Patent Grant
11536037
This application claims benefit to U.S. Provisional Application Ser. No. 63/041,131, filed Jun. 19, 2020, the contents of which are incorporated by reference herein.
The present disclosure is related to drywall compound tools. More particularly, the present disclosure is related to drywall compound tools having interchangeable tool portions.
The finishing tasks of drywall applications in buildings require a variety of tools and implements. During the construction process of internal walls, panels of drywall are affixed to support members such as wood or metal studs. If necessary, drywall panels may be cut to fit as needed for a certain wall configuration. Typically, drywall panels are affixed to the support members using screws or nails. After drywall panels have been affixed to the support members, the screw/nail depressions and the gaps between abutting drywall panels must be sealed to provide a surface suitable for finishing techniques such as painting, wallpaper, and the like. The finishing process involves the steps of filling screw and nail depressions with drywall compounds. Such applications can utilize a putty knife, wall board knife, taping knife, and the like. Once the wall compounds dry, the elevated areas are removed by one or more processes to level the wall compound to the wall. Such processes include and are not limited to sanding, wet sponging, etc.
The mating surfaces or joints of the drywall panels also require finishing techniques. In these areas, the combined use of wall compound and paper strips are used in combination. This process is commonly called taping. In this process, the wall compound is forced into the wall board seams using the aforementioned putty knife, wall board knife, and/or taping knife. While wet, a layer of paper strip is place along the wet portion of the wall compound covering the seams of the drywall panels. Once dried, another layer of wall board compound is added along the seam. The process is continued until the wall compound is at or above the drywall panel surface. Once the wall compounds dry, the elevated areas are removed by one or more processes to level the compound to the wall. Such processes include and are not limited to sanding, wet sponging, and the like.
In many areas, the application involves leveling the flat areas of the wall. In other areas, there exist internal and external corners. These are finished in the same manner using wall board compound and paper stripping. The mating surfaces of the inside and outside corners have a similar finishing technique. In these areas, the combined use of wall compound and paper strips are also used in combination with the added step of folding the paper strip in half along its length. Similar to the flat wall portions, the wall compound is applied along the internal and/or external wall board seams using the aforementioned putty knife, wall board knife, and/or taping knife. While wet, a layer of folded paper strip is place along the wet portion of the wall compound. The folding line being aligned to the seam of the external and internal corners of the drywall panels. Once dried, another layer of wall board compound is added along the seams. The process is again repeated until sufficient wall compound is applied. Once the wall compound dries, the elevated areas are removed by one or more processes to level the compound to the wall. Such processes include and are not limited to sanding, wet sponging, and the like.
Those having skill in the art can recognize that dealing with external and internal corners require specialized tools.
Therefore, there is a need for drywall compound tools that overcome, alleviate, and/or mitigate one or more of the aforementioned and other deleterious effects of prior art drywall compound tools.
The process of dealing with external and internal corners require specialized tools for the application of drywall compound. Some users prefer to use an internal corner tool for applying wall compound in a single pass. In such an application, wall compound is applied along both sides of the internal corner. Once applied and while the compound is still workable, the internal corner tool is used along the internal corner in one or more strokes creating a smooth application of wall board compound along the internal corner. Such tools allow for a single application for the internal corner rather than multiple applications using a conventional flat putty knife.
With respect to an external corner, similar to working with internal corners, some users prefer to use an external corner tool for applying wall compound to the external corner in a single pass. In such an application, wall compound is applied along both sides of the external corner. Once applied and while the compound is still workable, the external corner tool is used along the external corner in one or more strokes creating a smooth application of wall board compound along the external corner. Such tools allow for a single application for the external corner rather than multiple applications using a conventional flat putty knife.
As those skilled in the art can appreciate, the process of working on internal and external corners requires multiple tools which may require the taper or drywaller to carry numerous tools. This also forces the drywaller the burden of dealing with the task of switching between the needed different tool styles. Thus, it would be beneficial for a single tool that can be use on both external and internal corners.
Wall board tools are provided that include multiple ends configured to apply wall compounds to external and internal corners of walls.
In one example, a versatile compound tool comprises a handle assembly having a first end and a second end. The handle assembly includes a handle along the first end and an extension extending from the handle along the second end including a first connection feature. The versatile compound tool includes a first implement having a first end and a second end. The first implement comprises a second connection feature along the first end and is configured for a first function along the second end. The versatile compound tool further comprises a retainer.
The first implement is removably securable to the handle assembly by the retainer when the first connection feature is engaged to the second connection feature so that the first implement is selectively removable for assembly of a second implement.
The second implement comprises a first end and a second end and is configured for a second function along the second end. The second implement includes a second connection feature along the first end.
In one example, the first connection feature is a threaded hole and the retainer comprises a threaded shaft engageable to the threaded hole for securing the first or second implement to the handle assembly.
In one example, the first implement is configured for forming compound in an internal corner and the second implement is configured for forming compound on an external corner.
The extension extending from the handle assembly comprises an offset which facilitates clearance from the wall to the handle to allow a user to grasp the handle in an ergonomic manner. The offset comprises a first portion, a second portion, and a third portion. The second portion is located at an angle from first portion and the third portion is located at an angle from second portion.
In one example, the extension forming the first connection feature extending from the handle comprises a square cross section and is engageable to a complimentary opening along the first or second implement. The complimentary opening comprises a clearance hole transverse the complimentary opening such that the threaded hole and the threaded shaft can be aligned for securing the first or second implement to the handle assembly by the retainer.
In one example, the handle assembly is fabricated in stainless steel, plated carbon steel, aluminum, plastic, metal, rubber, and any combinations thereof.
The first and second implements are fabricated in stainless steel, plated carbon steel, aluminum, plastic, metal, and any combinations thereof.
The above-described and other features and advantages of the present disclosure will be appreciated and understood by those skilled in the art from the following detailed description, and drawings.
Referring to the drawings and in particular to
Advantageously, internal implement 14 is removably secured to handle assembly 12 utilizing retainer 16. In this configuration, tool 10 finds use with the leveling, forming, and/or smoothing of compound C along internal corner IC along direction 18 (
In the event that a taper is required to work on an external corner, tool 10 can be configured to level, form, and/or smooth an external corner. By reference to
Turning now to
In the present embodiment, the term drywall technician or taper can include a working professional or can include a periodic user or non-professional such as a homeowner performing home repairs or improvements.
Details of tool 10 will now be described with reference to the version of tool 10 configured for use on internal corners. By simultaneous reference to
Along a second direction, more specifically as detailed in
Turning back to
Additional grasping clearance in addition to the clearance derived from angle 38 is included as per the configuration of extension 28. With simultaneous reference to
The aforementioned angle 38, angle 40, and offset 50 work in combination and allows the taper to utilize an ergonomic grip of tool 10 during use.
In the illustrated embodiment, the elements of internal implement 14 is fabricated in stainless steel sheet and formed using a stamping process. It is contemplated by this disclosure that other suitable materials can be used to fabricate the elements of internal implement 14 including and not limited to plated sheet metal, aluminum sheet, plastic sheets, among others. It is also contemplated that other suitable manufacturing methods can be used to fabricate the elements of internal implement 14 including and not limited to machining, molding, casting, and the like.
Addition details of internal implement 14 are now described by simultaneous reference to
It should be noted that instead of utilizing a plurality of spot welds 68 to attach housing 58 to form opening 64, opening 64 can be formed integral to internal implement 14 (a single component) such as a single molded component or a single machined component with opening 64 included thereto. Internal implement 14 further includes an angle 68 when orientated along the side. Angle 68 is a result of the interactions of aforementioned angle 58 and back angles 34 detailed above.
The details of securing internal implement 14 to handle assembly 12 are now described with simultaneous reference to
Turning to
Extension 28 comprises a proximal end 76 and a distal end 78. Proximal end 76 is assembled to handle 26. Distal end 78 of extension 28 includes the aforementioned threaded hole 70. Extension 28 further comprises the aforementioned first portion 42, second portion 44, third portion 46, angle 48, and angle 50 detailed above.
In the illustrated embodiment, extension 28 is fabricated using stainless steel wire having a square cross section and formed using a plurality of bending operations to form angle 48 and angle 50. It is contemplated by this disclosure that other suitable materials can be used to fabricate extension 28 including and not limited to plated carbon steel, aluminum, thermoplastic, among others. It is also contemplated that other suitable manufacturing methods can be used to fabricate extension 28 including and not limited to machining, molding, stamping, casting, and the like.
Handle assembly 12 is now described with simultaneous reference to
Retainer 16 is now detailed with simultaneous reference to
In one embodiment, threaded shaft 74 is integral to body 72 forming retainer 16 in a single component. Such a configuration is achieved by forming retainer 16 from stainless steel bar stock using a lathe turning process. The lathe would cut the general shape of retainer 16 forming body 72 and stepping down to form threaded shaft 74. Once completed, retainer 16 is removed from the bar stock and the next retainer 16 is formed. A CNC lathe can form a plurality of retainers 16 automatically. In one embodiment, the completion of the lathe process would create retainer 16 without the aforementioned bumps 88. In another embodiment, a secondary milling operation can be employed to create the plurality of bumps 88.
Other suitable materials for forming retainer 16 using a lathe process are also possible including and not limited to plastic, aluminum, metal, and the like. It is also contemplated that retainer 16 can be manufactured using alternate methods including and not limited to milling, metal injection molding (MIM), power metal, and the like.
Those having skill in the art can appreciate that shaft 74 and body 72 can be formed individually and then assembled to one another. In this example, body 72 can be manufactured using any chosen material and process such as thermoplastic injection molding. Other suitable materials and manufacturing methods are possible including and not limited to machining of steel or plastic, casting, and the like.
Threaded shaft 74 can also be formed using any chosen material and manufacturing method such as and not limited to steel formed on a lathe, steel formed using a screw machine, metal injection molding and sintering (MIM), and the like.
Threaded shaft 74 can then be assembled to body 72 in any known manner such as and not limited to interference fit connection, welded connection, heat-stake connection, and the like. It is also contemplated that body 72 can be over-molded onto threaded shaft 74.
In the event that a taper is required to work on an external corner, tool 10 can be adjusted for the purposes of working on external corners. In this manner, internal implement 14 can be removed from handle assembly 12. With reference to
With simultaneous reference to
Along a second direction, more specifically, external implement 20 of tool 10E includes an angle 100 defining symmetrical subsequent first edge 90 and subsequent second edge 92. Angle 100 is central to subsequent contact edge 94. In the illustrated embodiment, angle 100 is about 90 degrees. Those skilled in the art can appreciate that angle 100 can find use in a range of alternate values. In one embodiment, angle 100 is 85 degrees to about 95 degrees where 88 degrees to about 92 degrees is a common range. Of course, other angular values are contemplated.
The configuration of tool 10E in use with external corners EC allows tool 10E to rotate away from external corner EC at an angle 102 (
Additional grasping clearance in addition to the clearance derived from angle 102 is included as per the configuration of extension 28. As detailed above, and turning back to
The aforementioned angle 102, angle 104, and offset 98 works in combination and allows the taper to utilize an ergonomic grip of tool 10E during use.
In the illustrated embodiment, the elements of external implement 20 is fabricated in stainless steel sheet and formed using a stamping process. It is contemplated by this disclosure that other suitable materials can be used to fabricate the elements of external implement 20 including and not limited to plated sheet metal, aluminum sheet, and plastic sheets, among others. It is also contemplated that other suitable manufacturing methods can be used to fabricate the elements of external implement 20 including and not limited to machining, molding, casting, and the like.
With simultaneous reference to
External implement 20 is removably secured to handle assembly 12 in the same manner as with respect to internal implement 14. The details of securing external implement 20 to handle assembly 12 is briefly describe with reference to the similar details of internal implement 14. Extension 28 of handle assembly 12 is inserted into opening 110 formed along the assembly of housing 96. Once extension 28 is inserted into opening 110, the threaded hole 70 is aligned to hole 112 of housing 58. Hole 112 allows for retainer 16, more specifically threaded shaft 74 of retainer 16 to pass therethrough and engage threaded hole 70 of extension 28. Once threaded shaft 74 is engaged to threaded hole 70, retainer 16 can be secured by grasping and rotating body 72 of retainer 16 and forming a tight threaded connection. When it is desired to remove external implement 20 from handle assembly 12, the steps are repeated in the reverse. More specifically, the threaded connection of threaded shaft 74 of retainer 16 to threaded hole 70 of extension 28 is removed so that retainer 16 can be removed. This allows for external implement 20 to be removed from handle assembly 12.
It should be noted that in addition to handle assembly 12 accepting internal implement 14 and external implement 20, both configured for use on internal and external corners respectively, handle assembly 12 can find use with other style implements. In one example, a taping knife can be configured for securement onto handle assembly 12. In another example, a first style putty knife can be configured for securement onto handle assembly 12. In yet another example, a scraper can be configured for securement onto handle assembly 12. Those having skill in the art can appreciate that any sundry tool portion can be secured to handle assembly 12.
It should also be noted that the terms “first”, “second”, “third”, “upper”, “lower”, and the like may be used herein to modify various elements. These modifiers do not imply a spatial, sequential, or hierarchical order to the modified elements unless specifically stated.
While the present disclosure has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope thereof. Furthermore, it should be understood that there is no intention to limit this disclosure to specific forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and the equivalents falling within the spirit and scope of this disclosure. Therefore, it is intended that the present disclosure not be limited to the particular embodiment(s) disclosed as the best mode contemplated, but that the disclosure will include all embodiments falling within the scope of the disclosure.
It should be noted that the various features as described by reference to tool 10 can be selectively altered to create different products. For example, the use of a threaded connection to secure the implements to the handle assembly can be substituted with a variety of alternatives such as and not limited to snap fits, quarter turn fasteners, magnetic connections, etc.
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|---|---|---|---|
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| Number | Date | Country |
|---|---|---|
| 200481098 | Aug 2011 | KR |
| WO-2004033820 | Apr 2004 | WO |
