Abstract:
An improved flocked foam applicator has a cylindrically shaped hollow rigid shell configured to slide onto a rigid core coupled to a handle. A rigid planar surface extends from the bottom of the hollow rigid shell forward. Applicator flock extends downward from the rear cylindrical portion of the hollow rigid shell, around the bottom of the hollow rigid shell, and outward to the distal edge of the rigid planar surface. The distal edge of rigid planar surface extends further forward than the leading edge of the cylindrical hollow rigid shell. As a result of this design, the improved flocked foam applicator can apply a liquid applicant to a floor all the way up to a baseboard or wall, and will further prevent the leading edge of the cylindrical portion from coming into contact with a baseboard or wall and depositing fluid in an undesired location.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims priority from, and incorporates by reference in its entirety, U.S. Provisional Application 60/900,149 to Felton, which was filed on Feb. 7, 2007 and entitled “Flocked Foam Applicator.” 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention is directed to methods and apparatus for applying liquid finishes to horizontal surfaces. 
       BACKGROUND 
       [0003]    Today, there are several methods for a applying liquid finishes, such as paint, polyurethane, and other formulations, to planar rigid surfaces such as floors and walls. These methods have included brushing, rolling, spraying, and various applicators such as brushes, lambswool, synthetic and natural fiber brushes, spray heads, and flocked foam applicators. A common way to apply a liquid finish with a flocked foam applicator is to pour a liquid finish on floor, and spread the liquid finish with the flocked foam applicator. Prior art embodiments of a flocked foam applicator is formed in a tubular or cylindrical shape. In application, the tubular or cylindrical lambswool spreader covering at least part of a cylindrical core acts as both a squeegee for advancing a fluid head of the liquid finish, and an applicator, for applying the liquid finish to the floor. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0004]      FIG. 1  is a side elevation view of a prior art flocked foam applicator assembly. 
           [0005]      FIG. 2  depicts a top plan view of the flocked foam applicator assembly  100  of  FIG. 1 . 
           [0006]      FIG. 3  depicts is a side elevation view a flocked foam applicator  300  according to an embodiment of the present invention. 
           [0007]      FIG. 4  depicts a side elevation view of the flocked foam applicator with a resistance member for holding the planar application section against the floor. 
           [0008]      FIG. 5  depicts a side elevation view of a wedge shaped member that can function as the resistance member of  FIG. 4   
           [0009]      FIG. 6  depicts a side elevation view of the flocked foam applicator attached to a handle. 
       
    
    
     DETAILED DESCRIPTION 
       [0010]      FIG. 1  is a side elevation view of a prior art flocked foam applicator assembly  100 . The flocked foam applicator assembly includes a flocked foam applicator  121  comprising a hollow rigid shell  115  to which an absorbent applicator surface  103  is affixed. The hollow rigid shell is preferably curved about an axis, and more preferably, cylindrically shaped about a cylindrical axis. However, other shapes are envisioned for the hollow rigid shell. The absorbent applicator  103  is typically comprised of a textile-like materials such as lambswool or synthetic flock. A rigid core  105  can be slide into the inner cavity of the hollow rigid shell. The rigid core is fixedly coupled to rigid extension  107  which extends between the rigid cylindrical core  105  and a rigid handle  119 . Within  FIG. 1 , the absorbent applicator  103  of the flocked foam applicator  121  is pictured at the juncture of a floor  104  and a wall  111 . A liquid applicant  117  such as paint or polyurethane is depicted on the floor adjacent the absorbent applicator. A gap  113  is visible in front of the flocked foam applicator. Prior art flocked foam applicators are not capable of properly applying a liquid applicant to this region. 
         [0011]      FIG. 2  depicts a top plan view of the flocked foam applicator assembly  100  of  FIG. 1 . A longitudinal gap  201  extends the entire length of the cylindrical portion of hollow rigid shell  115 , oriented parallel to the axis of the cylinder. The rigid extension  107  extends through the longitudinal gap, thereby coupling the handle  119  to the rigid cylindrical core  105 . The rigid extension  107 , and the rigid cylindrical core  105  affixed thereto, can be slid parallel to the axis of the flocked foam applicator assembly, so as to insert the rigid cylindrical core  105  into the cavity of the hollow rigid shell  115 , or alternatively, to withdraw the rigid cylindrical core  105  from the hollow rigid shell  115 . By this design, the hollow rigid shell  115 , and the absorbent applicator  103  affixed thereto may be disposed of, without disposing of the handle  119 , the rigid extension  107  or the rigid cylindrical core  105 . Following disposal of a used applicator, a new flocked foam applicator comprising a hollow rigid shell  115  with an absorbent applicator  103  affixed thereto, may be slid over the rigid selectable core  105 , thereby providing a fresh flocked foam applicator  121  for applying a liquid applicant  117  to the floor  104 . 
         [0012]    Referring again to  FIG. 1 , because of the cylindrical shape of the flocked foam applicator  121 , the most horizontally advanced portion  123  of the flocked foam applicator  121  typically engages the wall  111 , baseboard, or other vertical member during operation. There are two problematic aspects of this event, owing to the existing design of the flocked foam applicator. The first problem is that the absorbent applicator  103  does not touch the floor  104  within the corner section  113 . As a consequence, the flocked foam applicator cannot properly apply the liquid applicant  117  to the floor  104  in the corner section  113 . Additionally, because the liquid applicant typically saturates large portions of absorbent applicator  103 , when the most horizontally advanced portion  123  of the flocked foam applicator  121  touches wall,  111 , baseboard, or other vertical surface, it can inadvertently deposit the liquid applicant  117  on a wall baseboard. 
         [0013]      FIGS. 3 and 4  depict side elevational views a flocked foam applicator  300  according to an embodiment of the present invention. The flocked foam applicator  300  includes an absorbent applicator  303  having an absorbent exterior surface, and in interior surface coupled to a hollow rigid shell  301 . A longitudinal gap  305  formed in the hollow rigid shell  301  and absorbent applicator  303 . According to one embodiment, the longitudinal gap extends the length of the hollow rigid shell  301 , from end to end. In alternative embodiments, the longitudinal gap can extend from one end of the shell  301  to approximately the center of the shell, thereby limiting insertion of the rigid extension  107  from only one end of the shell. As illustrated in  FIG. 3 , the absorbent applicator extends from adjacent the longitudinal gap at the top of the hollow rigid shell  301 , down the right-hand side of the hollow rigid shell, to the bottom of the hollow rigid shell. The point at which the hollow rigid shell is tangent the floor is depicted as point C. At approximately the tangent point C, the orientation of the absorbent applicator  303  ceases to conform to the exterior curvature of the hollow rigid shell  301 . The absorbent applicator  303  to the left of the tangent point D forms a planar application section  401  that, in use, is configured to remain in a substantially horizontal orientation. To maintain a fixed orientation, the interior surface (or “upper surface” in  FIGS. 4 and 5 ) of the planar application section  401  of the absorbent applicator  303  is coupled to a rigid member  309 . 
         [0014]    Referring to both  FIG. 3  in  FIG. 4 , the rigid member  309  functions to ensure that the planar application section  401  of exorbitant applicator  303  remains in contact with the floor  311 . 
         [0015]    In an embodiment depicted in  FIG. 4 , the leading edge of the hollow rigid shell  301  is depicted as point “D” and by the dotted perpendicular line  405 . The planar application section  401  extends beyond the leading edge  405  of the hollow rigid shell  301 . The first advantage of this design is that the absorbent applicator does not deposit the liquid applicant on the wall parallel to the leading edge  405  of the hollow rigid shell, because the is no absorbent applicator along the leading edge  405  of the hollow rigid shell  301 , and because the distal edge of the planar application section  401  extends further forward than the leading edge  405  of the cylindrical hollow rigid shell. This design further ensures that the absorbent applicator  303  will not lose contact with the floor  311  in the last few centimeters of where the floor abuts a wall or baseboard. 
         [0016]    In the embodiment shown in  FIG. 4 , the orientation of the planar application area  401  is maintained by a rigid member  309  such as a flat rigid piece of material. According to an embodiment, the thickness of rigid member  309  ranges from about 2 mm to about 15 mm, though embodiments of greater or lesser thickness are envisioned. 
         [0017]    In an alternative embodiment, as shown in  FIG. 5 , a wedge shaped member  501  functions to maintain a constant vertical orientation of the planar application section  401 . The wedge shaped member  501  can be held in place by securing the lower surface of the wedge shaped member to the upper surface of the absorbent applicator  303 , by securing the right hand surface of the wedge shaped member to the hollow rigid shell  301 , or by securing both of these surfaces. As noted in  FIG. 5 , the right hand edge of the wedge shaped member  501  is curved to match the curvature of the outer surface of the hollow rigid shell. In a preferred embodiment, the wedge shaped member  501  is formed from an elastomer or sponge material so that it can deform under pressure, and regain its original shape after the pressure is released. 
         [0018]      FIG. 6  depicts an embodiment of the flocked foam applicator of  FIGS. 3 and 4  during use. The longitudinal gap  305  within the rigid cylindrical core  301  is positioned such that when the handle  119  is positioned at the normal angle of use, the planar application section  401  of the absorbent applicator  303  is oriented in a substantially horizontal orientation. However, in the embodiment of  FIG. 6 , as a user pushes the handle forward, the handle will typically rotate clockwise (from the perspective of the drawing). As a consequence, the planar application section  401  may rise off the floor by an angle θ, thereby failing to properly coat the floor with the fluid or liquid. 
         [0019]      FIG. 7  shows an alternative embodiment to  FIG. 6 , wherein the distal edge of the planar application section  401  is oriented in a slightly downward angle α relative to the floor when the handle is at an angle typically held by a user. When a deformable wedge described in  FIG. 5 . is used in conjunction with this embodiment, a downward pressure on the handle  119  by the user will deform the wedge and bend the planar application section  401  at roughly the point beneath the leading edge  405  shown in  FIG. 4 , thereby engaging the floor. As the handle is pushed forward by a user, the assembly rotates clockwise. However, instead of raising the distal edge of the planar application section  401  off of the floor, the foam wedge will expand, forcing the tip downward. By the use of a “soft” elastomer or sponge wedge that can easily be deformed by slight pressure, the natural angle α may be as great as 45 to 85 degrees, allowing forward thrust of the handle to a distance wherein the handle is nearly parallel to the floor. Such an embodiment would be useful in spreading a liquid applicant on a floor underneath a fixed structure, requiring the handle to be rotated downwards. However, in most applications, an angle of between zero and 45 degrees would be preferred. 
         [0020]    Throughout this disclosure, many specific details have been offered to enable one skilled in the art to make and use the invention described herein. These details are offered to be enabling, and are not intended to limit the scope of the appended claims, which comprehends alternative embodiments depicted within the scope of the claims.