Grout dispensing apparatus

An apparatus for dispensing grout into joints formed between laterally adjacent floor tiles comprises a hopper for holding a quantity of grout mounted on a mobile frame assembly. The apparatus includes a plurality of nozzle assemblies coupled to the hopper through tubular channels. The nozzle assemblies are slidably coupled to a mounting bracket which extends parallel to the front of the frame assembly such that the lateral distance between the nozzle assemblies is adjustable to correspond to the lateral distance between the joints formed by various sizes of floor tiles. A rack and pinion assembly is connected to the mounting bracket such that the vertical distance between the nozzle assemblies and the floor tiles is also adjustable.

BACKGROUND OF THE INVENTION
 The present invention relates generally to an apparatus for dispensing
 grout and, more particularly, to a wheeled apparatus having multiple grout
 dispensing nozzles that are vertically and horizontally adjustable for
 simultaneously dispensing grout into multiple grout lines about tiles.
 Grout is a thin mortar for filling cracks or joints such as those formed
 between tiles on a floor, shower wall, or the like. Grout is generally
 applied by spreading grout over the entire tile surface, compacting it
 into the joints, and then wiping the excess grout off of the tile surfaces
 before it dries. The grout can only be applied to small areas at a time
 because of the necessity of cleaning the grout off of the tile surfaces
 before it hardens. The inherent disadvantages of applying grout to tile
 surfaces are the time requirements for completing large jobs and the labor
 intensity of bending or working on one's knees.
 Systems which use a hand-held device similar to a caulking gun for applying
 grout directly into joints have been proposed in U.S. Pat. Nos. 5,571,538
 and 5,314,100. Although assumably effective for their intended purposes,
 the existing devices do not allow grout to be applied simultaneously and
 uniformly in multiple joints.
 Therefore, it is desirable to have an apparatus with multiple nozzle
 assemblies which can simultaneously and uniformly dispense grout into the
 joints between tiles. It is further desirable to have an apparatus in
 which each of the nozzle assemblies is laterally and vertically adjustable
 for use with tiles of various dimensions.
 SUMMARY OF THE INVENTION
 Accordingly, an apparatus for dispensing grout constructed according to the
 present invention includes a mobile frame assembly having a base with
 front and rear walls and spaced apart side walls therebetween. The
 apparatus further includes a hopper for holding an amount of grout. An
 auger is mounted within the hopper and is coupled to an elongate shaft
 extending longitudinally in the hopper. A lid is releasably attached to
 the hopper and includes an electric motor. The shaft is engaged by the
 electric motor when the lid is secured to the hopper to operate the auger.
 A plurality of tubular channels are coupled to an end of the hopper into
 which grout is delivered as the auger operates. Each channel is connected
 to one of a plurality of nozzle assemblies adapted to dispense grout. Each
 nozzle assembly is slidably connected to a mounting bracket which is
 displaced from and extends parallel to the front wall of the mobile frame
 assembly. Therefore, the nozzle assemblies are selectably slidable along
 the mounting bracket so as to position each nozzle assembly above a joint
 between tiles. A rack and pinion gear assembly is also coupled to the
 mounting bracket for increasing or decreasing the distance between the
 nozzle assemblies and the joints between tiles. Therefore, the
 adjustability of the nozzle assemblies enables the present apparatus to be
 used to properly dispense grout into the joints between tiles of various
 sizes and into joints of various depths.
 Therefore, a general object of this invention is to provide an apparatus
 having multiple nozzles assemblies for dispensing grout simultaneously
 into the joints between multiple tiles.
 Another object of this invention is to provide an apparatus, as aforesaid,
 in which each nozzle assembly is laterally slidable along a mounting
 bracket such that the nozzle assemblies can dispense grout into joints
 between tiles having various dimensions.
 Still another object of this invention is to provide an apparatus, as
 aforesaid, in which the distance between the nozzle assemblies and
 respective joints is adjustable.
 Yet another object of this invention is to provide an apparatus, as
 aforesaid, having continuous track wheel assemblies for moving the nozzle
 assemblies along respective joints without disrupting previously grouted
 areas.
 A further object of this invention is to provide an apparatus, as
 aforesaid, which can deliver grout from a refillable hopper to each nozzle
 assembly.
 A still further object of this invention is to provide an apparatus, as
 aforesaid, which is powered by rechargeable batteries.
 Another object of this invention is to provide an apparatus, as aforesaid,
 having a hand-held nozzle assembly for dispensing grout into joints not
 accessible by the plurality of nozzle assemblies
 Other objects and advantages of this invention will become apparent from
 the following description taken in connection with the accompanying
 drawings, wherein is set forth by way of illustration and example, an
 embodiment of this invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT
 An apparatus 10 for dispensing grout constructed according to the preferred
 embodiment of the present invention is shown in FIGS. 1-8. The apparatus
 10 includes a mobile frame assembly 20 having a base platform 22 with
 front 24 and rear 26 walls. Spaced apart side walls 28 extend between the
 front 24 and rear 26 walls. Each side wall 28 presents a generally
 U-shaped configuration having an open bottom for housing a wheel assembly
 30. Each wheel assembly 30 includes a pair of drive wheels 32 and a
 continuous belt-like track 34 extending about the wheels 32 (FIGS. 3 and
 4). The track 34 is constructed of rubber or other flexible material which
 will not disturb grout already dispensed in a joint between tiles, as to
 be further described below. The drive wheels 32 are connected to a first
 electric motor 36 mounted on the base 22 of the frame assembly 20 (FIG.
 1). The first electric motor 36 is electrically connected to a
 rechargeable battery within a battery housing 38 on the base 22. Although
 a conventional power cord or pneumatic hose would also be suitable power
 sources for the first electric motor 36, use of battery power is
 preferable in that no cords or hoses are needed which could disrupt grout
 that has not yet cured.
 A pair of handles 40 are pivotally coupled to the base 22 adjacent the rear
 wall 26 and extend upwardly therefrom. The handles 40 are pivotal so as to
 accommodate users of different heights. A control panel 42 extends between
 the handles 40 adjacent free ends thereof (FIG. 1). The control panel 42
 includes a lever 44 which is electrically connected to a clutch and gear
 assembly (not shown) of the wheel assemblies 30. Accordingly, the frame
 assembly 20 can be moved forward or backward or placed in neutral, as
 desired by a user. The control panel 42 also includes a variable speed
 controller 46 electrically connected to the first motor for controlling
 the speed of the first electric motor 36 and thus the speed of the drive
 wheels 32. Electrical connections are known in the art and, therefore, are
 not shown.
 The apparatus 10 further includes a framework 52 having a first annular
 support member 54 and a plurality of vertical support members 58 depending
 therefrom. The framework 52 also includes a second annular support member
 56 spaced apart from the first annular support member 54. The vertical
 support members 58 are downwardly inwardly arcuate such that the framework
 52 provides a receptacle for a grout hopper 70, as to be further described
 below. The first annular support member 54 includes a pair of opposed
 threaded recesses.
 A pair of support arms 60 are fixedly attached to respective handles 40.
 Each arm 60 includes a slot 62. A knob 64 having a threaded shaft
 extending therefrom can be inserted through each slot 62 and into
 respective threaded recesses of the support member 54 and tightened for
 holding the framework 52 at a desired position relative to the slot 62. A
 collar 66 is attached to lower free ends of the vertical support members
 58 and pivotally attached to the base 22 with spaced apart struts 68.
 The apparatus 10 further includes a hopper 70 for storing a quantity of
 grout to be dispensed. The hopper 70 is configured to slidably mate with
 the framework 52. The hopper 70 includes a plurality of fasteners 72 for
 selectably securing the hopper 70 to the framework 52. The hopper 70
 includes a first end having a neck portion 74 which extends through the
 collar 66 when the hopper 70 is resting in the framework 52. An aperture
 is formed in the end of the neck portion 74. An auger 76 is mounted within
 the neck portion 74 and includes an elongate shaft 78 extending therefrom
 longitudinally through the hopper 70. The shaft 78 includes a free end 80
 having a socket configuration.
 A large aperture is formed in an opposed second end 82 of the hopper 70 for
 depositing grout into the hopper 70 therethrough. A lid 84 is releasably
 coupled to the second end 82 for covering the aperture. The lid 84 is
 threadably coupled to the hopper 70 although the use of clips, clamps, or
 other fasteners would also be suitable. A second electric motor is housed
 within the lid 84 and selectively coupled to the battery (not shown). When
 the lid 84 is coupled to the hopper 70, the shaft 78 engages the second
 motor. An on/off switch 50 mounted on the control panel 42 is used to
 activate the second motor. A pair of arcuate agitator rods 88 are fixedly
 attached to the shaft 78 and operate to agitate or stir the grout within
 the hopper 70 upon rotation of the shaft 78. Accordingly, the hopper may
 be filled with grout and then dispensed through the aperture in the neck
 portion 74 by gravitational forces aided by operation of the auger 76. It
 should be appreciated that the second electric motor may be a variable
 speed motor coupled to a second speed controller 48 on the control panel
 42 such that the flow rate of grout through the neck portion aperture is
 selectively variable.
 The apparatus 10 further includes a nozzle coupling 90 frictionally
 attached at a first end 92 to the neck portion 74 of the hopper 70. The
 coupling 90 may be separated easily from the neck portion 74 when the
 hopper 70 is removed from the framework 52 or for cleaning purposes. A
 plurality of primary outlets 96 are formed in a second end 94 of the
 nozzle coupling 90. A secondary outlet 98 is formed in a side wall 100 of
 the coupling 90. The coupling 90 includes a main shutoff valve 102
 positioned to selectively regulate the flow of grout through the primary
 outlets 96. A second valve 104 is positioned on the secondary outlet 98
 for regulating the flow of grout therethrough.
 Each primary outlet 96 is coupled to a first end 108 of a tubular channel
 106, the channel being a rubber hose or conduit. A second end 110 of each
 channel 106 is connected to a nozzle assembly 112 having a nozzle housing
 114 and a dispenser tip 116 (FIG. 6). Each nozzle housing 114 includes a
 valve 118 for individually regulating the flow of grout through the tip
 116.
 As best shown in FIG. 6, the apparatus 10 includes a mounting assembly 120
 for retaining and positioning the nozzle assemblies 112 above a work
 surface. The mounting assembly 120 includes a pair of spaced apart bars
 122 fixedly attached to and extending from the front wall 24 of the mobile
 frame assembly 20. A pair of racks 124 having a plurality of teeth 126 are
 normal to ends of respective bars 122, the racks 124 extending vertically
 therefrom. Each rack 124 extends through a bore in a rack housing 128, the
 rack housing 128 being slidable therealong as to be described below. The
 rack housings 128 are connected by a guide bar 130 extending through
 respective flanges 132 on the housings 128. Pinion gears 134 having teeth
 136 are pivotally coupled to the guide bar 130 and positioned to mesh with
 the teeth 126 of respective racks 124. Accordingly, as an adjustment knob
 138 attached to an end of the guide bar 130 is rotated, the rack housings
 128 are selectively raised or lowered.
 A mounting bracket 140 is fixedly attached to the rack housings 128 and
 extends therebetween. The mounting bracket, therefore, is also raised or
 lowered by operation of the rack and pinion arrangements. It is understood
 that other vertical adjustment means could also be utilized, such as
 sleeved shafts with selectable pin placement, an incrementally adjustable
 socket arrangement, or the like.
 The nozzle assemblies 112 are slidably coupled to the mounting bracket 140
 with mounting clips 142. Each clip 142 includes a female channel which
 slidably mates with a male attachment structure extending longitudinally
 along the mounting bracket 140 and is frictionally held in the desired
 position. The mounting bracket 140 also includes scale indicia 144 thereon
 to aid proper positioning of the nozzle assemblies 112 thereon according
 to the dimensions of the tile being grouted. It should be appreciated that
 each nozzle assembly 112 can be slidably removed from the mounting bracket
 140 and replaced, if necessary.
 The apparatus 10 further includes a hand-held nozzle assembly 150 connected
 to the nozzle coupling 90 with a tubular channel 152 as described above.
 The hand-held nozzle assembly 150 includes a handle 154, nozzle housing
 156 and an elongated dispenser tip 158. The nozzle housing 156 includes a
 valve 160 for regulating the flow of grout to the dispenser tip 158. The
 hand-held nozzle assembly 150 can be stored in ring fasteners 162 attached
 to a handle 40 when not in use.
 In operation, the lid 84 is removed from the hopper 70 and previously mixed
 grout is deposited therein or, alternatively, the grout can be mixed in
 the hopper 70 itself. With the lid 84 coupled to the hopper 70, the second
 motor may be activated by a user pressing the on/off switch 50. As the
 shaft 78 is rotated, the grout is agitated and delivered from the hopper
 70 to the nozzle coupling 90. If the main valve 102 is open, grout is
 further delivered to the plurality of nozzle assemblies 112 through the
 channels 106. If the valve 104 is open, grout is delivered to the
 hand-held nozzle assembly 150. The nozzle assemblies 112 may be slidably
 positioned along the mounting bracket 140 according to the distance
 between joints of the tile surface. The nozzle assemblies may also be
 vertically adjusted according to the depth of the joints to be filled with
 grout.
 The variable speed controller 48 may be adjusted by a user to modify the
 speed of the second motor and therefore the flow rate of grout to the
 nozzle assemblies 112. The variable speed controller 46 may be adjusted by
 a user to modify the speed of the first motor 36 and thus the speed of the
 drive wheels 32 which provide forward or backward movement to the mobile
 frame assembly 20. The valve 104 to the hand-held nozzle assembly 150 may
 be opened for dispensing grout therethrough when application of grout to
 areas not accessible to the other nozzle assemblies 112 is desired.
 In addition, the tightening knobs 64 may be loosened and the framework 52
 pivoted rearward during use to enhance a user's line of sight relative to
 the nozzle assemblies 112. As the framework 52 is pivoted, the shafts
 slide along the slots 62 to a desired position whereat the knobs 64 can be
 tightened again, as in FIGS. 3 and 4.
 It is understood that while certain forms of this invention have been
 illustrated and described, it is not limited thereto except insofar as
 such limitations are included in the following claims and allowable
 functional equivalents thereof.