as part of the finishing process, often involves applying a bead on to the external corner. Beads used for this purpose are typically made of plastic/polymer, metal (e.g. PVC, paper faced PVC, other plastics, other paper faced plastics, metal, paper faced metal etc) or some similar material that has at least a degree of inherent rigidity such that, when the external corner is finished, the bead helps to support the corner. An example image showing a bead (which in this case is a plastic bead) is given in
In any case, the tape or bead (whichever is used in the finishing of a given corner) generally extends along at least most of the length of the corner, and the tape or bead (whichever is used) is adhered or secured to edge portions of the panels on either side of the corner. The tape or bead is often secured in place (secured to the edge portions of the panel on either side of the corner) by an adhesive paste, commonly referred to as finishing compound or simply “compound” or “mud”. This compound can be applied in the form of a liquid or paste before the tape or bead is applied onto (or into) the corner. Alternatively, in some cases, the tape or bead may be supplied with some form of adhesive pre-applied to it (whilst this is possible for both tapes and beads, it is more commonly done with beads and not as common with tapes). For example, some beads are supplied with a water-activated adhesive already on them (i.e. on the relevant portions of the bead which are to become adhered to the panels on either side of the corner), such that all that is required is to wet the adhesive on these portions of the bead (to activate the adhesive) before pressing the bead on to (or into) the corner so that the portions of the bead which have the (activated) adhesive thereon then adhere to the edge portions of the surfaces of the panels on either side of the corner.
As alluded to above, the finishing of corners (e.g. by applying a tape or bead to “finish” in the corner, as described above), in addition to just covering the gap between the panels on either side of the corner for cosmetic purposes (i.e. in addition to the fact that this can allow a smooth finish to then be created over/in and along the corner gap prior to painting), also serves a reinforcing purpose. This is because the finishing (and the tape or bead used for this) can also help to reinforce the corner by helping to further secure the panels on either side of the corner relative to one another. For example, in cases where the tape or a bead is secured in place by an adhesive compound (or “mud”) which is applied to the corner as a paste before the tape or bead is applied, the adhesive compound that secures the tape or bead may also become squeezed into the gap and at least partly fill the gap between the panels on either side of the corner. In such cases, when compound that has been squeezed into the gap between the panels sets, it helps to join/bond the panels on either side of the corner together, and this helps to reinforce the panels and the corner/joint between them. Also, as alluded to above, in cases where a bead (which itself has a degree of inherent rigidity) is used, the bead itself (especially once the bead has been properly pressed/embedded onto/into the corner and the adhesive has set) helps to reinforce the corner.
As also alluded to above, as part of the process of finishing a corner, after the tape or bead has been applied to the corner, but before the adhesive used to secure the tape or bead in place has set, it is common to use a roller to firmly press (embed) the tape or bead into/onto the corner, along the whole length thereof, thereby ensuring that the tape or bead is firmly secured/embedded (in the correct position) in the corner when the adhesive sets.
A range of rollers have traditionally been used for this purpose. For example, in order to roll tapes or beads that are applied as part of the finishing process in 90° internal corners, a range of “fixed” 90° internal corner rollers have been designed and are still commercially available and widely used. An example of one such “fixed” 90° internal corner roller is shown in
It can be seen in both images in
In order to roll the beads that are typically applied as part of the finishing process on 90° external corners, a range of “fixed” 90° external corner rollers have been designed and are still commercially available and widely used. An example of one such “fixed” 90° external corner roller is shown in
Like the “fixed” 90° internal corner roller shown in
The previous “fixed” 90° internal corner roller shown in
However, it is quite common in building and construction for internal and external corners to be created between e.g. walls, walls and ceilings, etc, that have angles that are not (i.e. angles that are other than) 90°.
Accordingly, a number of other tools have also previously been proposed which can be used for rolling internal and external corners in which the angle is not exactly 90°. In particular, a range of roller tools have been designed (and are available) for use in finishing corners having angles between the panels which are between 90° and 180° (i.e. 90°<corner angle 180°), and for finishing corners in which the angle between the panels is between 180° and 270° (i.e. 180° corner angle <270°), and also for finishing corners which are less than 90° or greater than 270°. Some such existing roller tools are “fixed” tools with a design that is generally similar to the tools shown in
In an attempt to try and address this issue, a range of “adjustable” roller tools have also previously been proposed in which the angle between the respective sets of rollers of the tool can be adjusted so as to enable the same tool to be used to roll corners having a range of different angles. In general, these kinds of adjustable roller tools have a pair of wings, where each wing has a number of rollers, such that the rollers on each respective wing can be used to roll the tape or bead on either side of a corner, and the angle between the wings is able to be adjusted to enable the rollers on the respective wings to be used to roll portions of the tape or bead on either side of internal or external corners having a range of angles. Typically, such adjustable tools are able to be used on corners which are both less than 180° (internal corners) and more than 180° (external corners). In most of these adjustable tool designs, some kind of securing mechanism is provided such that, when the securing mechanism is released, the angle between the respective wings of the tool is able to be changed, but when the securing mechanism is engaged/tightened, the angle between the respective wings of the tool becomes fixed. Accordingly, with these previous kinds of adjustable roller tools, it is generally necessary to first release the tool's securing mechanism and then manually adjust (i.e. set) the angle between the respective wings of the tool to correctly orient the rollers on the respective wings to the required angle before then engaging/tightening the securing mechanism to fix the angle between the wings (and hence fix the orientation of the tool's rollers) before commencing use of the tool on a given corner.
U.S. Pat. No. 5,203,954 to Moore provides one example of an adjustable roller tool of the kind just described. The tool in U.S. Pat. No. 5,203,594 has two plates, each of which supports a number of rollers, and the rollers on the respective plates are intended to roll surfaces on the respective sides of a corner. The two plates of this tool are connected to one another via a hinge mechanism, so the angle of one plate relative to the other plate can be adjusted via the hinge mechanism. The hinge mechanism includes a threaded pin onto which is screwed a wingnut. Loosening the wingnut loosens the hinge mechanism so that the angle between the plates is able to be adjusted/changed. On the other hand, tightening the wingnut causes the plates to become secured/fixed relative to one another so that the angle between them is held fixed. Thus, before the tool in U.S. Pat. No. 5,203,954 is put to use, the wingnut can first be loosened to allow the plates to be moved/adjusted relative to one another so as to orient the plates (and thus the rollers of the respective plates) at the angle required to roll the surfaces on either side of the particular corner on which the tool is to be used. Then, once the angle between the plates has been correctly set, the wingnut can be tightened thereby securing the plates together with the desired angle between them, and thereafter the tool can be put to use for rolling the surfaces on either side of the corner.
U.S. Pat. No. 9,938,731 assigned to Columbia Taping Tools, Ltd. provides another example of a previous manually adjustable roller tool. The tool in U.S. Pat. No. 9,938,731, which Columbia Taping Tools refer to as its “Corner Cobra” tool has two wings, each of which supports a number of rollers. The rollers on the respective wings are intended to roll surfaces on the respective sides of a corner. The two wings of this tool are connected directly to one another in a pivotal manner such that the orientation of one of the wings relative to the other (i.e. the angle between the wings) is able to be changed. A particular mechanism is provided to enable the angle between the wings of this tool to be changed. This mechanism includes a pair of rods. One of the rods has one of its ends pivotably attached to one wing, and the other rod has one of its ends pivotably attached to the other wing. The other ends of the rods (i.e. the ends of the rods which are not connected to the respective wings) connect to a common support block. The support block is also the part that the tool's hand pivotably attaches to. Thus, both of the rods connect to the support block, and more specifically, each rod is pivotably connected to the support block so that the angle of orientation of the (each) rod relative to the support block can change. An adjusting wheel (or barrel adjuster) mechanism provided which extends between the rods at a location close to the support block. Turning the adjusting wheel (barrel adjuster) in one direction causes the rods to move in such a way that the ends of the rods where the respective rods connect to the wings move apart. This, in turn, causes the wings to open relative to one another, i.e. bringing them closer to being in a common plane with one another. Conversely, turning the adjusting wheel in the other direction causes the rods to move in such a way that the ends of the rods where the respective rods connect to the wings move toward one another. This, in turn, causes the wings to “close” relative to one another, i.e. decreasing the size of the internal or external corner angle between the wings. Turning the adjusting wheel (barrel adjuster) in the direction that causes the wings to “close” relative to one another may cause the wings to either (i) close towards each other in a way that would orient the wings for rolling for an increasingly acute internal corner, or alternatively (ii) close towards each other that would orient the wings for rolling an increasingly sharp external corner—this depends on how the wings are oriented relative to one another at the time when the user begins to turn the adjusting wheel in the direction that causes the wings to “close”.
A problem with many previous manually adjustable roller tools, including tools like the ones in U.S. Pat. Nos. 5,203,594 and 9,938,731 just described (and others), is that, if the adjustment of the tool is inaccurate, i.e. if the angle between the wings (or plates) is not set so that the orientation of the rollers is perfectly set for (i.e. so that it perfectly/exactly matches) the angle of the particular corner (i.e. so that the rollers on the respective wings/plates of the tool press perfectly perpendicularly against the surface is on the respective sides of the corner), then when the tool (with the imperfectly angled the rollers) is used, the tape or bead is not pressed or bedded into the corner at the correct angle (e.g. the tape or bead may be pressed into the finishing compound, and it may become set, at an angle that does not match or is slightly different to the actual angle of the corner between the plasterboard panels). This can result in a poor (or at least an aesthetically suboptimal) finish.
Also, the adjustment of these previous manually adjustable tools is often difficult to get “right”, i.e. it can be difficult to ensure that the angle between the wings (or plates) of the tool is adjusted to perfectly match the angle of the corner on or in which the tool is to be used. The difficulty with this can be particularly pronounced in situations where the angle between the wings of the roller needs to be set so that the tool can be used to roll perspective surfaces on either side of a joint or gap which are close to “flat”, i.e. where the angle is close to 180°. In other words, with these previous manually adjustable tools, it is often inherently difficult to get the angle of the tool right (i.e. to ensure that the angle at which the wings/plates of the tool are set relative to one another exactly matches the angle of the particular corner on which the tool is to be used), but this is particularly difficult at near-180° geometries. This problem is particularly pronounced for the tool in U.S. Pat. No. 9,938,731 because that tool, due to its configuration, is practically unable to hold the two wings of the tool firmly and rigidly relative to one another if the angle between the wings is 180° or near-180°. The reason is because the wings of this tool have a natural tendency (due to the inherent design of the tool) to “pop” to an angle that is to one side or the other of the 180° (flat) configuration.
A related problem with these previous manually adjustable tools is that, because the tool must first be adjusted or “set” (i.e. with the orientation of respective wings or plates of the tool fixed/secured relative to one another) before the tool is used, consequently, these kinds of tools often perform relatively poorly when used on corners where the angle at which the plasterboard panels meet varies longer length of the corner. This (i.e. variation, even if only slight, in the exact angle between the plasterboard on either side of the corner) is relatively common, particularly on, for example, long corners between walls and ceilings, or the like, where the corner may run for most or all of the length of a building.
Another problem with a number of the manually adjustable roller tools that have previously been provided is that the means by which the respective wings of the tool are connected and made able to pivot/be adjusted relative to one another, and also the size and configuration of the securing mechanism by which the respective wings are secured (and released) relative to one another, often means that the location of the point where the tool's handle pivotally connects to the body of the tool (which includes the tool's wings/plates) is a considerable distance from the location where the rollers on the respective wings/plates actually press against the tape or bead. This relatively large distance between the locations where the rollers press against the tape or bead, and the location where the handle connects to the body of the tool, often results in these previous adjustable roller tools being quite unstable and difficult to use, and/or difficult to achieve a high-quality finish with. For example, this relatively large distance between the locations where the rollers press against the tape or bead, and the location where the handle connects to the body of the tool, can make it difficult to apply equal pressure to all of the tool's rollers at all times when the tool is in use.
The tool in U.S. Pat. No. 9,938,731 described above is an example of a tool for which this is a particular issue. Indeed, in this tool, there are numerous components (including the rods, the barrel adjuster, and support block) located in between where the rollers of the respective wings contact the surfaces to be rolled and where the tool's handle connects to the support block. In fact, in commercial versions of this tool, the distance between locations where the rollers of the respective wings contact the surfaces to be rolled and the location on the support block where the tool's handle connects is over 100 mm. This significant distance between the locations where the rollers of the respective wings contact the surfaces to be rolled and the location on the support block where the tool's handle connects means that it can be difficult for a user to apply constant and even pressure to all of the tool's rollers at the same time, which can mean that the surfaces to be rolled are not rolled evenly, which can lead to an uneven or less perfect finish.
Yet another problem with many of the previous manually adjustable roller tools like those described above (and others) is that they often use quite small diameter rollers, i.e. much smaller than the diameter of the rollers used on the kinds of “fixed” tools described above and shown in
It is thought that it would be desirable to provide a roller tool for use in drywall and plasterboard finishing, and also possibly for use in other applications, which helps to address or reduce one or more of the issues discussed above, or which at least provides an alternative to other roller tools currently available in the marketplace.
It is to be clearly understood that mere reference in this specification to any previous or existing devices, apparatus, products, systems, methods, practices, publications, patents, or indeed to any other information, or to any problems or issues, does not constitute an acknowledgement or admission that any of those things, whether individually or in any combination, formed part of the common general knowledge of those skilled in the field or is admissible prior art.
In a first form, albeit not necessarily the only or broadest form, the invention relates to a roller tool for use in plasterboard finishing, the tool having
wherein, in use, the tool can be pressed against surfaces on respective sides of a joint or line where adjacent plasterboard panels on either side of that joint or line meet or come together, such that the first wing roller(s) contact with the surface on one side of the joint or line and the second wing roller(s) contact with the surface on the other side of the joint or line (e.g. the tool may be pressed against a tape or bead that extends along the joint or line between adjacent plasterboard panels such that the first wing roller(s) contact with portions of the tape or bead that are to be adhered to the panel(s) on one side of the joint or line and the second wing roller(s) contact with portions of the tape or bead that are to be adhered with the panel(s) on the other side of the joint or line, and parts of the tool may also, at the same time, contact with portions of the plasterboard panels themselves on one or both sides of the joint or line e.g. on the outside of the tape or bead), and when the tool is pressed against the surfaces on the respective sides of the joint or line, the first wing and the second wing of the tool self-align (by pivoting relative to one another, if necessary) with the plasterboard panel(s) on the respective sides of the joint or line, such that the first wing roller(s) become(s) correctly oriented relative to the plasterboard panel(s) on one side of the joint or line (to press perpendicularly against (including while rolling along the surface of) the plasterboard panel(s) on that side of the joint or line), and the second wing roller(s) become(s) correctly oriented relative to the plasterboard panel(s) on the other side of the joint or line (to press perpendicularly against (including while rolling along the surface of) the plasterboard panel(s) on that other side of the joint or line).
In some embodiments, the first wing and the second wing may be symmetrical.
The first wing may have more than one first wing roller and/or the second wing may have more than one second wing roller. Also, one or both of the first wing and the second wing may include one or more additional rollers. The additional roller(s) may be positioned more outwardly, and it/they may help to provide stability, and/or it/they may assist the first wing rollers on the first wing and/or the second wing rollers on the second wing, as applicable, to roll the tape or bead).
The first wing and the second wing of the tool may be able to pivot relative to one another such that the angle between the first wing and the second wing on a surface-engaging side of the tool can be any angle in between (and including) two range extremes. At a first of the range extremes, the angle α between the first wing and the second wing on the surface-engaging side of the tool may be between 90° and 180°. Preferably, at the first of the range extremes, the angle α between the first wing and the second wing on the surface-engaging side of the tool may be at least as low as 90°. Even more preferably, at the first of the range extremes, the angle α between the first wing and the second wing on the surface-engaging side of the tool may be at least as low as 80°. Yet more preferably, at the first of the range extremes, the angle α between the first wing and the second wing on the surface-engaging side of the tool is at least as low as 75°.
At a second of the range extremes, the angle α between the first wing and the second wing on the surface-engaging side of the tool may be between 180° and 270°. Preferably, at the second of the range extremes, the angle α between the first wing and the second wing on the surface-engaging side of the tool may at least at as high as 270°. Even more preferably, at the second of the range extremes, the angle α between the first wing and the second wing on the surface-engaging side of the tool may be at least at as high as 280°. Yet more preferably, at the second of the range extremes, the angle α between the first wing and the second wing on the surface-engaging side of the tool is at least at as high as 285°.
The first wing and the second wing may both have one or more cut-outs and/or other shaped portions the shape and/or configuration of which helps to enable the first and second wings to pivot relative to one another without the roller(s) on one wing colliding with the other wing. Also, one or more of the first wing rollers may be mounted within a space within the first wing, and one or more of the second wing rollers may be mounted within a space within the second wing.
It is envisaged that, in most embodiments, it will be possible for a handle to be connected to the tool. The handle may be connected (often indirectly via one or more intermediate components) to the first wing and also (again indirectly via one or more intermediate components) to the second wing.
The tool may include a linking component, and the handle may be connected to the tool via the linking component. The tool may also have a first force transfer mechanism via which some force/pressure applied to the tool by the handle is transferred to the first wing, and a second force transfer mechanism via which some force/pressure applied to the tool by the handle is transferred to the second wing. Preferably, the amount of pressure/force from the handle which is transferred to the first wing by the first force transfer mechanism may be equal to the amount of pressure/force from the handle which is transferred to the second wing by the second force transfer mechanism. In some embodiments, the tool may include a first force transfer mechanism in the form of a first force transfer member (such as e.g. an arm or the like) which is pivotably connected to the first wing, and the tool may also include a second force transfer mechanism in the form of a second force transfer member (such as e.g. an arm or the like) which is pivotably connected to the second wing. In such embodiments, the first force transfer member (e.g. arm) and the second force transfer member (e.g. arm) may each also have a portion that is pivotally connected to the linking component. In some particular embodiments, the first and second force transfer members may both pivot relative to the linking component, but the movement of the first and second force transfer members relative to the linking component may also be “linked” such that the movement of the second force transfer member is always equal (in rate and amount of movement) and opposite (in direction) to the movement of the first force transfer member.
In some embodiments, an edge portion of the first wing may be connected to an edge portion of the second wing in a manner that permits the wings to pivot relative to one another about a wing pivot axis, and when the tool is configured with the first wing and the second wing pivoted relative to one another to enable the first wing rollers and the second wing rollers to roll respective sides of an internal corner having an angle that is less than 180°, the wing pivot axis may be located closer to the apex of the internal corner than a point of intersection between an axis about which the first wing roller(s) rotate and an axis about which the second wing roller(s) rotate.
In another form, albeit not necessarily the only or broadest form, the invention relates to a roller tool for use in plasterboard finishing, the tool having
wherein, when the tool is configured with the first wing and the second wing pivoted relative to one another to enable the first wing rollers and the second wing rollers to roll in an internal corner having an angle that is less than 180°, the wing pivot axis is located closer to the apex of the internal corner than the point of intersection between the first wing roller axis and the second wing roller axis.
Features described in connection with one form of the invention above may also be used or incorporated in other forms of the invention.
Other features and aspects of the invention will be made evident from the Detailed Description below.
Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description makes reference to a number of Figures as follows:
As mentioned above,
As the Figures show, the tool 10 has a first wing 100 and a second wing 200. The first wing 100 and the second wing 200 are pivotally connected to one another.
The first wing 100 and the second wing 200 are symmetrical. In other words, the shape of the first wing 100 and the shape of the second wing 200 are identical. Nevertheless, for ease of reference and for explanatory purposes, parts and features associated with the first wing 100 will be referred to using 1XX reference numbers, and parts and features associated with the second wing 200 will be referred to using 2XX reference numbers.
The first wing 100 is pivotally connected to the second wing 200 such that the two wings can pivot relative to one another about the wing pivot axis WP. The way in which the two wings are pivotally connected to one another is that there are a number of protruding noses on each wing. Specifically, the protruding nose portions on the first wing 100 are labelled 106, and the protruding nose portions on the second wing 200 are labelled 206. All of the nose portions 106 (being the ones on the first wing 100) and 206 (being the ones on the second wing 200) have a cylindrical through-bore extending therethrough in a direction parallel to the length direction of each wing. When the wings are brought together as the tool is being assembled, the nose portions 106 on the first wing are positioned directly adjacent to the corresponding nose portions 206 on the second wing, such that the through bores in each adjacent pair of nose portions 106/206 become aligned (and in fact the through bores in all of the nose portions 106/206 become aligned) along the wing pivot axis WP. A pivot pin (the length of which is the same as the length of the through bores in two of the nose portions combined) is then inserted into the aligned bores in each pair of nose portions 106/206, thereby securing each pair of nose portions 106/206 together. This in turn secures the first wing and the second wing together but still permits pivotable movement of the wings relative to one another about the wing pivot axis WP.
It can also be seen that, on the first wing 100, there are two first wing rollers 110 and 120. Likewise, on the second wing 200, there are two second wing rollers 210 and 220. The first wing rollers 110 and 120 on the first wing 100, and also the second wing rollers 210 and 220 on the second wing 200, are the tool's “main” rollers, i.e. these are the rollers that mainly function to press the tape or bead onto the surface when the tape or bead is being rolled using the tool. However, in addition to the main first wing rollers 110 and 120, and the main second wing rollers 210 and 220, there are also two outer rollers on each wing. The outer rollers on the first wing 100 are labelled 115 and 125, and the outer rollers on the second wing are labelled 215 and 225. The outer rollers 115, 125, 215, 225 on the respective wings provide stability to the tool. More specifically, the outer rollers provide stability in the transverse direction (i.e. in a direction perpendicular to the wing pivot axis WP) because they are located a greater distance away from the wing pivot axis WP than the main first wing rollers 110 and 120 and the main second wing rollers 210 and 220. The outer rollers also provide stability in the longitudinal direction (i.e. in a direction parallel to the wing pivot axis WP) because the outer rollers are located a greater distance apart in a direction parallel to wing pivot axis WP (i.e. the distance between rollers 115 and 125 on the first wing, which is the same as the distance between the rollers 215 and 225 on the second wing, is greater than the distance between any of the main rollers on the first and second wings in the longitudinal direction).
In addition to providing stability, the outer rollers 115, 125, 215, 225 may sometimes also function to, or assist in, rolling the tape or bead, if the tape or bead that is being rolled is wide enough for the outer rollers to also come into contact with the tape or bead.
Similarly,
However, in some situations, the tape or bead which the tool is being used to roll may be thinner/narrower than the ones shown in
As mentioned above,
Thus,
At this point, it is important to note that, on each of the wings 100, 200, there are a number of cut-outs and other specifically shaped portions, which will now be discussed.
On the first wing 100, there are a pair of cut-outs (or places where the edge of the wing 100 is indented/recessed) on the edge of the wing 100 nearest the wing pivot axis WP. These cut-out portions on the first wing are labelled 101 and 102 in
The purpose of the cut-outs 101 and 102 in the first wing, and the cut-outs 201 and 202 in the second wing, can be understood by initially comparing
Specifically, it can be seen from these Figures that, as the wings are pivoted relative to one another to progressively increase the size of the angle on the surface-engaging side of the tool up to and beyond 180° (or in other words when the wings are pivoted so as to progressively reduce the size of the angle between the wings on the non-surface-engaging side of the tool down to and below 180°), the inner ends of the first wing rollers 110 and 120 (i.e. the ends of these rollers that are closest to the wing pivot axis WP) move into the spaces provided by the cut-outs 202 and 201 in the second wing. Likewise, as the wings are pivoted relative to one another to progressively increase the size of the angle on the surface-engaging side of the tool up to and beyond 180°, the inner ends of the second ring rollers 210 and 220 move into the spaces provided by the cut-outs 102 and 101 in the first wing.
The cut-outs also serve a similar function when the wings are pivoted the opposite way relative to one another, that is, to reduce the size of the angle on the surface-engaging side of the tool down to and below 180° (or in other words to increase the size of the angle between the wings on the non-surface-engaging side of the tool up to and beyond 180°). An example of this is given in
Therefore, the cut-outs 201 and 202 in the second wing 200 are important because they prevent the inner ends of the first wing rollers 110 and 120 from colliding with the second wing 200 when the wings are pivoted away from the “flat” 180° configuration shown in
The cut-out portions 101, 102, 201, 202 discussed above are important for enabling the tool to pivot without the main rollers on one wing colliding with the opposite wing, and consequently these cut-out portions help to allow the tool 10 to have a range of motion which extends from one of the range extremes described above to the other range extreme described above.
In addition, the cut-out portions 101, 102, 201, 202 are also important because they enable the tool to operate with larger-diameter main rollers. In this regard, the diameter of the main rollers 110, 120, 210, 220 is similar to the diameter of the rollers used on the fixed tools described in the Background section above. In other words, the diameter of the first wing rollers 110 and 120, and the diameter of the second wing rollers 210 and 220, is able to be larger than would be possible if the cut-outs 101, 102, 201, 202 were not provided. This means that the problems that can arise for adjustable tools with smaller diameter rollers, in particular their propensity to “flick” wet joint compound up as the tool moves along, is reduced. The diameter of the outer rollers 115, 125, 215, 225 is also the same as the diameter of the main rollers 110, 120, 210, 220, and therefore the outer rollers also have a reduced propensity to “flick” wet joint compound.
The cut-out portions 101, 102, 201, 202 also allow the main rollers 110, 120, 210, 220 to be longer than would be possible if those cut-out portions were not provided. In fact, the length of the main rollers 110, 120, 210, 220 is such that the inner ends of these main rollers extend beyond (i.e. past) the wing pivot axis WP. This enables the rollers (despite their larger diameter) to get very close to the apex in internal corners in particular, and to roll portions of the tape or bead in internal corners that are very close to the apex of the corner, where this would not have been possible (i.e. the inner ends of the main rollers would not have been able to get in as close to the apex in internal corners) if the cut-out portions 101, 102, 201, 202 were not provided.
It can also be seen from e.g.
The purpose of these sloping portions 105 and 205 can again be understood by comparing
In addition to the cut-out portions and shaped/sloping portions of the respective wings described above, on each wing there are also spaces provided for the various rollers to be mounted. For example, on the first wing, there are large gaps in the wing where (and into which) the first wing rollers 110 and 120 are mounted, and there are cut-outs (or indented portions) on the outer side of the first wing where the outer rollers 115 and 125 are secured on the outside of the wing at either end. All of these things are also present on the second wing 200 (the shape of which is identical to the first wing 100).
Turning next to
It should be noted that, on the axle bolt 121, only the end portion of the bolt's shaft, namely the portion which screws into the side of the wing 100, is threaded. The remainder of the bolt's shaft has a smooth surface and is un-threaded. This helps to provide a smooth (and lower friction) surface for the main body of the roller to rotate around. It should also be noted that the bolt 121 is (and indeed all of the other axle bolts are also) made from steel, and the body of the roller 120 is (and indeed the bodies of all of the rollers are) made from acetal, which is a high-strength, low friction engineering plastic. Of course, no strict limitation as to the particular materials used for the axle bolts or roller bodies is to be implied, and it will be understood that any suitable material may be used for the axle bolts and/or for the bodies of the rollers.
The way in which all of the other rollers are assembled and mounted to the respective wings is the same as just described for first wing roller 120. Thus, for example, when the tool is being assembled, the cylindrical outer ‘roller” portion of the outer roller 125 (i.e. the outer body of the outer roller 125, which in the depicted embodiment is made from acetal) is first slotted onto the shaft of the axle bolt 126, and the axle bolt 126 (with the outer body of the roller 125 then mounted thereon) is then screwed into a hole in the indented end portion on the outer edge of the wing 100 that is provided for this.
In each case, the head of the axle bolt is larger in diameter than the hollow interior of the roller body, such that the head of the axle bolt prevents the roller from sliding off the bolt and thereby secures the body of the roller to the relevant wing.
The main rigid body portion of each of the wings 100 and 200 will typically be made from metal. It is thought that aluminium alloys will often be suitable because of the relative ease with which these can be cast and/or machined to have the appropriate shape, etc, and also because of their comparatively high-strength and rigidity, and low weight. In the particular embodiment depicted in, e.g.,
As mentioned above, a handle (not shown in
The way in which the handle (not shown) connects to the tool 10 in the particular embodiment shown in
The handle mount component 350 is pivotably attached to the linking component 300. The linking component 300 is the generally “shackle” shaped component via which the handle mount component 350 (and the handle adapter component, and the handle) connects to the arms 150 and 250, as discussed below. The fact that the handle mount component 350 (to which the adapter and handle are connected) is pivotable relative to the link component 300 means that, in a generally similar way to the fixed roller tools shown in
It should be noted that other mechanisms could alternatively be used for connecting the handle to the handle mount component. For example, a friction fit connection directly between the handle and the handle mount component could be used, or a part of the handle mount component to which the handle connects could be externally threaded such that the internally-threaded portion on the handle could connect directly thereto, etc. These alternatives would, of course, require the configuration of the handle mount component to be different to the one (350) shown in the Figures.
As mentioned above, the linking component 300 is the generally “shackle” shaped component via which the handle mount component 350 (and the handle adapter and the handle) connect to the arms 150 and 250. The arms 150 and 250 are the components that connect the linking component 300 to (and which transfer force/pressure from the handle into) the respective wings 100 and 200 when the tool 10 is in use. More specifically, there is a first arm 150 which connects the link component 300 to the first wing 100, and there is a second arm 250 which connects the link component 300 to the second wing 200. The upper end of each of the arms 150 and 250 is pivotally connected to the link component 300, and the lower end of each arm 150 and 250 is pivotally connected to the relevant wing, i.e. the lower end of the first arm 150 is pivotally connected to the first wing 100 and the lower end of the second arm 250 is pivotally connected to the second wing 200.
The operation of the arms 150 and 250 (i.e. how they work and the role they play in the functioning of the tool 10) may perhaps be more easily understood from (and following) a general explanation of the way in which the tool 10 is used. Therefore, before discussing further details about the configuration of the arms 150 and 250 and how they work, a general explanation of how the tool 10 is used will be provided.
Reference will be made initially to the way in which the tool 10 can be used to roll an external corner.
When the tool 10 is to be used to roll an external corner, if, before the tool comes into contact with the panels (or the bead) on either side of the external corner, the wings 100 and 200 of the tool are oriented (relative to one another) in a configuration that is more closed than the corner (i.e. if the angle between the wings 100 and 200 on the surface-engaging side of the tool 10 is smaller than the angle of the external corner to be rolled), then when tool first contacts the panels (or the bead) on either side of the corner, it will be the outer edges of the tool 10, in particular the outer rollers 115, 125, 215, 225, that will first come into contact with the panels (or the bead) on either side of the external corner. Then, when further pressure is applied to the tool 10 (i.e. when the tool is further pressed onto (and into engagement with) the corner) this pressure will force the tool further open. In other words, the respective wings 100 and 200 will be caused to pivot relative to one another such that the angle between the wings on the surface-engaging side widens/increases as the tool moves into full contact/engagement with the corner. This will continue until the main wing rollers 110, 120, 210, 220 come into full contact (i.e. until each of the main wing rollers 110, 120, 210, 220 is in contact along most or all of its length) with the bead on the respective sides of the external corner. Then, once the tool 10 is thus properly engaged with (and pressed against) the bead (and possibly also in contact with portions of the panels) on either side of the corner, the tool can be moved along the bead to “roll” the corner and embed the bead into the adhesive on the corner. (It should be noted that, in embodiments which utilise a flexible band to provide the tool with an inherent bias, as discussed below, it may sometimes be the case that before the tool comes into contact with the panels (or the bead) on either side of an external corner, the wings 100 and 200 of the tool may be oriented (relative to one another) in a configuration that is more closed than the corner (i.e. the angle between the wings 100 and 200 on the surface-engaging side of the tool 10 may be smaller than the angle of the external corner to be rolled). This is because the flexible band may bias the tool towards one or other of the tool's range extremes, and one of these range extremes is where the angle between the wings 100 and 200 on the surface-engaging side of the tool is minimum (approximately 75° in the depicted embodiment).)
Alternatively, if, before the tool comes into contact with the panels (or the bead) on either side of the external corner, the wings 100 and 200 of the tool are oriented (relative to one another) in a configuration that is more open than the corner (i.e. if the angle between the wings 100 and 200 on the surface-engaging side of the tool is larger than the angle of the external corner to be rolled), then when the tool first contacts the bead on either side of the corner, it will be the inner portions of the tool, in particular the inner portions of the main wing rollers 110, 120, 210, 220, that will first come into contact with the bead on either side of the corner. Then, when further pressure is applied to the tool (i.e. when the tool is further pressed onto (and into engagement with) the corner) this pressure will force the tool to effectively close around the corner. In other words, the respective wings 100 and 200 will be caused to pivot relative to one another such that the angle between the wings on the surface-engaging side decreases as the tool moves into full engagement with the corner, until most or all of the length of each main wing roller 110, 120, 210, 220 is in contact with the bead on the respective sides of the external corner, and the outer rollers 115, 125, 215, 225 may also be in contact with the bead or with portions of the panel on the outside of the bead on either side. Thereafter, once the tool 10 is thus properly engaged with (and pressed against) the bead (and possibly also in contact with portions of the panels) on either side of the external corner, the tool can be moved along the bead to “roll” the corner and embed the bead into the adhesive on the corner.
Reference will now be made to the way in which the tool 10 can be used to roll an internal corner.
When the tool 10 is to be used to roll an internal corner, if, before the tool comes into contact with the panels (or the tape or bead) on either side of the internal corner, the wings 100 and 200 of the tool are oriented (relative to one another) such that the angle between the wings on the surface-engaging side is not large enough (e.g. if the angle between the wings 100 and 200 on the surface-engaging side is, say, 225°, but the angle between the panels in the particular internal corner to be rolled is, say, 100°, which would therefore require the angle between the wings 100 and 200 on the surface-engaging side to be 260°), then when the tool first contacts the panels (or the tape or bead) on either side of the corner, it will again be the outer edges of the tool, in particular the outer rollers 115, 125, 215, 225, that will first come into contact with the panels (or the tape or bead) on either side of the internal corner. Then, when further pressure is applied to the tool (i.e. when the tool is further pressed into the internal corner) this pressure will force the tool further into the corner. In other words, the respective wings 100 and 200 will be caused to pivot relative to one another such that the angle between the wings on the surface-engaging side widens/increases further (i.e. so that the angle between the wings on the non-surface-engaging side decreases) as the tool moves into full engagement with the internal corner, until most or all of the length of each main wing roller 110, 120, 210, 220 is in contact with the tape or bead on the respective sides of the internal corner, and the outer rollers 115, 125, 215, 225 may also be in contact with the tape or bead or with portions of the panel on the outside of the tape or bead.
Or, if (on the other hand), before the tool comes into contact with the bead on either side of the internal corner, the wings 100 and 200 of the tool are oriented (relative to one another) such that the angle between the wings on the surface-engaging side is too large (e.g. if the angle between the wings 100 and 200 on the surface-engaging side is, say, 285°, but the angle between the panels in the particular internal corner to be rolled is, say, 140°, which would therefore require the angle between the wings 100 and 200 on the surface-engaging side to be 220°), then when the tool first contacts the tape or bead on either side of the internal corner, it will be the inner portions of the tool, in particular the inner portions of the main wing rollers 110, 120, 210, 220, that will first come into contact with the tape or bead on either side of the corner. Then, when further pressure is applied to the tool (i.e. when the tool is further pressed into the internal corner) this pressure will force the respective wings 100 and 200 to pivot relative to one another such that the angle between the wings on the surface-engaging side decreases as the tool moves into full engagement with the surfaces on either side in the internal corner, until most or all of the length of each main wing roller 110, 120, 210, 220 is in contact with the tape or bead on the respective sides of the internal corner, and the outer rollers 115, 125, 215, 225 may also be in contact with the tape or bead or with portions of the panel on the outside of the tape or bead. (It should be noted that, in embodiments which utilise a flexible band to provide the tool with an inherent bias, as discussed below, it may also sometimes be the case that before the tool comes into contact with the panels (or the tape or bead) on either side of an internal corner, the wings 100 and 200 of the tool may be oriented (relative to one another) such that the angle between the wings on the surface-engaging side is too large. This is because, as mentioned above, the flexible band may bias the tool towards one or other of the tool's range extremes, and the other/second of these range extremes is where the angle between the wings 100 and 200 on the surface-engaging side of the tool at its maximum (approximately 285° in the depicted embodiment).)
The configurations and arrangements of the arms 150 and 250, and the way in which the arms 150 and 250 help the tool to function in the manner described above, will now be explained.
As mentioned above, the lower end of the first arm 150 is pivotally connected to the first wing 100 and the lower end of the second arm 250 is pivotally connected to the second wing 200. The way in which the lower end of each of the arms is pivotably connected to the relevant wing can be understood with reference to
In
It will be understood that the way in which the lower end of the second arm 250 is pivotably secured relative to the second wing 200 is the same as just described above for the first arm 150.
It is relevant to note that, because of the way the arms 150/250 are pivotally connected to the relevant wings 100/200, the location of the pivotal connection between the lower end of each arm and the relevant wing is actually recessed into or “within” the thickness of the relevant wing. This, and also the configuration of the arms 150/250, the link component 300 and the way it connects the upper ends of the arms to the handle mount component 350, etc, all help to reduce the distance between the pivot axis WP and the location about which the handle is able to pivot relative to the tool. And this (i.e. reducing this distance), in turn, helps to improve the overall stability of the tool.
It is also mentioned above that the upper ends of the respective arms 150 and 250 are pivotally connected to the link component 300. The way in which the upper ends of the arms 150 and 250 are pivotally connected to the link component 300 can, again, be understood from
However, it can also be seen from
This “linking” of the pivotal movement of the respective arms (such that the movement of one arm is always equal but opposite to the movement of the other) is important to the operation of the tool. In particular, this is what ensures that, in use, when the user presses the tool onto an external corner, or into an internal corner, the amount of pressure applied to each of the wings (caused by the pressure which the user applies via the handle) is equal, and it also ensures that the respective wings always (at all times) pivot by the same amount (but in opposite directions) relative to the plane containing the handle. This helps to give the tool it's “self-aligning” functionality, i.e. such that the tool automatically conforms to the shape of the (internal or external) corner on (i.e. into or onto) which the tool is applied. It also significantly improves the stability and usability of the tool.
Referring next to
Turning to
Also, for reasons explained above (i.e. because of the way the movement of the arms, and hence the movement of the wings, is “linked”, such that the movement and angle of one arm (and its wing) will always be equal and opposite to the movement and angle of the other arm (and its wing), it follows that the angle θ that one wing (and the rollers thereon) forms to the plane containing the handle will always be equal to the angle θ that the other wing (and the rollers thereon) forms to the plane containing the handle. This is particularly helpful when rolling internal corners as it helps to enable the user to provide an accurate centre line for aligning and bedding the tape or bead in the internal corner.
In this specification, the term “comprising” is (and likewise variants of the term such as “comprise” or “comprises” are) intended to denote the inclusion of a stated integer or integers, but not necessarily the exclusion of any other integer, depending on the context in which the term is used.
Reference throughout this specification to ‘one embodiment’ or ‘an embodiment’ means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases ‘in one embodiment’ or ‘in an embodiment’ in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.
In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2022900784 | Mar 2022 | AU | national |
