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 
       [0001]    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. 
         [0002]    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. 
         [0003]    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. 
         [0004]    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. 
         [0005]    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 
       [0006]    According to the present invention, a paint roller having improved features is provided. 
         [0007]    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 retainers; and 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 retainers may slidingly engage the axially movable portion such that axial motion of the axially movable portion causes the retainers move radially relative to the elongated portion of the frame. Pivoting the locking lever to the locked position may cause the retainers to move radially away from the elongated portion of the frame and pivoting the locking lever to the released position may cause the retainers to move radially towards the elongated portion of the frame. Moving the locking lever from the locked position to the released position may cause the axially movable portion to move toward the terminal end and moving the locking lever from the released position to the locked position may cause the axially movable portion to move toward the contiguous end. 
         [0008]    An embodiment of the first aspect may include a flange on the axially movable portion that at least partially disengages the roller cover from the roller assembly when the locking lever is moved from the locked position to the released position. During installation of the roller cover, 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, thus causing the locking lever to pivot from the released position to the locked position. 
         [0009]    In another embodiment of the first aspect, the retainers may each have a first end pivotably captured by a portion of the roller assembly and a second end including a contact surface that slidably contacts the axially movable portion. Further, the radius of the contact portion of the axially movable portion may vary along its axial length such that the second ends of the retainers are moved radially away from the elongated roller portion of the frame as the axially movable portion is moved axially toward the contiguous end. The retainers may be composed of metal and may each include a tab adapted to mechanically engage the roller cover when the locking lever is in the locked position. In an embodiment, the paint roller may include four retainers. The retainers may also be composed of other materials such as, but not limited to, plastic. 
         [0010]    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; a roller assembly rotatably coupled to the elongated portion of the frame that is adapted to receive a removable paint roller cover and including an axially movable portion and metal retainers; 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 retainers may slidingly engage the axially movable portion such that axial motion of the axially movable portion causes the retainers move radially relative to the elongated portion of the frame and the retainers may each have a first end pivotably captured by a portion of the roller assembly and a second end including a contact surface that slidably contacts the axially movable portion. Pivoting the locking lever to the locked position may cause the retainers to move radially away from the elongated portion of the frame and pivoting the locking lever to a released position may cause the retainers 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 contact portion of the axially movable portion may have a radius that varies along its axial length such that the second ends of the retainers are moved radially away from the elongated roller portion of the frame as the axially movable portion is moved axially toward the contiguous end. Each retainer may include a tab adapted to mechanically engage the roller cover when the locking lever is in the locked position. 
         [0011]    In an embodiment of the second aspect, the paint roller may include a flange on the axially movable portion that at least partially disengages the roller cover from the roller assembly when the locking lever is moved from the locked position to the released position. During installation, the roller cover may push axially on the flange, causing the locking lever to pivot from the released position to the locked position. An embodiment of the paint roller may include four retainers. 
         [0012]    In a third 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 that is adapted to receive a removable paint roller cover and includes an axially movable portion having a flange; and retainers. The retainers may slidingly engage the axially movable portion such that axial motion of the axially movable portion causes the retainers move radially relative to the elongated portion of the frame and each retainer may have a first end pivotably captured by a portion of the roller assembly and a second end including a contact surface that slidably contacts the axially movable portion. A locking lever pivotably coupled to the frame may be adapted to cause axial movement of the axially movable portion of the roller assembly when the locking lever is pivoted relative to the frame such that pivoting the locking lever to a locked position causes the retainers to move radially away from the elongated portion of the frame and pivoting the locking lever to a released position causes the plurality of retainers 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 flange may at least partially disengage the roller cover from the roller assembly when the locking lever is moved from the locked position to the released position and 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 installed on the roller assembly, thus causing the locking lever to pivot from the released position to the locked position. The axially movable portion may include a contact portion having a radius that varies along its axial length such that the second ends of the retainers are moved radially outward from the elongated portion of the frame as the axially movable portion is moved toward the contiguous end. The retainers may be composed of metal and may each include a tab adapted to mechanically engage the roller cover when the locking lever is in the locked position. An embodiment of the paint roller may include four retainers. 
         [0013]    These and 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 
         [0014]    The detailed description particularly refers to the accompanying Figures in which: 
           [0015]      FIG. 1  is a front view of an exemplary embodiment of a paint roller according to the present invention; 
           [0016]      FIG. 2  is a front isometric exploded view of an exemplary embodiment of a paint roller in accordance with the present invention; 
           [0017]      FIG. 3  is a front section view of an exemplary embodiment of a paint roller in accordance with the present invention; 
           [0018]      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; 
           [0019]      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; 
           [0020]      FIG. 6  is a front view of an exemplary embodiment of a paint roller including a short roller cover in accordance with the present invention; 
           [0021]      FIG. 7  is a detailed section view of an exemplary embodiment of a paint roller including a short roller cover in accordance with the present invention; 
           [0022]      FIG. 8  is a front view of an exemplary embodiment of a paint roller including an alternative short roller cover in accordance with the present invention; 
           [0023]      FIG. 9  is a detailed section view of an exemplary embodiment of a paint roller including an alternative short roller cover in accordance with the present invention; and 
           [0024]      FIG. 10  is a detailed section view of an exemplary embodiment of a paint roller including alternative embodiment retainers. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0025]    As shown in the appended drawings described above, the present invention is comprised of a paint roller  10 . Turning to  FIG. 1 , paint roller  10  preferably includes a frame  12  to which a handle  14  and a roller assembly  16  are attached. The paint roller  10  also includes an locking lever  18  that is pivotally attached to the frame  12 . 
         [0026]    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  40  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. 
         [0027]    As depicted in  FIG. 2 , the frame  12  preferably 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 grove  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 . 
         [0028]    The roller assembly  16  includes an end cap  22 , a roller cage  24 , a fixed hub  26 , a sliding hub  28 , and retainers  30 . When assembled, the locking lever  18  rotates about pivot point  40 . The components of the roller assembly  16  are preferably composed of molded plastic, with the exception of the retainers  30  which are preferably composed of metal. 
         [0029]    As shown in  FIG. 3 , the roller assembly  16  is adapted to accept a roller cover  32 . The roller cover  32  is preferably a removable paint roller cover as is well known in the art. The roller cover includes a rigid tube  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 tabs  38  are engaged as described below. 
         [0030]      FIG. 4  shows a detailed section view of a portion of the roller assembly  16  with a roller cover  32  mounted thereon. The locking lever  18  is in the locked position and the retainers  30  are in the extended position, such that tabs  38  are extended radially into contact with the rigid tube  34  of the roller cover  32 . In this position, the tabs  38  exert sufficient force on the rigid tube  34  of the roller cover  32  that the roller cover is not readily slidable along the roller assembly  16 . The roller assembly  16  remains rotatable relative to the shaft  20 . It is within the scope of the invention to utilize retainers  30  having other shapes. In particular, tabs  38  may have alternative shapes or may be comprised of alternative structures. For example, the tabs  38  may have a sloped profile as discussed below with regard to  FIG. 10 . Further, the retainers  30  may include no tabs  38  or an alternative tab structure such as, but not limited to, a series of small teeth, a rubber coating, or a coating composed of another non-slip material. 
         [0031]      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 released position. The tabs  38  are retracted radially inward towards the shaft  20  and are not in contact with the rigid tube  34  of the roller cover  32 . In this position the tabs  38  do not restrict the axial movement of the roller cover  32 . The retainers  30  are captured between the fixed hub  26  and the roller cage  24  such that the retainers can pivot radially to engage and disengage the tabs  38  as described above. 
         [0032]    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 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 , end portions  48  of the retainers  30  slide from the outer surfaces  46 , radially inward on the engaging inclines  44 , and onto the inner surfaces  50 . It is possible that the retainer  30  will not freely move radially inward towards shaft  20 . In such a case, the end portions  48  will slide along disengaging inclines  45  that positively direct end portions  48  radially inward towards inner surfaces  50 . With the end portions  48  of retainers  30  resting on the inner surfaces  50 , the tabs  38  are within the diameter of the assembly  16 . 
         [0033]    The user may then install a new roller cover  32  onto the paint roller  10 . The user inserts the roller assembly  16  into the rigid tube  34  of a roller cover  32 . Because the tabs  38  of the retainers  30  are retracted, the roller cover  32  slides freely until it contacts flange  42  of the sliding hub  28 . Once the roller cover 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, the end portions  48  of the retainers  30  slide over the engaging inclines  44  and onto the outer surfaces  46 . As a result, retainers  30  pivot radially outward and tabs  38  engage 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. 
         [0034]    With the tabs  38  engaging the roller cover  32  and the locking lever  18  in the locked position, the roller cover  32  is firmly affixed to the roller assembly  16 . The user may use the paint roller  10  as desired to apply paint to a surface. 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. 
         [0035]    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, sink, 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  20  towards end cap  22 . Alternatively, the user may firmly tap the locking lever  18  against the edge of a trash can, bucket, sink, or other receptacle to achieve the same effect without having to directly touch the locking lever  18 , which may be covered in paint. 
         [0036]    The axial movement of the sliding hub  28  along the shaft  20  towards end cap  22  has two effects. First, end portions  48  of retainers  30  slide along engaging inclines  44  as sliding hub  28  moves towards the end cap  22 . This causes the retainers  30  to rotate such that tabs  38  disengage from the rigid tube  34  of the roller cover  32 . As discussed above, the end portions  48  may also contact disengaging inclines  45  which may force end portions  48  radially inward towards the shaft  20 . Once the tabs  38  are disengaged from the rigid tube  34 , the roller cover  32  slides freely along the roller assembly  16 . 
         [0037]    Second, flange  42  on sliding hub  28  pushes on rigid tube  34  of 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 during use. 
         [0038]    Although  FIGS. 1-5  depict a 1.5″ (3.81 cm) diameter by 9″ (22.86 cm) long roller, 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.,  FIGS. 6 and 7  depicting a 1.5″ (3.81 cm)×3″ (7.62 cm) roller and  FIGS. 8 and 9 , depicting a 1.5″ (3.81 cm)×4″ (10.16 cm) roller. In addition, the roller may be 1.5″ (3.81 cm) in diameter and either 7.0″ (17.78 cm) or 9.5″ (24.13 cm) in length. It is also within the scope of the invention to utilize the locking mechanism of the exemplary embodiment on roller frames adapted to accept roller covers of other diameters and lengths. 
         [0039]    In the embodiment shown in  FIGS. 6 and 7 , the construction and operation of the paint roller  110  is similar to that described above with regard to the standard sized paint roller  10 . 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 , retainers  130  with tabs  138 , and a fixed hub  126 . This embodiment differs from the standard sized paint roller embodiment described above in that the end cap  122  is located immediately adjacent to the fixed hub  126 , rather than including a roller cage  24  between the fixed hub  126  and end cap  122 . This difference is due to the shorter length of the roller cover  132  for which this embodiment is designed. 
         [0040]    Likewise, in the embodiment shown in  FIGS. 8 and 9 , the construction and operation of the paint roller  210  is similar in construction and operation to that described above with regard to the standard sized paint roller  10 . The paint roller  210  includes a handle  214 , a frame  212 , a locking lever  218 , and a pivot point  240 . The roller cover  232  includes a rigid tube  234  and a nap portion  236 . The roller assembly  216  includes a sliding hub  228 , retainers  230  with tabs  238 , and a fixed hub  226 . Unlike the embodiment shown in  FIGS. 6 and 7  (and similar to the embodiment shown in  FIGS. 1-5  for a standard sized roller cover), this embodiment includes a roller cage  224  located between the fixed hub  226  and the end cap  222 . 
         [0041]      FIG. 10  depicts an exemplary embodiment of a paint roller assembly including an alternative embodiment of retainer  30  with sloped tabs  38 . The sloped tabs  38  permit installation of the roller cover  32  while the locking lever  18  is in the locked position. In this exemplary embodiment, installing the roller cover  32  causes the rigid tube  34  to contact the sloped tabs  38 . The retainers  30  deflect slightly radially inward towards shaft  20  and rigid tube  34  deforms slightly as the rigid tube  34  slides over the tabs  38 . Removal of the roller cover  32  from the roller assembly  16  is accomplished as described above. 
         [0042]    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.