Abstract:
A caulking gun for dispensing caulking material from a standard caulk tube. The gun is fabricated in three basic parts; a trigger assembly, a trigger housing and a barrel cage for holding the tube. The facing portions of the barrel cage and trigger housing is provided with a mating configuration which enables the gun to be easily assembled for use and easily disassembled for storage in a toolbox. A novel drip/no drip feature is provided wherein a cam actuator conveniently positioned on the trigger housing enables an operator to select between no drip operation or drip type operation when caulking material and application requirements warrant such. A thumb release mechanism is provided on the rear of the trigger housing so the operator can release the driving rod for insertion of another tube of caulk when the unit has been placed in the drip position.

Description:
This application is a divisional application of U.S. patent application Ser. No. 10/874,628 to be issued on Jul. 11, 2006 as U.S. Pat. No. 7,073,691 which claims the benefit of U.S. Provisional Application No. 60/491,353, filed Jul. 31, 2003. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The invention relates to hand-held material-dispensing devices such as caulking guns and, more particularly, to a specific type of construction for caulking guns. 
   2. Description of the Related Art 
   Hand-held material dispensing devices are well known in the art and generally rely on the action of a piston to push fluid out of a receptacle toward the application area. The movement of the piston is induced by the advancement of a piston rod in the direction of the receptacle, with the piston rod being advanced in the direction of travel by the operator&#39;s squeezing of a trigger in engagement therewith. 
   One such fluid dispenser is disclosed in U.S. Pat. No. 4,461,407 to Finnegan. The Finnegan patent incorporates an automatic pressure release mechanism such as is typical in many caulking guns of the prior art. 
   In U.S. Pat. No. 4,081,112, issued to Chang, there is disclosed a caulking gun having a forward-biasing spring to urge the trigger back to the cocked position after an application cycle. U.S. Pat. No. 4,033,484, issued to Ornsteen, discloses a hot melt adhesive gun which operates in the conventional manner of the prior art. 
   U.S. Pat. No. 3,069,053, issued to Nilsson and U.S. Pat. No. 3,189,226, issued to Sherbondy, each show a caulking gun with an alternative piston rod-trigger engagement arrangement. In these references, the trigger urges the piston rod toward the fluid receptacle by means by a ratchet mechanism. 
   The above-cited patents are merely examples of the plethora of caulking guns in the prior art. As is clear from these examples, that a standard caulking gun provides an arrangement for receiving and retaining a tube of caulking material. The caulk tube has a pointed nozzle at the forward end for dispensing the caulking material as it is pushed from the other end by a driven back plate. A long pusher rod in the body of the caulking gun serves to drive the caulk tube back plate to extrude the caulking material. A trigger mechanism at the back end of the caulking gun serves to advance the pusher rod when activated by a user. A pusher plate is mounted on the forward end of the pusher rod to distribute the forces from the rod to the back plate at the end of the caulking tube. 
   U.S. Pat. No. 5,887,765, issued to Broesamle, discloses a caulking gun that enables the pressure on the back plate to be eased when an operator is no longer engaging the trigger. Thus, a non-dripping capability is achieved using a mechanism that permits the pusher rod to slide backwards slightly thus stopping further extrusion of the caulking material. However, some types of caulking material for proper application require a continued pressure against the back plate even when the trigger is not being pulled, i.e., the ratchet type of mechanism. 
   Model CG-00122 caulking gun, manufactured by Great American Manufacturing, Inc. of Sun Valley, Calif. 91352, features a ratchet-type caulking gun wherein a user can select either dripless or non-drip operation. The selector switch changes the angle by which a spring biased plate engages one of the plurality of notches that are provided along the piston rod. This achieves the alternative methods of operation. The barrel cage does not rotate but is riveted to the hand grip housing. 
   Model SI 300, manufactured by Dripless, Inc. of Santa Rosa, Calif. 95403, is no drip, drip selectable caulking gun. In this model, a dog is provided on the rear of the hand grip housing. This dog is biased by a compression spring that also is exposed on the rear of the hand grip housing so that the mechanism is potentially vulnerable to damage due to being struck or by due to dirt accumulation. 
   There is not found in the prior art, a caulking gun that can function as either a dripless unit as taught by Broesamle or a drip-type of device as discussed above by merely activating a lever switch on the handle of the caulking gun that selects either a dripless or a standard method of operation and features a rotatable barrel that can be easily removed so that the caulking gun can be more conveniently packed within a tool box. 
   SUMMARY OF THE INVENTION 
   Particular arrangements in accordance with the present invention comprise a caulking gun for the dispensing of caulking material commonly used in construction work and the repair and remodeling of residential and other types of buildings. The caulking material is conventionally provided in cylinders or tubes having a hollow tip from which the caulking material is extruded by the action of a piston or back plate which is advanced from the rear of the tube toward the tip. Because of the length and weight of the caulk tube, it is not uncommon to provide a support member (a “barrel”) extending forward of the handle underneath the caulk tube. Caulking guns are designed to hold such a caulk tube in a receiver housing, often barrel-shaped in the form of a half cylinder, within which there is installed a longitudinally movable rod with a piston member at the forward end of the rod for pushing the caulking material out of the caulk tube. 
   The caulking gun further includes a pistol grip handle secured to the handle housing, a trigger pivotably mounted to the housing so as to cooperate with the handle and a drive mechanism for coupling the trigger to the rod to drive it forward when the trigger is squeezed. There is also a mechanism for uncoupling the trigger from the rod when the trigger is released. Through repeated operation of the trigger, the rod and piston member may be advanced in the direction of the caulk tube tip, thereby providing the means for dispensing the contents of the caulk tube through the forward nozzle. 
   A precision cutter for cutting the tip of a caulk tube is also provided that is activated when the trigger is squeezed. The cutter is accessed by inserting the tip through an opening in the handle to the desired length and angle and then squeezing the trigger so that the tip is cleanly and easily cut with a blade that is inside the handle and attached to the trigger. 
   The caulking gun handle also includes a lever operated cam switch that enables the apparatus to function so that the rod is not uncoupled from the trigger when the trigger is released. 
   Caulking guns of the prior art typically are fabricated so that the elongated barrel is an integral part of the gun; i.e., the barrel and trigger housing or handle are fabricated together in a single unit. This makes for a rather cumbersome tool, difficult to fit into a toolbox with other tools and prone to be bent or distorted from contact with other tools in the toolbox. 
   The invention features a caulking gun that is provided with a thumb activatable cam lever that engages or disengages a dog mechanism so that a dripless condition or a standard operation condition can be selected. Further, an extra long clean out rod is provided on the handle top. The grip is ergonomically shaped having an integral soft overmolded cushion to prevent operator fatigue. The invention also features a detachable barrel which can be readily removed from the handle at the end of the job and stowed in a toolbox or other carrying device. The barrel can also be easily and quickly reassembled when needed for use. 
   In brief, particular arrangements of the present invention include two main parts which can be easily secured together or taken apart. When assembled, the connection between the long barrel portion and the handgrip portion is firmly and rigidly established. Yet the structural configuration of the connection joint is such that the two components can be easily and quickly separated from each other, and just as easily and quickly joined together again. To that end, each of the two components is provided with a flat planar surface at the end facing the other component. Thus, the forward end of the handgrip portion comprises a round flat base. Projecting from the forward face of this base is a round flat disk joined to the base by a portion of reduced diameter relative to the flat disk. The disk and the base are spatially separated by the reduced diameter portion. This configuration establishes a circumferential slot which defines a circumferential lip around the disk. 
   The rearward end of the caulking gun barrel is shaped in a configuration which mates with the forward end of the handgrip portion. To this end, the rearward portion of the barrel is shaped with a circumferential, inwardly projecting lip extending approximately 180.degree. about the center opening in a U-shaped configuration. This U-shaped lip engages the outwardly projecting lip of the handgrip portion by receiving the flat round disk in an interlocking configuration until the two components are fully engaged. The lip on the barrel slides over the lip on the handgrip portion and is locked in place with the insertion of the push rod. This makes for easy assembly without requiring additional hardware and allows the barrel to be rotated relative to the handgrip portion. The friction feel of the rotation is accomplished by using different material hardness for the handgrip portion and the barrel. For example, in one preferred embodiment, the lip and flat attachment member of the handgrip portion is fabricated of fiber reinforced nylon, whereas the lip and adjacent surface of the barrel portion is made of polypropylene or polyethylene. Assembly of the gun is completed by placing a pusher plate on the forward end of the push rod end securing it in place with a nut threaded onto the end of the push rod. The caulking gun may then be operated in a conventional manner, with repetitive squeezes of the trigger mechanism ratcheting the push rod forward to cause material to be extruded from the caulk tube. This construction advantageously permits the barrel and caulk tube to be rotated as desired, relative to the handgrip portion, for better placement of the nozzle when extruding caulking material. 
   The handgrip portion itself is formed with a number of features which constitute improvements over prior art caulking guns. A thumb operable lever is positioned on the top side of the handle so that a drip/no drip position can be easily selected. Positioned entirely within the handle top portion at the rear is a compression spring loaded silicon washer which enables the no drip operation. In the middle section of the handle interior is a cam actuator which is operates a thumb releasable dog switch which serves to provide the drip/no drip conditions. A leaf spring is used to urge the dog against the cam actuator. By using the leaf spring, the mechanism is able to be fitted into a smaller compartment that would be experienced if a compression type of spring had been utilized. The top of the handgrip portion is provided with a narrow, pivoted rod for piercing the nozzle of a caulk tube. The rod is adapted to be moved to a position in line with the adjacent handgrip portion. A retainer element projecting from the handgrip portion is provided to stow the rod. Rearward of that is an L-shaped projecting guard member which receives the rod when stowed and protects the user&#39;s hand from being pierced by the rod. 
   The handgrip itself is coated, at least in part, with a cushioning layer to ease the stress on the user&#39;s hand from repetitive squeezing of the trigger of the handgrip. This cushioning layer may be of any resilient material, such as foam or sponge rubber, foam polyurethane, or the like. Near the top of this cushioning layer is a molded projection of generally U-shape which extends around the back of the handgrip. This helps the handgrip to seat in the user&#39;s hand by stopping the hand as it is moved upward along the handgrip to a working position. 
   The trigger member is shaped with three finger-receiving portions extending downwardly from the upper end of the trigger. The first two are shaped to fit the first and second fingers of the average user; the third one which is near the tip of the trigger is shaped to accommodate two fingers, the third and fourth fingers on the hand of the user. This provides a substantially more comfortable handgrip, better accommodated to the user&#39;s hand. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A better understanding of the present invention may be realized from a consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which: 
       FIG. 1  is a schematic perspective review, taken from the left rear quarter, of one particular arrangement of a caulking gun in accordance with the present invention; 
       FIG. 2  is an exploded view of the caulking gun of  FIG. 1  showing only the takedown barrel feature; 
       FIG. 3  is a schematic top view of the caulking gun of  FIG. 1 ; 
       FIG. 4A  is a side sectional view of the caulking gun of  FIG. 1 , taken along the line  4 - 4  of  FIG. 3 ; 
       FIG. 4B  is an enlarged view of the section identified in  FIG. 4A ; 
       FIG. 5  is a perspective view of the handgrip portion of the caulking gun of  FIG. 1  showing the rod  40  in position for use; 
       FIG. 6  is a side elevational view of the handgrip portion of  FIG. 5 , taken from the right-hand side thereof; 
       FIG. 7  is a perspective view of the barrel portion of the caulking gun of  FIG. 1 , disassembled from the handgrip portion; and 
       FIG. 8  is a schematic elevational view of the barrel portion of  FIG. 7 , taken from the left-hand side thereof. 
       FIG. 9  is a perspective view of the drip switch dog. 
       FIG. 10  is a perspective view of the leaf spring. 
       FIG. 11  is a perspective view of the cam lever assembly. 
       FIG. 12  is a top view of the precision cutter. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   As shown in the drawings and with particular reference to  FIG. 1 , a preferred embodiment  10  is shown comprising a barrel-shaped tube housing  12  and a handgrip portion or trigger housing  14 . The barrel-shaped tube housing  12  is cut away along the side walls  22  to provide easy access for inserting a caulk tube into the tube housing. The elements  22  are reinforcing ribs which are mounted lengthwise along the outside of the tube housing  12  to add stiffness and support for the tube housing, particularly for the edge portions of the half-cylinder. Another pair of reinforcing ribs below the elements designated  22  provide reinforcement for the tube housing at the location of the lower central cutout shown in  FIG. 7 . 
   Also shown in  FIG. 7  (as well as in  FIG. 2 ) are a pair of triangular sections  27  which are placed at the forward end of the tube housing  12  to provide reinforcement for the forward wall  25  where it attaches to the tube housing. 
   Passing through these two housings is a piston rod  16 . Although the piston rod  16  is shown as installed in the trigger housing  14 , it can be withdrawn out the rearward end of the housing  14  for complete removal. With the piston rod removed, the two portions can be easily disassembled. When the caulk gun is completely assembled, the piston rod  16  passes through central holes  20 A and  20 B in the barrel-shaped tube portion and the handgrip portion, respectively. Also shown in  FIG. 2 , push plate  24  and a retaining nut  26  for mounting on the threaded forward end  28  of the piston rod  16 . 
   Positioned within the seamless box design trigger housing  14  in middle section  66  is the drip/no drip selection mechanism  60  which is described in detail below. Lever arm  90  (shown in  FIG. 11 ) enables mechanism  60  to be moved to drip position  62  or to no drip position  64  as indicated by the indicia provided on trigger housing  14 . Thumb release portion  68  which extends downwardly from trigger housing  14  enables an operator to easily release rod  16  so that it can be withdrawn rearward. 
     FIGS. 2 ,  5  and  6  are views of the handgrip portion  14  with the dripless/no drip mechanism  60  removed for clarity. Both show the round flat base surface  30  and the attached lip  32  displaced by a circumferential slot  34 . Also shown is a trigger  36  pivotably mounted in the handgrip housing  14  and forming, with the downwardly extending portion  38 , a handgrip for the housing  14 . A thin rod  40  is shown extending vertically from the mounting member  42 . The rod  40  is provided for puncturing the nozzle of a caulk tube or for cleaning the opening in the caulk tube once it has been punctured. Rod  40  is stowed by rotation about the pivot member  42  to a retainer member  41  extending along the side of the housing  14 . 
   Near the rearward end of the housing  14  is an L-shaped projection  43  into which the end of the rod  40  fits when it is stowed into the retainer member  41 . The projection  43  is a guard which protects a user&#39;s hand from being jabbed by the end of the rod  40  as the caulking gun is used. 
   Also shown in  FIGS. 5 and 6  is a cushioning layer  37  along the back of the downwardly extending portion  38 . This layer  37  is affixed to portion  38  as, for example, by fusing in the molding process and it has an outwardly projecting U-shaped stop portion  39 . Both the layer  37  and projection  39  are molded together, and extend around the back and along both sides of the portion  38 . The projecting U-shaped member  39  helps to locate the caulk gun in the hand of a user, since the gripping portion of the hand rides directly up to the U-shaped projection  39 . 
   Along the length of the trigger  36  are a series of finger grooves  35 A and  35 B. These are shaped to fit the user&#39;s fingers; the two upper grooves  35 A are shaped to receive the first and second fingers of the user&#39;s hand. The lowest indentation  35 B is longer in order that it will accommodate the third and fourth fingers of the user&#39;s hand. This configuration provides for a very comfortable, natural gripping tool which, by virtue of its shape, enables the user to hold the handgrip portion in his hand, with less likelihood that the handgrip will slip from its natural position. 
     FIGS. 7 and 8  are views of the barrel. A U-shaped opening  23  in the forward wall  25  of the barrel  12  is provided to permit the nozzle of the caulk tube to extend forward from the barrel. The rearward end of the barrel  12  is formed with a planar face  50  which has an inner cavity  52  having radially inwardly projecting edges  54  formed in an inverted U-shape defining an inner lip suitable for engaging the outwardly extending lip  32  of the handgrip portion  14 . The edges  54  form a circular groove extending halfway around the central opening  20 A. 
     FIG. 8  is an enlarged view of the barrel portion  12  as depicted in  FIG. 4 . The edges  54  of the cavity  52  are displaced from the inner termination of the cavity  52  by a semi-circular slot separating the edges  54  from the forward surface  56  and form an inwardly directed lip positioned to engage the lip  32 . 
   The barrel  12  is shaped to form a central trough  21  to hold a caulk tube. The barrel  12  is open above the trough  21  to permit the ready insertion of the caulk tube. When in place, the caulk tube projects into the recess  55  at the rear of the barrel  12 . 
   The barrel  12  of the present invention constitutes a significant improvement over the prior art by the formation of two mating parts of the gun which are capable of ready assembly or disassembly when setting up for use or for storage in a toolbox. The connecting members between the two parts of the caulking gun have a particular configuration which establishes a strong, rigid connection as needed for the support of the caulk tube when in use. 
   Barrel  12  can be configured as sized to hold standard caulking tubes or the larger one quart size by merely adjusting the dimensions of the barrel cage  12  accordingly. 
   Referring now to  FIGS. 4A ,  4 B,  9 ,  10 ,  11 , the dripless/no drip mechanism  60  of invention  10  is shown. The dripless mechanism functions similarly to that disclosed in U.S. Pat. No. 5,887,765, incorporated herein by reference. Drive dog  74  which is biased by compression spring  76  causes rod  16  to advance when the trigger  36  is pulled, thus causing caulk (not shown) to be extruded. Silicon washer grip  72  provides a forward biasing for rod  16 . This mechanism, by action of gripping force of grip  72  and resilient force of spring  78  biases rod  16  in the forward direction, preventing rod  16  from moving back more than is required to relieve the pressure in the caulk tube when trigger  36  is released. The friction grip can be overcome by pulling rod  16  rearward so that a new tube of caulking material can be inserted. 
   The no drip mechanism has three major components: cam lever actuator  61 , drip switch dog  70  and leaf spring  80 . When cam lever actuator  61  is turned toward no drip position  64 , invention  10  operates as explained above. However, when cam lever actuator  61  is moved toward drip position  62 , the “drip feature” is provided. Leaf spring  80  is urged against drip switch dog  70 . Rod  16  passes through opening  92  which has sharp edges. Preferably dog  70  has a bright zinc coat finish. When in the no drip position, cam  74  causes dog  70  to be substantially perpendicular to rod  16  so that rod  16  can pass through hole  92  unobstructed. When in the drip position, cam  74  is as shown in  FIG. 4B  such that the edge of opening  92  engages rod  16  and prevents rod  16  from moving backward thus keeping in the caulk tube even when trigger  36  is released. To release cam  74 , an operator merely pushes on thumb release  68  of dog  70 . Dog  70  is fitted into slots  71  and biased with leaf spring  80  via rivets through openings  84  in dog  70  and openings  82  in leaf spring  80 . As shown, the entire drip/no drip mechanism  60  is housed within middle section  66 . The use of leaf spring  80  rather than a compression spring such as spring  78  and  76  reduces the amount of space required to house this structure. 
   As shown in  FIG. 12 , precision cutter  102  is provided to cut off the tip  100  of a caulking tube (not shown). Cutter  102  is attached to trigger assembly  36  so that pulling the trigger causes cutter  102  to slide forward, thus cutting off the tip  100  that has been inserted through opening  99  in the trigger housing  14 . 
   While certain representative embodiments of the invention have been described herein for the purposes of illustration, it will be apparent to those skilled in the art that modification therein may be made without departure from the spirit and scope of the invention.