Abstract:
A tool for spreading material such as drywall compound generally comprises a plate, a handle, and a frame. The plate includes a first edge and second edge that are substantially parallel to one another. A frame is coupled to the first edge of the plate, and a handle is coupled to the frame, thereby attaching the handle to the plate, the second edge of which is used for spreading material. The handle extends away from the frame and plate, and bends to extend toward and substantially transverse to the second edge of the plate, thereby increasing both the effectiveness of the tool and the comfort of the user during use of the tool.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     Not Applicable  
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
       [0002]     Not Applicable  
       FIELD OF INVENTION  
       [0003]     This invention relates to a tool, and, more particularly, to a tool used to spread drywall compound or other material.  
       BACKGROUND OF INVENTION  
       [0004]     There currently are two types of tools used for finishing drywall: the taping knife and the drywall trowel. A taping knife typically is used to spread drywall compound in a way that fills the joint between two pieces of plasterboard and spreads the compound approximately three inches on each side of the joint. While the drywall compound is still wet, the taping knife is used to press perforated paper over the joint until the paper stays in place. While using firm pressure, the blade of the taping knife is held at an approximately forty-five degree angle to the surface so that the paper is firmly embedded and excess drywall compound is forced out at the edges of the paper. Once the joint is dry, the taping knife or drywall trowel is used to spread an additional layer of drywall compound to dress the joint. Finally, using a drywall trowel, a thin finishing coat is built up over the joint and feathered to a distance of about four or five inches on both sides of the joint.  
         [0005]     The current state of the art in drywall compound spreading tools presents a number of limitations. First, the operation of current drywall tools places a large amount of stress on a user&#39;s wrist. Prior art taping knifes and drywall trowels are illustrated in FIGS.  1  and  2 . As seen in  FIGS. 1 and 2 , a blade  1  is placed into contact with a wall  2  to spread drywall compound or to press perforated paper over the joints in the wall  2 . A user  3  typically applies force through the blade  1  and handle  4  in directions  5  and/or  7 , and the wall  2  provides a resistance force away from the wall  2  in a direction  6 . As a result of the forces applied by the user and the wall, a resultant moment  8  is formed, for which the user  3  must physically compensate with his or her wrist or arm.  
         [0006]     Second, the grip techniques used for controlling the forces on the blade negatively affect the user. It is common for a drywall finisher to use a pinch-type grip in which the user&#39;s opposing fingers grip in a pinching fashion to hold and control the drywall tool as illustrated in  FIG. 1 . This type of grip requires the user to exert a significant amount of force to hold onto handle  4 . Further, when the drywall tool is used at a significant distance away from the user&#39;s body, excessive wrist flexure may be needed to control the blade edge and apply the necessary pressure to spread drywall compound or press perforated paper against the wall  2 .  
         [0007]     Moreover, it is common for a user to extend his or her index and middle finger on the blade to control the forces and leave the weaker fingers to grasp the tool. When compared to the pinch-type grip, this technique requires more effort to finish smoothing a joint and reduces the amount of control the user has on the spreading edge. It is common for a user to rotate the tool about the handle centerline, pressing an end of the blade into the wall to apply the drywall compound. This technique is also detrimental to a user&#39;s wrist since additional torque must be applied to the handle for adequate control. It has been shown that a repetitive combination of the aforementioned grips and wrist flexure, while employing high-grip forces, can lead to carpal tunnel syndrome.  
         [0008]     Third, the current handle designs are uncomfortable for a user. Specifically, when a user grips the handle of a drywall finishing tool, the design of the handle causes pressure points and discomfort on the inside of the user&#39;s hand. Additionally, as seen in  FIG. 1 , the end of the handle  4  interferes with the user&#39;s wrist when his or her wrist is bent or flexed since the handle is typically longer than the user&#39;s hand.  
         [0009]     Finally, the current drywall tools provide an ineffective finishing stroke length. Typically, a user begins a drywall joint finishing stroke by extending his or her arm to position the drywall tool away from his or her body, and brings the drywall tool toward his or her body when finishing the stroke. Once the user finishes the stroke, the drywall tool must be lifted away from the plasterboard and drywall compound, set at the opposite end of the joint, and brought toward his or her body again. The user must use two strokes to complete a joint and, in the process, experiences severe wrist flexure when the tool is brought toward the body.  
         [0010]     Thus, while drywall spreading tools are well known and commonly used, there remains a need in the construction industry for a drywall tool that reduces the amount of stress on a user&#39;s wrist. Additionally, there is a need for a drywall tool that allows a user to more easily control the forces placed on the drywall tool. Further, there is a need for a drywall tool handle design that eliminates pressure points on the user&#39;s hands and reduces interference with the user&#39;s wrist. Still further, there is a need for a drywall tool that allows a user to utilize an effective finishing stroke length and reduces wrist flexure.  
       SUMMARY OF THE INVENTION  
       [0011]     The present invention provides a tool that reduces the amount of stress on a user&#39;s wrist and allows a user to more easily control the forces placed on the drywall tool. Further, the present invention provides a tool handle design that eliminates pressure points on the user&#39;s hands and reduces interference with the user&#39;s wrist. Still further, the present invention provides a tool handle design that utilizes an effective finishing stroke length.  
         [0012]     According to the present invention, the foregoing and other objects are achieved by a tool generally including a plate, a handle, and a frame. The plate includes a first edge and a second edge that are substantially parallel to one another. A frame is coupled to the first edge of the plate, and a handle is coupled to the frame. The second edge of the plate is generally used for spreading drywall compound. The handle extends away from the frame and plate and bends to extend toward and substantially transverse to the second edge of the plate.  
         [0013]     Additional objects of the invention, together with the advantages and novel features appurtenant thereto, will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned from the practice of the invention. The objects and advantages of the invention may be realized and attained by means and instrumentalities and combinations particularly pointed out in the appended claims. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]     In the accompanying drawings which form a part of this specification and are to be read in conjunction therewith and in which like reference numerals are used to indicate like parts in the various views:  
         [0015]      FIG. 1  is a side view of a prior art taping knife being operated by a user against a spreading surface;  
         [0016]      FIG. 2  is a side view of a prior art drywall trowel being operated by a user against a spreading surface;  
         [0017]      FIG. 3  is a perspective view of a tool according to the present invention;  
         [0018]      FIG. 4  is an upper plan view of the tool shown in  FIG. 3 ;  
         [0019]      FIG. 5  is a lower plan view of the tool shown in  FIG. 3 ;  
         [0020]      FIG. 6  is a front elevational view of the tool shown in  FIG. 3 ;  
         [0021]      FIG. 7  is a rear elevational view of the tool shown in  FIG. 3 ;  
         [0022]      FIG. 8  is a side elevational view of the tool shown in  FIG. 3 ;  
         [0023]      FIG. 9  is a side elevational view of the tool shown in  FIG. 3  being operated by a user against a spreading surface;  
         [0024]      FIG. 10  is a side, elevational, cross-sectional view of an additional embodiment of the tool;  
         [0025]      FIG. 11  is a perspective view of an adjustment mechanism and flange of the additional embodiment of  FIG. 10 ;  
         [0026]      FIG. 12  is a side, elevational, cross-sectional view of the additional embodiment of  FIG. 10  where the angle between the handle and flange has been changed;  
         [0027]      FIG. 13  is a front, elevational, cross-sectional view of the additional embodiment of  FIG. 10  taken along the line  13 - 13 ;  
         [0028]      FIG. 14  is a side, elevational view of another additional embodiment; and  
         [0029]      FIG. 15  is a front, elevational, cross-sectional view of the additional embodiment of  FIG. 14  taken along the line  15 - 15 .  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0030]     Referring to the drawings in greater detail, and initially to  FIG. 3 , a tool according to the present invention is generally designated in the drawings by reference numeral  10 . The tool  10  is used to spread drywall compound in the joint formed between two sheets of plasterboard, over imperfections in the plasterboard, and over joint paper or joint tape. Although the tool  10  is described as being used to spread drywall compound, it should be understood that the tool  10  can be used to spread plaster, stucco, cement, grout, mortar, caulk, elastomeric material, adhesive material, and any other soft, malleable material. Further, tool  10  can be used to spread such material on a wall, floor, ceiling, or other location made of plasterboard, drywall, cement, asphalt, wood, metal, or any other material. The tool  10  generally includes a handle  12 , a frame  14 , and a plate  16 . The handle  12  is coupled to the frame  14 , which in turn is coupled to the plate  16 . As seen in  FIGS. 3 and 6 - 8 , the handle  12  includes a grip  18 , a support  20 , and a base  22 . As described below, the grip  18  and the support  20  are adapted such that handle  12  is positioned over plate  16 .  
         [0031]     The grip  18  of the handle  12  is held by a user in order to operate the tool  10 . With reference to  FIGS. 4 and 6 - 8 , the grip  18  and the support  20  of the handle  12  are shaped and contoured in such a way to minimize or eliminate pressure points that occur when a user grasps and operates the tool  10 . In one embodiment, the grip  18  and the support  20  of the handle  12  are integrated in a single unit. Alternatively, the grip  18  and the support  20  may be separate units in which the grip  18  is press-fit, molded onto, or otherwise attached to the support  20 . However, is should be understood by one of ordinary skill in the art that the grip  18  and support  20  may be connected by other means such as rivets, bolts, clasps, screws, adhesive, glue, welding, or the like. Further, the handle  12  can be made of wood, metal, rubber, polymeric material, or any other suitable material that will enable a user to grip the handle  12  and operate the tool  10 .  
         [0032]     With reference to  FIGS. 4 and 6 - 8 , the support  20  and base  22  will be discussed. The base  22  is adapted to rigidly mount the support  20  to the frame  14 . With reference to  FIG. 8 , the support  20  extends generally vertically from the frame  14  and base  22  and curves rearward such that a longitudinal axis of grip  18  is positioned at an angle with respect to the plane of plate  16 .  
         [0033]     Referring now to  FIGS. 5-8 , the base  22  will be discussed. The base  22  includes apertures or holes, not shown, that are adapted to receive screws  26  to couple the support  20  to the frame  14 . It should be understood that the frame  14  and the support  20  may be formed as an integral member, thereby eliminating the need for fastening the two parts by screws, nuts, bolts, welds, rivets, adhesive, or the like. Further, the support  20  may be formed of metal, wood, plastic, polymeric material, or any other material that will provide a rigid connection between the handle  12  and the frame  14 .  
         [0034]     The frame  14  is generally used to connect the handle  12  to the plate  16 . With reference to  FIGS. 4 and 5 , the frame  14  is generally rectangular with two rounded corners. Referring now to  FIG. 8 , the frame  14  includes a mounting portion  28  and a channel portion  30 . The mounting portion  28  and a channel portion  30  may be integrally formed, or may be separate pieces coupled together. Referring now to  FIG. 5 , the mounting portion  28  contains apertures or holes, not shown, that are adapted to correspond to the apertures or holes, not shown, located in the base  22  of the handle  12 . The screws  26  are inserted into and through corresponding apertures or holes in the base  22  and mounting portion  28  to interconnect the handle  12  to the frame  14 . It will be understood that handle  12  and frame  14  may be connected by rivets, bolts, welding, adhesive, or other means well known to those of skill in the art. The frame  14  may be made of metal, wood, plastic, polymeric material, or any other material that will provide a rigid connection between the handle  12  and the plate  16 .  
         [0035]     Referring again to  FIG. 8 , the channel portion  30  of the frame  14  extends away from the mating portion  28 . In one embodiment, the channel portion  30  extends in a horizontal direction and lies along the same plane as the mating portion  28 . Alternatively, the channel portion  30  may be bent relative to the mating portion  28  to adjust the angle between the grip  18  and the plate  16 . Thus, the angle at which grip  18  is positioned with respect to the plane of the plate  16  can be fixed by bending the frame  14  or the plate  16 . The channel portion  30  also includes a channel  32 , as seen in  FIG. 8 . The channel  32  extends along the longitudinal edge of the frame  14  and is adapted to receive an attachment edge  36  of plate  16 . It should be understood that the base  22 , support  20 , and frame  14  are not the exclusive fastening means for attaching the handle  12  to the plate  16 . It is within the scope of this invention to employ fastening means having one or more members connecting the handle  12  to the plate  16 , provided the handle  12  is positioned over the plate  16  and the handle  12  is coupled to the plate  16 .  
         [0036]     With reference to  FIGS. 4-8 , plate  16  generally is substantially planar and rectangular shaped. As stated above, it should be understood that plate  16  could be bent or curved to vary the angle at which handle  12  is positioned with respect to the plane of plate  16 . Further, plate  16  includes a spreading edge  34  and an attachment edge  36 . As best seen in  FIGS. 4 and 8 , the attachment edge  36  is received in the channel  32  and the plate  16  is coupled with the channel portion  30  by punches  38 . It should be understood that the plate  16  may be fixably coupled to frame  14  by other means such as rivets, bolts, clamps, screws, adhesive, glue, welding, or the like. The spreading edge  34  is the portion of plate  16  that makes contact with the wall and is used for spreading drywall compound or pressing joint paper or tape in the joints of the wall. As seen in  FIG. 4 , the handle  12  is preferably positioned over the plate  16  and extends toward and transversely to the spreading edge  34 . It should be understood that the plate  16  may be made out of metal, plastic, polymeric material, or any other material suitable for spreading drywall compound.  
         [0037]     In operation and as best seen in  FIG. 9 , a user  3  grasps the tool  10  by handle  12 . User  3  then begins to apply drywall compound with the plate  16  of tool  10 . While the user is applying the drywall compound, the line of force imparted to tool  10  extends, in direction  5 , substantially parallel to the axis of the user&#39;s wrist and through the point at which plate  16  makes contact with wall  2 . As with the prior art tools shown in  FIGS. 1 and 2 , wall  2  provides a resistive force in direction  6  away from wall  2 . However, because the present invention allows a user  3  to impart a force through the point of contact between plate  16  and wall  2 , the amount of resultant moment  8  that must be resisted by the user  3  is substantially reduced. Further, the grip implemented by user  3  and depicted in  FIG. 9  substantially reduces or eliminates the possibility that handle  12  will interfere with the user&#39;s wrist.  
         [0038]     It should be understood that the angle between the longitudinal axis of the grip  18  and the plane of the plate  16  can be varied by, for example, pivotally coupling the base  22  to the frame  14  such that the pivotal connection between the base  22  and the frame  14  allows a user to selectively position the handle  12  and grip  18  to a desired angle with respect to the plane of plate  16 . In addition, the angle between the longitudinal axis of the grip  18  and the plane of the plate  16  can be varied by pivotally coupling the base  22  to the support  20  or by pivotally coupling the support  20  to the grip  18 .  
         [0039]     Referring now to  FIGS. 10-13 , an additional embodiment of the tool  10 A will be discussed. The tool  10 A contains a handle  12 A, a frame  14 A, and an adjustment mechanism  40 . The handle  12 A is pivotally attached to the frame  14 A. As best seen in  FIGS. 10, 12 , and  13 , the handle  12 A includes the grip  18 , a support  20 A, and a base  22 A. The remainder of the elements of the tool  10 A are the same as the previous embodiment, discussed above. As best seen in  FIG. 13 , the support  20 A and the base  22 A have a cavity  42  formed therein for receipt of the adjustment mechanism  40 , see  FIG. 11 , as will be discussed further below. The cavity  42  contains a channel  44  and a bore  46 . The channel  44  extends transversely across the base  22 A. Referring specifically to  FIGS. 12 and 13 , the bore  46  is formed within the support  20 A and extends upwardly from the channel  44 . The bore  46  has a lower section  48 , a middle section  50 , and an upper section  52 , the importance of which will be discussed further below. The upper section  52  has a cylindrical space  54  formed therein. The base further contains a cylindrical opening  56 . The opening  56  is located at a rearward portion of the base and receives a pin  58  to couple the handle to the frame  14 A.  
         [0040]     Referring now to  FIG. 11 , the frame  14 A contains a recess  60  and a front and rear set of flanges  62 ,  64 . The flanges  62 ,  64  extend upwardly from the frame  14 A. With the exception of the recess  60  and the flanges  62 ,  64 , the frame  14 A is the same as discussed above. The flanges  62 ,  64  are used to attach the handle  12 A to the frame  14 A via the adjustment mechanism  40 .  
         [0041]     Referring again to  FIG. 11 , the adjustment mechanism  40  includes a T-shaped member  66 , a bolt  68 , and an insert  70 . The T-shaped member includes a mount  72  and a collar  74 . As best seen in  FIGS. 10, 11 , and  13 , the mount  72  is cylindrical and received within the channel  44  in the cavity  42 . The mount  72  is rotatably coupled to the front set of flanges  62 . The pin  58  received in the opening  56  is rotatably coupled to the rear set of flanges  64 . It should be understood that any suitable attachment method may be used.  
         [0042]     The collar  74  extends upwardly from the mount  72  and is received within the bore  46 . Specifically the collar  74  is received within the lower section  48  of the bore  46 . The collar  74  contains a slot  76  at an intermediate position that receives a clip  78 . The clip  78  serves to limit the axial movement of the bolt  68  while still allowing rotational movement. The bolt  68  extends within the upper portion  52  of bore  46 .  
         [0043]     The adjustment mechanism  40  further includes the insert  70  located at an intermediate position within the support  46 A. The insert  70  is a cylindrical collar that is fixably coupled within cylindrical space  54  in the support  46 A. The insert contains a threaded aperture  80  that is aligned with the bore  46  and receives the bolt  68 .  
         [0044]     As stated above, the additional embodiment of the tool  10 A contains a handle  12 A that is pivotally attached to the frame  14 A. The angle of orientation of the handle  12 A may be changed with respect to the frame  14 A by the user simply rotating the bolt  68 . Rotation of the bolt  68  causes the handle  12 A to move with respect to the frame  14 A as shown when viewing  FIGS. 10 and 12 . Specifically, rotation of the bolt  68  causes the bolt  68  to move within the bore  46  due to the threaded engagement of the bolt  68  with the insert  70  in the cylindrical space  54  within the support. More specifically a counterclockwise rotation of the bolt  68  would raise the handle  12 A while a clockwise rotation would lower the handle  12 A.  
         [0045]     Referring now to  FIGS. 14 and 15 , yet another additional embodiment of the handle  12 B will be discussed. The remainder of the components are the same as discussed above. The handle  12 B is a two-piece member including a base  82  and a grip  84 . The base  82  is adapted to rigidly mount the handle  12 B to the frame  14  as discussed above with respect to the first embodiment. The grip  84  is rotatably coupled to the base  82  by a bolt  86 . As best seen in  FIG. 15 , the base  82  includes a cylindrical hole  88  and a mating surface  90 . The grip  84  also includes a mating surface  92  and a threaded hole  94 . The mating surface  90  of the base  82  and the mating surface  92  of the grip  84  align and abut. The bolt  86  is threaded through the cylindrical hole  88  and into the threaded hole  94 . As such, when the bolt  86  is tightened, the mating surfaces abut and the grip  84  cannot move relative to the base  82 . However, a simple loosening and tightening of the bolt  86  allows the mating surface to disengage and engage thereby allowing the orientation of the grip  84  to be changed relative to the base  82 .  
         [0046]     Constructed and operated as previously described, the invention has numerous advantages that remedy the deficiencies of the prior art. Specifically, the present invention provides a tool that is configured to reduce the amount of torque on the user&#39;s wrist, making it easier and more comfortable for the user to perform the task of applying drywall compound to plasterboard. Additionally, the handle configuration of the present invention makes it is easier to control the forces to the ends of the blade or plate when the user is feathering the compound away from the sides of a joint to make the plasterboard appear flat and smooth. The configuration provides the ability to easily apply lateral torsion to the handle to allow the tool to be controlled and twisted from side to side. Further, the handle of the present invention is contoured in such a way as to reduce the gripping power required to control the tool and to reduce or eliminate pressure points on the hand of a user. Still further, the present invention is designed such that the length of the tool&#39;s handle is not critical and ensures that the handle does not interfere with the user&#39;s wrist during operation of the tool.  
         [0047]     From the foregoing, it will be seen that this invention is one well-adapted to attain the ends and objects herein above set forth together with other advantages which are obvious and which are inherent to the structure. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims. Since many possible embodiments may be made of this invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.