Abstract:
A paint roller including a roller cover retainer that is releasable to permit a roller cover to be easily removed. The device includes a locking lever pivotable relative to the frame which actuates retainers located within the roller assembly. The locking lever also exerts an axial force adapted to disengage the roller cover from the roller assembly when the retainer is disengaged. A used roller cover can be removed without the need to grasp the used roller cover. Installation of a roller cover onto the roller assembly automatically engages the retainers and shifts the locking lever into the locked position.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a roller assembly for use in applying a coating to a surface, and, more particularly, to a paint roller frame and roller support assembly that allows easy installation of a roller cover onto the roller support, securely retains the roller cover on the roller support during painting, and permits convenient and minimally messy removal of the roller cover from the roller support following use. 
     Paint rollers with removable covers are well known. Normally a roller cover is installed on a roller support such that the roller cover can be removed from the roller support and cleaned or discarded after use. Paint rollers with mechanisms designed to releasably retain a roller cover on the roller support are known. See, for example, U.S. Pat. Nos. 5,345,648 and 5,490,303 to Graves. Roller frames and support assemblies of this type utilize a plurality of small, flexible metal fingers that are deflected radially inward as a roller cover is installed. The metal fingers press outward against the inner surface of the roller cover, thus holding the cover in place during use. The roller cover is removed from the support assembly by grasping it and pulling it axially off of the support assembly. Alternatively, the roller cover may be removed from the support assembly by striking roller frame on a solid object, causing the roller cover to slide off of the support assembly. Both of these methods for removing the roller cover are undesirable because they are potentially messy for the user. U.S. Pat. No. 7,028,365 discloses a similar paint roller which utilizes the same undesirable methods for removing the roller cover. 
     Other known roller cover retention devices include spring-biased tabs that are manually retracted by depressing a button on the roller handle. These designs are significantly disadvantageous because the tabs must be retracted prior to installing a roller cover. Some consumers find this counterintuitive and their attempts to install a roller cover without properly retracting the tabs may result in dissatisfaction with or damage to the device. Additionally, the button mechanism may require the user to apply a substantial amount of force to overcome the biasing force of the springs which extend the tabs. This makes the device less consumer-friendly, particularly for those with smaller hands or limited grip strength. Some roller cover retention devices incorporating flexible fingers suffer from similar disadvantages. See, e.g., U.S. Pat. No. 3,060,555 disclosing a roller cover retention device including flexible fingers that requires the user to move and hold a metal lever to overcome a biasing spring force to permit installation or removal of a roller cover. 
     All of the previously described paint rollers are designed to accommodate standard paint roller covers, meaning that many manufacturers produce roller frames and roller covers to the same general specifications such that the frames and covers are generally interchangeable among manufacturers. Other devices utilize non-standard paint roller covers. See, e.g., U.S. Patent Application Publication No. 2006/0130261. These devices are inherently disadvantageous because they do not permit the use of widely-available and inexpensive standard roller covers. 
     Based on the foregoing, it would be desirable to provide a paint roller assembly using standard roller covers that allows easy installation of the roller cover, securely retains the roller cover during painting, and permits convenient and minimally messy removal of the roller cover following use. 
     BRIEF SUMMARY OF THE INVENTION 
     According to the present invention, a paint roller having improved features is provided. 
     In a first aspect, the present invention paint roller may include a frame having an elongated portion with a terminal end and a contiguous end; a roller assembly rotatably coupled to the elongated portion of the frame and adapted to receive a removable paint roller cover, the roller assembly including an axially movable portion and a fixed portion with fingers extending generally parallel to the elongated portion of the frame. The fingers may slidably engage the axially movable portion such that axial motion of the axially movable portion causes the fingers move radially relative to the elongated roller portion of the frame and the fingers may be contiguous with the fixed portion of the roller assembly. An elastic member may extend around the fingers and hold the fingers in sliding engagement with the axially movable portion. 
     In an embodiment of the first aspect, the present invention paint roller may further include a locking lever pivotably coupled to the frame and adapted to cause axial movement of the movable portion of the roller assembly when the locking lever is pivoted relative to the frame. Pivoting the locking lever to a locked position may cause the fingers to move radially away from the elongated portion of the frame and pivoting the locking lever to a released position may cause the fingers to move radially towards the elongated portion of the frame. Motion of the locking lever from the locked position to the released position may cause the axially movable portion to move toward the terminal end and motion of the locking lever from the released position to the locked position may cause the axially movable portion to move toward the contiguous end. The thickness of the fingers may vary along the length of each finger, the thickness increasing as a distance from the terminal increases. The axially movable portion may include a flange adapted to push the roller cover at least partially off of the roller assembly when the locking lever is moved from the locked position to the released position. The roller cover may exert a force on the flange generally parallel to the elongated portion of the frame and generally in the direction of the contiguous end as the roller cover is being installed, thus causing the locking lever to pivot from the released position to the locked position. The elastic member may be composed of rubber and may be an o-ring. 
     In a second aspect, the present invention paint roller may include a frame having an elongated portion with a terminal end and a contiguous end and a roller assembly rotatably coupled to the elongated portion of the frame and adapted to receive a removable paint roller cover. The roller assembly may include an axially movable portion, a fixed portion including fingers which may extend generally parallel to the elongated portion of the frame, and an o-ring extending around the fingers and holding the fingers in sliding engagement with the axially movable portion. The fingers may slidably engage the axially movable portion such that axial motion of the axially movable portion causes the fingers move radially relative to the elongated roller portion of the frame and the fingers may be contiguous with the fixed portion of the roller assembly. 
     In an embodiment of the second aspect, the present invention paint roller may further include a locking lever pivotably coupled to the frame and adapted to cause axial movement of the movable portion of the roller assembly when the locking lever is pivoted relative to the frame. The axially movable portion may include a flange adapted to push the roller cover at least partially off of the roller assembly when the locking lever is moved from a locked position to a released position. The roller cover may exert a force on the flange generally parallel to the elongated portion of the frame and generally in the direction of the contiguous end as the roller cover is being installed, thus causing the locking lever to pivot from the released position to the locked position. Pivoting the locking lever to the locked position may cause the fingers to move radially away from the elongated portion of the frame and pivoting the locking lever to the released position may cause the fingers to move radially towards the elongated portion of the frame. Motion of the locking lever from the locked position to the released position may cause the axially movable portion to move toward the terminal end and motion of the locking lever from the released position to the locked position may cause the axially movable portion to move toward the contiguous end. The thickness of the fingers may vary along the length of each finger, the thickness increasing as a distance from the terminal end increases. 
     In a third aspect, the present invention paint roller may include a frame having an elongated portion adapted to releasably couple with a removable paint roller cover having an integral bearing and having a terminal end and a contiguous end; a sliding block slidably coupled with the elongated portion of the frame and adapted to push the roller cover off of the elongated portion of the frame; and a locking lever pivotably affixed to the sliding block. The locking lever may be pivotable between a locked position and an unlocked position, the locked position being such that the sliding block is rigidly retained at the contiguous end of the elongated portion of the frame and the unlocked position permitting movement of the sliding block along the elongated portion of the frame, thus allowing the roller cover to be pushed off of the elongated portion of the frame. The sliding block may be slidable along substantially all of the elongated portion of the frame when the locking lever is in the unlocked position. The locking lever may prevent the sliding block from sliding beyond the terminal end of the elongated portion of the frame. 
     In a fourth aspect, the present invention paint roller may include a frame having an elongated portion with a terminal end and a contiguous end; and a roller assembly rotatably coupled to the elongated portion of the frame and adapted to receive a removable paint roller cover including an axially movable portion, and a fixed portion. The fixed portion may include a plurality of fingers slidably engaging the axially movable portion such that axial motion of the axially movable portion in a first direction may cause the fingers to elastically deform radially away from the elongated portion of the frame and axial motion of the axially movable portion in a second direction, the second direction being opposite the first direction, allows the fingers to return to a less elastically-deformed position thereby moving radially towards the elongated portion. The paint roller may include a locking lever pivotably coupled to the frame and adapted to cause axial movement of the axially movable portion of the roller assembly when the locking lever is pivoted relative to the frame. The axially movable portion may include a flange adapted to push the roller cover at least partially off of the roller assembly when the locking lever is moved from a locked position to a released position. 
     Other features and advantages of the present invention will become apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments exemplifying the best mode of carrying out the invention as presently perceived. The drawings are only to serve for reference and illustrative purposes, and are not intended to limit the scope of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       The detailed description particularly refers to the accompanying Figures in which: 
         FIG. 1  is a front view of an exemplary embodiment of a paint roller according to the present invention; 
         FIG. 2  is a front isometric exploded view of an exemplary embodiment of a paint roller in accordance with the present invention; 
         FIG. 3  is front section view of an exemplary embodiment of a paint roller in accordance with the present invention; 
         FIG. 4  is a detailed section view of an exemplary embodiment of a paint roller in accordance with the present invention with the locking lever in the locked position; 
         FIG. 5  is a detailed section view of an exemplary embodiment of a paint roller in accordance with the present invention with the locking lever in the released position; 
         FIG. 6  is front view of an exemplary embodiment of a paint roller including a narrow-diameter roller cover according to the present invention; 
         FIG. 7  is a detailed section view of an exemplary embodiment of a paint roller including a narrow diameter roller cover according to the present invention with the locking lever in the locked position; 
         FIG. 8  is a detailed section view of an exemplary embodiment of a paint roller including a narrow diameter roller cover according to the present invention with the locking lever in the released position; 
         FIG. 9  is a front view of an alternative exemplary embodiment of a paint roller using a roller cover with an integral bearing; 
         FIG. 10  is a detailed section view of the alternative exemplary embodiment of  FIG. 9  with the locking lever in the unlocked position; and 
         FIG. 11  is a detailed top section view of the alternative exemplary embodiment of  FIG. 9 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As shown in the appended drawings described above, the present invention is comprised of a paint roller  10 . As depicted in  FIG. 1 , paint roller  10  preferably includes a frame  12  to which a handle  14  and a roller assembly  16  are attached. In this view, a roller cover  32  is installed on roller assembly  16 . The paint roller  10  also includes an locking lever  18  that is pivotally attached to the frame  12 . 
     The frame  12  is preferably made from heavy gauge wire or metal rod. In alternative embodiments, the frame may be made from other suitable materials including plastic or fiberglass. The handle  14  is preferably molded of plastic. Additionally, the handle  14  may be hollow and may include a threaded hole  39  adapted to couple with the end of an extension rod (see  FIG. 3 ). Alternatively, other hand grips known in the art may be used without departing from the scope of the invention. 
     As depicted in  FIG. 2 , the frame  12  includes a roller shaft  20  about which the roller assembly  16  freely rotates. The frame  12  preferably includes a groove  21  near the end of shaft  20 . The roller assembly  16  includes tabs  17  that couple with groove  21 , thus preventing axial movement of the roller assembly  16  (see  FIG. 4 ). In alternative embodiments, the roller assembly  16  may couple with the frame  12  using other means such as, but not limited to, a retaining ring instead of tabs  17 , the end of frame  12  may be swaged to retain the roller assembly  16 , or the end of frame  12  may be drilled and tapped to permit the use of a shoulder screw to retain roller assembly  16  on frame  12 . 
     The roller assembly  16  includes an end cap  22 , a fixed hub  26 , a sliding hub  28 , and an o-ring  30 . The components of the roller assembly  16  are preferably composed of molded plastic, with the exception of the o-ring  30  which is preferably composed of an elastic material such as rubber. When assembled, the o-ring  30  is supported by the fingers  31  of the fixed hub  26 . The sliding hub  28  is slidable axially along the shaft  20 . The locking lever  18  is pivotable about pivot point  40 . 
     As shown in  FIG. 3 , the roller assembly  16  is adapted to accept a roller cover  32 . The roller cover  32  is preferably a “mini” removable paint roller cover as is known in the art, meaning that it is narrower in diameter than standard 1.5″ (3.81 cm) diameter roller covers. In the first exemplary embodiment the roller cover is 1″ (2.54 cm) in diameter. The roller cover includes a rigid tubular portion  34  around which a nap portion  36  is affixed. The outer diameter of the roller assembly  16  is slightly less than the inner diameter of the rigid tube  34  of the roller cover  32 , thus permitting the roller cover  32  to easily slide over the roller assembly  16  except when the o-ring  30  is expanded to engage the rigid tube  34  as described below. 
       FIG. 4  shows a detailed section view of a portion of the roller assembly  16  with a roller covered  32  mounted thereon. The locking lever  18  is in the locked position and the fingers  31  are in the expanded position. Because the o-ring  30  is pressed outward into contact with the rigid tube  34  of the roller cover  32 , the roller cover  32  is not freely movable relative to the roller assembly  16 . The roller assembly  16  remains rotatable relative to the shaft  20 . 
       FIG. 5  shows a detailed section view of the same portion of the roller assembly  16  as is depicted in  FIG. 4 , however the locking lever  18  is in the unlocked position. Notably, the fingers  31  are retracted radially inward towards the shaft  20  and the o-ring  30  is not in contact with the rigid tube  34  of the roller cover  32 . In this position the o-ring  30  does not restrict the axial movement of the roller cover  32  relative to the roller assembly  16 . 
     The exemplary embodiment of the paint roller  10  is operated as follows. Starting without a roller cover  32  installed, the user places the locking lever  18  in the released (unlocked) position as is depicted in  FIG. 5 . This causes the sliding hub  28  to slide axially along the shaft towards the end cap  22 . As the sliding hub  28  moves towards the end cap  22 , surface  29  of the sliding hub  28  slides along the fingers  31  from contact portion  48  to contact portion  49 . Because the fingers  31  are thicker at contact portion  48  than at contact portion  49 , the fingers  31  are retracted radially by the o-ring  30  as the sliding hub moves axially towards the end cap  22 . With the locking lever  18  in the unlocked position, the fingers  31  are retracted sufficiently for the o-ring  30  to be completely within the inner diameter of the rigid tube  34  of the roller cover  32  to be installed. 
     The user then inserts the roller assembly  16  into the rigid tube  34  of a roller cover  32 . Because the fingers  31  and o-ring  30  remain retracted, the roller cover  32  slides freely until it contacts flange  42  of sliding hub  28 . Once the roller cover  32  contacts the flange  42 , the user continues to insert the roller assembly  16  into the roller cover  32 . This causes the roller cover  32  to push on the sliding hub  28  in the axial direction away from the end cap  22 . The movement of the sliding hub  28  away from the end cap  22  has two effects. First, surface  29  of the axially movable portion slides from contact portion  49  to contact portion  48 . As a result, fingers  31  move radially outward and the o-ring  30  frictionally engages the rigid tube  34  of the roller cover  32 . Second, the movement of the sliding hub  28  away from end cap  22  causes the sliding hub  28  to rotate locking lever  18  into the locked position as shown in  FIG. 4 . 
     With the o-ring  30  engaging the roller cover  32  and the locking lever  18  in the locked position, the roller cover  32  is firmly attached to the roller assembly  16 . The user may use the paint roller  10  as desired. Of note, although the device is conventionally referred to as a paint roller, it is well understood in the art that paint rollers may be used to apply a wide variety of coatings in addition to paint. 
     When the user has finished using the paint roller  10  or wishes to replace the roller cover  32 , the user holds the paint roller  10  such that the end cap  22  points towards the floor. The user preferably holds the paint roller over a trash can, bucket, or other receptacle appropriate for receiving a used roller cover  32  that is wet with paint. The user then moves locking lever  18  from the locked position to the released position, thus rotating the locking lever about pivot point  40 . This causes the locking lever  18  to push the sliding hub  28  axially along the shaft towards end cap  22 . 
     The axial movement of the sliding hub  28  along the shaft  20  towards the end cap  22  has two effects. First, surfaces  29  slide along the fingers  31  from contact portions  48  to contact portions  49 , thus allowing the o-ring  30  to retract the fingers  31 . Once the o-ring  30  is disengaged from the rigid tube  34  of the roller cover  32 , the roller cover  32  can freely slide axially along the roller assembly  16 . 
     Second, flange  42  on sliding hub  28  pushes on rigid tube  34  of the roller cover  32 . This causes the roller cover  32  to slide partially off of roller assembly  16 . This partial disengagement should be sufficient to free the roller cover  32  from adhering to the roller assembly due to paint accumulated paint. 
     Although  FIGS. 1-5  depict a 1″ (2.54 cm) diameter roller cover, it is within the scope of the invention to utilize the locking mechanism of the exemplary embodiment on other sizes of rollers. See, e.g.,  FIG. 6-8  depicting a 0.5″ (1.27 cm) diameter roller cover. 
     In the embodiment shown in  FIGS. 6-8 , the construction and operation of the paint roller  110  is similar to that described above with regard to  FIGS. 1-5 . The paint roller  110  includes a handle  114 , a frame  112 , a locking lever  118 , and a pivot point  140 . The roller cover  132  includes a rigid tube  134  and a nap portion  136 . The roller assembly  116  includes a sliding hub  128 , fixed hub  126  with fingers  131 , and an o-ring  130 . The sliding hub  128  includes surface  129  that slides along the fingers  131  on contact portions  148  and  149 . 
       FIGS. 9-11  depict an alternative embodiment of the present invention paint roller  310  designed to accommodate removable roller covers  332  having an integral bearing  333 . This type of roller cover  332  typically includes a frictional retaining portion  335  adapted to frictionally engage the shaft  320  of the frame  312 . The frictional retaining portion prevents the roller cover from sliding off of the shaft  320  during use. The bearing  333  is designed to allow free rotation of the outer portion of the roller cover  332 , the nap  336  and the rigid tube  334 , while leaving the frictional retaining portion  335  engaged with the shaft. The paint roller  310  includes a locking lever  318  pivotably attached to a sliding block. The sliding block  328  is slidable along the shaft  320 . 
     This embodiment of the invention is operated as follows. The roller is ready to be used to apply paint when a roller cover  332  is installed and the locking lever  318  is in the locked position as shown in  FIG. 9 . To remove the roller cover  332 , the user pivots the locking lever  318  to the unlocked position as shown in  FIG. 10 . The user preferably holds the paint roller  310  over an appropriate receptacle for a used roller cover which may be wet with paint. The user then pushes the locking lever  318  towards the terminal end of the shaft. Because the locking lever  318  and the sliding block  328  are attached at pivot point  340 , the locking lever  318  causes the sliding block  328  to slide along the shaft  320  towards the terminal end. The sliding block  328  pushes on the bearing portion  333  of the roller cover  332 , causing the roller cover  332  to slide off of the shaft  320 . The total travel of the sliding block  328  is limited such that the sliding block  328  does not slide beyond the terminal end of the shaft  320 . This limit is effected by the length of the hollow portion  319  of the locking lever. The user then returns the sliding block  328  and locking lever  318  to their initial positions. With the locking lever  318  in the locked position, the user is free to install a replacement roller cover  332  by sliding it onto the shaft  320 . 
     In the above-described exemplary embodiments, the o-ring provides a mating component that is deformable such that it helps the paint roller accommodate variations on the inside diameter of a roller cover. Additionally, in the above-described exemplary embodiments, the o-ring biases the fingers radially inward such that the fingers move radially inward when the locking lever is moved to the unlocked position. It is within the scope of the invention replace or supplement the o-rings with one or more other components, such as, but not limited to, one or more springs and/or flexible protrusions which may be molded into the fixed hub. 
     It is also within the scope of the invention to mold one or more fingers of the fixed hub such that their natural state would be the retracted position. In such an embodiment, no additional component may be required to retract the fingers or to accommodate varying roller cover inside diameters. In such an embodiment, the natural state of the fingers may be approximately the position of finger  31  in  FIG. 5  (or finger  131  in  FIG. 8 ). With the locking lever  18  in the locked position, the fingers of such an embodiment may be held radially outward in approximately the position of finger  31  in  FIG. 4  (or finger  131  in  FIG. 7 ). 
     While preferred embodiments of the invention have been set forth above for the purpose of disclosure, modifications of the disclosed embodiment of the invention as well as other embodiments thereof may occur to those skilled in the art. Accordingly, the appended claims are intended to cover all embodiments which do not depart from the spirit and scope of the invention.