Patent Publication Number: US-11047140-B2

Title: Mud applicator

Description:
CLAIM OF PRIORITY 
     This application is a United States non-provisional application, and claims priority to U.S. Provisional Application No. 62/688,508, filed Jun. 22, 2018, entitled MUD APPLICATOR, the entirety of which is hereby incorporated by reference as if fully set forth herein. 
    
    
     FIELD OF THE EMBODIMENTS 
     This invention relates to applicators for applying product like joint compound or mastic, commonly referred to as “mud”, and in particular to an applicator apparatus that can be clamped onto an original container of the product for supply. 
     BACKGROUND 
     New construction and remodeling projects may require installing materials such as drywall panels, wood paneling, laminate flooring, tiles for floors or walls, and the like. Such projects may require applying a layer of viscous mud-like material during installation. For example, mastic or mortar to adhere paneling or tiles to a wall or floor, or joint compound or spackle to fill spaces between drywall sheets or tiles. In the prior art, this typically included filling a hawk or mud box with the spreadable material, or filling a hopper of a powered appliance that feeds an applicator. However, prior art methods and apparatus can be difficult to master, sloppy to use, difficult to clean up a workspace and equipment after use, too expensive to buy for only occasional use, and the like. 
     SUMMARY 
     A mud pumping apparatus that can be removably coupled to a container in which the mud was originally contained when first obtained by the user. The mud may be mastic, mortar, grout, joint compound, spackle, or the like. The apparatus may be sized to be used with various standard sized containers, and adjustably powered and controllable to be used with different types, consistencies, and viscosities of spreadable material. 
     It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate disclosed embodiments and/or aspects and, together with the description, serve to explain the principles of the invention. The embodiments described are not intended to be limiting. Instead, the scope of the invention is determined by the claims. 
       In the drawings: 
         FIG. 1  is a first exemplary embodiment of a mud supply apparatus clamped to a container of mud in accordance with the disclosure. 
         FIG. 2  is a second exemplary embodiment of a mud supply apparatus clamped to a container of mud in accordance with the disclosure. 
         FIG. 3  is an exploded view of an exemplary mud applicator, comprising a feed tube and an applicator head. 
         FIG. 4  is an exemplary embodiment of a mud supply apparatus including a piston to provide positive pressure to the mud being pumped, in accordance with the disclosure. 
         FIG. 5  is another exemplary embodiment of a mud supply apparatus including a piston to provide positive pressure to the mud being pumped, in accordance with the disclosure. 
         FIG. 6  is yet another exemplary embodiment of a mud supply apparatus including a piston to provide positive pressure to the mud being pumped, in accordance with the disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Aspects of exemplary embodiments of the claimed invention will now be described with reference to the drawings, in which identical elements have the same reference numerals. These embodiments are provided by way of explanation of the present invention, which is not intended to be limited thereto. Those of ordinary skill in the art may appreciate upon reading the present disclosure and viewing the present drawings that various modifications and variations can be made thereto without departing from the scope and spirit of the invention. In addition, it is noted the disclosure pertains to embodiments suitable to accommodate a variety of spreadable materials, to be used in conjunction with various hoses and mud applicator heads. It will be readily understood that the components of the present invention, as generally described and illustrated in the figures herein, may be arranged and designed in a wide variety of different configurations without departing from the scope and spirit of the invention. Thus, the following detailed description of the embodiments and aspects of various apparatus and methods, and the illustrated embodiments and aspects as represented in the attached figures, are not intended to limit the scope of the invention as claimed, but are merely illustrative of selected exemplary embodiments. 
       FIG. 1  illustrates an embodiment of a mud ingestion system  100  removably coupled to a container  110  in which the mud was originally obtained, from a store for example. Any convenient type of power source may be used to power embodiments of the mud ingestion system, such as an alternating current (AC) outlet, a battery, liquid propane or natural gas, or compressed air. The illustrated apparatus utilizes a pump  130  with an auger type bit inside a mud pipe  120  that is inserted directly into the mud in the container  110 . Other types of rotating mud movers may alternatively be used, such as a progressive cavity pump, for example. The mud pipe is configured to have a length extending from the pump inlet to a position near the bottom of the mud container when the apparatus is installed on the container. 
     In  FIG. 1 , the mud pipe is an auger tube having a circular cross section. The auger is disposed within the auger tube, coextensive with the second end of the auger tube. The auger has a helical flute inclined to convey mud from its bottom end to the inlet  170 . The auger has a diameter that fits snugly within the interior diameter of the auger tube. The auger also has a central shank operatively coupled to a rotating motor shaft of the mud pump. 
     A central shaft  125  of the auger is connected to an electric motor or fueled engine (collectively, “motor”) of the pump  130 . The pump  130  is encased in a housing  140  that fits over the top of the open end of the container  110 . The housing  140  has a cover portion  141  permanently affixed/attached to a bottom portion  142 . The bottom portion  142  of the housing  140  forms an air-tight seal when installed onto a top of an open container of mud. Moreover, the bottom portion  142  of the housing  140  comprises an opening/hole  143  thorough which mud is drawn. The cover portion  141  of the housing  140  comprises a hole/opening  144  through which the drawn mud is pushed. In an embodiment, the bottom portion  142  of the housing  140  contains a replaceable gasket (not shown) or similar compressible impermeable material such as rubber that is pressed on and secured to the top of the container to form an air tight seal. The housing  140  may be secured, for example, with one or more clamps  150  connected to the housing  140 , disposed around a circumference of the container to engage a lip  155  or the like around the circumference of the container. Alternatively or in addition, straps  160  may be clamped around the bottom of the container, or clamped to an edge around a bottom circumference of the container. The clamps  150 , straps  160 , or the like, may be adjustable to provide for the housing  140  to be pressed against the top of the container when the apparatus is installed thereon, to make an air tight seal. The clamps  150  may also be replaceable. 
     The pump and housing have an inlet  170 . As the pump  130  runs, the mud is drawn into the bottom end of the mud pipe and conveyed to inlet  170 . The mud passes through the pump  130  and out of the outlet  180 , where it is fed into an applicator feed tube (not shown). The outlet  180  is terminated in an outlet coupling device  190  of any appropriate type known in the art. In an embodiment having a flexible feed tube and applicator head components, a first end of the feed tube has a surface configured to match a surface of the container outlet coupling device  190 . This matching pair of surfaces can be pushed or screwed together make an air tight seal. Likewise, the applicator head can have a surface configured to match a surface of the other end of the feed tube, to be pressed or screwed onto that end to make another air tight seal. 
     The matching surface pairs (i.e., an end of the feed tube coupled to the outlet coupling device  190 , and the other end of the tube coupled to a connector on the applicator head) are configured with matching surfaces to make their respective air tight seals. There are a variety of matching surfaces that can be used to couple the components together, including ribbed, threaded, and smooth surfaces with a latching element to prevent the surfaces from decoupling. In embodiments, either of the coupling components may be configured as a male end, to be inserted into a matching female end of the other component being joined. 
       FIG. 2  illustrates an embodiment of a mud ingestion system  200  that is substantially similar in many ways to that of  FIG. 1 . The differences have to do with the mechanism by which the mud is conveyed through the system. In particular, the mud pipe can be configured as a siphon  220  that sucks mud from near the bottom of container  110 , and conveys the mud through the inlet  170  and the pump  230  and out of outlet  180 . The siphon is connected to the pump  230 , which is encased in housing  140 . In this exemplary embodiment, the pump may be a centrifugal pump, for example. As before, the housing  140  is secured to the top of the container  110  to form a seal around the top of the container, with clamps  150  that connect to the housing, disposed around a circumference of the container, or straps  160  that are clamped to the bottom of the container, or both. The clamps  150  or straps  160 , or both, are adjustable to allowing for the housing  140  to be fully sealed against the top of the container  110 , making an air tight seal. 
     As the pump  230  runs, mud is sucked into the inlet  170  and pumped out of the outlet  180 , where it is fed into the feed tube (not shown). The outlet  180  is again terminated in a coupling device  190  of any appropriate type known in the art, to which an applicator feed tube is coupled. 
     As illustrated in  FIGS. 1 and 2 , in embodiments a mud ingestion system outlet tube  180  may terminate at one end in a coupling device  190  configured to connect to a matching coupling device of an applicator arm to form an air tight seal. Referring now to  FIG. 3 , coupling device  190  is coupled to matching coupling device  300  of an exemplary applicator feed tube  310 . During operation mud is fed from the mud ingestion system outlet into the applicator feed tube  310  coupled thereto, to an applicator head  320 , through which the mud is extruded onto a work surface. As noted, in embodiments the feed applicator tube  310 , applicator head  320 , or both, may be attached to a handle  330  that the user can use to control the placement of the mud onto the work surface. 
     In embodiments, the pump may be activated and controlled by an on/off control switch  340 . The control switch may be placed at any convenient location, such as on or next to the applicator handle  330 , or on the feed tube  310 , or on the applicator head  320 . The pump may be continually or intermittently activated by operating the control switch, which may be combined with the on/off switch  340  as shown, or may be separate from the on/off switch. In embodiments, variable controller  340  may be used to control the speed at which mud is taken up from the container and extruded from the applicator head  320 . In embodiments, the control switch may be operatively coupled to the pump using a wireless connection such as a radio frequency (RF) interface, such as a wifi or Bluetooth compliant connection, to send control or other signals to or from the pump. Alternatively, the control switch may be operatively coupled to the pump using a wired connection (not shown), in which the wires may be run along the feed tube  310 , for example. In embodiments, two or more feed lines may be supplied by a single mud ingestion system. Preferably, each line may be supplied with its own control switch. 
     In embodiments, the pump  130  and housing  140  may also comprise an inlet with a threaded end,  195 . A water hose may be connected to the inlet  195  so that, as mud is drawn through the pump  130 , the viscosity of the mud may be modified by adding a desired amount of water to the mud at the pump. In such an embodiment, the control switch may operate a valve disposed inside or adjacent to the inlet  195  as the pump is controlled. The valve may be activated together with the pump. In embodiments, the control switch may be further configured and arranged to modify the valve opening independently of the pump, to modify the percentage by weight of water in the mud-water mixture as the pump operates, to better adjust the viscosity of the mixture as the mud and water flow through the pump. 
     Different types of applicator heads  320  can be attached to the feed tube  310 , suitable for different types of mud and different applications. The different types of applicator heads may provide a flow rate, extrusion shape, and distribution of mud appropriate for a particular application. For example, an applicator head that extrudes mud to have parallel groves can be used to spread an adhesive compound for use in installing tile, wherein the grooves aid in drying the adhesive and securing the tiles to the work surface. In another example, the applicator head can extrude a smooth, flat layer of joint compound to fill joints and cover tape between dry wall panels to create a uniformly flat wall surface. Other applicator heads may alternatively be used, configured for use in different applications. 
     In embodiments, as illustrated in  FIG. 4 , wheels  422  can be secured to the bottom of the mud container by supporting straps  424 . The wheels may be placed under the mud container so the container may be wheeled while the system is being used. In embodiments, a feed line holder (not shown) may be coupled to the feed line that attaches to the operator&#39;s belt or waist to carry some of the weight of the loaded feed line. This would be especially useful when applying mud above the level of the operator. 
     In embodiments, an auxiliary system that works in conjunction with the mud ingestion system previously described may be included that provides a positive flow of mud from within the bucket to the mud pump. One such embodiment is illustrated in  FIG. 4 , in which a flat piston type system initially has the piston  402  at the top of the motor housing  404  or top of the bucket of mud  406 . The piston is pushed downward into the bucket against the mud  408  to push the mud into the mud ingestion system as the mud ingestion system is operated. The piston  402  is shaped to fit snugly within the inside surface of the bucket  406 , and has an opening through which the mud pump inlet tube  410  slides, typically along the central axis of a right circular cylindrical shaped bucket. In an embodiment, a flange  418  can be included between the piston opening and the outer casing of the mud pump inlet tube  410  that slides against the outer casing of the pump inlet tube to prevent mud from leaking around the tube as the piston  402  presses against the mud. 
     In embodiments, the piston  402  may turn clockwise or counter clockwise as it moves downward into the bucket, or it may not rotate as it moves. In embodiments, the piston may slide directly against the smooth outer casing of the mud pump tube, or may slide along matching inter-meshing grooves  412  in the opening of the piston and the outer casing of the mud pump tube. This may help guide the piston to move straight down to the bottom of the bucket as it is pushed against the mud. The piston may be pushed downward into the bucket in a straight non-screwing motion by extendible or fixed arms  414  extending from a piston motor  416  to the top of the piston  402 . These are arranged to push the piston down into the bucket via gearing, hydraulics, or other means known in the art. 
     In other embodiments, the piston  402  may be configured to be screwed down into the bucket along the inter-meshing grooves  412  in a screw-like configuration, similar to a bolt and nut, the bolt being the outer surface of the mud pump inlet tube  410  and the nut being the piston  402 . The piston may be pushed downward into the bucket in a circular screwing motion by extendible or fixed arms  414  extending from a piston motor  416  to the top of the piston  402 . These are arranged to push the piston down into the bucket via gearing, hydraulics, or other means known in the art. 
     Another auxiliary system embodiment that works in conjunction with the mud ingestion system previously described includes a flat piston embodiment with motor(s) and interlocking teeth/gears in the straight down or screwed down motion. The piston can be pushed downward into the bucket in a straight motion by providing the piston with an outer casing and piston shaft having teeth on one or more sides which intermesh with the teeth of one or more motors. When the motor(s) are activated in conjunction with the mud ingestion system, the piston is pushed down into the bucket by the gearing action of the intermeshing teeth in a downward motion. 
     In embodiments, the piston can be pushed in a downward screwing motion into the bucket by providing the piston outer casing and piston shaft with screw threads that intermesh with screw threads of one or more motors. When the motor(s) are activated in conjunction with the mud applicator, the piston is screwed down into the bucket by the screw gearing action of the intermeshing screw threads. 
     Alternatively, the mud pump inlet tube  410  may itself be turned by a motor of its own in a clockwise or counter clockwise direction. In such an embodiment, the piston  402  may slide straight down against the mud pump inlet tube  410 , similar to a bolt and nut arrangement with the bolt turning and the nut remaining stationary. The piston  402  may be pushed down into the bucket by gearing, hydraulics or other means emanating from a motor system. A second inner casing may encase the mud pump inlet tube  410 , allowing the auger bit  420  to be in a tube during the activation of the mud applicator. In an embodiment, the outer casing/piston shaft can be fixed in place and the flat piston can be screwed down into the bucket by gearing, hydraulics or other means emanating from the motor system. In another embodiment, the auger bit can be screwed down to the bottom of the bucket at the time the mud ingestion system is installed on the mud bucket. As the mud ingestion system is operated, the auger bit  420  is simultaneously turned and pulled in an upward motion by auger bit motor  421 . The upward motion of the auger bit  420  causes mud to be pushed up against the bottom of the motor housing (at the top of the bucket) and fed at a constant rate into the pump inlet as the auger bit rotates. 
     Another auxiliary system embodiment that works in conjunction with a mud ingestion system is illustrated in  FIG. 5 . Similarly to the auxiliary system embodiment illustrated in  FIG. 4 , a piston  502  pushes mud from its original container  504  to a feed chamber  506 , with inter-meshing grooves  508  or the like guiding the piston  502  downward. However, in this embodiment, piston  502  is coupled to piston feed chamber sleeves (PFCS)  512  that are initially disposed against the walls of the feed chamber  506 . As the piston  502  pushes the mud in the mud container  504  down, the PFCS  512  also descend into the mud container, extending downward to the bottom of container  504 . 
     The PFCS  512  may have feed chamber closing flaps  510  coupled to the bottom of each side of the PFCS. The feed chamber closing flaps  510  may move from horizontal (perpendicular to each PFCS) to vertical when they lay flat against the PFCS. The chamber closing flaps  510  lay vertically against the PFCS when the piston  502  is pushed down into the container  504  and the mud is pushed up into the feed chamber  506 . Conversely, after the piston reaches the bottom of the mud container and mud resides only in the feed chamber, the piston may be pulled up in the container  504 . This causes the chamber closing flaps  510  to close, sealing the bottom end of the feed chamber  506 , and causing the mud still contained in the feed chamber  506  to be pushed toward the top of the feed chamber and out of the mud outlet  180 . 
     In embodiments, the chamber closing flaps  510  can be replaced with a feed chamber sealing plate pushed into place by a motor and interlocking teeth (not shown), that operate on the top side of the piston. 
       FIG. 6  illustrates another embodiment, activated by a trigger at the end of the feed line (not shown). This embodiment has a first pump chamber  604  having an opening  606  to a second pump chamber  608 . A chamber separator  610  is disposed therebetween, slidable between an open position in which the chamber separator  610  resides in housing  612  and leaves the opening  606  uncovered, and a closed position (represented by a dotted line adjacent to opening  606 ) that covers and closes opening  606 . When the system is activated, the chamber separator  610  remains in its open position as piston  602  is pushed down into the mud container, pushing mud into the first pump chamber  604 , through the opening  606  and into the second pump chamber  608  to a feed tube opening  614 . When the mud reaches the feed tube opening  614 , pressure builds up in the second pump chamber  608 . A pressure sensor  616  detects the elevated pressure, and sends a signal to a driver of chamber separator  610  (not shown), causing the chamber separator  610  to slide to its closed position. 
     Thereafter, at each trigger pull the pump piston  618  is activated and pushes the mud in the second pump chamber through the feed tube opening  614  and into the feed line to the mud applicator. When the pump piston  618  reaches the top of the second pump chamber  608  a contact/sensor (not shown) will activate, causing a pump piston driver (not shown) to return the pump piston  618  to the bottom of the second pump chamber  608 , and at the same time causing the chamber separator  610  to return to its open position within its housing. Until these operations are completed, the trigger may also be deactivated, and mud will stop being dispensed. 
     Thereafter, the piston motor independently or upon activation of the trigger will reactivate the piston  602 , pushing it further down into the mud container to push more mud into the first pump chamber  604 , and continuing the cycle just described. When the piston  602  reaches the bottom of the mud container, mud still resides in the first and second feed chambers. The bottom of the first feed chamber  606  may then be sealed to retain the mud in the feed chambers  604 ,  608  as the piston  602  is lifted by its motor back up to the top of the mud container. The first feed chamber  604  can be sealed in any convenient manner. For example, feed chamber closing flaps (not shown in  FIG. 6 ) may be attached to the bottom of the walls of the first feed chamber. The closing flaps may be pushed flat against the chamber walls as mud is pumped into the chamber, and pulled down again as piston  602  is raised, as described in connection with  FIG. 5 . Alternatively, a feed chamber closing plate (not shown) may be activated to seal the feed chamber opening. 
     In embodiments, the feed lines and the mud applicators may be provided with one or more air release valves (not shown), to allow air being pushed through the feed line to escape during priming of the feed line, filling the mud applicator with mud only. 
     The disclosed embodiments can be used to supply tile grout, mortar, mastic, joint compound, or other premixed material of similar consistency and flow properties, directly from the original container. The flowing materials may be obtained pre-mixed in their container, or may be mixed in their container, and applied using the apparatus. 
     After use, if the entire contents of the container have not been applied and will be used again within a reasonably brief amount of time, such as within a day or two, or perhaps more depending on the flowing material being used. The air tight seal between the apparatus and the container will maintain the proper consistency of the material as effectively as if the apparatus was removed from the container, and the lid of the container replaced. The material inside the feed tube may also be maintained in a similar condition by removing the applicator head and sealing the end of the feed tube. The applicator head should generally be washed between uses. This practice may give acceptable results for brief periods of time between uses. However, for a somewhat longer period of time between uses, such as several days, the feed tube should also be removed from the outlet coupling device  190  and outlet  180  sealed at the coupling end. This will store the material within the original storage bucket and the motor housing. The feed tube may then also be cleaned. 
     In embodiments, at the end of use until the next day or longer thereafter, the applicator may be disconnected from the feed line and washed clean with water or other solvent if appropriate, depending on the type of mud material that was extruded. Mud remaining in the feed line can be pushed back into the feed chamber by inserting a feed line cleaning rod (not shown) into the feed line. The feed line cleaning rod fits snugly inside the feed line, with just enough spacing to allow it to be pushed into the feed line. The feed line cleaning rod may be pushed into the feed line until it reaches the end of the feed line where it is coupled to the motor housing. This pushes the mud remaining in the feed line back into the feed chamber. 
     When finished using the disclosed apparatus, water or other appropriate cleaning agent may be run through the entire apparatus, feed tube, and applicator head for cleaning. Moreover, embodiments having one or more piston feed chamber sleeves can include chamber scrapers on the top of the chamber sleeves, to scrape and prevent mud from clogging space between the flat piston feed chamber sleeves and the feed chamber walls. In an embodiment, the end of the mud tube may advantageously be configured to be coupled to a threaded hose connector. A water hose can then easily provide water to flush through the apparatus, feed tube, and applicator head in a single operation. Alternatively or in addition, a water hose can be coupled to the housing inlet  195  to clean the apparatus. 
     It is noted that prior art mud appliances generally require the mud to be removed from its original container and placed into a holding tank of the appliances. Other prior art approaches may require manual solutions such as placing mud in a mud box or on a hawk and, using a trowel with a handle or pole affixed to it, spread the mud by drawing the trowel across the work surface, such as a wallboard, floor board, or like surface. 
     Advantages of the disclosed apparatus include that the mud (spackle, joint compound, adhesive, etc.) is not removed from its original container prior to use, unlike prior art practices. Moreover, the mud can be stored for reasonably short periods in its original container with the apparatus installed, such as to continue a job in progress the next day. Further, the disclosed apparatus does not rely on gravity as a mud mover. Instead, it is fed using a powered auger tube or suction pipe. The apparatus can be manufactured in various sizes to accommodate various standard size containers, commonly 1 lb., 2 lb., 3.5 lb., 4 lb., or 5-lb. containers, although other sizes may also be accommodated. The container contents may be measured by volume or by weight, using metric, imperial, or other measuring bases. In embodiments, the disclosed apparatus can be transported in one piece, with or without being installed on a mud container. 
     In the foregoing, when introducing disclosed embodiment(s) or aspects thereof, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements or aspects. Similarly, the adjective “another,” when used to introduce an element, is intended to mean one or more elements. The terms “including” and “having” are intended to be inclusive such that there may be additional elements other than the listed elements. 
     Although the embodiments have been described with a certain degree of particularity, it is to be understood that the foregoing disclosure has been made only by way of illustration and not limitation. Numerous changes in the details of construction and arrangement of parts may be made without departing from the spirit and the scope of the invention as defined by the appended claims.