Flocked foam applicator

An improved flocked foam applicator has a cylindrically shaped hollow rigid shell configured to slide onto a rigid core coupled to a handle. A rigid planar surface extends from the bottom of the hollow rigid shell forward. Applicator flock extends downward from the rear cylindrical portion of the hollow rigid shell, around the bottom of the hollow rigid shell, and outward to the distal edge of the rigid planar surface. The distal edge of rigid planar surface extends further forward than the leading edge of the cylindrical hollow rigid shell. As a result of this design, the improved flocked foam applicator can apply a liquid applicant to a floor all the way up to a baseboard or wall, and will further prevent the leading edge of the cylindrical portion from coming into contact with a baseboard or wall and depositing fluid in an undesired location.

FIELD OF THE INVENTION

The present invention is directed to methods and apparatus for applying liquid finishes to horizontal surfaces.

BACKGROUND

Today, there are several methods for a applying liquid finishes, such as paint, polyurethane, and other formulations, to planar rigid surfaces such as floors and walls. These methods have included brushing, rolling, spraying, and various applicators such as brushes, lambswool, synthetic and natural fiber brushes, spray heads, and flocked foam applicators. A common way to apply a liquid finish with a flocked foam applicator is to pour a liquid finish on floor, and spread the liquid finish with the flocked foam applicator. Prior art embodiments of a flocked foam applicator is formed in a tubular or cylindrical shape. In application, the tubular or cylindrical lambswool spreader covering at least part of a cylindrical core acts as both a squeegee for advancing a fluid head of the liquid finish, and an applicator, for applying the liquid finish to the floor.

DETAILED DESCRIPTION

FIG. 1is a side elevation view of a prior art flocked foam applicator assembly100. The flocked foam applicator assembly includes a flocked foam applicator121comprising a hollow rigid shell115to which an absorbent applicator surface103is affixed. The hollow rigid shell is preferably curved about an axis, and more preferably, cylindrically shaped about a cylindrical axis. However, other shapes are envisioned for the hollow rigid shell. The absorbent applicator103is typically comprised of a textile-like materials such as lambswool or synthetic flock. A rigid core105can be slid into the inner cavity of the hollow rigid shell. The rigid core is fixedly coupled to rigid extension107which extends between the rigid cylindrical core105and a rigid handle119. WithinFIG. 1, the absorbent applicator103of the flocked foam applicator121is pictured at the juncture of a floor104and a wall111. A liquid applicant117such as paint or polyurethane is depicted on the floor adjacent the absorbent applicator. A gap113is visible in front of the flocked foam applicator. Prior art flocked foam applicators are not capable of properly applying a liquid applicant to this region.

FIG. 2depicts a top plan view of the flocked foam applicator assembly100ofFIG. 1. A longitudinal gap201extends the entire length of the cylindrical portion of hollow rigid shell115, oriented parallel to the axis of the cylinder. The rigid extension107extends through the longitudinal gap, thereby coupling the handle119to the rigid cylindrical core105. The rigid extension107, and the rigid cylindrical core105affixed thereto, can be slid parallel to the axis of the flocked foam applicator assembly, so as to insert the rigid cylindrical core105into the cavity of the hollow rigid shell115, or alternatively, to withdraw the rigid cylindrical core105from the hollow rigid shell115. By this design, the hollow rigid shell115, and the absorbent applicator103affixed thereto may be disposed of, without disposing of the handle119, the rigid extension107or the rigid cylindrical core105. Following disposal of a used applicator, a new flocked foam applicator comprising a hollow rigid shell115with an absorbent applicator103affixed thereto, may be slid over the rigid selectable core105, thereby providing a fresh flocked foam applicator121for applying a liquid applicant117to the floor104.

Referring again toFIG. 1, because of the cylindrical shape of the flocked foam applicator121, the most horizontally advanced portion123of the flocked foam applicator121typically engages the wall111, baseboard, or other vertical member during operation. There are two problematic aspects of this event, owing to the existing design of the flocked foam applicator. The first problem is that the absorbent applicator103does not touch the floor104within the corner section113. As a consequence, the flocked foam applicator cannot properly apply the liquid applicant117to the floor104in the corner section113. Additionally, because the liquid applicant typically saturates large portions of absorbent applicator103, when the most horizontally advanced portion123of the flocked foam applicator121touches wall,111, baseboard, or other vertical surface, it can inadvertently deposit the liquid applicant117on a wall baseboard.

FIGS. 3 and 4depict side elevational views of a flocked foam applicator300according to an embodiment of the present invention. The flocked foam applicator300includes an absorbent applicator303having an absorbent exterior surface, and an interior surface coupled to a hollow rigid shell301. A longitudinal gap305is formed in the hollow rigid shell301and absorbent applicator303. According to one embodiment, the longitudinal gap extends the length of the hollow rigid shell301, from end to end. In alternative embodiments, the longitudinal gap can extend from one end of the shell301to approximately the center of the shell, thereby limiting insertion of the rigid extension107from only one end of the shell. As illustrated inFIG. 3, the absorbent applicator extends from adjacent the longitudinal gap at the top of the hollow rigid shell301, down the right-hand side of the hollow rigid shell, to the bottom of the hollow rigid shell. The point at which the hollow rigid shell is tangent to the floor is depicted as point C. At approximately the tangent point C, the orientation of the absorbent applicator303ceases to conform to the exterior curvature of the hollow rigid shell301. The absorbent applicator303to the left of the tangent point D forms a planar application section401that, in use, is configured to remain in a substantially horizontal orientation. To maintain a fixed orientation, the interior surface (or “upper surface” inFIGS. 4 and 5) of the planar application section401of the absorbent applicator303is coupled to a rigid member309.

Referring to bothFIG. 3andFIG. 4, the rigid member309functions to ensure that the planar application section401of exorbitant applicator303remains in contact with the floor311.

In an embodiment depicted inFIG. 4, the leading edge of the hollow rigid shell301is depicted as point “D” and by the dotted perpendicular line405. The planar application section401extends beyond the leading edge405of the hollow rigid shell301. The first advantage of this design is that the absorbent applicator does not deposit the liquid applicant on the wall parallel to the leading edge405of the hollow rigid shell, because there is no absorbent applicator along the leading edge405of the hollow rigid shell301, and because the distal edge of the planar application section401extends further forward than the leading edge405of the cylindrical hollow rigid shell. This design further ensures that the absorbent applicator303will not lose contact with the floor311in the last few centimeters of where the floor abuts a wall or baseboard.

In the embodiment shown inFIG. 4, the orientation of the planar application area401is maintained by a rigid member309such as a flat rigid piece of material. According to an embodiment, the thickness of rigid member309ranges from about 2 mm to about 15 mm, though embodiments of greater or lesser thickness are envisioned.

In an alternative embodiment, as shown inFIG. 5, a wedge shaped member501functions to maintain a constant horizontal orientation of the planar application section401, as depicted further inFIGS. 6 and 7. The wedge shaped member501can be held in place by securing the lower surface of the wedge shaped member to the upper surface of the absorbent applicator303, by securing the right hand surface of the wedge shaped member to the hollow rigid shell301, or by securing both of these surfaces. As noted inFIG. 5, the right hand edge of the wedge shaped member501is curved to match the curvature of the outer surface of the hollow rigid shell. In a preferred embodiment, the wedge shaped member501is formed from an elastomer or sponge material so that it can deform under pressure, and regain its original shape after the pressure is released.

FIG. 6depicts an embodiment of the flocked foam applicator ofFIGS. 3 and 4during use. The longitudinal gap305within the rigid cylindrical core301is positioned such that when the handle119is positioned at the normal angle of use, the planar application section401of the absorbent applicator303is oriented in a substantially horizontal orientation. However, in the embodiment ofFIG. 6, if a user is standing in a fixed position and pushes the handle forward, extending his arm away from his body) such that the application head slides across the floor, the user will typically lower his hand as he slides the applicator forward. As a result, the handle will typically rotate clockwise (reducing the angle between the handle and the floor from the perspective of the drawing). As a consequence, the planar application section401may rise off the floor by an angle θ as the user extends his arm, thereby failing to properly coat the floor with the fluid or liquid on the section of floor wherein the floor abuts a wall or molding along a bottom of a wall.

FIG. 7shows an alternative embodiment toFIG. 6, wherein the distal edge of the planar application section401is oriented in a slightly downward angle α relative to the floor when the handle is at an angle typically held by a user. When a deformable wedge described inFIG. 5. is used in conjunction with this embodiment, a downward pressure on the handle119by the user will deform the wedge and bend the planar application section401at roughly the point beneath the leading edge405shown inFIG. 4, thereby causing contact between the entire planar application section401and the floor. Again, imagining a user standing in a fixed position, as the user extends his arm forward (away from his body) to advance the flocked foam applicator across the floor, the handle the angle between the handle and the floor is progressively reduced, asserting a clockwise rotation on the applicator.

However, instead of raising the distal edge of the planar application section401off of the floor, the foam wedge will expand, forcing the tip downward, maintaining contact between the tip of the planar application section401and the floor. By the use of a “soft” elastomer or sponge wedge that can easily be deformed by slight pressure, the natural angle α may be as great as 45 to 85 degrees, allowing forward thrust of the handle to a distance wherein the handle is nearly parallel to the floor. Such an embodiment would be useful in spreading a liquid applicant on a floor underneath a fixed structure, or on the section of floor wherein the floor abuts a wall or molding along a bottom of a wall, a motion typically requiring the handle to be rotated downwards. However, in most applications, an angle of between zero and 45 degrees would be preferred.

Throughout this disclosure, many specific details have been offered to enable one skilled in the art to make and use the invention described herein. These details are offered to be enabling, and are not intended to limit the scope of the appended claims, which comprehends alternative embodiments depicted within the scope of the claims.