Abstract:
A tool for applying grout into a recess between adjacent tile surfaces comprises a body for gripping by the user formed with an elongate, resilient channel member adapted for retaining a line of grout and delivering the grout directly into the recess by aligning and pressing of the channel member over the recess. A finishing portion can be formed on the same body or a separate body for compressing and shaping the grout after delivery into the recess. The tool of the present invention avoids wasting of grout and increases the speed of application without sacrificing the appearance or integrity of the grout joint.

Description:
FIELD OF THE INVENTION  
         [0001]    This invention relates to tools for applying grout between tiles.  
         BACKGROUND OF THE INVENTION  
         [0002]    Grout is an initially fluid mortar material that is used to fill in the gaps between tiles mounted on an underlying surface. After application in a mouldable state, the grout hardens into a durable, protective and decorative layer between the tiles.  
           [0003]    The application of grout between tiles has traditionally been done by applying the grout atop the tiles to be finished and then using a spreading tool such as a trowel to spread the grout in a thin layer over the tiles with the result that grout is deposited in the gaps or recesses between the tiles. The excess grout is then scraped or sponged from the tiles to expose the tile surface. Subsequently, the grout in the recesses is preferably compressed and shaped to form a smooth grouting joint between adjacent tiles. Finishing a tile surface is therefore a labour intensive job that is time consuming and tends to result in wasted excess grout material.  
         SUMMARY OF THE INVENTION  
         [0004]    The present invention is directed to a grout application tool that delivers the grout directly to the recess between the tiles to avoid the need for a trowel tool and scraping of the grout over tile surfaces. The present invention also provides a finishing portion for compressing and shaping the grout to create a smooth and strong grout joint.  
           [0005]    Accordingly, the present invention provides a tool for delivering grout into a recess between adjacent tile surfaces comprising:  
           [0006]    a body for gripping by the user;  
           [0007]    an elongate, resilient channel member on the body adapted for retaining a line of grout and delivering the grout into the recess by aligning and pressing of the channel member over the recess.  
           [0008]    The present invention also provides a tool for compressing and shaping grout within a recess comprising:  
           [0009]    a body;  
           [0010]    a compressing member extending from the body to compress and shape the grout in the recess; and  
           [0011]    a scraping portion mounted to the body to channel grout into the recess and remove excess grout.  
           [0012]    In a further aspect, the present invention provides a combined tool for applying grout into a recess between adjacent tile surfaces comprising:  
           [0013]    a body for gripping by the user;  
           [0014]    an elongate, resilient channel member on the body adapted for retaining a line of grout and delivering the grout into the recess by aligning and pressing of the channel member over the recess; and  
           [0015]    a finishing portion on the body for compressing and shaping the grout after delivery into the recess.  
           [0016]    The tools of the present invention avoids wasting of grout and increase the speed of application without sacrificing the appearance or integrity of the grout joint.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]    Aspects of the present invention are illustrated, merely by way of example, in the accompanying drawings in which:  
         [0018]    [0018]FIG. 1 is a side elevation view of the grout applying tool of the present invention according to a first embodiment;  
         [0019]    [0019]FIG. 2 is a side view of the resilient channel member for applying grout that is removably mountable to the body of the tool;  
         [0020]    [0020]FIG. 3 is a longitudinal cross-section through the resilient channel member showing a preferred band mounting system;  
         [0021]    [0021]FIG. 4 is a transverse cross-section taken along line  4 - 4  of FIG. 3 showing the U-shaped channel and the ridges of the channel member;  
         [0022]    [0022]FIG. 5 is a detail view of the indicated portion of FIG. 3 showing the band mounting system of the channel member is section;  
         [0023]    [0023]FIG. 6 is a detail view of the indicated portion of FIG. 1 showing the resilient channel member in section mounted to the body of the tool;  
         [0024]    [0024]FIG. 7 is a detail view of the indicated portion of FIG. 1 taken along line  7 - 7  of FIG. 8 showing the finishing portion of the tool in partial section;  
         [0025]    [0025]FIG. 8 is a front elevation of the finishing portion of the tool with the resilient member installed;  
         [0026]    [0026]FIG. 9 shows the resilient member of the finishing portion dismounted from the body of the tool;  
         [0027]    [0027]FIG. 10 shows the tool of the present invention oriented to compress and finish a grout line;  
         [0028]    [0028]FIG. 11 is a cross-sectional view through a recess between two tiles showing the grout after application by the resilient member;  
         [0029]    [0029]FIG. 12 is a cross-section view through a recess between two tiles showing the grout after compressing and shaping by the finishing portion;  
         [0030]    [0030]FIG. 13 is a side elevation view of the tool according to a second embodiment that includes only the channel member; and  
         [0031]    [0031]FIG. 14 is a side elevation view of the tool according to a third embodiment that includes only the finishing portion. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0032]    Referring to FIG. 1, there is shown a tool  2  for applying grout according to a preferred embodiment of the present invention. The preferred embodiment provides a grout applying portion and a grout compressing and shaping portion formed on a single grip or handle. It will be apparent that the portions can be formed on separate grips or handles.  
         [0033]    The tool is used to apply grout into the gaps or recesses  4  between adjacent pairs of tiles  6  that are already mounted to an underlying surface  8  by tile adhesive  10 . In FIG. 1, tool  2  is aligned over a recess  4  that extends parallel to the plane of the drawing sheet. The other labelled recesses are transverse recesses that extend out of the plane of the sheet.  
         [0034]    The tool includes a body  12  adapted for gripping by the hand of a user along a gripping edge  14 . Body  12  is preferably a rigid planar sheet of material such a plastic with gripping edge  14  being formed with an angle  17 . Edge  14  is also preferably formed with a generally T shaped cross-section. Opening  18  provides a resting place to comfortably locate the user&#39;s thumb below and generally parallel to edge  14  on one side of body  12  while openings  20   a  and  20   b  locate the fingers of the handle on the opposite side of the body with the palm of the hand resting atop surface  16  of the T-shaped cross-section.  
         [0035]    At the working edge  25  of body  12 , there is provided an elongate, resilient channel member  30  adapted for retaining a line of grout and delivering the grout into the recess by the user aligning and pressing the channel member over a recess  4  between tiles  6 . Channel member  30  is preferably releasably mountable to body  12  to permit removal for cleaning and replacement.  
         [0036]    A finishing portion  60  is also formed on body  12  spaced apart from channel member  30 . Finishing portion  60  acts to compress and shape the grout after delivery into recess  4 . Preferably, finishing portion  60  is formed on body  12  such that the finishing portion is positioned for use immediately after the channel member delivers grout to the recess as will explained in more detail below.  
         [0037]    Referring to FIGS.  2 - 6 , channel member  30  preferably comprises a resilient, elongate member to define a channel to receive grout. A preferred material for the channel member  30  is synthetic rubber. As best shown in FIG. 4, which is a transverse cross-section to the longitudinal axis of the channel member  30 , a pair of spaced side walls  32  define an elongate, generally U-shaped cavity  34  which faces away from body  12 . Preferably, working edge  25  of body  12  is formed with an arcuate surface which deforms channel member  30  over its length into a corresponding arcuate configuration when mounted to the body. The arcuate shape of channel member  30  allows the user to place a first end of the member over a recess to be filled and gently pivot or rock the body forward in the direction indicated by arrow  36  in FIG. 1 to deposit grout from cavity  34  into recess  4  between the tiles. The user also applies a constant, gentle downward pressure during the rocking motion which acts to seal side walls  32  to the tile surface and deform the side walls slightly to release the grout stored therebetween. The arcuate configuration and resulting motion are desirable to ensure that grout within cavity  34  is readily expelled from the channel into the recess. The downward movement of the channel dislodges the grout from the channel so that the tendency of the grout to stick within the channel is minimized.  
         [0038]    To further assist expulsion of the grout from cavity  34 , the internal surface of the cavity is preferably formed to be adapted to release the line of grout when compressed over the recess. As best shown in FIG. 3 which is a section view through channel member  30  along its longitudinal axis, the internal surface of cavity  34  is preferably formed with a plurality of spaced, transverse ribs  38  along the length of the channel member. These ribs introduce discontinuities into the surface of cavity  34  so that any tendency of the grout material is stick to the surface and remain in the cavity is minimized.  
         [0039]    Channel member  30  can also have a planar linear configuration as illustrated in FIG. 2 when attached to a tool body  12  having a linear working edge  25 .  
         [0040]    In the illustrated embodiment, channel member  30  is removably mounted to tool body  12  by an elastic band-like mounting arrangement. It will be apparent to a person skilled in the art that alternative mounting schemes are possible such as permanently fastening the channel member  30  to the tool body by gluing, stapling or the like or by releasably mounting using clamping, however, the below-described mounting scheme is preferred based on its simplicity, reliability and ease of operation.  
         [0041]    The illustrated mounting arrangement for channel member  30  involves forming channel member  30  with an upper closed loop or band  40  adapted to be stretched over at least two anchor points  42  formed on the working edge  25  of body  12 . Band  40  extends upwardly from the roof  41  of cavity  34  and is joined to the roof  41  except at the ends of the band where an opening  44  is formed to receive anchor points  42 . FIG. 5 is a detail section view of an end of channel member  30  prior to installation on body  2 . As best shown in FIG. 6, projection  42  comprises a short flange extending forwardly or rearwardly for working edge  25 . To install channel member  30  on body  12 , projection  42  is inserted through the interior of band and through opening  44  at one end of the band into the position shown in FIG. 6. Band  40  is thereby wrapped about face  46  of body  12  and roof  41  of cavity  34  abuts against working edge  25 . The other end of band  40  is then stretched to insert the other projection  42  through opening  44  at the other end of the channel member to releasably couple the channel member to the body. Resilient channel member  30  is mounted adjacent arcuate working edge  25  surface which imparts an arcuate shape to the channel member over its length.  
         [0042]    In use, the body  12  is initially inverted to allow a user to place a line of flowable grout from a grout supply within channel  34 . The tool is then placed over a recess  4  with grout filled channel  34  facing downwardly as shown in FIG. 1. Referring to FIG. 11, channel member  30  is positioned such that the channel side walls  32  straddle the recess and abut against the upper surfaces of the adjacent tiles  6  whose edges define the recess. The grout will tend to remain in channel  34  until the user applies gentle pressure against the tile surfaces to deform channel side walls  32  outwardly slightly to release the grout into recess  4 . In the case of a channel member that is formed into an arcuate configuration, the user also pivots or rocks the tool about the arcuate channel member  30  as pressure is applied. After the grout is released into recess  4 , it will tend to assume the domed shape  49  shown in FIG. 11 which is a cross-section taken through the recess. Note that the applied grout is essentially confined to the recess and is not spread over the upper surfaces of the tile as in conventional grout applying techniques.  
         [0043]    FIGS.  7 - 9  show the finishing portion  60  of the tool of the present invention for compressing and shaping the grout  49  just applied to recess  4 . FIG. 7 is a detail view of the indicated portion of FIG. 1 and FIG. 8 is a front elevation view of the finishing portion. Finishing portion  60  includes a compressing member  62  adapted to be inserted into recess  4  to compress and shape the grout in the recess and a scraping portion  64  to channel grout into the recess and remove excess grout.  
         [0044]    Compressing member  62  is preferably in the form of a projecting post extending from body  12  having a distal end surface  66  to engage the grout on dragging of the finishing portion along the freshly deposited line of grout. Distal surface  66  is preferably angled to present a profile that decreases in thickness in the direction of movement of the finishing portion  60 . Surface  66  is also generally convex in cross-section in a plane transverse to the direction of movement to impart a concave shape to the grout in the recess.  
         [0045]    Surrounding distal end surface  66  is a resilient, generally triangular member  67  extending between a flat base  67   a  and a rounded apex  67   b  that defines scraping portion  64 . Triangular member  67  includes a face  69  adapted to engage and scrape across the upper surfaces of the tiles adjacent recess  4 . Face  69  is preferably formed with a pattern of angled ridges  68  symmetric about centre line  71  that act to direct grout on the upper tile surface toward recess  4  as the face is dragged over the tile surfaces along a recess. The base  67   a  of triangular member  67  is formed with a generally V-shaped passage  70  which also acts to collect and direct grout into the recess.  
         [0046]    At least one opening extends through face  69  to receive excess grout and direct the grout away from the resilient surface. In the illustrated embodiment, a first opening  73  communicates with V-shaped passage  70  and a second opening  74  is formed adjacent the apex  67   b.  Second opening  74  is positioned to receive and retain compressing and shaping member  62  when the triangular member is mounted in place on body  12 . Second opening  74  provides a passage through which the compressing and shaping member protrudes to engage the grout.  
         [0047]    Triangular member  67  is preferably removably mounted to body  12  for ease of cleaning and replacement. FIG. 9 shows triangular member  67  dismounted from body  12 . Referring to FIG. 7, body  12  is formed with an upper bracket  80  and a lower bracket to retain triangular member  67  on the body. Bracket  90  is inserted through opening  73  to engage against lower strip  82  extending between the side walls of V-shaped passage  70  adjacent base  67   a.  Bracket  80  and projection  62  are inserted through opening  74  to retain the apex  67   b  of triangular member  67  in place. Compressing and shaping surface  66  is positioned to extend below the plane of scraping face  69 .  
         [0048]    [0048]FIG. 10 shows the manner in which finishing portion  60  is used. After channel member  30  is positioned over a recess between tiles and pressed and pivoted to deliver grout into the recess, finishing portion  60  is automatically oriented for use. Surface  69  is pressed onto the tiles surfaces such that projecting compressing and shaping surface  66  extends into recess  4 . The tool is then pulled toward the user in a smooth stroke in the direction of arrow  95  in FIG. 10. V-shaped channel  70  and ridges  68  on surface  69  act to collect and direct any excess grout on the surface of the tiles into recess  4  for compression and shaping by protruding surface  66 . Any excess grout is directed through openings  73  and  74  as indicated by arrows  98  and  99 . The small amount of excess grout that collects is cleaned from the body preferably after each stroke of the tool. FIG. 12 illustrated the finished appearance of grout  49  after compressing and shaping by finishing portion  60 .  
         [0049]    The tool of the present invention has been illustrated in FIGS.  1 - 10  as having both a grout applying portion and a grout compressing and finishing portion attached to a single body or handle, however, the portions can be formed on separate bodies and used independently. FIG. 13 illustrates a second embodiment of the invention in the form of a grout applying tool that includes the previously described channel member  30 . FIG. 14 illustrates a third embodiment which is useful as a grout compressing and finishing tool that includes the finishing portion  60  described above.  
         [0050]    Although the present invention has been described in some detail by way of example for purposes of clarity and understanding, it will be apparent that certain changes and modifications may be practised within the scope of the appended claims.