Abstract:
An applicator system comprises a reservoir, a conduit extending from a first end at the reservoir to an opposite terminal end, an applicator connected with the conduit, a flow control engaging the conduit, and a holder releasably coupling with the applicator. The applicator has a liquid impermeable back, an opposite porous face, and a plenum. The plenum, situated between the back and face, releasably couples with the conduit terminal end and distributes fluid to the face. The face and plenum may be replaceable and disposable. The holder is a rigid member that releasably couples with the applicator, provides a structural foundation to the applicator, and includes a handle for manipulation by a user. An extension can be employed to connect the flow control to the handle, effectively extending the length of the handle. A helical coil portion of the conduit can be conveniently wrapped around the extension to prevent kinking.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is based on and claims the benefit of the filing date of Applicant&#39;s provisional patent application No. 60/798,116, filed May 5, 2006, the disclosure of which is incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     The invention relates to the application of finishes. More specifically, the invention is directed to fluid finish application from a finish reservoir, including a hose or tube to dispense finish from the reservoir to an applicator. 
     A variety of painting or finish applicator systems may be found in the market, on the shelves of home centers and hardware stores. The prior systems are known to draw or press a fluid finish from a can, bucket, or other reservoir and through a hose to an applicator in the form of a brush, a roller, or a pad. The reservoir may be an open container and a pump may be used to draw or suck a finish from the container. Alternatively, the reservoir may be a pressurized vessel from which a finish is pressed out with air pressure. 
     A pressurized fluid reservoir is commonly known and configured as a lawn and garden sprayer, for example, and includes a liquid-dispensing tank or reservoir that is connected, by means of a length of flexible hose, to a spray wand. The dispensing tank also includes a means for pressurizing its liquid contents, typically a hand-operated air pump assembly. Common prior pressurized tanks include a dip tube that extends to the bottom of the tank. The fluid contents of the tank are pressed through the dip tube and out of the tank when the tank is pressurized by air pressure. The flexible hose is commonly connected with the dip tube direct the fluid from the tank and to an applicator as desired. Various methods are used to make the connection between the flexible hose and the dip tube, including various hose clamps and alternatively, various compression screw fittings. 
     Unfortunately, prior methods of connecting the flexible hose with the dip tube include some problems. The prior connection methods are expensive to assemble for the manufacturer and ultimately the customer. The prior connections are also subject to failure, including fluid leakage. As a person uses a pressure tank, the dispensing hose is pulled, bent, and twisted at the connection with the dip tube. This tugging tends to pull the dispensing hose away from the dip tube, even in the presence of a metal band hose clamp and the like. The problem increases with increased use and with rough handling; lack of care. Other than the dispensing hose being damaged, the top of the dip tube, where the dispensing hose connects, may break or otherwise fail. 
     When the finish flows through the hose from the reservoir to the applicator, the finish is ultimately transferred to a surface by a surface contacting device. The applicator typically includes an applicator head with a handle and some surface contacting device, which may include a brush, a roller, a pad, or the like. A typical path of delivering the finish is to include the applicator head, so the fluid finish flows through the head from the hose and to the surface contacting device. Thus, the finish must contact the applicator head and, in fact, accumulates inside the head. This results in the applicator head being one more item of equipment that the user must clean. One will not typically dispose of the applicator head instead of cleaning it because the head is not a “throw away” item. 
     Further, the path of the fluid finish through the applicator head may include large passageways in which the finish may collect as in small reservoirs within the applicator head. The common use of a finish path that passes through the head, including its reservoirs, wastes finish and increases the mess of cleaning. This is not merely an obvious inconvenience and expense, it is also an unnecessary environmental burden. 
     Thus, a need to improve stain and sealant applicator systems is readily understood. 
     BRIEF SUMMARY OF THE INVENTION 
     Accordingly, a stain and sealant applicator system of the invention includes a reservoir that is adapted to contain a fluid finish, a conduit that is adapted to conduct a fluid finish from the reservoir, an applicator that is adapted to dispose a fluid finish upon a surface, a flow control that is adapted to control flow of a fluid finish through the conduit, and a holder that is a rigid member that is adapted to releasably couple with the applicator. 
     In various aspects of the invention, the conduit may extend from a first end at the reservoir to an opposite terminal end at the applicator. The applicator may have a back that is liquid impermeable and an opposite face that is porous. A plenum may be formed in the applicator and be adapted to distribute a fluid finish to the face. The plenum may further include a coupler that releasably couples with the conduit terminal end in liquid tight engagement. The flow control may engage the conduit to regulate a flow of a fluid finish through the conduit. Further, the holder may provide structural foundation to the applicator and may include a handle that is adapted to be grasped and manipulated by a user. 
     In other aspects of the invention, the applicator may be fabricated with the back defining a base portion as a liquid impermeable structural substrate that has opposing front and back surfaces and has a circumscribing perimeter edge that extends between the opposing front and back surfaces. The base substrate may further be adapted to releasably couple at the back surface with the holder, so a user may manipulate the applicator with the holder. Thus, the front surface faces away from the holder. The applicator may also be fabricated with an application face portion defined over the front surface of the base substrate. The application face portion may be configured as a liquid permeable layer of the applicator, so the application face extends from the front surface and extends in a direction away from the back surface. The applicator may further be fabricated with a plenum portion that distributes a fluid finish to the application face. The plenum may be connected with the application face at the base front surface. The plenum may include a coupler that releasably couples with the conduit terminal end in liquid tight engagement. Thus, a fluid finish may be dispensed from the reservoir, through the conduit, into the applicator at the base front surface, and distributed about the application face. 
     In another aspect of the invention, the reservoir may be provided with an annular stem that defines a passageway through the annular wall. The conduit may be provided with a one piece tubular member that extends from a first end within the reservoir, through the annular stem, and to an opposite second end. The conduit may further be provided with a cap that couples with the annular stem and secures the conduit relative to the reservoir. 
     In yet other aspects of the invention, the flow control may have an elongated body with opposite upstream and downstream ends. A valve may be located in the body and may further include an actuator, so the valve may be manipulated between open and closed conditions by a user. A stain and sealant applicator system of the invention may also include an optional extension that releasably couples with the handle and optionally effectively extends the handle. The extension may be an elongated member with opposite first and second ends. The first end may be adapted to releasably couple with the handle. The second end of the extension may include a recess that corresponds with the elongated body of the flow control, so the flow control releasably couples with the extension. 
     These and other features, objectives, and benefits of the invention will be recognized by one having ordinary skill in the art and by those who practice the invention, from this disclosure, including the specification, the claims, and the drawing figures. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
         FIG. 1  is a perspective view of an exemplary stain and sealant applicator system according to the invention; 
         FIG. 2  is a cross section view, partially in elevation, of a reservoir thereof; 
         FIG. 3  is an enlarged view of detail III of  FIG. 2 ; 
         FIG. 4  is an enlarged view of detail IV of  FIG. 1 ; 
         FIG. 5  is the view of  FIG. 4  showing a flow control separated from an extension; 
         FIG. 6  is a lengthwise cross section view of an extension pole end that couples with the flow control; 
         FIG. 7  is a top plan view thereof; 
         FIG. 8  is a perspective view of head assembly of the finish applicator system of  FIG. 1 , showing an applicator, a foundation, and a handle thereof; 
         FIG. 9  is an exploded view of the head assembly of  FIG. 8 , showing the applicator, foundation, and handle thereof separated; 
         FIG. 10  is a right side elevation of the head assembly of  FIG. 8 ; 
         FIG. 11  is an exploded view of the head assembly of  FIG. 10 ; 
         FIG. 12  is a left side elevation of the head assembly of  FIG. 8 ; 
         FIG. 13  is the view of  FIG. 12 , showing the handle pivoted over to the other side of the foundation; 
         FIG. 14  is a cross section view of the foundation along sight line XIV-XIV of  FIG. 9 ; 
         FIG. 15  is the cross section view of  FIG. 14 , showing the applicator mounted on the foundation; and 
         FIG. 16  is the cross section view of  FIG. 14 , showing an alternative bristle brush applicator mounted on the foundation. 
     
    
    
     DETAILED DESCRIPTION 
     A preferred and exemplary embodiment of a stain and sealant applicator system  50  according to the invention is generally shown in the drawing figures and discussed below. The applicator system is directed to the application of a stain or sealant and the like to a floor, deck, or other generally planar surface. The applicator system includes a reservoir  100 , a conduit  200 , an applicator  300 , a flow control  400 , and a holder  500 . An extension  600  may optionally be used between the flow control and the holder. 
     A fluid finish  60  is placed in the reservoir  100  for dispensing through the applicator system  50  to a selected surface (not shown and commonly known). The reservoir  100  may preferably be provided as a pressure tank as is commonly known for lawn and garden sprayer tanks ( FIGS. 1-3 ). A perimeter sidewall  112  generally defines the tank, which may be fabricated of any suitable engineering material for a low pressure tank and by any method that is suitable to the selected material. The tank is provided with a fill mouth  114  through which fluids are received in the tank. A pressurizing device  120 , such as a hand operated air pump, may be used to pressurize the tank and to form a stopper for the tank by screw thread engagement of the stopper with the mouth, as is commonly known to one having ordinary skill in the art and by those who use lawn and garden sprayer tanks. 
     The conduit  200  extends from a first end  212  at a bottom  104  of the tank  100  and through the perimeter wall  112  to a terminal end  214  at the applicator  300  to dispense fluid contained or placed in the tank. Thus, the tank perimeter wall is provided with an annular stem  130  through which the fluid may be dispensed from the tank by way of the conduit, which conduit may also be considered a dispensing tube or hose  200 . The conduit may be fabricated as is suitable for a dispensing hose and may result in a typical size of about 9/32 inch (7.14 mm) outside diameter. 
     A distinction of the present tank  100  and its conduit or hose configuration  200  is that the conduit includes a one piece tubular member  220  that extends from the first end  212  within the reservoir  100 , through the annular stem  130 , and to an opposite second end. This is in contrast to commonly known pressure tank arrangements in which a separate dip tube and a separate dispensing tube are used with a joint or connection outside the tank between the two pieces of tubing or hose. More specifically, prior pressure tank arrangements commonly have a dip tube extending inside the tank to the tank bottom. A separate dispensing tube or hose then couples with the dip tube at a location outside the tank. The prior dip tube tends to be a relatively more rigid member and the dispensing hose relatively more pliable. Thus, the prior arrangement with separate dip and dispensing tubes is prone to fatigue and failure near their interface, with associated fluid leakage. 
     Further as to the present dispensing tube  200  of the invention, the one piece tubular member  220  is circumscribed by a sealing O-ring  132  as one having ordinary skill in the art understands, and a compression grommet  134  ( FIG. 3 ). An appropriate grommet may include a Heyco® Shorty Bushing, B 406-281, for cooperating with a dispensing hose having an about 9/32 inch (7.14 mm) outside diameter, for example. 
     When assembled ( FIG. 3 ), the one piece tubular member  220  extends through the annular stem  130 , from the first end  212  near the tank bottom  104 . The O-ring  132  is located outside the tank  100  and abuts the tubular stem  130 . The grommet  134  is positioned opposite the O-ring from the tubular stem. A compression nut  136  or other similarly functioning device overlays the grommet and O-ring and couples with the annular stem. Thus, the annular stem may be provided with external threads  142  that cooperate with internal threads  144  of the compression nut  136 . While threaded engagement of the compression nut with the annular stem provides for removal, that is disassembly and reassembly, alternative compression nut devices may include a press-on nut device that is not intended to disengage the stem. 
     The one piece tubular member  220  extends from the reservoir  100  to the flow control  400 , which allows a user to open and close and otherwise control a flow of fluid finish  60  from the reservoir  100  through the dispensing hose  200  to the applicator  300 . Known flow control or valve mechanisms may be used. The flow control  400  may have an elongated body  312 , preferably a generally tubular member with opposite upstream  314  and downstream  316  ends, for comfort and ease of use ( FIGS. 4 and 5 ). A valve (not shown and commonly known) is located in the body and may be positioned near the upstream end, as shown. An actuator  322  in the form of a control lever is connected with the valve. Thus, a user may manipulate the actuator, control the valve between open and close conditions, and regulate fluid flow through the dispensing hose  200 . 
     The dispensing tube  200  continues from the downstream end of the flow control, as shown, and directly to the applicator  300 . The applicator has a base portion  310 , a plenum portion  330 , and an application face portion  350  ( FIGS. 8-16 ). The base portion  310  is a liquid impermeable structural substrate. The base has opposing back and front surfaces,  312  and  314  respectively, and a circumscribing perimeter edge that extends between the front and back surfaces. The application face  350  may be a liquid permeable layer that is defined over the front surface of the base portion  310 , so the application face extends from the front surface and extends in a direction away from the back surface of the base portion. The application face is a liquid permeable layer and may be configured in a number of formations, including a surface engaging pad or bristle brush  352 . The applicator  300  is preferably fabricated as a multi-strata unitary molding. 
     The plenum portion  330  of the applicator is most preferably connected in fluid communication with the application face  350  through openings leading to the front surface  314  of the base portion  310  and distributes the fluid finish  60  to the application face at the base front surface. The plenum also includes a coupler  334  that releasably couples with the dispensing hose terminal end  214  in liquid tight engagement. This arrangement of the dispensing hose  200  connecting directly with the applicator  300  does not involve the holder  500  and keeps the holder clean of unnecessary contamination with the finish  60 , in contrast to configuration of prior finish application devices in which a unified head arrangement conducts the finish through the holder to reach a surface engaging pad and the like. 
     The holder  500  of the present invention is a rigid member that releasably couples with the applicator  300  and provides a structural foundation for the applicator ( FIGS. 8-16 ). The holder also has a generally tubular handle  504  for grasping and manipulation by a user. While the holder may be fabricated with various configurations, the exemplary preferred embodiment is shown with a generally rectangular footprint, with a first pair of opposing side edges  512  and  514 , and a pair of orthogonal opposing end edges  516  and  518 . A face  522  of the holder is defined as a generally planer surface that extends between the opposing side edges and the opposing end edges. The side edges are provided with a champher or taper back away from the holder face  522 . These tapered side edges  512  and  514  cooperate with the applicator for releasable coupling of the applicator with the holder. Thus, the applicator is further provided with a pair of corresponding flanges  362  and  364  that extend over and around the holder tapered side edges  512  and  514 , when the holder  500  and applicator  300  are coupled. 
     A recess  526  is preferably defined in at least one end  516  of the holder  500  to accommodate and provide clearance for the hose coupler  334  of the applicator  300 . Assembly of the holder with the applicator is then by sliding the applicator over the holder face  522  from the notched end  516  of the holder until the applicator and the holder align, with the hose coupler  334  located in the end notch  526  of the holder. 
     The handle  504  is preferably pivotally connected with the holder  500 . A pair of pivot flanges  532  extend from a back of the holder and away from the holder face  522 . The handle has a cooperating end  506  that nests between the pivot flanges  532 . The handle and the pivot flanges are secured by a pivot pin  534 . 
     The extension  600  may be provided as a pole and used between the flow control  400  and the handle  504  of the holder  500  and optionally effectively extend the handle. Thus, the extension is an elongated member with opposite first and second ends,  604  and  606  respectively. The first end  604  is adapted to releasably couple with the handle  504  and the second end  606  is adapted to releasable couple with the flow control  400 . A preferred interface between the extension and the handle is by screw threading the extension into the handle as is commonly known in the broom handle and painting roller areas of technology. The second end  606  of the handle is provided as a tubular portion with a lengthwise slot  612 . The tubular portion and lengthwise slot extend about as far as the flow control elongated body  312  is long. The flow control and extension are coupled by inserting the downstream end  316  of the flow control into the second end  606  of the extension with the dispensing hose  200  laying in and extending through the slot  612 . Further, a sloped wall  616  or ramped portion may be provided in the tubular portion of the extension second end  606 . The ramped wall may be positioned as a stop to position the flow control  400  by limiting placement of the flow control elongated body  312  into the extension second end and also to guide the dispensing hose without kinking. 
     A portion of the dispensing hose that extends from the downstream end  316  of the flow control  400  to the applicator  300  is most preferably provided as a helical coil hose. This helical coil configuration helps keep the dispensing hose organized in use. The helical coil portion  242  of the dispensing hose  200  may also conveniently corkscrew about the extension  600  by merely inserting the extension through the helical coil, then coupling the flow control in the second end  606  of the extension and coupling the extension first end  604  with the holder handle  504 . Thus, the dispensing hose and the extension become a tidy assembly for convenient use. When assembled in this configuration, the extension may retract and extend without binding with the hose  200 , while the hose is kept organized by the coiled portion  242 . An expected common range of extension and retraction of the extension  600  is of the order of about 42 to 24 inches (1067-609 mm), although this is not a limitation of the invention. 
     One having ordinary skill in the art and those who practice the invention will understand from this disclosure that various modifications and improvements may be made without departing from the spirit of the disclosed inventive concept. One will also understand that various relational terms, including left, right, front, back, top, and bottom, for example, are used in the detailed description of the invention and in the claims only to convey relative positioning of various elements of the claimed invention.