Abstract:
A unique, clean, fast and low cost method for the application of a textured ceiling, and if necessary the removal of acoustical ceiling, including improved tooling that does not include the use of ladders, scaffolding or other such dangerous structures. The tooling includes a unique changeable tool holder for readily exchanging the tools required, such as a ceiling scraping tool, ceiling brush, texture application pad, and spreading blade. Improved means for isolating the work area are disclosed.

Description:
RELATED APPLICATION  
       [0001]    The applicant is the inventor of the invention shown, described and claimed in pending utility patent application Ser. No. 09/494,448 filed Jan. 31, 2000, and entitled “METHOD AND APPARATUS FOR REMOVING ACOUSTICAL CEILING AND REPLACEMENT THEREOF WITH TEXTURED CEILING”. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    The background of the invention will be discussed in two parts.  
           [0003]    1. Field of the Invention  
           [0004]    This invention relates to apparatus for the process of applying a textured ceiling that includes, if necessary, the removal of acoustical ceiling, and more particularly to improved tooling providing for a faster, cleaner and less expensive process.  
           [0005]    2. Description of the Prior Art  
           [0006]    Textured ceilings are common in the building industry and have become quite popular during renovation and remodeling, especially during remodeling of older residences In such instances, it is often necessary that an existing acoustical ceiling must first be removed before applying the new textured ceiling  
           [0007]    Prior art methods of both the application of a textured ceiling, and where necessary, removal of acoustical ceiling, have been cumbersome, messy, labor extensive and time consuming. For example, the application of a textured ceiling generally is by use of compressed air guns that are extremely messy by nature. Additionally, in the removal of acoustical ceiling, common hand-held putty knifes have been used as ceiling scrapers which necessitate the use of such structures as “A” frame ladders, scaffolding, and even stilts, to reach the ceiling. Use of such ladders, scaffolding or stilts is time consuming in set-up and relocation Further, such means are dangerous due to the necessity for working above the floor in a commonly slippery area to access the ceiling.  
           [0008]    Additionally, the use of such conventional methods in application of a textured ceiling, and as is usually the case in renovation of older residencies, the removal of an existing acoustical ceiling, generally results in excessive contamination of the work area as well as areas adjacent to the work area Also, the use of such conventional methods is unnecessarily labor extensive, which thus increases time for job completion. As an example, use of these conventional methods, when coupled with corresponding necessary clean up, commonly takes 3-5 days for a typical residence The same process in accordance with the apparatus and method of the present invention commonly takes no more than one day for the typical residence.  
           [0009]    Thus, prior art procedures are unsatisfactory in that they are comparatively inefficient, time consuming, expensive and dangerous. Accordingly, it is a feature of this invention to provide improved apparatus, and method of use thereof, for both the application of textured ceiling, and where necessary the removal of existing acoustical ceiling, that is comparatively more quick, clean, less expensive, and safer for the workers than conventional methods  
         SUMMARY OF THE INVENTION  
         [0010]    The invention provides improved tooling and method of use thereof for the application of a textured ceiling, and if necessary, the removal of acoustical ceiling. Use of the tooling as described does not include the use of ladders, scaffolding or other such dangerous structures In accordance with the invention, improved tooling having handle extension means is used to enable the user to access the ceiling while standing on the floor beneath the ceiling. In applying a textured ceiling, a spreading tool is first used to apply thin amounts of drywall “mud” to cover exposed drywall tape joints and other flaws. An application pad is then used to apply the new texture, such as a coat of drywall “mud”, to the ceiling. The texture is then spread over the ceiling as desired with the use of the spreading tool. If desired, the texture applicator can have surface means thereon for applying a design to the ceiling.  
           [0011]    When removal of acoustical ceiling is desired, the area is first moisturized, by application of a fine mist of water, to loosen the ceiling including any clinging debris. The loosened ceiling and debris is then removed with an improved scraping tool, after which an improved ceiling brush is used to further clean the ceiling and to prepare it for readily accepting the new ceiling texture material Both the scraping tool and ceiling brush embody handle extension means  
           [0012]    The scraping tool, ceiling brush, spreading knife, and texture applicator are specially designed to perform their respective functions. As more completely explained below, there is provided universal mating means for easy acceptance, and replacement, of the improved tooling apparatus so as to optimize their use in performance of their respective work functions.  
           [0013]    It is thus an aspect of the invention to provide improved tooling for application of a textured ceiling, and where desired removal of acoustical ceiling, that is comparatively more quick, clean, less expensive, and safer for the workers than conventional methods.  
           [0014]    Other objects, features and advantages of the invention will become apparent from a reading of the specification, when taken in conjunction with the drawings, in which like reference numerals refer to like elements in the several views. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]    [0015]FIG. 1 is a perspective view of specialized tooling in accordance with the invention assembled for use and showing the combination of the tool holder, handle bracket, tool locking means, handle bracket sleeve, and a first embodiment of the apparatus tool,  
         [0016]    [0016]FIG. 2 is an exploded view of the specialized tooling of FIG. 1;  
         [0017]    [0017]FIG. 3 is a partial sectional view showing the tool holder, apparatus tool, and tool locking means of FIG. 1, taken along lines  3 - 3  of FIG. 1,  
         [0018]    [0018]FIG. 4 a  is a sectional view showing positioning of the locking and release tabs for attachment and locking of the bracket sleeve to the handle bracket, taken along lines  4 - 4  of FIG. 1;  
         [0019]    [0019]FIG. 4 b  is a sectional view showing operation of the locking and release tabs for releasing the handle bracket from the bracket sleeve;  
         [0020]    [0020]FIG. 5 is an end view of the ceiling brush, in accordance with the invention;  
         [0021]    [0021]FIG. 6 is a back view of the ceiling brush showing the method of attachment of the brush to the brush mounting plate;  
         [0022]    [0022]FIG. 7 is a bottom view of the ceiling brush showing the brush bristles as extending across the mounting plate;  
         [0023]    [0023]FIG. 8 is a bottom view of the spreading knife in accordance with the invention;  
         [0024]    [0024]FIG. 9 is a bottom view of the texture application pad;  
         [0025]    [0025]FIG. 10 is a side view of the texture application pad of FIG. 9; and  
         [0026]    [0026]FIG. 11 is a perspective view of an alternate embodiment of the specialized tooling in accordance with the invention.  
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0027]    The preferred embodiment of the tooling in accordance with the invention is described while referring to designated figures of the drawings, and relates to specialized tooling for an improved process of applying a textured ceiling and, if necessary, the removal of an existing acoustical ceiling. The improved tooling and method of use provides for a faster, cleaner, less expensive and safer process.  
         [0028]    Prior to describing the specialized tooling, the method of application of the tooling will be addressed. When applying a textured ceiling, or especially if removing an existing acoustical ceiling, best results are realized when the work area is first sufficiently isolated to protect surrounding areas, as described below, to insure a clean process with minimum escape of ceiling material, moisture, dust, etc.  
         [0029]    When applying a textured ceiling, and after the work area is isolated from surrounding areas, the ceiling is brushed, or swept, clean with ceiling brush  16  (See FIGS.  5 - 7 ). Then, spreading knife  17  (See FIG. 8) is used to apply thin amounts of drywall “mud” to cover all ceiling tape joints and other flaws. Texture application pad  18  (See FIG. 9) is then used to apply a texture coating coat of drywall “mud” to the ceiling In this step, pad  18  is dipped into a container of “mud” of desired consistency and then pressed firmly against the properly scraped and swept ceiling. Spreading knife  17  is then used as necessary to finish the applied texture.  
         [0030]    Although not shown, if desired the face of application pad  18  can be provided with a pattern that can be transferred to the ceiling upon pressing of the patterned pad against the ceiling  
         [0031]    When it is desired to remove an acoustical ceiling, the ceiling is first moistened with a fine spray or mist of water to loosen the acoustical material and any accumulated debris. It has been found satisfactory to use a high-pressure (300-psi) construction grade water hose having attached thereto a garden type adjustable spray nozzle The nozzle is adjusted to provide a fine spray or mist that loosens the ceiling material while decreasing any contaminants, such as dust, from being blown from the ceiling.  
         [0032]    After the acoustical material is sufficiently moistened, the ceiling is scraped with scraper tool  13  (See FIG. 1) and then swept with ceiling brush  16  to remove any remaining acoustical material and associated debris. This prepares the ceiling for accepting the new texture material as described above After completion of the ceiling renovation, the means for protecting areas adjacent to the work area is detached, collected to contain the debris resulting from the ceiling project and removed from the work area.  
         [0033]    Referring now to the drawings, and more particularly to FIGS. 1 and 2, there is shown, generally designated  10 , the assembled combination of the tool holder  11 , handle bracket  12  composed of two identical halves generally designated  12   a,  apparatus tool  13 , tool locking knobs  14 , and handle bracket sleeve  15   
         [0034]    Tool holder  11  is of an elongated, hollow, substantially square, both inside and outside, configuration with generally planar surfaces. Tool holder  11  can satisfactorily be constructed of stamped, bent, and welded anodized aluminum. As shown in FIG. 2, two longitudinal slots  11   a  are shown in dotted lines on the underside of holder  11  for receiving the two upturned portions  13   a  of tool  13  Tool  13  is positioned in holder  11  as shown in FIGS. 1 and 3 such that non-threaded holes  11   b  of holder  11  match up with threaded holes  13   b  of tool  13  when upturned, or curved, tool portions  13   a  are fully inserted through slots  11   a . Tool  13  has two cutouts  13   d  to permit insertion of upturned portions  13   a  sufficiently into holder  11  to align holes  11   b  and  13   b    
         [0035]    Tool  13  is then secured to tool holder  11 , as indicated in FIG. 3, by means of threaded knobs  14  passing through non-threaded holes  11   b  and securely threaded into threaded holes  13   b  to thereby effect a secure and firm attachment of the tool  13  to tool holder  11 .  
         [0036]    Tool holder  11  is secured to tool handle  20  by means of handle bracket  12  and sleeve  15  As seen in FIG. 2, handle bracket  12  is comprised of two identical halves, generally designated  12   a,  each of which include semi-circular portions  12 b, hook means comprised of planar portions  12   c,    12   d,  and  12   e,  and finger  12   f  including locking tab  12 g. When hook portions  12   e  of halves  12   a  are hooked onto slot  11   c  of tool holder  1 , joined together as a cylindrical unit, and partially encompassed by sleeve  15 , tool holder  11  and bracket  12  become securely locked together and function as one single unit. Tool  13  has a cutout  13   c  between upturned portions  13   a  to permit insertion of hook portions  12   e  into slot  11   c  to capture holder  11 .  
         [0037]    Handle bracket  12  can be stamped from an appropriate planar metal sheet with semi-circular portions  12   b,  hook means  12   c - e , and locking tabs  12   g  formed as indicated The semi-circular portions  12   b  can be formed from the planar metal sheet in a conventional manner To form appropriate hook means, in each case, planar hook portion  12   d  is bent downwardly from portion  12   c  at 90 degrees in the same direction as semi-circular portion  12   b,  and portion  12   e  is bent rearwardly at 90 degrees from portion  12   d  to be substantially parallel with portion  12   c    
         [0038]    [0038]FIG. 12 f  is stamped into the planar metal sheet with the open end, or finger tip, bent upwardly and away from the surface of the sheet to form tab  12   g.  In order to function as locking means as will hereafter be explained, it is necessary that the metal composition of the sheet provides sufficient spring resiliency such that tab  12   g  returns to its original position after depression and release.  
         [0039]    Bracket sleeve  15  (See FIGS. 1, 2,  4   a  and  4   b ) is typically an aluminum tube having an inside diameter sufficient to slip over semi-circular brackets  12   a  after they have been joined with tool holder  1  and collapsed to form a complete cylindrical unit In the locking operation collapsed halves  12   a  are positioned in sleeve  15  so that tabs  12   g  fit into and protrude from holes  15   a , as shown in FIG. 4 a,  thereby securely locking the sleeve  15 , tool holder  11 , and tool  13  into a single operational unit. To unlock the unit it is only necessary to depress tabs  12   g  and disengage brackets  12   a  from sleeve  15 , as indicated in FIG. 4 b.  In this manner the various specialized tools of the invention may be interchanged  
         [0040]    Sleeve  15  may be an integral portion of handle  20  of a desired length, such as to provide access to the ceiling by a user standing on the floor of the room, or may be affixed a handle of another material in any conventional manner. For instance, a handle may be extendible into various lengths by any conventional means such as sections of tubing having interlocking means such as snap-in spring tabs, or by telescoping tubes as is known in the art  
         [0041]    As described above, ceiling brush  16  is used to sweep the acoustical debris from the ceiling. An end view of brush  16  is shown in FIG. 5, brush  16  being mounted to base plate  16   a  as indicated in the back view of brush  16  shown in FIG. 6 FIG. 7 is a bottom view of brush  16  showing brush bristles extending across base plate  16   a  Brush  16  has dimensions generally of 1×18 inches. Base plate  16   a  is spring steel of any convenient dimensions.  
         [0042]    After the ceiling is brushed clean and it is desired to replace the removed acoustical ceiling with a desired textured ceiling, spreading, or floating, knife  17  (see FIG. 8) is used to apply thin amounts of drywall “mud” to cover all drywall tape joints and other flaws. Spreading knife  17  is made of thin, flexible, hardened steel with dimensions of approximately 6×18 inches, 18 inches being the width of the leading edge. The thickness is generally about 0.020 inches.  
         [0043]    After preparation of the ceiling, texture applicator  18  (FIGS. 9 and 10) is used to apply texture to the ceiling as heretofore described. Pad  18  is comprised of a metal base plate  18   a  to which is added a surface pad  18   b  composed of a high density, light weight, flexible foam material similar to that of the “boogie” board familiar to water sports enthusiasts. Base plate  18   a  is formed of thin, flexible, hardened steel with dimensions of approximately 12×24 inches,  24  inches being the width of the leading edge The thickness is generally about 020 inches. Surface pad  18   b  is added to the surface of plate  18   a  in any conventional manner  
         [0044]    In the removal of an existing acoustical ceiling, the scraping tool, or blade,  13  is used Scraping tool  13  is shown attached to tool holder  11  in FIGS. 1 and 2. Blade  13  is generally made from a plate of stiff, smooth surfaced, hardened spring steel, 6×14 inches, 14 inches being the width of the front or leading edge. The thickness of the blade is about 0 028 inches. The combination of stiff hardened material and the smooth surface of blade  13  provide for efficient scraping and removal of the moistened ceiling. After adjusting the handle length as described, the moistened acoustical ceiling is removed by scraping with tool  13  until the drywall joints and the paper of the drywall sheet are exposed. For ceilings having a different pitch, any of the above tools may be manufactured with different “strike angles”, that is, the angle of the working surface of the tool with respect to the handle as indicated by the angle α in FIGS. 5 and 10.  
         [0045]    An adequate means for protecting areas adjacent to the work area consists of isolating the area with plastic sheeting, applied in a manner to ensure quick and easy clean up of debris. A preferred method includes first sticking sufficient lengths of masking tape, generally a two-inch strip, to select spots on the interior walls with the remainder of such strips not stuck to the wall but left hanging loose toward the floor. A sheet of plastic is then placed under the loose portions of tape and stuck against the respective exposed adhesive sides of the tapes. In order for the tape to properly hold the plastic sheeting in place it is necessary to use sufficiently lightweight sheeting since heavy plastic sheeting will lift the adhesion of the sheeting from the tape. After attachment to the respective tape portions, the remainder of the plastic sheet is placed to lie upon and cover the floor. As required, additional sheets of plastic are cut to fit the dimensions of the other wall surfaces and likewise attached until the protective envelope is completed The tape portions covering the floor, and other areas as required, such as each corner where plastic has been taped to the wall, are reinforced as necessary to provide the desired protection.  
         [0046]    In accordance with the invention there has been shown and described improved apparatus, and method of use thereof, for the application of a textured ceiling, and if necessary the removal of an acoustical ceiling. It is to be understood that various other adaptations and modifications may be apparent to those skilled in the art and may be made without departing from the spirit and scope of the invention. For instance, FIG. 11 shows an embodiment omitting the bracket  12   a,  sleeve  15  being welded or otherwise connected directly to holder  11   
         [0047]    While there has been shown and described a preferred embodiment, the invention is not limited to the specific form as described and illustrated but rather limited only by the literal interpretation of the claims herein.