Liquid coating applicator

A liquid coating applicator includes a support of a pad coupled to the support. The pad has a front side, a rear side and a lower arcuate convex surface between the front side and the rear side to spread coatings. Preferably, the support has at least one pad engaging surface configured to engage the pad and to support the pad in the arcuate convex cross-sectional shape. Preferably, the pad includes a backing configured for being removably coupled to the support, a substrate having a front arcuate side, a rear arcuate side and a lower surface between the front and rear sides and a flocking material coupled to the substrate. The backing and the substrate have the arcuate convex shape upon being coupled to the support.

FIELD OF THE INVENTION
 The present invention relates to liquid coating applicators for applying
 liquid coatings such as paints, varnishes, liquid sealants, stains and the
 like to surfaces. In particular, the present invention relates to a liquid
 coating applicator having an arcuate convex application surface for
 spreading liquid coatings across larger surface areas.
 BACKGROUND OF THE INVENTION
 Liquid coating applicators are typically used to apply and spread liquid
 coatings such as paints, varnishes, stains and liquid sealants to
 different surfaces such as walls, ceilings, and floors. Floors, such as
 decks and driveways, are coated using a relatively large liquid
 applicator. Liquid applicators used to apply coatings to floors, decks and
 driveways comprise either an elongate roller or a flat pad. Roller
 applicators typically comprise an elongate, cylindrical roller having a
 covering of liquid absorbing cloth or nap and mounted to the end of an
 elongate handle or pole. As the roller is pushed across the floor, deck or
 driveway, the roller rolls and dispenses the coating across the surface.
 Because the roller rolls along the surface, the roller is easy to push
 with very little friction. However, due to its circular shape and
 practical size limitations, the roller maintains contact with the surface
 along only a single line having a severely limited surface area. As a
 result, the roller applicator does not consistently spread the coating
 across the surface.
 Flat pad applicators typically comprise an elongate, generally rectangular
 flat foam or sponge pad mounted to the end of an elongate handle or pole.
 In contrast to roller applicators, flat pad applicators have a large
 surface area adapted to contact the surface being coated. Unfortunately,
 to maintain the large surface area of the flat pad applicator in contact
 with the surface being coated requires that the flat pad be perfectly
 parallel with the floor, deck or driveway. During the back and forth
 sweeping motion of the applicator, it is extremely difficult to maintain
 the flat pad perfectly parallel with the surface being coated. The
 difficulty of maintaining the flat pad perfectly parallel with the floor,
 deck or driveway is further increased because conventional flat pad
 applicators are not designed to accommodate users having different
 heights. It has been found that extremely tall or extremely short users
 tend to elevate either the front or the rear of the flat pad relative to
 the floor, deck or driveway. If the flat pad is not maintained perfectly
 parallel with the floor, deck or driveway, the flat pad contacts the
 surface being coated along only a single line of contact. Consequently,
 despite having a large surface area adapted to contact the surface being
 coated, flat pad applicators rarely achieve greater surface contact than
 roller applicators. Thus, neither roller applicators nor flat pad
 applicators consistently spread coating across surfaces.
 Thus, there is a continuing need for a liquid coating applicator that
 contacts the floor, deck or driveway with a relatively large surface area
 and that is easily maintained in contact with the floor, deck or driveway
 during to and fro movement of the applicator across the floor, deck or
 driveway, regardless of the user's stature. There is also a continuing
 need for a relatively large liquid coating applicator which is easily
 moved across a floor, deck or driveway with minimal frictional resistance.
 SUMMARY OF THE INVENTION
 The present invention is directed to a liquid coating applicator which
 includes a support and a pad coupled to the support. The pad has a front
 side, a rear side and a lower arcuate convex surface between the front
 side and the rear side to spread coatings.
 According to first aspect of the present invention, the arcuate convex
 surface has a radius of at least 5 inches and less than 27 inches.
 According to a more preferred embodiment, the arcuate convex surface has a
 radius of between about 12 inches and about 20 inches.
 According to a second aspect of the liquid coating applicator, the pad
 includes a backing configured to be coupled to the support and a flocking
 material coupled to the backing. The pad preferably additionally includes
 a substrate coupled to the backing, wherein the flocking material is
 coupled to the substrate. The backing and the substrate are preferably
 flexible. In addition, the support preferably includes at least one pad
 engaging surface configured to engage the pad and to support the pad in an
 arcuate convex cross-sectional shape. The support preferably includes a
 plurality of spaced ribs, wherein each rib has an arcuate convex surface
 in engagement with the pad.
 According to a third aspect of the coating applicator, the pad is removably
 coupled to the support. Preferably, the pad slidably mounts to the
 support. In one exemplary embodiment, the pad includes a plurality of
 resiliently flexible pads that form a channel to releasably receive the
 support.
 According to yet a fourth aspect of the coating applicator, the applicator
 includes an elongate pole and a support includes a mounting portion
 configured to be coupled to the pole.
 According to yet a fifth aspect of the coating applicator, the support
 includes a first wall portion extending from the pad, a second wall
 portion extending from the pad and a third wall portion interconnecting
 the first and second wall portions opposite the pad.
 The present invention is further directed to a coating applicator support
 for use with an applicator pad. The support includes a body having at
 least pad engaging surface. The at least one pad engaging surface is
 configured to engage the pad and to support the pad in an arcuate convex
 cross-sectional shape.
 Preferably, the applicator support includes a plurality of spaced ribs.
 Each rib includes at least one pad engaging surface. The at least one pad
 engaging surface is preferably configured to support the pad in an arcuate
 convex cross-sectional shape having a radius between 5 inches and 27
 inches. Preferably, the at least one pad engaging surface supports the pad
 in an arcuate convex cross-sectional shape having a radius of between 12
 and 20 inches.
 The present invention is also directed to a coating applicator pad for use
 with a pad support. The pad includes a backing configured for being
 removably coupled to the support, a substrate having a front arcuate side,
 a rear arcuate side and a lower surface between the front and rear sides
 and flocking coupled to the substrate. The backing and the substrate are
 configured so as to have an arcuate convex shape upon being coupled to the
 support. Preferably, the backing and the substrate are resiliently
 flexible so as to resiliently deform to the arcuate convex shape upon
 being coupled to the support.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
 FIGS. 1-6 illustrate an assembled liquid coating applicator 10. FIG. 1 is a
 top perspective view of liquid coating applicator 10. FIG. 2 is a front
 elevational view of the liquid coating applicator. FIG. 3 is a rear
 elevational view of the liquid coating applicator. FIG. 4 is a top plan
 view of the liquid coating applicator. FIG. 5 is a bottom plan view of the
 liquid coating applicator. FIG. 6 is a right side elevational view of the
 liquid coating applicator, the left side elevational view of the coating
 applicator being a mirror image thereof. As best shown by FIGS. 1-6,
 coating applicator 10 generally includes support 12 and pad 14. Support 12
 is an elongate, relatively rigid member configured for supporting pad 14
 as pad 14 is moved across surface 16. Support 12 includes a mounting
 portion 18 configured for mounting support 12 to an elongate pole 20
 having a handle portion (not shown). As best shown by FIGS. 1 and 9,
 mounting portion 18 preferably includes a central sleeve or bore 19 sized
 for receiving an end of pole 20. Although mounting portion 18 is
 specifically adapted to removably couple support 12 to pole 20, mounting
 portion 18 may alternatively be adapted for permanently coupling support
 12 to pole 20.
 As further shown by FIGS. 1-6, support 12 has a longitudinal length
 substantially equal to the longitudinal length of pad 14. Although support
 12 is preferably designed as shown in FIGS. 1-6 so as to support pad 14
 while providing a sleek, robust and visually attractive appearance,
 support 12 may have other various sizes, shapes and configurations. For
 example, in the exemplary embodiment illustrated, support 12 is configured
 to support a 24 inch pad. In particular, support 12 preferably has a
 length of approximately 24.13 inches and a width of approximately 3.344
 inches. Pad 14 has a length of approximately 23.75 inches and a width of
 approximately 3.56 inches. To accommodate shorter pads, such as 18 inch
 pads, or longer pads, such as 32 inch pads, support 12 may be modified as
 necessary. As will be appreciated, both support 12 and pad 14 must have a
 minimum longitudinal length of at least 12 inches to efficiently coat
 larger surfaces, such as floors, decks and driveways. In the exemplary
 embodiment illustrated, support 12 is specifically configured for being
 removably coupled to pad 14. Alternatively, support 12 may be configured
 for being permanently attached to pad 14.
 Pad 14 is an elongate, paint carrying, releasing and spreading medium which
 is carried and supported by support 12 substantially along the entire
 longitudinal length of support 12. Pad 14 is configured for being
 removably coupled to support 12. Alternatively, pad 14 may be configured
 for being permanently coupled to support 12. Pad 14 generally includes a
 front side 24, a rear side 26 and a lower arcuate surface 28. Front side
 24 and rear side 26 extend opposite one another substantially parallel to
 the longitudinal axis of pad 14 and support 12. As a result, front side 24
 and rear side 26 spread liquid coating across surface 16 as applicator 10
 is pushed and pulled to and fro across surface 16. Front side 24 and rear
 side 26 preferably have an arcuate convex shape to spread excess coating
 on the front and rear sides of pad 14.
 Lower surface 28 extends between front side 24 and rear side 26 of pad 14.
 Lower surface 28 is preferably configured so as to have an arcuate convex
 cross-sectional shape when mounted to support 12. Because surface 28 has
 an arcuate convex cross-sectional shape, surface 28 enables the user of
 applicator 10 to more consistently maintain a larger surface area of pad
 14 in contact with surface 16 during the application of liquid coating. In
 particular, because surface 28 has an arcuate convex cross-sectional
 shape, a greater surface area of surface 28 is kept in contact with
 surface 16 even when applicator 10 is tilted either towards the front or
 the rear during to and fro sweeping movement of applicator 10 across
 surface 16 by users having different statures. Surface 28 preferably has a
 radius of at least 5 inches. It has been found that with this minimum
 radius, surface 28 and pad 14 more consistently maintain an enlarged
 surface area in contact with surface 16 independent of variations caused
 by to and fro movement of applicator 10 as well as the use of applicator
 10 by different users having different statures. Surface 28 preferably has
 a maximum radius of about 27 inches. At this maximum radius, surface 28 of
 pad 14 has a larger surface area in contact with surface 16 as compared to
 the minimum radius of 5 inches. However, with this maximum radius, surface
 28 is less accommodating to the variations caused by to and fro movement
 of applicator 10 as well as variations caused by different users having
 different statures. It has been found that the optimum range of radii for
 surface 28 falls between 12 inches and 20 inches. Within this range,
 surface 28 maintains an acceptable amount of surface area in contact with
 surface 16 while still adequately adapting to angular variations caused by
 the to and fro movement of applicator 10 and the use of applicator 10 by
 different users having different statures. In the exemplary embodiment
 illustrated, surface 28 is configured so as to have an arcuate convex
 cross-sectional shape of approximately 21 inches. With this exemplary
 embodiment, the ability of applicator 10 to accommodate different users
 having different statures has been sacrificed slightly in favor of an
 increased amount of surface area of surface 28 in contact with surface 16.
 Overall, applicator 10 consistently maintains an enlarged surface area of
 its applicating surface carrying liquid coatings in contact with surface
 16 to more uniformly spread and apply the coatings to surface 16 despite
 angular variations of pad 14 relative to surface 16.
 FIGS. 7-11 illustrate liquid coating applicator 10 in greater detail. In
 particular, FIG. 7 is an exploded perspective view of applicator 10
 illustrating pad 14 removed from support 12. FIG. 8 is an enlarged end
 elevational view of pad 14 removed from support 12. FIGS. 9-10 are
 sectional view illustrating pad 14 mounted to support 12. As best shown by
 FIG. 7, pad 14 is removably coupled to support 12. In particular, pad 14
 is slid onto and off of support 12. To this end, support 12 includes
 outwardly projecting front and rear flanges 30 and 32, respectively.
 Although flanges 30 and 32 may have any one of a variety of shapes, sizes
 and configurations, flanges 30 and 32 are specifically configured to
 slidably engage pad 14 so as to releasably couple pad 14 to support 12.
 As shown by FIGS. 7 and 8, pad 14 is configured for being slidably coupled
 to support 12. Pad 14 generally includes backing 36, mounting tabs 38,
 substrate 40 and applicating medium 42. Backing 36 is an elongate member
 configured for being positioned adjacent to support 12. Backing 36 carries
 and supports substrate 40 as well as applicating medium 42. Backing 36
 preferably has a thickness and is preferably made from a material such
 that backing 36 is resiliently flexible so as to resiliently deform when
 coupled to and engaged by support 12. Backing 36 preferably comprises
 rigid polychloride having a thickness of about 0.020 inches.
 Alternatively, backing 36 may comprise a variety of other well-known
 resiliently flexible materials. Alternatively, backing 36 may be formed of
 a more rigid in flexible material, wherein backing 36 is preformed so as
 to support substrate 40 and applicating medium 42 such that surface 28 of
 applicating medium 42 has an arcuate convex cross-sectional shape or
 contour. For example, backing 36 may be preformed so as to have an arcuate
 convex cross-sectional shape or contour prior to being mounted to support
 12, wherein the rigid structure of backing 36 provides least applicating
 medium 42 with an arcuate convex shape along surface 28.
 Mounting tabs 38 comprise protuberances or flanges that project away from
 backing 36 so as to form a channel 46 sized and configured for slidably
 receiving flanges 30 and 32 of support 12. Mounting tabs 38 are preferably
 made from a resiliently flexible material and are sized and configured so
 as to resiliently flex away from backing 36 upon slidably receiving
 flanges 30 and 32 of support 12. As best shown by FIG. 11, tabs 38
 resiliently return towards their initial shape so as to frictionally clamp
 pad 14 to flanges 30 and 32 of support 12. As best shown by FIG. 7,
 mounting tabs 38 are preferably spaced from one another along the
 longitudinal length of backing 36 and pad 14. As will be appreciated, the
 exact number and length of mounting tabs 38 along the front and rear sides
 24 and 26 of pad 14 may be varied depending upon the resiliency of the
 mounting tabs, the amount of surface contact between support 12 and pad 14
 and the desired degree of hold between support 12 and pad 14. In the
 exemplary embodiment illustrated, tabs 38 are integrally formed out of
 polyvinyl chloride with backing 36. Alternatively, mounting tabs 38 may be
 individually formed and otherwise secured to backing 36. Furthermore, in
 lieu of mounting tabs 38, backing 36 may be provided with various other
 means for removably attaching pad 14 to support 12 such as mechanical
 fasteners, hook and loop systems, releasable adhesives or mechanical
 interlocking structures.
 Substrate 40 comprises a layer of supporting material coupled to backing 36
 opposite mounting tabs 38. Substrate 40 supports applicating medium 42.
 Substrate 40 preferably comprises a layer of material having a limited
 degree of compressibility such that surface 28 of medium 42 is maintained
 in an arcuate convex shape when normal pressure is applied to applicator
 10. Substrate 40 is preferably resiliently deformable so as to deform with
 backing 36 when backing 36 is mounted adjacent to support 12.
 Consequently, applicating medium 42 extending along substrate 40 also
 deforms so as to have an arcuate convex cross-sectional profile. Front 24
 and rear 26 of substrate 40 are preferably arcuate so as to avoid cracking
 or degradation due to the resilient deformation of substrate 40 when pad
 14 is mounted to support 12. Front 24 and rear 26 each preferably have a
 radius of approximately 0.75 inches. In the exemplary embodiment,
 substrate 40 is formed from closed cell foam such as polyester-based
 polyurethane foam. Substrate 40 is preferably bonded to backing 36 by a
 solvent-resistant two-part epoxy system comprising a base resin and
 activator. Alternatively, substrate 40 may be bonded to backing 36 by
 urethane or various other adhesives. Although presently viewed as less
 desirable, substrate 40 may also be coupled to backing 36 by various
 mechanical fasteners and interlocking structures. For example, substrate
 40 may be comolded with backing 36 depending upon the material selected
 for backing 36 and substrate 40. In the exemplary embodiment, substrate 40
 preferably has a thickness of 0.5 inches.
 Applicating medium 42 extends along substrate 40 opposite backing 36 and
 defines surface 28 as well as front side 24 and rear side 26 of pad 14.
 Applicating medium 28 comprises a liquid coating medium capable of
 retaining, releasing and spreading coating across a surface 16 which may
 comprise roughened concrete, polymers or woodgrain such as those found in
 driveways and decks. Applicating medium 42 preferably comprises a layer of
 flocking. Flocking comprises a fabric of individual filaments or fibers
 which are bonded to substrate 40. In the exemplary embodiments
 illustrated, flocking may comprise any one of a variety of materials such
 as acrylic, modacrylic, cotton, wool, polyester, other polyolofines,
 nylon, rayon, mohair, and others. The flocking preferably has a minimum
 height of at least 0.03 inches. The flocking preferably has a pile height
 of approximately 0.180 inches and a density between about 15 to 25 ends
 per inch. Preferably, 21 ends per inch are employed. In the exemplary
 embodiment illustrated, applicating medium 42 comprises nylon flock which
 is specially coated to hold electric charge and which is bonded to
 substrate 40 using a solvent resistant adhesive such as modified plasticol
 or acrylics. Alternatively, the flocking material of application medium 42
 may be bonded to substrate 40 with various other adhesives.
 Because applicating medium 42 preferably comprises a layer of flocking
 material, applicator 10 is advantageous over conventional fabric nap
 roller applicators employing fabric nap and flat applicators employing
 sponge material. First, only the ends of the individual filaments or
 fibers of applicating medium 42 frictionally contact surface 16. As a
 result, pad 14 has a lower coefficient of friction such that applicator 10
 may be more easily moved across surface 16 during the application of
 coatings. Second, because applicating medium 42 preferably comprises
 flocking, applicating medium 42 has a greater three-dimensional surface
 area to hold and retain liquid coatings as compared to fabric nap or
 sponge material. As a result, applicating medium 42 of pad 14 is better
 able to hold low viscosity fluids such as those containing water sealants
 and the like which are frequently used to coat decks and driveways. Third,
 the flocking material of pad 14 more uniformly deposits and releases
 liquid coating to surface 16 at a better and more controllable rate.
 Fourth, because the individual fibers of the flocking material are able to
 individually deflect, the flocking material better conforms to high and
 low points in surface 16 being coated. As a result, pad 14 is better
 adapted to spread coatings to roughened surfaces such as those frequently
 found on decks and driveways.
 FIGS. 9 through 11 illustrate pad 14 mounted to support 12. As best shown
 by FIG. 9, support 12 generally includes front wall portion 52, rear wall
 portion 54, intermediate wall portion 56 and ribs 58. Front wall portion
 52 extends from front flange 30 while rear wall portion 54 extends from
 rear flange 32. Intermediate wall portion 56 interconnects front wall
 portion 52 and rear wall portion 54 opposite pad 14. As a result, walls
 52, 54 and 56 form a hollow lightweight structure that is also
 sufficiently stiff so as to adequately support pad 14 as liquid coating
 applicator 10 is moved across surface 16. Although walls 52, 54 and 56
 form a semi-cylindrical half-pipe extending along the longitudinal length
 of support 12, walls 52, 54 and 56 may alternatively be configured so as
 to have square or rectangular cross-sectional shapes that extend along the
 longitudinal length of support 12. The semi-spherical cross-sectional
 shape of support 12 provides a sleek, robust and visually attractive
 appearance.
 Ribs 58 extend between walls 52, 54 and 56 into engagement with pad 14. In
 the exemplary embodiment, support 12 includes four such ribs 58 spaced
 between longitudinal ends of support 12. In particular, support 12
 includes a rib 58 at each of locations 62, 64, 66 and 68 as indicated in
 FIG. 4. Each of ribs 58 includes a lower edge or surface 70 configured so
 as to engage and contact backing 36 of pad 14.
 FIGS. 10 and 11 are enlarged sectional views illustrating the engagement of
 rib 58 with pad 14 in greater detail. As shown by FIGS. 10 and 11, surface
 70 of rib 58 has an arcuate convex contour such that surface 70 engages
 backing 36 of pad 14 to deform backing 36, substrate 40 and applicating
 medium 42 into a corresponding arcuate convex cross-sectional shape or
 contour. Preferably, surface 70 of rib 58 has a radius of between at least
 5 inches and 27 inches. Surface 70 more optimally has a radius of between
 about 12 inches and 20 inches. In the exemplary embodiment illustrated,
 surface 70 has a radius of approximately 21 inches. Because surfaces 70 of
 rib 58 engage and deform backing 36, substrate 40 and applicating medium
 42, pad 14 can be manufactured with a generally flat backing 36 such that
 the manufacture of pad 14 is less complex and less expensive.
 Although the present invention has been described with reference to
 preferred embodiments, workers 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.