Abstract:
The present disclosure describes a finisher system for finishing joints, seams or gaps in wallboard. According to an example embodiment, the finisher system comprises a finisher for dispensing mastic onto wallboard and an adapter configured for pivotally connecting the finisher to a handle. The finisher and adapter are cooperatively configured to substantially prevent sliding motion of the finisher relative to the adapter, and to ensure appropriate registration and orientation of the finisher relative to the adapter. A fluid communication path is defined within the adapter, allowing mastic to flow through the adapter. A pivot pin enables a first portion of the adapter to pivot relative to a second portion of the adapter, and defines a bore therein that permits mastic to flow through the pivot pin and between the adapter&#39;s first and second portions. The adapter is configured for attachment to a handle having a substantially tear drop shaped cross-section.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/350,372, filed Jun. 1, 2010. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates, generally, to the field of tools for finishing gaps, seams, or joints between construction materials. 
       BACKGROUND 
       [0003]    Today, many construction materials come in the form of substantially planar panels or rolls which are unrollable into, essentially, planar panels. The construction materials are, in both cases, secured with appropriate fasteners and/or adhesives to the framing members, sheathing and/or decking of building walls, floors, ceilings and roofs. Such construction materials comprise, without limitation: (a) drywall, gypsum board, plasterboard, cement board, greenboard, blueboard, wood, and foam board for use in forming interior, and in some cases exterior, building walls and/or ceilings; (b) felt paper, underlayments, membranes, wraps, and other similar materials that are generally applied to sheathing and/or decking to protect underlying building materials from the effects of weather, to reduce the amount of air and/or moisture infiltration through a building&#39;s structure, and/or to provide insulation against heat and sound transmission; and (c) other similar construction materials. The term “wallboard” is used herein to mean and refer, collectively, to such construction materials. 
         [0004]    When individual panels or unrolled rolls of such wallboard are positioned side-by-side in/on a building structure as is often the case, the panels or unrolled rolls define gaps, seams or joints therebetween and are joined together with tape, sealant, filler and/or adhesive substances to form a monolithic structure. The tape may be manufactured from paper, fiberglass, or other material, be woven or non-woven, and be or not be backed with an adhesive substance. The tape is, generally, applied over the gaps, seams or joints either by hand or through use of a taping tool. The sealant, filler and/or adhesive substances may include, but not be limited to, drywall compound, glue, caulk, resin, epoxy, and other similar substances that are collectively referred to herein by the term “mastic”. The tape and mastic may be used alone or in combination to seal, fill and/or hide the gaps, seams or joints and secure the individual panels or unrolled rolls together. When the tape and mastic are used in combination to hide a joint between pieces of wallboard, the mastic aids in securing the tape to the wallboard while being featherable away from the joint to cause the joint and tape to blend in and provide a smooth, substantially level surface with the wallboard to either side of the joint. 
         [0005]    To apply, screed, smooth and/or feather the mastic relative to a gap, seam, joint, and/or tape, an appropriate finishing tool is selected and used based, at least, on the particular wallboard product, tape, and/or mastic being employed, and the location and orientation of the gap, seam or joint. In situations where the wallboard on both sides of a gap, seam or joint therebetween substantially defines a single plane, a finishing tool known as a “finisher” is often used to quickly apply a thin, uniform layer of mastic over tape covering the gap, seam or joint. The finisher generally comprises a partial enclosure defining a variable geometry cavity therein for holding the mastic to be applied over the tape. The partial enclosure may be supplied with mastic on a continual basis via a connected pump or may be manually loaded with mastic on an as needed basis by a user. The partial enclosure has a hingedly mounted pressure plate that is biased by one or more biasing members relative to the remainder of the partial enclosure so as to continually attempt to return the pressure plate to a retracted position and stop the flow of mastic from the partial enclosure via an opening therein. The pressure plate connects to a handle used by a user to hold the finisher in contact with wallboard and over tape covering a joint. By exerting a desired amount of pressure to the pressure plate via the handle and moving the finisher longitudinally over the joint, a user may partially overcome the forces exerted by the biasing members and apply a correspondingly desired amount of mastic over the tape and joint while feathering the mastic laterally away from the joint. 
         [0006]    In a finisher system of at least one manufacturer, the back of the finisher&#39;s pressure plate has an opposed pair of fasteners and captive wing nuts secured thereto and the handle has an adapter affixed to an end thereof such that the adapter (and, hence, the handle) is attached to the back of the pressure plate via the fasteners and wing nuts. More specifically, the adapter has a connector plate defining a pair of opposed slots that are appropriately sized and spaced apart to respectively receive the fasteners and wing nuts. To attach the adapter to the back of the finisher&#39;s pressure plate, the adapter&#39;s connector plate is first placed adjacent to and in contact with the back of the finisher&#39;s pressure plate. The connector plate is then slid relative to and against the back of the pressure plate until each of the slots receives a fastener. The wing nuts are then tightened against the connector plate to hold the connector plate and pressure plate together. 
         [0007]    Unfortunately, if a wing nut is not tightened sufficiently, the corresponding fastener may slide partially or entirely out of its respective connector plate slot during use of the finisher, thereby allowing the connector plate to slide at least partially free from the pressure plate at a possibly inopportune time and creating potentially disastrous consequences. To avoid such an undesired event, many users commonly use a hammer to strike the wing nuts and insure that the wing nuts are sufficiently tight to hold the connector plate and pressure plate together. Striking the wing nuts with a hammer tends to damage the wing nuts and could, ultimately, render the finisher&#39;s pressure plate unsecurable to the adapter&#39;s connector plate. 
         [0008]    Therefore, there is a need in the industry for a finisher system that securely attaches to a handle therefor with ease, and that may address other problems, difficulties, and/or shortcomings of current technology that may or may not be described herein. 
       SUMMARY 
       [0009]    Briefly described, the present invention comprises a finisher system, including systems, apparatuses and methods, for finishing joints, seams or gaps between pieces of wallboard. According to an example embodiment and without limitation, the finisher system comprises a finisher for dispensing mastic onto wallboard and an adapter configured for pivotally connecting the finisher to a handle. The finisher and adapter are cooperatively configured to substantially prevent sliding motion of the finisher relative to the adapter, and to ensure appropriate registration and orientation of the finisher relative to the adapter. A fluid communication path is defined within the adapter, allowing mastic to flow through the adapter. A pivot pin enables a first portion of the adapter to pivot relative to a second portion of the adapter, and defines a bore therein that permits mastic to flow through the pivot pin and between the first and second portions of the adapter. 
         [0010]    Advantageously, the cooperative configuration of the finisher and adapter of the finisher system virtually eliminates sliding between the finisher and adapter as is problematic with certain prior art finishers and adapters. Such cooperative configuration also enables rapid assembly and disassembly of the finisher and adapter to allow cleaning and/or stowage, while substantially ensuring proper registration between the finisher and adapter. Additionally, because the adapter of the example embodiment is configured for attachment to and interaction with a handle having a substantially tear drop shaped cross-section, the finishing system aids users in opposing torque tending to cause rotation of the finisher away from and out of contact with wallboard during use. 
         [0011]    Other advantages and benefits of the present invention will become apparent upon reading and understanding the present specification when taken in conjunction with the appended drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  displays a front perspective view of a finisher system in accordance with an example embodiment of the present invention. 
           [0013]      FIG. 2  displays a bottom perspective view of an adapter of the finisher system of  FIG. 1  in accordance with the example embodiment of the present invention. 
           [0014]      FIG. 3  displays a side perspective, hidden line view of the adapter of the finisher system of  FIG. 1  in accordance with the example embodiment of the present invention, showing internal features of the adapter. 
           [0015]      FIG. 4  displays a partial, exploded, rear perspective view of the finisher system of  FIG. 1  in accordance with the example embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    Referring now to the drawings in which like numerals represent like elements or steps throughout the several views,  FIG. 1  displays a front perspective view of a finisher system  100  in accordance with an example embodiment of the present invention. The finisher system  100  comprises a finisher  102 , a handle  104 , and an adapter  106  securedly affixed to an end  108  of the handle  104 . The finisher system  100  enables a user thereof to apply a desired layer of mastic over tape covering a joint between pieces of wallboard with confidence that the finisher  102  will not become uncoupled from or slip relative the attached handle  104  at an undesirable time during use. The finisher system  100  also ensures that the finisher  102  is registered and oriented properly relative to the adapter  106 , and is not oriented at an incorrect angle relative to the adapter  106 . By ensuring such correct orientation, the finisher system  100  improves the likelihood that mastic will be feathered properly in a lateral direction away from the joint. Additionally, the finisher system  100  permits the finisher  102  and adapter  106  to be readily detached from the system&#39;s handle  104  when desired for cleaning or stowage of the system&#39;s components. 
         [0017]    The finisher  102  comprises a partial enclosure  110  for holding mastic to be dispensed and applied over a taped joint between pieces of wallboard. The partial enclosure  110  has a base wall  112  that is placed by a user in contact with the wallboard and over the taped joint. The partial enclosure  110  also has a front wall  114  with a blade holder  116  depending therefrom that holds a blade (not visible) for screeding and feathering dispensed mastic. A slot in the base wall  112  rearward of the blade holder  116  permits mastic to be pushed out of the partial enclosure  110  and over the tape while being smoothed out by pulling of the base wall  112  over the tape. The partial enclosure  110  includes a rear wall  118  and a pressure plate  120  that is hingedly mounted to the rear wall  118 . Together with the various walls of the partial enclosure  110 , the pressure plate  120  defines a variable geometry, internal cavity (not visible) within the finisher  102  that holds the mastic. Movement of the pressure plate  120  relative to the base wall  112  and the remainder of the partial enclosure  110  causes the geometry and volume of the internal cavity to change. 
         [0018]    A pair of biasing members  122 A,  122 B are attached to the partial enclosure&#39;s rear wall  118  and to the pressure plate  120  near the forward wall  114 . The biasing members  122 A,  122 B exert forces on the pressure plate  120  tending to bias the pressure plate  120  into a first position relative to base wall  112  and the remainder of the partial enclosure  110 . When the pressure plate  120  is in the first position, the internal cavity of the partial enclosure  110  has maximum volume enabling the partial enclosure  110  to be loaded, or reloaded, with mastic. Also, if mastic is supplied to the partial enclosure  110  via a pump, a certain amount of mastic will be delivered to the partial enclosure  110  after the pump has been turned off and by virtue of the biasing members  122 A,  122 B pulling the pressure plate  120  toward the first position, such mastic may be received by the partial enclosure  110  without oozing of such mastic out of the finisher&#39;s slot. By applying a desired amount of force to the pressure plate  120  via the handle  104  attached to the pressure plate  120  by adapter  106 , a user may partially overcome the forces created by the biasing members  122 A,  122 B, thereby exerting pressure on the mastic present in the partial enclosure&#39;s internal cavity and causing the mastic to exit the partial enclosure&#39;s slot. According to the example embodiment, the biasing members  122 A,  122 B comprise extension springs, but it should be appreciated that other forms of biasing members may be used in other example embodiments. 
         [0019]    The finisher system&#39;s pressure plate  120  has a pair of fasteners  124 A,  124 B (see  FIG. 4 ) that protrude from the back of the pressure plate  120 . In accordance with the example embodiment, the fasteners  124 A,  124 B are threaded for receipt by corresponding fasteners  134 A,  134 B of the finisher system&#39;s adapter  106 . The fasteners  124 A,  124 B are threaded through threaded inserts (not visible) in the pressure plate  120  so that the fasteners  124 A,  124 B are securely mounted thereto. The finisher system&#39;s adapter  106  is releasably secured to and between the system&#39;s finisher  102  and handle  104 . 
         [0020]    The adapter  106  comprises, according to the example embodiment, a coupling portion  126  and a connector portion  128  pivotally connected to the coupling portion  126 . The coupling portion  126  couples to the finisher system&#39;s handle  104  and has a longitudinal axis substantially collinear with a longitudinal axis of the handle  104 . More specifically, the coupling portion  126  has a collar  130  that is secured to and receives therein an end portion of the handle  104 . The collar  130  defines an internal bore therein that is cooperatively shaped and sized relative to the periphery of the handle  104  such that the collar  130  extends substantially around and in snug contact with the periphery of the handle  104 . In accordance with the example embodiment, the handle  104  and the bore of the collar  130  have a generally tear drop cross-sectional shape. The handle  104  and bore of the collar  130  may, in other embodiments, have other cooperative cross-sectional shapes. 
         [0021]    The connector portion  128  of the adapter  106  releasably connects to the finisher  102  and is rotatable relative to the adapter&#39;s coupling portion  126  about a transverse axis extending through parts of the coupling and connector portions  126 ,  128 . Pivoting of the connector portion  128  relative to the coupling portion  126  enables the finisher  102  to pivot relative to the handle  104 , thereby enabling a user to manipulate the handle  104  relative to the finisher  102  as needed during use to maintain the finisher  102  in appropriate contact with wallboard while moving the finisher  102  over a taped joint. Pivoting of the connector portion  128  relative to the coupling portion  126  also aids a user in applying appropriate force to the finisher&#39;s pressure plate  120  as the finisher  102  is moved over a taped joint. 
         [0022]    The connector portion  128  of the finisher system&#39;s adapter  106  has a connector plate  132  and a pair of threaded fasteners  134 A,  134 B secured to the connector plate  132  such that each fastener  134 A,  134 B is positioned so as to receive a respective cooperatively threaded fastener  124 A,  124 B therein when the finisher  102  is attached to the finisher system&#39;s adapter  104 . According to the example embodiment, each fastener  134 A,  134 B comprises a captive wing nut secured to the connector plate  132  to avoid the loss thereof during use of the finisher system  100 . In other embodiments, the fasteners  134 A,  134 B may not be captive or, alternatively, comprise other forms of fasteners. 
         [0023]      FIG. 2  displays a bottom perspective view of the adapter  106  of the finisher system  100  in accordance with the example embodiment of the present invention. As seen in  FIG. 2 , the adapter  106  comprises a brake assembly  136  for controlling pivoting of (and, if desired by a user, to stop pivoting of) the connector portion  128  relative to the coupling portion  126  and, hence, pivoting of the finisher  102  relative to the handle  104 . The brake assembly  136  includes a brake arm  138  secured to the adapter&#39;s coupling portion  126  by a fastener  140  of the brake assembly  136  that allows the brake arm  138  to rotate about a longitudinal axis of the fastener  140 . A brake linkage  142  exits the end of the handle  104  proximate collar  130  and is affixed to a first end  144  of the brake arm  138 . 
         [0024]    The brake assembly  136  further comprises a brake disk  146  mounted so as to pivot in unison with the connector portion  128  relative to the adapter&#39;s coupling portion  126 . A fastener  148  is located at a second end  150  of the brake arm  138  and positioned to contact or engage the brake disk  146 . According to the example embodiment, the fastener  148  comprises a set screw, but may comprise other forms in other embodiments. The brake disk  146  has a plurality of radially-extending ridges  152  that are contacted or engaged by the fastener  148  to restrict or limit movement rotation of the brake disk  146  in response to a force exerted on the first end  144  of the brake arm  138  by the brake linkage  142  tending to rotate the brake arm&#39;s first end  144  generally toward the collar  130 . Such rotation brings the fastener  148  into contact or engagement with the radially-extending ridges  152  of the brake disk  146 , thereby limiting or preventing rotation of the brake disk  146  and, hence, rotation of the attached finisher  102  relative to the handle  104 . It should be appreciated that in other embodiments, the brake disk  146  may have a plurality of dimples, a plurality of holes or slots corresponding to different orientations of a finisher relative to the handle  104 , an abrasive finish, or take on another form in lieu of the radially-extending ridges  152  in order to limit or restrict movement of the finisher  102  when desired by a user. 
         [0025]    As described above with reference to  FIG. 1  and as illustrated again in  FIG. 2 , the adapter&#39;s connector portion  128  comprises a connector plate  132  having first and second fasteners  134 A,  134 B captive thereto. Each fastener  134 A,  134 B defines a respective bore  154 A,  154 B for receiving a respective threaded fastener  124 A,  124 B extending from the pressure plate  120  of the system&#39;s finisher  102 . According to the example embodiment, the threaded fasteners  124 A,  124 B have a substantially circular cross-section, and the bores  154 A,  154 B have a substantially circular cross-section and are sized to snugly receive respective threaded fasteners  124 A,  124 B in threaded engagement therewith. The fasteners  134 A,  134 B and fasteners  124 A,  124 B are positioned so as to allow cooperative mating between the connector plate  132  and the finisher  102 . Once the fasteners  124 A,  124 B are received within the respective bores  154 A,  154 B and the fasteners  134 A,  134 B are tightened, the system&#39;s finisher  102  is appropriately registered relative to the connector plate  132  with very little relative movement or slippage being possible between the connector plate  132  and attached finisher  102 . 
         [0026]    The adapter&#39;s connector portion  128  defines a channel  156  therein for conveying mastic. The connector plate  132  has a first surface  158  that resides in contact with the finisher  102  when attached thereto. The first surface  158  defines an opening  160  therein that is in fluid communication with the channel  156 . The finisher  102  has a hole  174  therein (see  FIG. 4 ) that is cooperatively located to align with opening  160  of the connector plate  132 . During use, mastic flows through channel  156 , out of the connector portion  128  via opening  160 , and into the finisher  102  via the cooperatively located hole  174  in the pressure plate  120  of the finisher  102 . 
         [0027]      FIG. 3  displays a side perspective, hidden line view of the adapter  106  of the finisher system  100  in accordance with the example embodiment of the present invention. As seen in  FIG. 3 , the adapter&#39;s coupling portion  126  defines a bore  162  therein that is in fluid communication with a channel in the handle  104  at an end  108  thereof. The bore  162  is configured to receive mastic from the channel in the handle (which receives mastic from a pump in fluid communication with the handle&#39;s channel) and to convey the mastic toward the finisher  102 . The adapter&#39;s connector portion  128  further comprises a pivot pin  164  attached to the connector plate  132  and to brake disk  146  such that connector plate  132 , pivot pin  164 , and brake disk  146  rotate together relative to the adapter&#39;s coupling portion  126 . The pivot pin  164  defines a bore  166  therein that is in fluid communication with channel  156  of the connector portion  128  and with the coupling portion&#39;s bore  162  via a plurality of holes  168  defined by pivot pin  164 . During use, mastic flows from the coupling portion&#39;s bore  162 , through holes  168  and bore  166 , and into the connector portion&#39;s channel  156  for subsequent delivery to the finisher  102  via the connector plate&#39;s opening  160 . 
         [0028]      FIG. 4  displays a partial, exploded, rear perspective view of the finisher system  100  in accordance with the example embodiment of the present invention. As seen in  FIG. 4 , the first surface  158  of the adapter&#39;s connector plate  132  is substantially planar and the connector plate  132  has a second substantially planar surface  170  opposed to the first surface  158 . Fasteners  134 A,  134 B are fixedly attached to second surface  170  in alignment with bores  172 A,  172 B extending through the connector plate  132  (see  FIG. 2 ) and are readily accessible for turning by a user during assembly of the connector plate  132  to pressure plate  120  and disassembly of the connector plate  132  from pressure plate  120 . 
         [0029]    To assemble the finisher system&#39;s adapter  106  to the system&#39;s finisher  102 , the adapter&#39;s connector plate  132  is positioned with fasteners  124 A,  124 B received by bores  154 A,  154 B of fasteners  134 A,  134 B. Fasteners  134 A,  134 B are then rotated relative to the fasteners  124 A,  124 B to engage respective fasteners  124 A,  124 B and, upon further similar rotation, to bring the first surface  158  of the adapter&#39;s connector plate  132  into contact with the pressure plate  120 . When the system&#39;s adapter  106  is fully connected to the finisher  102 , the first surface  158  of the connector plate  132  resides adjacent to and in contact with the pressure plate  120  with fasteners  124 A,  124 B, respectively, protruding through bores  154 A,  154 B and engaged by fully tightened fasteners  134 A,  134 B. According to the example embodiment and in the assembled position, hole  174  defined by the pressure plate  120  is aligned with opening  160  of the adapter&#39;s connector portion  128  to allow mastic to flow from the system&#39;s handle  104  and adapter  106  into the partial enclosure  110  of the finisher  102 . 
         [0030]    To dissemble the finisher system&#39;s adapter  106  from the system&#39;s finisher  102 , fasteners  134 A,  134 B are rotated relative to fasteners  124 A,  124 B in the opposite angular direction used during assembly, to disengage the fasteners  124 A,  124 B and fasteners  134 A,  134 B. Once the fasteners  124 A,  124 B are disengaged, the finisher  102  and adapter  106  are pulled apart removing the fasteners  124 A,  124 B from corresponding bores  154 A,  154 B and taking connector plate  132  out of contact with pressure plate  120 . 
         [0031]    Because the fasteners  124 A,  124 B reside within appropriately sized bores  154 A,  154 B of fasteners  134 A,  134 B (and can only reside within bores  154 A,  154 B in a single, proper orientation) when the finisher  102  is coupled to the adapter  106 , the finisher  102  is correctly registered relative to the adapter  106 . Also by virtue of the fasteners  124 A,  124 B residing within bores  154 A,  154 B when the finisher  102  is coupled to the adapter  106 , slight loosening of the fasteners  134 A,  134 B as may occur during use will not cause the finisher  102  to become separated from the handle  104  and adapter  106 . 
         [0032]    It should be appreciated that while the adapter  106  of the example embodiment has been described herein as providing a continuous flow of mastic to an attached finisher, the adapter  106  may be used with attached corner finishing tools and other finishing tools that are designed to receive a continuous flow of mastic, and may be used with attached finishers, corner finishing tools, or other finishing tools that are not designed to receive a continuous flow of mastic. It should be also appreciated that while the adapter  106  of the example embodiment has been described herein as being configured to apply a braking force to limit or restrict the movement of an attached finisher or other finishing tool requiring limitation or restriction of movement relative to a handle  104 , the adapter  106  may be used with corner finishing tools or other finishing tools that do not require limitation or restriction of movement relative to a handle  104 . Additionally, it should be appreciated that in other example embodiments in which the adapter  106  need not deliver a continuous flow of mastic to an attached finisher or other finishing tool, the adapters  106  of such example embodiments may not define an internal bore  162  or channel  156  for the flow of mastic therethrough. In addition, it should be appreciated that while the finisher system  100  of the example embodiment has been described herein with respect to finishing wallboard, the finisher system  100  may be employed in connection with finishing other building materials and with other tools for finishing other building materials. 
         [0033]    Whereas the present invention is described in detail with respect to the example embodiment, it should be understood that variations and modifications may be effected within the spirit and scope of the present invention, as described herein before and as defined in the appended claims.