FIELD OF THE INVENTION
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The present invention relates to apparatuses for applying
paint and other liquid coatings to surfaces, and more particularly, to
apparatuses for creating customized patterns.
BACKGROUND OF THE INVENTION
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Paint applicators are generally used to apply paint to surfaces
such as walls, ceilings, floors, objects (e.g., cars, boats, or the like), etc.
One type of typical paint applicator includes a frame, a handle coupled to
one end of the frame, and a roller cage rotatably coupled to the other end
of the frame. The cage is configured to slideably receive a single
replaceable paint roller that spans substantially the entire length of the
roller cage. The paint roller includes a core and a paint absorbing material
covering the core, which is generally made of simulated lambs wool or
other cellular material that can retain paint. In use, the applicator is rolled
through a paint reservoir so that the material on the roller absorbs or
takes up paint. The roller may include a textured surface so that the roller
delivers a patterned coating. Conventional textured rollers are configured
to span the entire length of the cage; that is, the core is substantially the
same length as the roller cage. As such, the variety of possible patterned
coatings is dictated by rollers made available for purchase from the
manufacturers.
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Although the described systems may be used to create
attractive patterns, the conventional roller has several disadvantages.
Because the roller is one piece, the roller frame can only be used for
applying one texture or pattern. As a result, the conventional roller frame
is limited to the particular texture or a particular pattern that is provided
to the roller and cannot be customized by the user according to his or her
tastes or the requirements of an application. Because the rollers span the
entire roller cage, desirable complex or customized patterns are complex
and expensive.
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Thus, there is a long felt need to provide a paint applicator
that permits the user to customize the patterns and textures of paint
delivered by the applicator.
SUMMARY OF THE INVENTION
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The present invention relates to a modular applicator kit for
use with a liquid applicator. The modular applicator kit includes a plurality
of segments adapted to be coupled to the liquid applicator. Each segment
includes a core, a raised portion supported by the core and configured to
contact and transfer paint to a surface, and a depressed portion
configured to not contact the surface.
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The present invention also relates to a method of providing a
paint roller for use in applying a decorative effect to a surface. The
method includes positioning a first segment having a first decorative
effect on the paint roller and positioning a second segment having a
second decorative effect that is different from the first decorative effect
on the paint roller.
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The present invention also relates to a liquid applicating
system. The liquid applicating system includes a liquid applicator and a
plurality of segments coupled to the liquid applicator. Each segment
includes a core, a raised portion supported by the core and configured to
contact and transfer paint to a surface, and a depressed portion
configured to not contact the surface.
BRIEF DESCRIPTION OF THE DRAWINGS
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The present invention will become more fully understood
from the following detailed description, taken in conjunction with the
accompanying drawings wherein like reference numerals refer to like
parts, in which:
- FIG. 1 is an elevational view of a paint applicator
incorporating segments of the present invention;
- FIG. 2 is a sectional view of the paint applicator of FIG. 1
taken along lines 2 - 2;
- FIG. 3 is an exploded fragmentary elevational view of a paint
applicator incorporating segments according to an alternative
embodiment; and
- FIG. 4 is a fragmentary side elevational view of an alternative
embodiment of the paint applicator shown in FIG. 3.
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
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FIG. 1 illustrates a paint applicator 10 for applying a paint to
a surface. Paint applicator 10 includes a frame 12 and a modular
applicator kit 14 having segments 16. Frame 12 is configured to
rotatably support modular applicator kit 14 and may be manufactured
using conventional manufacturing techniques associated with single
shafted paint applicator. Frame 12 includes a handle 18, a shaft 20, and
a roller cage 22. Roller cage 22 is rotatably supported about shaft 20 and
is configured to support segments 16 about an axis A of shaft 20. As
shown in FIG. 3, shaft 20 is a single elongate rod extending through roller
cage 22 to rotatably support cage 22 about axis A. Cage 22 includes a
pair of hubs 24 journaled about shaft 20 and interconnected by wires 26.
Wires 26 are outwardly angled for frictional engagement with inner
circumferential surfaces of segments 16. As a result, wires 26 prevent
slippage or rotation of segments 16 relative to roller cage 22. According
to an alternative embodiment, roller cage 22 may comprise other known
cage structures integrally formed from plastic. According to alternative
embodiments, handle 18, shaft 20, roller cage 22, hubs 24, or wires 26
may be formed from any number of plastic materials.
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Modular applicator kit 14 includes a plurality of
interchangeable segments 16. Segments 16 are generally tubular-shaped
and are sized for being interchangeably positioned over and about roller
cage 22 and removable from roller cage 22 for cleaning or replacement.
As shown in FIGS. 1 and 2, segments 16 each include a rigid, tubular
core 28, a depressed portion 30, and a raised portion 32. Core 28 is
configured to support segments 16 upon roller cage 22 and is made from
a plastic. According to a preferred embodiment, core 28 is formed from a
multiplicity of spirally-wound, polypropylene plies that are wrapped around
a fixed mandrel and bonded together by heating and contact engagement
of the plies. Forming core 28 is further illustrated in U.S. Patent No.
5,206,968, the full disclosure of which is hereby incorporated by
reference. According to an alternative embodiment, core 28 is formed
from a single spirally-wound ply that is wrapped around a fixed mandrel
and bonded together by heating and contact engagement of adjacent
plies. According to an alternative embodiment, core 28 is formed by
extrusion and cut to desired widths. According to alternative
embodiments, core 28 is made from any number of a variety of materials,
including cardboard, fiberboard, metal, or the like.
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As shown in FIGS. 1 and 3, depressed portion 30 and raised
portion 32 are disposed along the axial length and circumference of
segments 16. Depressed portion 30 is configured to not contact the
surface and to provide spacing between adjacent raised portions, which
may or may not be on the same segment or on adjacent segments.
Raised portion 32 provides a membrane 34 made from liquid absorbent
material and is configured to contact the surface receiving the paint or
liquid. Membrane 34 is made from a thermoplastic material such as
acrylic, blended acrylic, or polyester fiber nap, and is configured to carry
paint or other liquids (such as varnish, stain, primer, adhesive, lubricant,
etc.) that are being applied upon a surface. According to alternative
embodiments, membrane 34 may be made from any number of liquid
absorbent materials including wool, simulated lambs wool, open-celled
material (such as foam, or sponge), closed cell material, and material
having liquid absorbent characteristics, or the like.
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Membrane 34 is affixed to core 28. According to a preferred
embodiment, membrane 34 is bonded or fused to core 28 by heating the
exposed outer surface of core 28 (e.g., by gas ribbon burners) and
applying membrane 34 in strip-form. Affixing membrane 34 to core 28
using heat is further illustrated in U.S. Patent No. 5,206,968 and U.S.
Patent No. 5,468,207, the full disclosures of which are hereby
incorporated by reference. According to an alternative embodiment,
membrane 34 is bonded or fused to core 28 by applying an adhesive to
the outer surface of core 28 and then applying membrane in strip-form
thereto. Affixing membrane 34 to core 28 using an adhesive such as
liquid polypropylene is further illustrated in U.S. Patent No. 5,572,790,
the full disclosure of which is hereby incorporated by reference.
According to alternative embodiments, membrane 34 is affixed to core 28
by double sided tape, interference-fit, or the like.
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According to a preferred embodiment, depressed portion 30
and raised portion 32, which provide the decorative effect (e.g., pattern,
texture, etc.) is formed by exposing membrane 34 to a heating element,
which causes the exposed material to shrink down (e.g., melt, burn,
singe, etc.). Forming depressed portion 30 and raised portion 32 using
heat as further illustrated in an earlier filed, commonly owned U.S. patent
application, U.S. Serial No. 09/134,554 titled "Method and Apparatus for
Forming a Decorative Pattern in a Liquid Coating Applicator" and filed
August 14, 1998, the full disclosure of which is hereby incorporated by
reference. Alternatively, depressed portion 30 and raised portion 32 are
formed by a chemically shrinking, melting, burning, dissolving, or
weakening (such that material may be removed to form depressed portion
30). According to alternative embodiments, depressed portion 30 is
formed by any number of a variety of methods for mechanically removing
portions of membrane 34 such as shearing or cutting.
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To prepare paint applicator 10 for use, segments 16 are
selected by the user (e.g., as having the desired pattern or texture) and
are inserted in the desired order onto roller cage 22. Modular applicator
kit 14 is versatile such that selection and arrangement of segments 16
may be made by the user or as the application requires. As further shown
in FIGS. 1 and 3, segments 16 may be variably positioned in any number
of a variety of combinations or permutations and may have any number of
a variety of decorative depressed portions 30 and raised portions 32 to
provide an ornamental or decorative application. By selectively using and
loading a variety of segments 16 on roller cage 22, the user may vary the
width of the stripes as well as the spacing between the stripes being
created upon the wall or other surface.
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Segments 16 are successively located on roller cage 22 in
close proximate relation to one another (e.g., configured to be in
successively adjacent relation to one another) and have a variable axial
length such that the total number of units span substantially the units
entire length of cage 22. As such, a greater or lesser number of
segments may be inserted on roller cage 22 (e.g., seven according to the
embodiment illustrated in FIG. 3), which is intended to provide more
customization and interchangeability, and provide a greater variety of
patterns. According to a preferred embodiment, the core of one segment
is in contact with the core of an adjacent segment. As can be
appreciated, roller cage 22 as well as segments 16 may be axially spaced
from one another about shaft 20 by a variety of distances and by a
variety of alternative structures. For example, raised portion 32 of
segments 16 may be positioned away from one another by utilizing a
spacer 36 (i.e., a segment that does not have membrane 34 or raised
portion 32) between adjacent segments 16 having raised portions 32. In
lieu of spacer 36, other structures could be used for slidably positioning
segments 16 along roller cage 22 to provide the desired spacing
therebetween. According to an alternative embodiment, the core of one
segment is not in contact with the core of the adjacent segment.
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Segments 16 are configured for creating any number of a
variety of patterns and/or textures. As shown in FIGS. 1 and 3, the
pattern may be applied by raised portions that are generally linear stripes
of varying widths 38, 40a and 40b, zig-zag stripes 42, circular or dotted
patterns 44, diagonal stripes 46, arcuate stripes 48, diagonal stripe
segments 50, or the like on a surface (such as a wall, floor, ceiling,
automobile, articles of manufacture, or the like). Patterns may be created
by a plurality of raised portions 32 on a single segment (for example,
narrower linear stripe 38 and wider linear stripe 40a, and diagonal stripe
segments 50). Additionally, segments 16 are configured for creating any
number of a variety of textures such that similar patterns having different
textures provide a different decorative effect. As shown in FIG. 3, linear
stripe 40a is provided with a different texture than linear stripe 40b.
Different textures may be provided by using different membrane materials
or material configurations (e.g., acrylic and polyester fabric, foam, looped
fabric nap, etc.). Such different membranes may be used on separate
segments or on separate raised portions on a single raised portion.
Additionally, stripes of multiple colors may be applied when modular
applicator kit 14 is used in conjunction with a multi-compartmentalized
tray containing different color paints.
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According to a preferred embodiment, frame 12 and/or
modular applicator kit 14 are configured to prevent segments 16 from
rotating with respect to each other or with respect to roller cage 22.
According to a particularly preferred embodiment shown in FIG. 3, shaft
20 of frame 12 further includes a threaded portion 52 located at an end
54 of shaft 20. Threaded portion 52 is configured to threadably receive a
retaining cap 56. According to alternative embodiments, retaining cap 56
couples to shaft 20 by any number of attachment methods, including an
interference-fit, snap fit, quick release, or the like. A shoulder 58 is
disposed at the opposite end of roller cage 22. Retaining cap 56 and
shoulder 58 are configured to secure segments 16 in place and to prevent
segments 16 from sliding longitudinally along roller cage 22 and to
provide friction between adjacent segments 16 to prevent rotation of
segments 16 relative to each other or relative to roller cage 22 while still
enabling roller cage 22 to rotate about shaft 20. According to an
alternative embodiment, segments 16 are sized to provide an interference
fit with roller cage 22 (e.g., an inner diameter of the segment is
approximately equal to the outer diameter of the roller cages).
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According to an alternative embodiment (shown in FIG. 4),
segments 16 are configured to prevent rotation relative to an adjacent
segment. Segments 16 each includes a cleat 60 and a notch 62
configured to receive cleat 60 of the adjacent segment. When cleat 60
and notch 62 are engaged, the segments uniformally rotate about the
shaft. According to an alternative embodiment, segments 16 are keyed
to roller cage 22 or keyed to shaft 20 such that the segments do not
rotate relative to the cage or one another.
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Thus, modular applicator kit 14 provides several advantages
over known conventional paint supply and finishing systems. First, the
user may select and employ any number of a variety of segments 16 and
combinations and presentations thereof to create different patterns and
textures. Such a variable selection provides for a customized application.
Further customization may be attained by employing a multi-compartmentalized
tray. Second, segments 16 are mounted to the roller
cage such that the segments do not rotate relative to each other and are
slidably fixed to roller cage 22. Such a configuration is intended to
provide a consistent deposition of liquid.
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As will be appreciated, modular applicator kit 14 may have
various other configurations while still embodying the concepts of the
present invention. For example, applicator kit 14 may be configured for
use with an alternative roller frame 12 configured to support greater than
one roller cage and additional segments along shaft 20. In lieu of being
removable from roller cage 22, each segment 16 may alternatively be
integrally formed with roller cage 22 as a single unitary body or may be
directly rotatably coupled to shaft 20 without the use of roller cage 22.
Those skilled in the art will appreciate that certain of these advantages
can be obtained separately through reconfiguring the foregoing structure
without departing from the spirit and scope of the present invention.
Additionally, although a paint applicator is discussed herein, it can be
appreciated that the modular applicator kit may be employed in any
number of a variety of applications wherein a liquid is applied to a
surface.
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Although the present invention has been described with
reference to preferred embodiments, persons skilled in the art will
recognize that changes may be made in form and detail without departing
from the spirit and scope of the invention. The present invention
described with reference to the preferred embodiments and set forth in
the following claims is manifestly intended to be as broad as possible.
For example, unless specifically otherwise noted, the claims reciting a
single particular element also encompass a plurality of such particular
elements.