Abstract:
A coating applicator tool and a method of making coating applicator tool with the coating applicator tool comprising a base member having a first surface and a second surface, a handle connected to the second surface of the base member and a plurality of flocked fibers supported on the first surface of the base member with the flocked fibers maintaining coating materials to a coating-receiving surface and distributing coating materials to the coating-receiving surface.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to currently pending U.S. Provisional Application Ser. No. 61/131,956; filed on Jun. 13, 2008; titled FLOCKED APPLICATOR TOOL AND METHOD OF MAKING. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates generally to coating applicator tools and more specifically to a coating applicator tool having flocked fibers that are applied to an applicating surface of the coating applicator tool. 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0003]    None 
       REFERENCE TO A MICROFICHE APPENDIX 
       [0004]    None 
       BACKGROUND OF THE INVENTION 
       [0005]    Tools having fibered applicating surfaces for applying surface coating are known in the art. The aforementioned tools are generally formed from a substrate comprising a roll of fabric having fibers that are continuously woven to form a plurality of loops throughout the fabric after which the top of each of the loop of the woven fibers are shaved off to form a velour or bristled like texture surface. The roll of fabric is then cut to size and secured to a base member of an applicator tool through the use of an adhesive. It should be noted that the fibers may alternatively be knitted onto the fabric. 
         [0006]    The above coating tools alternatively may also be formed by electrostatic flocking a plurality of fibers onto a foam substrate and then securing the fiber flocked foam substrate to a base member of an applicator tool by a variety of methods including but not limited to the use of the adhesive and through a frictional fit. Although the aforementioned tools generally work for their intended purposes, one of the main limitations of the prior art coating applicator tools is that they tend to have a shorter use life when use in the application of heavy and/or corrosive solvents. For example, it has been found that the presence of certain coating solvents may cause the adhesive binding the woven fabric to the base member of the coating applicator tool to break down, resulting in the woven fabric coming off of the base member of the coating applicator tool. In addition, certain coating solvents have been known to eat through the woven fabric. 
         [0007]    It has also been found that coating applicator tools containing the fiber flocked foam substrate also offers limitations in the application of heavy coating solvents as the foam substrate has a tendency to swell and weaken during the surface application process. That is the foam has a tendency tear when coating very rough or abrasive surfaces. Also, the foam can come loose from the tool when used in heavy solvent. 
         [0008]    The present invention provides a solution to the above problems by providing a coating applicator tool having flocked fibers that are applied to an applicating surface of the coating applicator tool that is durable and is resistant to damage in the application of heavy coating solvents or when used in very rough or abrasive surfaces so as to eliminate the need for the foam substrate or a woven fabric substrate. Eliminating the foam substrate and the woven fabric substrate allows the coating applicator tool of the present invention to be effectively used not only with traditional coating materials such as paint and oils but also with heavier and more corrosive coating solvents. In addition, eliminating the foam substrate and the woven fabric substrate reduces manufacturing cost while providing for a coating applicator tool that comprises a lower profile to enable the tool access to surface regions where traditional applicator tool are unable to reach doe to their profile. 
       BRIEF SUMMARY OF THE INVENTION 
       [0009]    The present invention comprises a coating applicator tool having a base member with a first surface and a second surface. The second surface of the base member includes a handle connected thereto. The first surface of the base member includes a plurality of flocked fibers supported thereon with the flocked fibers maintaining coating materials to a coating-receiving surface and distributing coating materials to said coating-receiving surface. The coating applicator tool may include a replaceable coating pad removably secured to the first surface of said base member with the replaceable coating pad having a surface supporting the flocked fibers thereon. 
         [0010]    The present invention may also comprise a coating applicator tool having a base member with a first surface and a second surface. The second surface of the base member includes a handle connected thereto. The coating applicator tool also includes a replaceable coating pad comprising a hook-and-loop fastener. The replaceable coating pad includes a first surface securable to the first surface of the base member by a pressure contact and a second surface supporting a plurality of flocked fibers thereon with the flocked fibers maintaining coating materials to a coating-receiving surface and distributing coating materials to said coating-receiving surface. The replaceable coating pad may comprise a first side having a plurality of tiny hooks extending therefrom and a second side having a plurality of small hair-like loops extending therefrom. 
         [0011]    The present invention may also include a method of making a coating applicator tool including the steps of coating a plurality of flocking fibers with a medium to make the flocking fibers electrically conductive or charged, coating a surface of a substrate with an adhesive, directing the adhesively coated surface of the substrate through a static charged field, to electronically drawing and embedding the flocking fibers to the adhesively coated surface of the substrate, hardening the adhesive on the substrate; and prepping the substrate to form the coating applicator tool. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is a side view showing an embodiment of the coating applicator tool; 
           [0013]      FIG. 2  shows a top view of a coating applicator tool similar to the coating applicator tool of  FIG. 1 ; 
           [0014]      FIG. 3  shows a side view of a coating applicator tool similar to the coating applicator tool of  FIG. 1 ; 
           [0015]      FIG. 4  shows a partial cross-sectional view of a roller applicator having a roller insert with a fiber flocked exterior surface; 
           [0016]      FIG. 5  shows a cross-sectional view of the roller insert of  FIG. 4 ; 
           [0017]      FIG. 6  shows a side view of a coating applicator tool similar to the coating applicator tool of  FIG. 3 ; 
           [0018]      FIG. 7  shows a side view of a portion of replaceable coating pad; 
           [0019]      FIG. 8  shows a side view of a coating applicator tool having a hook-and-loop fastener based replaceable coating pad secured thereto; 
           [0020]      FIG. 9  shows a cross-sectional view of an alternative embodiment of a roller insert having a replaceable coating pad secured thereto; 
           [0021]      FIG. 10  shows a side view of a replaceable coating pad having a first side containing a plurality of tiny hooks and a second side having fibers directly flocked thereto; and 
           [0022]      FIG. 11  shows a side view of a replaceable coating pad having a first side containing a plurality of small hair-like loops and a second side having fibers directly flocked thereto. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0023]    Referring to the drawings,  FIG. 1  is a side view showing an embodiment of a coating applicator tool  10  comprising a combination coating pad and rigid base member  11 . It is noted that alternative embodiments may comprise a flexible base member instead of a rigid base member  11 . Coating pad and rigid base member  11  includes a first surface  12  and a second surface  13  with the second surface  13  having a handle  14  secured thereto. A feature of the present invention is that the first surface  12  of the base member  11  includes a plurality of fibers  15  that are directly flock thereto with the flocked fibers  15  functioning to help maintain the loaded coating material to the coating-receiving surface such as a wall or a floor while also acting as a brush for the applicator. Directly flocking the flocked fibers  15  to base member  11  also provides coating applicator tool  10  with increase durability and resistance to damage such as when used in the application of heavy coating solvents or when used in very rough or abrasive surfaces. 
         [0024]      FIG. 2  shows a top view of an alternative embodiment of a coating applicator tool  16  of the present invention similar to the coating applicator tool  10  of  FIG. 1 . However the coating applicator tool  16  of  FIG. 2  includes a handle  17  that is removable attachable to a base member  18  through a sliding engagement of an attaching end  17   a  of the handle  17  with a pair of slots  19  located on a second surface  20  of the base member  18  of coating applicator tool  16 . The removability of the handle  17  allows for the replacement of an old or used coating pad and base member  18  with a fresh coating pad and base member  18 . 
         [0025]      FIG. 3  shows a side view of an alternative embodiment of a coating applicator tool  21  similar to the coating applicator tool  10  of  FIG. 1 . However in the embodiment of  FIG. 3  a handle  22  is shown permanently secured to a second surface  25  of a base member  23  with the handle  22  having a joint  22   a  that allows the base member  23  to swivel thereabout. In addition, unlike the coating applicator tool  10  of  FIG. 1 , the first surface  24  of the base member  23  is not directly flocked with fibers. Instead the first surface  24  of the base member  23  includes a set of parallel slots  26  extending from the first surface  24  of the base member  23  for securing a replaceable coating pad  27  to the first surface  24  of the base member  23 . 
         [0026]    In regards to the replaceable coating pad  27 , as shown in  FIG. 3 , the replaceable coating pad  27  comprises a first surface  27   a  and a second surface  27   b  with the first surface  27   a  having a plurality of fibers  28  that are directly flock thereto. The flocked fibers  28  functioning to help maintain the loaded coating material to the coating-receiving surface such as a wall or a floor while also acting as a brush for the applicator. A feature of coating pad  27  is that coating pad  27  durable and resistant to damage such as when used in the application of heavy coating solvents or when used in very rough or abrasive surfaces. The replaceable coating pad  27  also includes a pair of arms  29 ,  29   a  extending from the ends of the replaceable coating pad  27  for engaging the corresponding slots  26  of the base member  27  to secure the replaceable coating pad  27  to the first surface  24  of the base member  23 . 
         [0027]    Referring to  FIGS. 4 and 5 ,  FIG. 4  shows a partial cross-sectional view of a roller applicator  30  and  FIG. 5  shows a cross-sectional view of a roller insert  31  of the present invention. The roller insert  31  comprises cylindrically shaped, preferably replaceable coating pad and base member  32 . Coating pad and base member  32  includes an applicating surface  33  having a plurality of fibers  34  that are directly flock thereto. The flocked fibers  34  function to distribute coating materials to a surface such as a wall or a floor. It is noted that the cylindrically shaped base member  32  may be formed from a plurality of materials such as but not limited to various types of plastic and phenolic paper, depending upon the type of coating material that is intended for application by the roller applicator. It is also noted that although cylindrically shaped base member  32  is described as preferably comprising a replaceable coating pad material, the cylindrically shaped base member alternatively may be formed from a flexible material such as but not limited cardboard, elastomeric materials, and various types of flexible plastics so long as the material is durable and resistant to damage such as when used in the application of heavy coating solvents or when used in very rough or abrasive surfaces. 
         [0028]      FIG. 6  shows a side view of an alternative embodiment of a coating applicator tool  35  similar to the coating applicator tool  21  of  FIG. 3  in that a first surface  37  of a base member  36  is not directly flocked with fibers. The first surface  37  of the base member  36  instead includes a set of arms  38 ,  38   a  extending from the ends of the base member  36  for securing a replaceable coating pad comprising a metal plate  39  to the first surface  37  of the base member  36 . Although the replaceable coating pad of coating applicator tool  35  comprises metal plate  39 , the replaceable coating pad alternatively may be form from other materials including but not limited to metal, wood, plastic, various types of natural fibers, natural cellulose, and phenolic paper. 
         [0029]    In regards to the metal plate  39 , as shown in  FIG. 6 , the metal plate comprises a first surface  40  and a second surface  41  with the first surface  40  having a plurality of fibers  42  directly flocked thereto with the flocked fibers  42  functioning to help maintain the loaded coating material to the coating-receiving surface such as a wall or a floor while also acting as a brush for the applicator. The metal plate  39  is shown manipulated to form a pair of curve-shaped ends  43 ,  43   a  for engaging the corresponding arms  38 ,  38   a  of the base member  36  to secure the metal plate  39  to the first surface  37  of the base member  36 . 
         [0030]      FIG. 7  shows a side view of a portion of a replaceable coating pad  44  of the present invention. Replaceable coating pad  44  generally comprises a hook-and-loop fastener having a layer of fabric  45  with a hook side  46  identified by a plurality of tiny hooks  47  of plastic or the like extending therefrom and a loop side  48  identified by a plurality of small hair-like loops  49  extending therefrom. It is noted that hook-and-loop fasteners are generally identified or known by the brand name Velcro®, which is owned by the company Velcro Industries of the Netherlands. A feature of the embodiment of  FIG. 7  is that the replaceable coating pad  44  of  FIG. 7  includes a plurality of fibers  50  that are directly flocked to the loop side  48  of the layer of fabric  45  with the flocked fibers  50  functioning to help maintain the loaded coating material to the coating-receiving surface such as a wall or a floor while also acting as a brush for the applicator. The selection of hook-and-loop fastener-based replaceable coating pad  44  is desired for the present invention as the hook-and-loop fastener-based replaceable coating pad  44  may be form from a material(s) that have increase durability and resistance to damage such as when used in the application of heavy coating solvents or when used in very rough or abrasive surfaces. 
         [0031]      FIG. 8  shows a side view of a coating applicator tool  51  similar to the coating applicator tool  10  of  FIG. 1  in that coating applicator tool  51  comprises a base member  52  having a first side  52   a  and a second side  52   b.  Attached to the first side  52   a  of base member  52  is a griping handle  53  and extending from the second side  52   b  of base member  52  is a plurality of small hair-like loops  54  having qualities similar to the small hair-like loops  49  of the replaceable coating pad  44  of  FIG. 7 . The plurality of small hair-like loops  54  of coating applicator tool  51  function to secure the replaceable coating pad  44  to the base member  52  of coating applicator tool  51  when the hook side  46  of the replaceable coating pad  44  is pressed against the second side  52   b  coating applicator tool  51  causing the plurality of tiny hooks  47  of the replaceable coating pad  44  to catch in the plurality of small hair-like loops  54  of coating applicator tool  51 . Durability of coating applicator tool  51  is enhance as coating applicator tool  51  does not require the use adhesives to replaceable coating pad  44  to base member  52  thereby eliminating the connection site between replaceable coating pad  44  and base member  52  from potential attach by heavy and/or corrosive solvents. 
         [0032]    Once the replaceable coating pad  44  is no longer usable, replaceable coating pad  44  may be easily replaced with a fresh replaceable coating pad  44  by simply separating the used coating pad  44  from the base member  52  and securing a fresh replaceable coating pad  44  to the base member  52 . 
         [0033]      FIG. 9  shows a cross-sectional view of an alternative embodiment of a roller insert  55  having a replaceable coating pad  59  secured thereto. Replaceable coating pad  59  is similar to the replaceable coating pad  44  of  FIG. 7  except that a plurality of fibers  60  are directly flocked to a hook side  62  of a layer of fabric  61  instead of a loop side  63  of the layer of fabric  61  with the flocked fibers  60  functioning to help maintain the loaded coating material to the coating-receiving surface such as a wall or a floor while also acting as a brush for the applicator. Roller insert  55  comprises cylindrically shaped base member  56  similar to the base member  32  of the roller insert  31  of  FIG. 5 . Cylindrically shaped base member  56  includes an exterior surface  57  containing a plurality of tiny hooks  58  of plastic or the like extending therefrom. The plurality of tiny hooks  58  function to secure replaceable coating pad  59  to the exterior surface  57  of cylindrically shaped base member  56  when the a loop side  63  of the replaceable coating pad  59  is pressed against the exterior surface  57  of the cylindrically shaped base member  56  causing the plurality of tiny hooks  58  of the cylindrically shaped base member  56  to catch in a plurality of small hair-like loops  54  of replaceable coating pad  59 . Once the replaceable coating pad  59  is no longer usable, replaceable coating pad  59  may be replaced for a fresh replaceable coating pad  59  by separating the used coating pad  59  from the cylindrically shaped base member  56  and securing a fresh replaceable coating pad  59  to the cylindrically shaped base member  56 . 
         [0034]      FIG. 10  shows a side view of an alternative embodiment of a replaceable coating pad  64  similar to the replaceable coating pad  44  of  FIG. 7  in that replaceable coating pad  64  comprises a layer of fabric  65  having a first side  66  identified by a plurality of tiny hooks  67  of plastic or the like extending therefrom. However, unlike replaceable coating pad  44 , layer of fabric  65  includes a second side  68  having a plurality of fibers  69  that are directly flocked onto the second side  68  of the layer of fabric  65  with plurality of flocked fibers  69  functioning to help maintain the loaded coating material to the coating-receiving surface such as a wall or a floor while also acting as a brush for the applicator. Replaceable coating pad  64  may be used in conjunction with various coating applicator tools having a base member with a side or surface containing a plurality of small hair-like loops similar to the base member  52  of coating applicator tool  51  to enable the securement of replaceable coating pad  64  to the base member in a similar manner as described for applicator tool  51 . 
         [0035]      FIG. 11  shows a side view of an alternative embodiment of a replaceable coating pad  70 . Replaceable coating pad  70  is similar to the replaceable coating pad  44  of  FIG. 7  in that replaceable coating pad  70  comprises a layer of fabric  71  having a first side  72  identified by plurality of small hair-like loops  73  located thereon. However, unlike replaceable coating pad  44 , layer of fabric  71  includes a second side  74  having a plurality of fibers  75  that are directly flocked onto the second side  74  of the layer of fabric  71  with plurality of flocked fibers  75  functioning to help maintain the loaded coating material to the coating-receiving surface such as a wall or a floor while also acting as a brush for the applicator. 
         [0036]    Replaceable coating pad  70  may be used in conjunction with various coating applicator tools having a base member with a side or surface containing a plurality of plurality of tiny hooks similar to the base member  56  of coating applicator tool roller insert  55  to enable the securement of replaceable coating pad  70  to the base member in a similar manner as described for applicator tool  51 . 
         [0037]    In regards to an example of a process of manufacturing the coating applicator tool of the present invention, the process starts with a flat sheet of a substrate that may comprise of a variety of materials including but not limited to various plastics, phenolic paper, various types of natural fibers, natural cellulose, and various type of metal. 
         [0038]    A surface of the sheet of substrate first goes through a flocking process. Flocking allows for the coating of the surface of the substrate with any of a variety of materials. Flocking materials, which could be successfully employed to the sheet of substrate include fibers of either organic or synthetic origin, such as cotton, wool, rayon, nylon, plastic, or other materials. These materials may be chopped, cut to random lengths, or cut to precision lengths. The flocking material may be applied to the substrate by various methods including but not limited to electrostatic coating. 
         [0039]    In the electrostatic coating process, the flocking fibers are coated with a medium to make them electrically conductive or charged. The surface of the substrate is coated with an adhesive. The adhesively coated substrate surface is then passed through a static charged field and the flocked fibers are electronically drawn to it, causing them to become embedded in the adhesively coated substrate surface. The static electricity makes the fibers erect and stand straight on end, orienting the fibers generally perpendicularly to the surface of substrate. Once the surface of substrate has been flocked with the fibers, the adhesive on the substrate may then be heated, chemically cured or air dry to allow the adhesive to hardened. 
         [0040]    Once the adhesive has hardened, the substrate may then be cut to size. If desired the substrate may also manipulated such as by a stamping process, a bending process or by heat and formed into a desired shape. The resultant product may them be used to form the applicating surface of the coating applicator tool of the present invention.