Sheetrock knife and holder apparatus

A gypsum panel knife and blade holder apparatus includes a blade holding pan having a bottom panel, side panels, end panels and an open top. The side panels each have an inside surface and an upper edge, the edges defining a pan periphery. The blade holder includes a plurality of slots that extend longitudinally on the blade holder, each slot being of a length that approaches the greater dimension of the length or width of the blade holder. A plurality of knives fit the blade holder at the slots, each of the knives having a blade with a width and a length, the width being much greater than the width for at least some of the knives.

Not applicable

REFERENCE TO A “MICROFICHE APPENDIX”

Not applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to knives and holders that are used during the installation of sheetrock, the knives being of the type that have a very wide blade in relation to the length of the blade and holder therefor. More particularly, the present invention relates to an improved sheetrock knife, pan, and holder apparatus that provides a pan having an open top with a holder that removably affixes to the pan at the open top, the holder having spaced apart slots that are sized and shaped to receive the blade portion of the sheetrock knife and wherein a strap arrangement secures the blades to the holder in a storage position.

2. General Background of the Invention

In the construction of homes, building and the like, it is common to use a gypsum panel material (e.g. Sheetrock® brand) that is affixed to a framework of wooden or steel members known in the industry as “studs”. The gypsum panels are first affixed to the framework. Tape and coatings are then applied to eliminate unsightly seams.

During such an installation of gypsum panels, the installers utilize knives that have very wide blades in relation to the length of the blade. These installers also employ pans for holding the liquid, slurry or semi-solid material that is applied to the gypsum panels in order to fabricate the completed wall.

The knife blades must be very wide in relation to the length of the knife blade because often a very large area is to be covered with a selected material, plaster, chemical or the like.

BRIEF SUMMARY OF THE INVENTION

The present invention provides an improved sheetrock knife and pan apparatus. A pan is provided that has a bottom panel, side panels and an open top. The side panels each have an inside surface and an upper edge, the edges defining in combination a periphery of the pan at the open top.

A knife blade supporting panel is removably or permanently attached to the pan at the open top, the panel having a peripheral edge that engages the pan side panels at the pan periphery.

The panel includes a plurality of slots that extend longitudinally across the panel, each slot being of a length that approaches the greater dimension of the length or width of the pan. For example, the knife blade supporting panel can be about four to five inches (4″-5″) wide and about fourteen to fifteen inches (14″-15″) long. The slots can be about twelve inches (12″) long and spaced about one half to one inch (½″-1″) apart.

A plurality of sheetrock installation knives are provided, each having a handle and a blade that is very wide in relation to its length. For example, the dimensions of a typical blade can be 4, 6, 8, 10 and 12 inches wide and about 4 inches long.

The pan bottom panel can have an area that is smaller than the area of the open top. Grooves in the bottom panel of the pan can be provided for receiving a blade edge, and for maintaining each stored blade in a vertical position.

The pan has a length and a width, the length being greater than the width and at least one of the slots has a length that approaches the length of the panel.

The panel provides a length and a width, the length being greater than the width and a plurality of slots having a length that approaches the length of the panel, the slots being generally parallel.

Each of the knives has a width that extends transversely at least one half the length or width of the pan and the knife is sized and shaped to fit one of the slots on the panel.

In the preferred embodiment, at least some of the side walls of the pan are inclined, and preferably all of the side walls of the pan are inclined.

The panel can optionally provide a tapered surface that preferably rests upon the pan at the periphery and upon one or more of the inclined pan side walls.

DETAILED DESCRIPTION OF THE INVENTION

InFIG. 6, the present invention provides an improved sheetrock knife and pan apparatus10that includes a pan11having a pan interior that is sized and shaped to receive and knife holder12.

The pan11can be a commercially available pan that is used in gypsum panel installation, having a bottom, end walls, and side walls. The pan11can be made of any suitable structural material such as plastic, metal or the like. Pans of this type are commercially available, manufactured by Walboard Co. The pan11is used to contain a desired wall covering (e.g. plaster) to be applied using a selected knife or knives31,32,33,34.

Knife holder12has bottom17, end walls13,14and side walls15,16. The walls13,14,15,16can be inclined as shown. Knife holder12has an interior22. Top panel18fits the pan11periphery19that is positioned at the top of each wall13,14,15,16. Side walls15,16can be preferably inclined and define an angle of about 5-30 degrees. Likewise, end walls13-14are preferably inclined, forming an angle of between about 5-30 degrees. In this fashion, the holder12can be nested in pan11for transport or storage.

Pan11can typically have dimensions of 4-24 inches wide by 2-12 inches high by 2-12 inches deep (as measured when pan11is sitting on a surface and can be filled with fluid, high refers to the floor-to-ceiling direction dimension). Pan11can have dimensions of 12-18 inches wide by 2-6 inches high by 2-6 inches deep. Pan11can have dimensions of, for example, 14⅜ inches wide by 3¾ inches high by 4⅝ inches deep.

Knife holder12preferably has dimensions to fit in pan11, preferably by nesting in pan11as indicated inFIG. 6. Knife holder12is preferably made of high-impact polystyrene (HIPS) plastic, but could also be made of wood, foam (such as styrofoam), rubber, ABS plastic, PVC plastic, CPVC plastic, polybutylene plastic, or polyethylene plastic.

The panel18provides an upper surface20, lower surface21, and has a plurality of longitudinally extending generally parallel slots23.

A plurality of knives (commercially available and manufactured by e.g. Walpro/Stanley) can be stored in the slots23with the blades of the knives extending through the slots23until each blade rests upon the bottom17. Each blade is secured in slots37, as seen inFIGS. 5 and 7. The slots37are each defined by a pair of generally parallel, spaced apart ribs35,36(seeFIGS. 3,4and7).

Each of the knives31,32,33,34has a blade29and a handle30. Some blades29are very wide and can extend almost the full length of the pan as shown inFIG. 5. When a plurality of the knives31,32,33,34have been stored in panel18as shown inFIGS. 6 and 7, long straps24,25are provided that are attached to the short straps on holder12.

The straps24,25,26,27can be in the form of strap members as shown, or straps that are attached to strap eyelets mounted on holder12. The straps24,25,26,27can provide hook and loop connectors. For example, the short straps26,27can be provided with “hook” connectors while the long straps24,25can be provided with “loop” connectors, such connecting straps24,25,26,27being sold under the mark Velcro®.

Once the knives are in storage position as shown inFIGS. 5,6and7, a strap24or25is placed across the plurality of blades of the knives at the rear38of each blade until the opposing short strap26or27is engaged and connected (e.g. Velcro®, hook and loop connection). The holder12with knives therein can then nest in pan11.

PARTS LIST

The following is a list of suitable parts and materials for the various elements of the preferred embodiment of the present invention.