Patent Abstract:
An application roller for applying liquid or semi-liquid substances on surfaces comprises a frame having a shaft including a handle thereon for grasping by a user and a cross axle oriented at a right angle to the shaft. A cylinder having first and second ends rotatably mounted on the cross axle defines an outer surface having a first portion of an attachment system thereon. A cover wrap dimensioned to circumferentially encompass the cylinder has a liquid absorbent outer surface and an inner surface including a second portion of the attachment system. The first and second portions of the attachment system cooperate to permit selective removal and reattachment of the cover wrap on the cylinder.

Full Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a Continuation-in-Part of U.S. Non-Provisional Application Ser. No. 12/093,625, filed May 14, 2008, which claims priority to International application Ser. No. PCT/ZA07/00015 filed Feb. 14, 2007, which claims priority to foreign Application Ser. No. ZAP2006/1350 filed on Feb. 15, 2006. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to liquid applicators in general and more particularly to a roller applicator having a removable applicator surface. 
     2. Discussion of the Related Art 
     Paints and other liquid or semi-liquid substances have been developed over the years for multitudes of purposes. Paints are used to provide a protective and decorative coating to interior and exterior building walls. Liquid glues are utilized to bond two surfaces in permanent or semi-permanent contact. Various brushes were developed to assist in applying these substances in a controlled and regulated manner in order to spread the substance over the application surface and to provide a relatively uniform coating thickness. Most commonly, the surface to which the substance is to be applied is relatively large and flat, such as the wall of a room or a building exterior, and the use of a brush becomes a very time consuming effort. 
     In order to more efficiently apply these coatings, an apparatus was developed that facilitated covering a larger area in a shorter period of time while simultaneously applying a more uniform coat of the substance. The apparatus that was developed has become widely known and used, and is commonly known as a ‘paint roller.’ The roller, which usually has a “T” shaped frame wherein the stem of the “T” includes a grip to serve as a handle for the user. The top bar of the “T” generally has a structure resembling a wire cage that freely rotates about the axis of the top bar, and a cylindrical sleeve that is telescopically received over the structure. The cylindrical sleeve is typically rigid for durability and support and has a fibrous or porous outer layer. In use, the outer layer of the cylinder is introduced to the coating substance contained in an appropriately sized reservoir such that the entire fibrous or porous outer surface absorbs a portion of the substance. The roller is then transferred to the surface on which the substance is intended to coat and maneuvered to distribute the substance in the manner desired by the user. 
     Upon completion of the coating process, the user is faced with the task of cleaning the roller. While the sleeve is removable from the frame allowing the frame to be readily cleaned, the task is much more difficult for the cleaning the sleeve. Since the outer surface of the sleeve is porous or fibrous, it typically retains a significant amount of the coating substance within the pores or fibers. The coating substance must be removed if the sleeve is desired to be reused for a subsequent task. The removal of the substance from the fibrous or porous material generally involves utilizing a rigid edge of some kind to squeegee out the majority of the coating substance and then to thoroughly rinse the cylinder in an appropriate solvent to remove the remaining coating substance. Since the fibrous or porous material is permanently fixed to the rigid sleeve, this task is awkward at best and can be very difficult to almost impossible at worst when the knap of the fibrous material is relatively deep. Often, when a roller sleeve is attempted to be cleaned not all of the coating substance is removed and subsequently dries leaving an inferior surface for its subsequent reuse. Although sleeves are generally sufficiently sturdy for reuse, many users become frustrated with the process of cleaning the sleeve and treat them as one-time use items and then discard the sleeves upon completion of the coating task. This is an inefficient use of resources and can result in considerable expense when compared to cleaning and reusing sleeves. 
     Thus what is desired is an application roller wherein the fibrous or porous layer on the roller is readily removable and can be easily cleaned for reuse. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to an application roller that satisfies the need for an easily removable and cleanable application layer. The application roller for applying liquid or semi-liquid substances on surfaces comprises a frame having a shaft including a handle thereon for grasping by a user and a cross axle oriented at a right angle to the shaft. A cylinder having first and second ends rotatably mounted on the cross axle defines an outer surface having a first portion of an attachment system thereon. A cover wrap dimensioned to circumferentially encompass the cylinder has a liquid absorbent outer surface and an inner surface including a second portion of the attachment system. The first and second portions of the attachment system cooperate to permit selective removal and reattachment of the cover wrap on the cylinder. 
     Another aspect of the present invention is an applicator cover sleeve for a standard or pre-existing paint roller frame that has a freely rotating structure for receiving an applicator sleeve thereon. The applicator cover sleeve is constructed of a cylindrical sleeve having first and second ends and defines an outer surface having a first portion of an attachment system thereon. A cover wrap is dimensioned to circumferentially encompass the cylindrical sleeve and has a liquid absorbent outer surface for absorbing and releasing the coating substance. An inner surface of the cover wrap includes a second portion of the attachment system such that the first and second portions of the attachment system cooperate to permit selective removal and reattachment of the cover wrap on the cylindrical sleeve. 
     Yet another aspect of the present invention is a method for attaching a cover wrap for an application roller to a cylinder of the application roller, the method includes the steps of placing a cover wrap to be attached to an application roller on a flat surface such that the inner surface of the cover wrap faces up. The rotational axis of the application roller cylinder is aligned so that the axis is parallel to a line connecting two alignment marks on the inside surface of the cover wrap. The cylinder is registered over the cover wrap so that the cylinder is substantially centered between opposing edges of the cover wrap marked with the alignment marks. The cylinder is pressed against the inner surface of the cover wrap, and the roller is then translated in a first direction substantially perpendicular to the line connecting the two alignment marks until a first end of the cover wrap is affixed to the cylinder. Upon completion of the first translation the roller is then translated in a second direction opposite from the first direction until a second end of the cover wrap is affixed to the cylinder. 
     Still another aspect of the invention is an application roller including a shaft having a handle connected thereto. A circular cylinder has ends wherein each end forms a hub rotatable about the shaft. An outer layer covers the cylinder wherein the outer layer includes a plurality of small hooks extending radially outward therefrom. A non-rectangular parallelogram shaped fabric cover is dimensioned to fit on the cylinder when wrapped therearound. The cover has a fibrous surface on an inner side and has a dimension between a first pair of opposite sides equaling the length of the cylinder and a dimension between a second pair of opposite sides equaling the circumference of the cylinder. 
     These and other features, aspects, and advantages of the invention will be further understood and appreciated by those skilled in the art by reference to the following written specification, claims and appended drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a fuller understanding of the nature of the present invention, reference should be made to the accompanying drawings in which: 
         FIG. 1  is an exploded perspective view of an application roller embodying the present invention, wherein the wrap is removed from the sleeve; 
         FIG. 2  is a plan view of the wrap lying on a planar surface; 
         FIG. 3  is a perspective view of an alternate embodiment applicator cover sleeve for use with pre-existing roller assemblies; 
         FIG. 4  is a plan view of the roller and wrap positioned to affix the wrap to the roller sleeve; 
         FIG. 5  is a plan view of the roller and wrap combination with the wrap partially encircling the roller sleeve; 
         FIG. 6  is a plan view of the roller and wrap with the wrap almost fully engaged on the roller sleeve. 
     
    
    
     Like reference numerals refer to like parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     For purposes of description herein, the terms “upper”, “lower”, “left”, “rear”, “right”, “front”, “vertical”, “horizontal”, and derivatives thereof shall relate to the invention as oriented in  FIG. 1 . However, one will understand that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. Therefore, the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. 
     Turning to the drawings,  FIG. 1  illustrates an application roller  20  which is one of the preferred embodiments of the present invention and illustrates its various components. Application roller  20  includes a roller assembly  22  and a removable cover wrap  50 . Roller assembly  22  has a frame  24  that includes a shaft  26  on which a handle  28  is secured for comfortable grasping by the user. Frame  22  further includes a cross axle  30  which may be an integrally formed part of and extension of shaft  26 . Cross axle  30  is generally oriented at right angles to shaft  26  thereby orienting frame  24  in a generally T-shaped configuration. Those skilled in the art will readily recognize that other orientations and configurations of frame  24  are possible and, although not shown herein, are intended to be within the scope of the disclosure. 
     A cylinder  32  is supported on cross axle  30  in a freely rotating manner about an axis ‘A’ by hubs  34  at each of cylinder ends  36 ,  38 . Cylinder  32  has a length bounded by ends  36 ,  38  and a circumference defining an outer surface  42 . Surface  42  has attached thereto an attachment system layer  40  which substantially covers the entirety of cylinder surface  42 . Layer  40  is a portion of an attachment system such as a well known hook and loop system. In the most preferred embodiment, the hook portion of the hook and loop system comprises layer  40 .  FIG. 1  illustrates layer  40  as being a separately formed layer which is subsequently permanently bonded to surface  42 . However, cylinder  32  can be formed of a molded resin in such a manner as to integrally form the hook portion of the hook and loop fastening system as part of surface  42  without the necessity of bonding a separate hook layer to cylinder  32 . Other fastening systems that permit repeated removals and reattachments are also contemplated to be within the scope of this disclosure. 
     A cover wrap  50  is sized to circumferentially encompass cylinder  32  and includes a liquid absorbent outer layer  62 . Cover wrap  50  is typically constructed as a woven fabric wherein outer layer  62  is a fibrous pile interwoven into the fabric and is of a desired depth for absorbing a coating substance from a reservoir and then releasing the coating substance on the surface to be coated. The depth of the pile can vary depending on the resulting surface texture the user desires. Outer layer  62  can alternatively be a porous layer for yet a different type of texture. Cover wrap  50  also has an inner surface or layer  52  that comprises a second portion of the attachment system. In the most preferred embodiment, inner layer  52  comprises the loop portion of the hook and loop fastening system. Inner layer  52  can be separately formed and then permanently bonded to the woven fabric constructing cover wrap  50 . Alternatively, the woven fabric of cover wrap  50  can be formed in such a manner that the loop portion of the hook and loop fastening system is integrally formed or woven with the woven fabric and outer layer pile. 
     Referring to  FIG. 2 , in a most preferred embodiment, cover wrap  50  is formed as a parallelogram and most preferably as a non-rectangular parallelogram. The parallelogram describing cover wrap  50  includes a first pair of parallel edges  54 ,  56  spaced one from the other by a distance substantially equal to the length of cylinder  32 . Edges  58 ,  60  define a second pair of parallel edges of the parallelogram and are spaced apart by a distance substantially equal to the circumference of cylinder  32 . The geometry of the non-rectangular parallelogram is further defined by angle ‘B’ in  FIG. 2 . Angle ‘B’ is typically within the range of 65 to 85 degrees, and is most preferably 75 degrees. Inner surface  52  also carries a pair of alignment marks  64 . One alignment mark  64  is present at each of edges  54 ,  56 . The marks are positioned substantially on a line  66  that is perpendicular to edges  54 ,  56  wherein line  66  represents the length dimension of cylinder  32 . 
     Referring now to  FIGS. 4-6 , cover wrap  50  is affixed to cylinder  32  in the following manner. Cover wrap  50  is placed on a flat surface with outer layer  62  facing against the flat surface and inner surface  52  with alignment marks  64  visible to the user. Roller assembly  22  is oriented such that rotational axis ‘A’ of cylinder  32  is parallel to line  66  defined by alignment marks  64 . Cylinder  32  can then be registered over cover wrap  50  such that cylinder  32  is centered between opposing edges  54 ,  56 . Once cylinder  32  has been centered and aligned with marks  64 , cylinder  32  is then firmly pressed onto inner surface  52  of cover wrap  50  thereby initially engaging hooked layer  40  of cylinder  32  with the loops of inner surface  52 . With a firm grip by the user on handle  28 , roller assembly  22  is then translated in a first direction ‘C’ ( FIG. 5 ) toward edge  60  until edge  60  is affixed to cylinder  32 . The user then translates roller assembly  22  in an opposite direction ‘D’ ( FIG. 6 ) toward edge  58  until edge  58  is also affixed to cylinder  32 . Since the distance between edges  58  and  60  dimensionally define the circumference of roller  32 , upon cover wrap  50  being completely affixed to roller  32 , edges  58 ,  60  should be in a substantially abutting relationship on roller  32  thereby completing application roller  20 . 
     Application roller  20  is then utilized in the same manner as previously known application rollers wherein the outer surface  62  is introduced to a reservoir of liquid coating substance in a manner sufficient to saturate the entire surface  62 . Application roller  20  is then transferred to the surface to be coated and repeatedly translated thereacross until the pile of outer surface  62  requires resaturation. This procedure is repeated until the desired surface is adequately coated. To clean cover wrap  50 , any corner at the intersections of edges  54 ,  56  with edges  58 ,  60  can be grasped by the user and pulled to disengage the hook and loop fastening system. Cover wrap  50  can then be place on a substantially flat surface with outer surface  62  exposed. Excess coating substance can be squeegeed out from the pile utilizing a straight-edged object if desired. Cover wrap  50  can then be placed in a washing machine and laundered as a typical cloth object and thereby resulting in a clean cover wrap  50  for reuse at a later time. 
     The purpose of wrap  50  being other than a rectangular parallelogram is to orient the abutment of edges  58 ,  60  to be other than parallel to axis of rotation ‘A’. In this manner, only a single point of the abutment line of edges  58  and  60  is in tangential contact with the surface to be coated at any one time. If cover wrap were configured as a rectangle, the entire abutment line would simultaneously contact the surface at one time and thus potentially leave an undesirable visible aberration in the coating layer. 
     Referring now to  FIG. 3 , an alternative embodiment employing an application cover sleeve  132  is illustrated wherein cover sleeve  132  is intended for use with pre-existing rollers. The preexisting rollers are typically configured with a rotating cage (not shown) that accepts a standard sleeve thereover. Applicator cover sleeve  132  includes a cylindrical sleeve  133  having a length bounded by ends  136 ,  138  and a circumference defining an outer surface  142 . Sleeve  133  further defines a hollow interior  144  sized to snuggly fit over the rotating cage of a standard pre-existing roller assembly. Surface  142  has affixed thereto an attachment system layer  140  which substantially covers the entirety of sleeve outer surface  142 . Layer  140  is one portion of an attachment system, such as hook layer  40  shown in  FIG. 1 .  FIG. 3  illustrates layer  140  as being a separately formed layer which is subsequently bonded permanently to surface  142 . However, cylindrical sleeve  133  can be formed of a molded resin in such a manner as to integrally form the hook portion of the hook and loop fastening system as part of surface  142  without the requirement of bonding a separate hook layer to cylindrical sleeve  133 . In use, applicator cover roller  132  is sleeved over the rotating cage of a pre-existing roller assembly. A cover wrap  50  can then be selectively attached to and removed therefrom in the same manner as described above. 
     The above description is considered that of the preferred embodiments only. Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiments shown in the drawings and described above are merely for illustrative purposes and are not intended to limit the scope of the invention, which is defined by the following claims as interpreted according to the principles of patent law, including the doctrine of equivalents.

Technology Classification (CPC): 8