Patent Publication Number: US-8108966-B1

Title: Vacuum acoustic ceiling removal system

Description:
BACKGROUND OF THE INVENTION 
     This is a regular patent application that is being timely filed within the time period allotted from a Provisional Application Entitled Vacuum Acoustic Ceiling Removal System as filed on Jul. 10, 2007 having the same inventor as hereof and awarded Ser. No. 60/959,112. VACRS™ stands for Vacuum Acoustic Ceiling Removal System. As noted in the provisional application, this is an adopted Trademark designated for the blade and hopper portion of the system. The handle, being capable of supporting more than one ceiling treatment tool, has been named a Hi Pro Tool as an adopted trademark soon to be seen on Applicant&#39;s hiprotool.com web site. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to a ceiling treatment tool that is primarily useful for modernizing your home/office. Both a tool apparatus and a method of tool use for removing “popcorn” or “cottage cheese” from ceilings are presented. More specifically, the field of this invention relates to a vacuum assisted ceiling scraper system that will more readily and safely remove what is today called a “dreaded” acoustic ceiling covering. Additionally, the field of this invention relates to a hand held vacuum assisted ceiling tool for acoustic ceiling removal that greatly eases the tasks and does so with increased safety and convenience in comparison to manual ladder and hand held scraping trowels of the prior art. 
     Explanation of Terms. 
     Set out below are brief descriptions of certain relevant terms which further the understanding of the invention. These terms provide a basis for a detailed teaching of the improvements of this invention in the relevant arts. Such terms are not intended to replace the claims but rather serve as helpful guides in understanding my novel improvement in this art. 
     Acoustic Ceiling Covering. 
     According to the National Association of Home Builders, acoustic ceilings were the latest things in the 1950s and then inevitably fell out of favor. Whether it was originally featured as a noise deterrent or as a way of concealing imperfections in a large ceiling expanse, the “popcorn” look was at one time the “in” thing to do. Today it is hopelessly outmoded and is a sure sign of a dated appearance. With today&#39;s modern look to decorating, such ceilings simply have to be removed to give a home or office a more modern appearance. Like and old bath or old kitchen, the “popcorn” look simply has to go for modernization purposes. Removing such acoustic ceiling coverings, however, is not an easy thing at all. While working at floor level has gravity as an aid, ceiling work turns all that upside down and presents many unique challenges. 
     Asbestos Binder Material. 
     One of the first things that must be done in acoustic ceiling removal is to determine if the acoustic material includes asbestos. If the structure was built before 1979 the chances are pretty good that the ceiling binder used was an asbestos material. Even into the 1980s, and later on, the ceiling material may still be asbestos, since such ceilings were exempt from the 1979 ban on the use of asbestos. Testing laboratories are available for testing samples removed from the ceiling for the presence of asbestos. If asbestos is present, the principles of this invention may still be of great assistance when attached to a HEPPA™ Vacuum System. 
     Nevertheless, professional advice should be employed since asbestos removal involves special filter respirators, disposable protective clothing and special containment bags for holding all the debris that is removed. While not suggesting any violation of the asbestos prohibition laws, this invention is deemed of great assistance because of the ease and safety for treating ceilings as provided by the invention. 
     Scraper Blade &amp; Collection. 
     A scraper blade assembly is built into—or fastened onto—a hopper mounted at the upper end of a uniquely curved handle that is supported by the user and used to scrape acoustic material from a ceiling being treated. A scraper blade and collector is one of several ceiling tools that may be attached at the forward end of the unique supporting handle of this invention. In my invention, the handle—at its end nearest the user—includes a curved cantilever arm rest and an ergonomic handle grip. A curved concave surface at the handle end is shaped in such a manner that it conforms to the underarm part of a user&#39;s forearm above the elbow. That handle end further includes a handle grip which provides both a firm grip and a forearm arm support for the scraper tool. A user may then apply both an upward and transverse scraping force for removal of popcorn from an overhead ceiling. 
     Two Arm Force. 
     The handle of the invention provides—in addition to the forearm support end—a side handle grip that allows the user to exert force by one hand, while the forearm support/pistol grip area allows the user to provide additional force by the other hand to the scraper unit. A double bend portion—about forty-five degrees up and then forty five degrees down—is provided at about the mid point of the handle. That double bend provides an upward offset for the handle. Such an offset, together with the handle attachment/design, allows a joint two arms back and forward force to be exerted along the longitudinal length of the unit. A source of vacuum is connected by a length of lightweight vacuum hose to the scraper trough. “Popcorn” from a ceiling may thus be removed and contained in an easy and efficient manner by using this invention. 
     Tool Adjustability. 
     Additional features for the ceiling tool includes a means for adjusting either the blade per se or the entire collector tray, or trough, as they contact the ceiling for scraping. In the case of the blade it may be flexible and may be seated in any one of several adjustment slots for fine adjustments that allow small variations in the angle of attack by the blade against the ceiling. Additionally, adjustable skid plates mounted on the collector tray itself do several things. They immediately position the unit at the preferred angle when lifted aloft and placed against the ceiling. Being adjustable in a simple manner, such plates allow the user to further trim the angle of attack for the tray unit itself by a simple adjustment to the skid plate position. The forward part of the handle telescopes for height adjustments during tool use. 
     Additional VACRS™ Capabilities. 
     VACR is basically a multifunctional ceiling tool which provides a multitude of uses and structural variety, all of which readily stem from its basic novelty. For example, in acoustic ceiling removal, as explained more herein, it is often better to moisten and then let a mist of moisture “set” on the acoustic covering before scraping and collection. Such misting may readily be achieved by a set of water spraying tips positioned at the upper end of the handle of the invention. Additionally, the ceiling treatment may involve some power attachments that also are readily within the scope of the novel concepts disclosed and claimed herein. 
     Thus, electrical, cordless battery, lithium Ion, air or water supply connections to the tip of the handle may be utilized to energize any suitable power driven attachments. Such attachments may include, for example, a window brush, scrub and squeegee, sand blasting, power washing, paint roller and sleeve, ceiling tape and/or paper dispenser and similar such attachments. The novel configuration of the unique two-arm force handle for the invention allows a diverse type of uses and structural attachments to be achieved. 
     BACKGROUND OF THE INVENTION 
     Residential and business customers today are very design conscience about their home and office surroundings. Often they want the interior of their homes/offices to be modernized with the latest and sleek looking fashion trends. For some time now, a common practice is to modernize homes that contain what was once considered a trendy feature. Namely, acoustic ceilings. 
     It is known in the building trades to coat an exposed layer of sheetrock or stucco lattice in a ceiling with a base coat, and then spray on that coating a mixture of acoustic material that has a binding agent mixed therewith. It has often been referred to as a “popcorn” or “cottage cheese” ceiling, since the outward appearance resembles a bumpy layer of popped corn. For some time now, almost every redesign involves removing the popcorn—or acoustic ceiling—so that stucco, paint, or glazes in any number of shades and tones may be used to present a more up to date ceiling treatment. 
     Acoustic ceiling removal is a messy and potentially hazardous endeavor. It is labor intensive, mostly involving a trowel-like scraper, broom, plastic drop cloths, ladder, sand paper and dust pan and vacuuming equipment. If one uses a misting agent such as water to first soften the popcorn, such an approach may create a glue-like mixture that soon covers the work place and gets all over everything—including hand implements in use. Removal attempts on a dry basis are even a more potentially stringent problem because of the dust, dirt and debris that is created in the air. Some acoustic material may be mixed with asbestos. Breathing such a foul dust, dirt and debris mixture is not healthy, to say the least. 
     Moreover, this manual prior art approach is also time consuming, very costly and creates health hazards as mentioned above. Estimates for a 15 foot by 20 foot room run about $3,000.00 to $5,000.00 for the labor-intensive ceiling removal work when asbestos is involved. Additionally, it often becomes necessary to attempt to seal off the other rooms in the residence or office to minimize the disruption to the use of the rest of the office/home. Unless one wears some form of a mask and breathing apparatus, there is very little protection from the dust and dirt mixture in the air. All of these factors bring the safety and level of skill of the workers into play. 
     In short summary, acoustic ceiling removal is a drawn out, dangerous and costly affair. A better way is required, and that better way is presented by this invention which for the first time discloses a new and an improved method and apparatus for acoustic ceiling removal. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         FIG. 1  includes  FIG. 1A .  FIG. 1  is a perspective view of the combination arm and hand supported scraper and collection unit  150  for my VACRS™ approach, and  FIG. 1A  shows an enlarged view of the blade and skid plates for the hopper; 
         FIG. 2  is a front view of my material collector  107  and vacuum funnel head  195  and includes an enlargement  FIG. 2A  which depicts a variable adjustment and “set” for blade  100 ; 
         FIG. 3  is a simplified stick view of a ceiling  102  and the removal unit  150  and shows in very simplified form the angle of attack HFA for the handle  140  and the scraper and collector  110  as used during acoustic ceiling removal; 
         FIG. 4  includes  FIG. 4A .  FIG. 4  is a side view of the tray/collector  110 , shroud  195  and blade  100  in place during a ceiling scraping action, and 
         FIG. 4A  is an enlarged side view showing the blade during a scraping operation; and 
         FIG. 5  includes  FIG. 5A .  FIG. 5  is another perspective view that better shows the telescoping feature of the upper section of the handle  140  of  FIG. 1 , and the transparent material collector shroud  195  in more detail. 
         FIG. 5A  is an enlarged view of the forward slanted handle and arm rest of the handle for my tool invention. 
     
    
    
     SUMMARY OF THE PRESENT INVENTION 
     A ceiling scraper unit attached to an elongated handle allows a user to reach aloft and scrape acoustic “popcorn” ceiling material from an acoustic ceiling, and contain same via a tray-shaped trough, or hopper, which is connected at the forward end of said handle. The hopper has a scraper blade across a top front upper leading edge. The tray-shaped trough includes a vacuum opening in a lower rearward portion for a vacuum suction to be applied to the interior of said hopper for removal of debris scraped from a ceiling by said blade. The tool&#39;s handle includes a cantilever arm rest attachment at the lowest end of the elongated handle which allows a user to apply a two arm ceiling scraping force at said blade location. 
     The unit includes a concave upper surface at the handle end nearest the user which concave surface is shaped to conform to an underarm area; and located just forward of that concave area, the handle includes a pistol-like grip and a double bend upward offset in the handle. A transparent shroud covers the base of said collector, which transparency allows the user to see and guide the scraper blade during a ceiling scraping maneuver. Proper scraping of a ceiling has a range of preferred angles of attack by the flexible blade and said unit further includes adjustability features for the flexible blade per se and/or for the tray itself. Additionally, skid plates connected to the tray allows the user to apply proper—yet adjustable—angle positioning against the ceiling in a simple efficient manner. 
     OBJECTS OF THE INVENTION 
     It is an object of this invention to allow a ceiling treatment operation by a user standing on the floor below in a simple and efficient manner. 
     It is still a further object of this invention to provide a double bend cantilever handle of sufficient length and novel shape so as to provide lift and scraping and/or other two arm treating forces to be applied to an overhead ceiling by a new and improved ceiling tool. 
     It is still a further object of this invention to provide a novel tray and collection unit having a transparent shroud covering and a vacuum attachment for ceiling treatment by a user without ladders and hand held devices of the prior art. 
     DETAILED DESCRIPTION OF THE INVENTION 
     In  FIGS. 1 and 5  a scraper blade hopper assembly  110  is built into—or fastened onto handle  140 —including the forwardly-located telescope arm  105 —which arm extends from a side extension handle  115  and an arm support area  175 . A key feature of this invention resides in the overall design of handle  140  that is cantilever supported by the user in order to scrape acoustic material from a ceiling  102  being treated.  FIG. 5A  depicts—at a slightly different angle—an enlarged area of the end of handle  150  that is nearest the user. The cantilever nature of the handle is described in more detail hereinafter. 
     Handle  140  at it rearward end includes a cantilever arm support area  175  with rocker tip  176  a strut  167  and an ergonomic hand grip  177 . The upward rocker curvature of the cantilever support  176  and the forward leaning pistol-like hand grip  177  and forward strut  167  together provide a ready-made upward force to hold handle  140  aloft during a ceiling treatment procedure with my VACRS™ system. 
     Across the top of the closed hand grip area as shown in  FIG. 5A  is a stub extension  178  which fits within the user&#39;s arch joining the thumb and knuckle of the forefinger. As explained further herein, that stub extension  178  contributes to a cantilever holding feature for handle  140 . It is defined as a cantilever feature because, in effect, the weld area  178  (where several handle elements join together) acts as a fulcrum point in a fully moveable handle unit. 
     Returning briefly to  FIG. 1 , area  175  has, at the rearward end, an upward rocker-shaped curved and concaved surface  176 . This surface  176  is shaped to conform to the fleshy underarm part of the user&#39;s forearm above the gripping hand. A forwardly slanted handle grip  177  is molded or otherwise fashioned into the handle  140  which is located at the front of the concave rocker surface  176 . Elements  176 ,  177  and  178  together provide for the user a firm grip and lifting support for unit  150 . One may think of the area  175  as primarily forming an arm extension of the right arm of the user. That arm extension allows scraping and other ceiling treatment force to be applied to a ceiling. 
     At the forefront of the VACRS™ unit—is the scraper blade and hopper assembly  110 . A front view looking down shows the material collector and trough  110  in  FIG. 2 .  FIG. 2  clearly shows the scraper blade  100  mounted on the upper leading edge  106  of my scraper and hopper (or trough) assembly  110 . 
     Since the ceiling “popcorn” material which must be removed is several feet away from the user&#39;s location on the floor, handle  140  requires both a lifting support to hold it aloft against the ceiling while also providing a way for the user to apply a scraping force SF,  FIG. 3 , back and forth across the ceiling surface  102  as well. The handle  140  is well designed to give the user such force in a simple and direct manner. 
       FIG. 3  depicts in simplistic form the handle force axis “HFA” and it also shows—by the two headed arrow—the direction of scraping force “SF” needed for acoustic ceiling scraping. Thus, as shown, both an upward handle force axis HFA and a transverse scraping force SF is required for removal of the popcorn from the overhead ceiling  102 ,  FIG. 3 . These  FIG. 3  forces are applied to handle  140 ,  FIG. 1 , by means of a side handle extension  115  and the arm rest area  175 . 
     Returning again to  FIG. 1  side handle  115  (in the left hand side extension position on handle  140  as shown) and pistol hand grip  177 ,  178  allows the user to exert both a right and a left hand force. Please note also that the forearm resting area  175  and grip  177  allows the user to provide lift while applying both a right handed and left handed force to handle  140 . A double bend portion  185  (about 45° upward and about 45° downward) is provided at about the mid point of handle  140 . Those bends in handle section  185  provides a generally upward offset to the handle force axis HFA,  FIG. 3 , applied to handle  140 . 
     Thus, together the double bend  185 , handle  115  and arm support area  175  allow a joint two arm back and forward scraping force SF to be exerted along the length of unit  150 . (Handle  115  may be unscrewed and reattached on the other side of handle  140  for left arm users). In any event, the scraping force SF is applied to the ceiling  102  in question. Popcorn from ceiling  102  is thus scraped, removed and vacuum contained in an easy and efficient manner by using this invention. 
       FIG. 4  is an important Figure because it includes an enlarged view of  FIG. 4A  that demonstrates the scraper blade  100  held at about 32.5 to 33 degrees as a preferred angle of attack HFA for the scraper unit  150 . Quite obviously the preferred degree is an approximation in the range of about 30 to 38 degrees since it need not be precisely that as shown. Skid plates  201  allow the user to achieve a preferred angle of attack. Also skid plates via  212  and  213  are adjustable so that scraping angle can be varied as needed for any particular job. 
     What is important to note, however, in  FIG. 4A  is that the blade  100  is at an angle to ceiling  102  and is scraping away popcorn  101  even as the crowned roll  106  of the shroud  195  is not in direct contact with the acoustic material  101  to be removed.  FIG. 4A  may be considered as an enlarged cross sectional view taken down the main line of force HFA along the longitudinal force axis  146  of handle  140 ,  FIG. 4 . 
     As shown in  FIG. 2A  and  FIG. 4A , blade  100  may be positioned to lead slightly forward of the rolled crown edge  106  while the hopper  195  is in position to catch and collect the scraped-away acoustic popcorn “kernels”  101 ,  FIG. 4A . It only requires a pass or two for the user to ascertain the best angle of attack HFA ( FIG. 3 ) for removing popcorn  101  from ceiling  102 . 
     Blade  100  is a flexible blade that may be adjustable in the actual angle relative to the crown  106  which holds blade  100  in place. This adjustability feature  109  is demonstrated by the double headed arrow  109 A in the enlargement of  FIGS. 2A and 4A  and may simply be achieved by a vernier type screw adjustment  105 ,  FIG. 2A , applied to a rocking blade  100 , or by having blade  100  seated in different ones of a plurality of blade slots at different angle orientations as shown at  FIG. 2A . 
     Blade  100  may thus be “set” at one of a limited number of variable angles as shown by the double headed arrow  109 A. Such adjustment moves the scraping tip of the blade  100  slightly toward or away from the rounded crown  106  at the leading edge of the collector shroud  195 . Shroud  195 ,  FIG. 5 , is tilted in a downward direction in order to allow popcorn  101  removed from ceiling  102  to drop into the collector tray  107  of  FIG. 2 . At the low point  125  in tray  107  is the vacuum entrance  108  for the vacuum assist system of unit  150 . 
     Please note that the forward suction end  190  of a vacuum hose  180  removes debris and acoustic material that is being scraped and dropped into collector tray  107 . Hose  180  moves such debris into any suitable vacuum collector system such as for example, a Shop Vac™  210 ,  FIG. 1 , which vacuum  210  is connected to the outlet end of hose  180  as shown by the dashed line of  FIG. 1 . 
     At this point it is believed helpful to note that additional attachments either in conjunction with the vacuum hose  180  or by themselves may readily include electrical or water or air pressure connections for additional capabilities of my system invention. 
     Any of these additional power source connections may be provided by a hose or leads such as hose  161  in  FIG. 1 . Thus, for example, hose  161  may provide a watering or misting source  162  at the foremost tip  106  of the handle  150 . When a water mist is desired, as explained below, hose  161  and a set of misting jets  162 ,  FIG. 2 , are employed as a tip sprayer for misting the “popcorn”. 
     In my method I have found that misting the ceiling section to be treated is a valuable early step. A mist of a suitable loosing agent, such as water, sprayed from misting jets  162  will soften slightly the popcorn substance. After a few seconds the mist “sets” the substance and allows its easier removal by blade  100 . Hose  161 , under selective user control  164  from pressurized water source  158 ,  FIG. 1 , delivers such misting solution to the set of spray tips  162  in accordance with these steps of my method. 
     My system  150  thereafter collects the misted and “set” acoustic substance scraped away by blade  100  via any suitable vacuum  210 ,  FIG. 1 . Vacuum  210  is connected to tray  107  by a suitable length of vacuum hose  180 . Similarly, water under pressure from source  158  may be controlled by the user and control  164  to spray and clean the treated ceiling  102 . Popcorn or “cottage cheese” material may thus be easily removed and trapped in a suitable vacuum bag (not shown) within vacuum  210  mostly eliminating any mess or “glue” problems of the prior art. 
       FIG. 5  is another perspective view of scraper unit  150  including a portion of the forward telescoping arm  105 . The views of  FIGS. 2 and 4  clearly show the sides of the trough portion  107  of my VACRS collection system  110 . As scraper blade  100  ( FIG. 2 ) moves along the ceiling surface  102 , scraper blade  100  removes the acoustic “popcorn”. Such removed acoustic ceiling substance falls into trough  107  where it is guided by the bottom and sides of trough  107  into the lowest level vacuum opening(s)  125 . Please note that the telescope portion  105 ,  FIG. 5 , may be adjusted for different lengths as needed for a particular job. 
     It is preferable that the handle  140  be made of any suitable lightweight material so that the unit is not any heavier than absolutely necessary. Thus, as shown in  FIG. 1 , user controls and sources of vacuum, misting attachments and the like are kept at floor level so as to lighten the weight of handle  140 . Remember that gravity which helps at floor level is a deterrent and must be overcome for ceiling work as described and claimed herein. 
     For ease of presentation my invention has been shown and described as a vacuum assisted system. Quite obviously the type of suction assist may vary without detracting from the power and scope of my invention. Also, the drawing and description implicitly show my scraper head  150  as partially opaque, but it may be advantageous to have shroud  195  transparent—at least partially so—in order that the user may better control the trough placement and scraper head movement across an acoustic ceiling  102  being treated. 
     In general then, what has not yet been provided before by the art, in order to fill a long sought for need, is a flexible, easy-to-use apparatus and method for removing popcorn ceiling material. The invention provides a novel solution to this long sought for need by featuring a uniquely shaped tool for simplicity and vacuum assisted ceiling material removal. Quite obviously, the unique handle design may favor other tool attachment uses besides the hopper and collector device  110  described and claimed herein. 
     My invention has been described with reference to particular examples of some preferred embodiments, it is my intention to cover all modifications and equivalents within the scope of the following claims. It is therefore requested that the following claims, which define my invention, be given a liberal interpretation commensurate with my contribution to the relevant technology.