Abstract:
A device for touching up painted areas comprises a flexible container, and an applicator support connected to an opening of the container by threads or other attachment means. The applicator support carries an applicator for receiving paint or other coating material held in the container. The applicator is porous, allowing one to apply the paint to the painted areas in need of touch-up by squeezing the container. A cap having an interior space sized to contain the applicator can attach to the applicator support or container to enclose the applicator thereby creating a substantially airtight seal and preventing paint in the applicator and the container from drying out. By detaching the applicator support from the container, paint may be poured into the container.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    Surfaces are often coated for esthetic and protective purposes. Typically, this coating is applied as a liquid that then dries (hardens) to a layer that beautifies and protects the underlying material. This liquid will be hereafter referred to as “paint”, but may be any type of permanent or semi-permanent coating applied as a liquid to a surface of any kind. The process of applying this coating is universally known as “painting” and a surface so coated as a “painted” surface. 
         [0002]    The apparatus to be described is directed to maintaining the integrity of painted surfaces of buildings but also pertains to other types of painted surfaces, for example, vehicles and exterior furniture. 
         [0003]    Afterwards the initial coating is complete, people and animals interact with the painted surfaces and often through carelessness or inadvertence, damage relatively small areas of the coated surfaces. Frequently after paint has been applied to a surface, a quantity of the paint remains. This leftover paint is useful for repainting the damaged areas. 
         [0004]    It is the usual practice to keep the leftover paint in the original container and simply apply this paint with a brush, pad, or roller after damage occurs to a surface. However, this practice has numerous disadvantages. In the first place, the leftover paint more often than not occupies only a small fraction of the container. The paint may for this reason skin over or dry out because most of the volume in the container is air. 
         [0005]    Secondly, paint is usually supplied in gallon containers, which inconveniently occupy a significant amount of shelf space. Third, the seal between the cover and the container itself may be compromised when paint dries in the sealing grooves during the painting process. Fourth, deteriorated paint must be replaced, and it is by no means certain that the replacement paint will match the original paint, and in any case it is expensive and inconvenient to do so. One can see that usual practice in this situation is problematic. 
         [0006]    A number of solutions for this problem already exist. For example, U.S. Pat. No. 6,439,381 teaches individual storage containers for a number of different paints. &#39;381 shows an applicator that must be attached to the container before touchup and then either cleaned or discarded after touchup is done. 
         [0007]    U.S. Pat. No. 7,040,828 discloses a container for touchup paint having an applicator carried by a support that screws into the container. The user removes the applicator by unscrewing its support from the container. The applicator, having already been immersed in the paint, is instantly usable. The invention contemplates attaching the applicator to the container with a second thread set to prevent the paint in the container from drying while touching up occurs and to serve as a handle during the touchup process. 
         [0008]    U.S. Pat. No. 7,338,227 discloses a system for mixing two parts for an epoxy paint and includes an applicator for touching up an existing coating. 
         [0009]    Each of these designs solves the problem in some sense, but have disadvantages as well. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0010]    An improved device for applying relatively small quantities of a liquid coating material such as paint comprises a container having an interior space defined by flexible walls, and having an opening for filling the interior space with a liquid coating material. This container opening has a first annular attachment feature. The first annular attachment feature preferably comprises relatively rigid threads encircling the container opening. 
         [0011]    A coating material applicator has a porous applicator surface for receiving a liquid coating material. The applicator further comprises structure that distributes the coating material to the applicator surface. 
         [0012]    An applicator support has a second annular attachment feature that can mate with the first annular attachment feature to form a seal opposing migration of liquid between the first and second annular attachment features. The applicator support also has an interior passage in flow communication with the applicator. When the second annular attachment feature is mated with the first annular attachment feature said applicator surface is in flow communication with the container&#39;s interior space. 
         [0013]    A cap has an interior space sized to contain or enclose the applicator portion exterior to the container. The cap has an opening defined by a third annular attachment feature. The third annular attachment feature can mate with one or the other of the first and second annular attachment features to create a substantially airtight seal between them. 
         [0014]    When the cap&#39;s third annular attachment feature is so mated with the one of the first and second annular attachment features, the cap&#39;s interior space holds the applicator. Little or no external air can reach the container interior space and the applicator, preventing paint held within the container and the applicator from hardening. 
         [0015]    When touching up an area of the painted surface, the user squeezes the flexible walls of the container, reducing the internal space and forcing paint through the applicator from the first to the second applicator end portion. Liquid paint appears on the second end and may be then applied to the touchup area. 
         [0016]    In one preferred version, the applicator comprises pliable, permeable, foam material. By squeezing the container walls, a user can force paint in the container through the applicator support and the applicator itself to the applicator surface. The coating material appears on the applicator surface, from which it may be transferred to a surface such as a wall. Releasing the container walls allow air exterior to the container to pass through at least a part of the applicator support to the container interior, replacing the volume of coating material previously applied and allowing the container walls to return to their unstressed (normal) shape. 
         [0017]    In a second embodiment, the applicator support includes a tubular projection in flow communication with the applicator support&#39;s interior passage. The applicator includes a plenum mounted on and having an interior space in flow communication with the tubular projection. The plenum has a surface having an aperture therein and facing away from the tubular projection, and defining in part the plenum&#39;s interior space. A permeable fabric pad overlies the plenum&#39;s flat surface and the aperture therein to form the applicator surface. 
         [0018]    In either embodiment, a vent in the applicator support can function to allow airflow to the container interior space. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]      FIG. 1  is a perspective view of a liquid coating material application device when in a “storage configuration.” 
           [0020]      FIG. 2 . is an exploded perspective view of the liquid coating material application device, showing the various components thereof. 
           [0021]      FIG. 3  is a perspective view of an alternate configuration for an applicator element of the liquid coating material application device. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0022]    Referring first to  FIGS. 1 and 2 , the liquid coating material application device  10  shown therein provides the user with structure into which leftover paint or other liquid coating material may be place for later touch and repair use. Device  10  is intended for use with liquids such as paint that harden or dry when exposed to air for a period of time. 
         [0023]    The exploded view of  FIG. 2  discloses a container  15  having a mouth  37  and a longitudinal axis  18 . The walls of container  15  are flexible so that a typical user can compress them with hand force alone to reduce the volume of container  15 . A first annular attachment feature  31  encircles mouth  37 , and in a preferred embodiment comprises threads. Container  15  includes a relatively rigid tubular ring or band  16  defining mouth  37  into which the threads comprising a first annular attachment feature  31  may be molded. 
         [0024]    An applicator support  41  has an interior passage allowing liquids to flow through support  41  generally along axis  18 . Support  41  in one preferred embodiment includes a tubular projection  25  in flow communication with this interior passage. 
         [0025]    Support  41  includes a second annular attachment feature  28  shown here as threads encircling an opening of support  41 . Second annular attachment feature  28  is designed to mate with the threads comprising the first annular attachment feature  31  to attach support  41  to container  15  and form a seal opposing migration of liquid between the threads comprising the first and second annular attachment features  31  and  28 .  FIG. 2  shows second annular attachment feature  28  structured to thread into the interior of container  15 . 
         [0026]    A coating material applicator  20  in one version of this invention includes a plenum  22  carried by projection  25 . “Plenum” in the context here means a structure having an enclosed space in which liquid coating material can flow. Plenum  22  has an interior space in flow communication with projection  25 . 
         [0027]    Plenum  22  includes a wall  27  facing away from projection  25  and defining at least a part of the plenum space. Wall  27  has at least one aperture  51 . A permeable fabric pad  54  on the wall  27  overlies aperture  51 . Preferably wall  27  is substantially rectangular and tilted with respect to axis  18 . Wall  27  and plenum  22  may be semi-rigid, resisting flexure, but also allowing some deflection of these components to conform to a wall surface. 
         [0028]    Liquid coating material such as paint is poured into container  15  and then support  41  is threaded into container  15 . By tilting the assembly so that applicator  20  is below container  15 , and then squeezing the flexible walls of container  15 , liquid is forced through projection  25  and aperture  51  to soak pad  54 . Rubbing or dabbing pad  54  on a surface then applies the liquid to the surface. 
         [0029]    The intent here is for a user to fill container  15  with leftover paint or other liquid coating material when an entire surface such as a wall is first coated. After filling container  15 , then applicator support  41  is mated with container  15 . First and second annular attachment features  31  and  28  form a seal preventing migration of air into the container  15 . However, air can migrate into container  15  through applicator  20  and applicator support  41 . This will cause the liquid within container  15  and applicator  20  to eventually harden and become worthless. 
         [0030]    A cap  13  that encloses container  15  and applicator  20  will prevent deterioration of paint within them. Cap  13  has an interior space sized to contain applicator  20  and in this embodiment, fit around applicator support  41  as well. Cap  13  has an opening defined by a third annular attachment feature  19 , and in the preferred embodiment shown here comprises threads that mate with one of the other of the first and second annular attachment features  31  and  28 . 
         [0031]    For example, first annular attachment feature  31  may comprise threads molded into the wall of container  15  that are engageable both for the interior and exterior of container  15 . In this embodiment, the configuration of the threads comprising third annular attachment feature  19  allow their mating with the exterior pattern of first annular attachment feature  31  on container  15 . Thus the threads comprising first annular attachment feature  31  mate with the second annular attachment feature  28  on the inside of container  15  and also mate with the third annular attachment feature  19  on the outside of container  15 . 
         [0032]    The first and third annular attachment features  31  and  19  have a mating connection that forms a substantially airtight seal to prevent migration of air into the space between cap  13  and support  41 . The liquid material in container  15  and applicator  20  will not normally dry out or harden when exposed to such a small volume of air. Accordingly, the liquid may be suitable for use even years after attaching the cap  13  to container  15  using the first and third annular attachment features  31  and  19 . 
         [0033]    It is likely that the smaller volume of air in intimate contact with the liquid material in container  15  and applicator  20  means that the shelf life of the material in container  15  will be longer than if left in a conventional can from which much of the coating material has already been removed and replaced with air. 
         [0034]    Further experience may show that threads alone comprising mated annular attachment features  28  and  31  may not provide adequate sealing against migration of coating material from container  31  between them. Experience may also show that threads alone comprising mated annular attachment features  19  and  31  may not provide adequate sealing against migration of air between them into the internal space of cap  13 . In that case, an O-ring or other type of gasket may be necessary to provide the desired performance. 
         [0035]    It is also possible that attachment features other than mated threads will serve to prevent air from entering the space that cap  13  encloses. For example, the caps that prevent felt tip markers from drying have a simple type of close-fitting detent that is substantially airtight. Note however, that the openings of these caps are typically only ½″ or in diameter. It may be true that such detent-type caps do not scale up effectively to a cap than may be 1-3″ in diameter, if for no other reason than attaching and detaching the cap requires too much strength. 
         [0036]    In another design not currently preferred, the configuration of the threads comprising third annular attachment feature  19  allows their mating with the threads comprising second annular attachment feature  28 . In this case, the threads of second annular attachment feature  28  should extend axially along support  41  to an amount sufficient to allow engagement with third annular attachment feature  19 . 
         [0037]    Typically after application and during use, a wall coating becomes damaged in only a few places. It is a great convenience for a user to simply remove cap  13 , squeeze the flexible walls of container  15  to force a suitable amount of liquid into applicator  20  for application to the damaged spots. 
         [0038]    In the case of latex paint as the coating material, it may be helpful to simply run water over applicator  20  for a few seconds before attaching cap  13 . This removes and dilutes the paint within pad  54  and thereby lengthens the time that the paint remains usable. 
         [0039]    Experience may show that air does not flow freely into container  15  through applicator  20  when releasing pressure on the walls of container  15 . If that is the case, vent hole  49  and closure flap  45  may allow airflow into container  15 . In the example shown, flap  45  is biased to move away from vent hole  49 . The user presses flap  45  against hole  48  when squeezing the container  15  walls to prevent liquid from seeping through hole  48 . Other types of vents such as self-closing vents may be usable as well. 
         [0040]      FIG. 3  shows another embodiment have an alternate applicator support  41 ′ and applicator  36 , and is intended to thread directly into container  15  of  FIG. 1 . Support  41 ′ comprises a hollow tube having threads  28  that will mate with the threads  37  of container  15 . Possibly the support  41 ′ and applicator  36  will be included in a commercial kit that also includes the components of  FIG. 1 . 
         [0041]    Applicator  36  comprises a permeable open cell foam block that fits closely within support  41 ′ and bonds to the interior walls thereof. The sidewall surface  38  of applicator  36  has a coating or layer substantially impervious to passage of coating material. 
         [0042]    The end surface  34  of applicator  36  is preferably substantially flat and rectangular, and tilted with respect to axis  18 . Surface  34  must be permeable for the coating material, to allow coating material to flow to the surface. Surface  34  may have bristles  57  as shown or a permeable fabric surface to assist in applying the coating material to the surface to be coated, and to provide a desired texture of the final wall surface. 
         [0043]    By squeezing the walls of container  15  when applicator support  41 ′ is mounted thereon, coating material is forced through applicator  36  to surface  34 . The coating material on surface  34  can then be applied to a surface as with the device of  FIG. 1 . Sidewall  38  should be impervious to flow of coating material to properly channel coating material to surface  34 . 
         [0044]    If experience shows that insufficient air can flow backwards through a fully saturated foam applicator  36 , a vent arrangement as shown in  FIG. 2  may be necessary to allow replenishing air in container  15 . 
         [0045]    When a particular project is complete, the user attaches cap  13  by mating the threads comprising annular attachment feature  19  and the outside of annular attachment feature  31 . If desired, a user may wish to rinse out applicator  36  partially or completely before attaching cap  13 .