Abstract:
An applicator comprising: a casing defined by two side walls and a cylinder wall, said cylinder wall comprising an opening on one side of said casing; a material container coupled to a side of said casing opposite said opening in a position that allows gravity to direct drywall material in said material container towards the interior of said casing, said container including a flow gate configured to control the flow of said drywall material from said material container to the interior of said casing; an adjustable flick plate coupled to said casing at the bottom of said opening; a brush assembly rotatably coupled to said casing, said brush assembly configured to project said drywall material from said opening; and a handle comprising a trigger that controls said flow gate.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application claims priority to U.S. Provisional Application Ser. No. 60/558,738, filed Mar. 31, 2004, which is hereby incorporated by reference as if set forth herein. 

   BACKGROUND 
   1. Field of the Invention 
   The present invention relates to general drywall texture application and to the area of matching and repair of spray on drywall textures. More particularly, the present invention relates to a rotating applicator for texturing. 
   2. The Prior Art 
   The most common type of texture application utilized in commercial and residential construction today and over the last 30 years is the spray on type. Spray guns coupled with compressors have been the apparatus of choice. They produce an assortment of speckled patterns that are applied primarily to drywall surfaces. Although fairly economical and popular, the application method is messy and the patterns produced are limited and tired. There is a need for something new. Additionally, the repairing of damaged areas that utilize this type of texture application has also been a problem. Present solutions are inadequate, all having serious flaws and limitations. There are presently three commercial approaches that address these problems. 
   Air guns coupled with compressors are the main means of texture application today. Air guns and compressors are used for both new surfaces and in the repair of damaged areas. For both applications, there are serious drawbacks. Air guns and compressors are expensive and due to their complexity, they usually require the use of a contractor. The compressors are large, very often requiring a truck to move them around. Long hoses are needed to supply the guns with compressed air. They are impractical for small jobs or your typical home-owner re-modeler. The use of high-pressure air is also a major issue. This creates significant over-spray and dust disturbance. Neatness is a very important factor, especially in the area of remodeling. To minimize the potential mess, significant area preparation is required along with cleanup time. This added time equals added expense. The type of textures that can be produced by air guns are limited. Spray guns can generate droplets of different diameters and density only. A speckled type pattern is the only pattern possible. 
   Aerosol cans with texture compound inside are also available. Aerosol cans are expensive, contain little material, deliver poor results, and cannot be re-used. They are practical for small area repair only. 
   Bazooka type mechanisms, such as in U.S. Pat. No. 3,188,295, are also used, forcing air and material thru a nozzle with the force of your arm acting on a piston. This type of application does not allow for a steady stream of material, resulting in uneven, hard to control patterns. They are not practical to cover larger areas in either a uniform or timely manner. 
   U.S. Pat. No. 2,865,325 (Leston et al.) shows a device capable of flinging material, but with fatal defects in its applicability to accomplish the task desired, the ability to produce modern spray on type texture patterns. In its shown configuration the controls, portability, and other modifications required are just not present. This device was never intended nor capable of applying any decorative patterns in anything but a limited way. “The Leston device was only practical in applying much more dense coatings. The title itself “Applicator For Splattering of Masses” points directly to this fact. The use of spray on modern type textures was not in use at the time the application for this invention was filed in November 1954. 
     FIG. 1  in Leston shows a mass of material in a bottom-mounted reservoir  12 . With this lower position, serious problems arise. Accurately controlling the amount of dispensed material is not possible. As the bristles or tines are passed thru the reservoir medium they pick up an amount of substance controlled only by the shape of the tines and amount of material present in the reservoir. Adjusting the bristles or tines would not significantly address this problem. As the material is ejected from the device, the reservoir level changes. This directly impacts the amount of material present on the tines or bristles, and ultimately the density of the pattern emitted. 
   It is imperative to be able to accurately control medium flow in order to control the devices output. This inability directly impacts droplet size, pattern density and over all versatility. The ease of directing the dispensed medium with the Leston device is also in question. As a hand held device, comfort, stamina, and portability is severely limited. The handle  18 , as seen in  FIG. 1 , is located in an awkward, off centered, and unsupported position. Since the device is an unsealed unit, being open at the front and back, tipping the device significantly in either direction would cause the material to spill. The tripod mount system, as shown in  FIG. 7 , would be the most viable way of using the device. As a result, moving the device around would be quite cumbersome in anything but a vacant room. 
     FIG. 1  in Leston shows a splatter plate  33   a  in a fixed position. The splatter plate is referred to as a flick plate in the present invention. This plate is neither adjustable nor removable. There are major advantages in the ability to do so. Different plates produce different results. 
     FIG. 1  in Leston also shows a rotating brush assembly  26 . This item is also in a fixed position. The inability to remove this brush and replace it with brushes of different density and pattern is a major limitation of Leston and the rest of the prior art. 
   The Leston device is incapable of producing or directing the type of spray-on texture patterns needed to match or duplicate what is needed in the market place of today. The fact that this invention is not now commercially produced points directly to its flaws. 
   SUMMARY 
   The present invention provides a new and superior way to reproduce existing spray on texture patters along with the application of new texture patterns as yet unseen. With the introduction of major modifications such as a top mounted hopper, medium flow control, modified casing, interchangeable brushes and flick plates of different configurations, exceptional and surprising results are obtained. It&#39;s ease of use, low cost, portability, and versatility make it a unique and needed addition to the present art. 
   In one preferred embodiment, the applicator comprises a top mounted hopper with a lid, a main body casing that attaches to the hopper, a primary handle that attaches to the hopper and casing, a trigger that is within the handle, an arm rest, a flow control tab attached to the trigger that controls the medium flow, an inlet slot at the bottom of the hopper that allows the medium to enter the brush chamber, a casing that contains the circular brush, a circular brush within the casing attached to a drive shaft, a removable cover on one side of the casing for brush removal and replacement, a flick plate with mounting bracket located at the bottom of the main casing cylinder wall, a series of gears attached to the drive shaft, a gear shaft that attaches to variable speed drill, and a variable speed screwdriver or crank handle for rotating the brush. 
   In another preferred embodiment, the hopper is replaced with a tank for containing the texture material and a supply line for delivering the texture material to the brush chamber. 
   It is an object of the present invention to provide an applicator with superior performance in its ability to match existing spray on type texture patterns as well as the ability to produce new custom patterns. 
   It is yet another object of the invention to provide an applicator that is hand held, easily directed, simple in operation, and low in cost; 
   It is yet another object of the invention to provide an applicator capable of many variations making it adaptable to any size job. 
   It is yet another object of the invention to provide an applicator that minimizes over spray, area preparation, and is not dependent on the use of high pressured air; 
   It is yet another object of the invention to provide an applicator that provides a consistent, steady, uninterrupted, uniform pattern of material. 
   It is yet another object of the invention to provide an applicator whose contents is contained in a sealed unit. 
   It is yet another object of the invention to provide an applicator with a easily accessed dedicated texture flow control. 
   It is yet another object of the invention to provide an applicator providing good balance, comfort and portability; 
   It is yet another object of the invention to provide an applicator capable of producing a variety of new texture patterns; 
   It is yet another object of the invention to provide an applicator that is capable of being powered by varied means including a standard variable speed drill. 
   It is yet another object of the invention to provide an applicator whose contents can be directed in a highly controlled and adjustable manner. 
   It is yet another object of the invention to provide an applicator with an array of circular brushes that are easily interchangeable. 
   It is yet another object of the invention to provide an applicator with flick plates that are interchangeable, and of various shapes. 
   Still further objects and advantages will become apparent from the consideration of the ensuing description and drawings. 

   
     DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a left side view of a first embodiment of a texturing applicator; 
       FIG. 2  is a right side view of the first embodiment; 
       FIG. 3  is a front view of the first embodiment; 
       FIG. 4  is a cross sectional view of the first embodiment at line  4 ; 
       FIG. 5  is a cross sectional view of the first embodiment at line  5 ; 
       FIG. 6  is a left side view of a second embodiment of a texturing applicator; 
       FIG. 7  is a cross sectional view of the second embodiment at line  7 ; 
       FIG. 8  is an illustration of an exemplary holding tank; 
       FIG. 9  is left side view of an exemplary brush cartridge and saddle; and 
       FIG. 10  is an illustration of exemplary flick plates. 
   

   DETAILED DESCRIPTION 
   Persons of ordinary skill in the art will realize that the following disclosure is illustrative only and not in any way limiting. Other embodiments of the invention will readily suggest themselves to such skilled persons having the benefit of this disclosure. 
     FIGS. 1 through 5  show an exemplary embodiment of a texturing applicator according to the present invention. The basic operation of the applicator is as follows. A top mounted hopper  20  is filled to the desired level with texture medium. A hopper lid  22  seals the texturing material within the hopper  20 . The device is held by a primary handle  26  and directed at the area to receive the texture coating. A crank handle  42  (shown in  FIG. 1 ) or a conventional variable speed drill (not shown) may be used to rotate a circular brush  40  located within the main body casing  18 . It is contemplated that other means may be employed to rotate the circular brush  40  as well. As the brush  40  turns, the bristles are forced against a flick plate  38 . Once the desired rotation is reached, a flow control trigger  24  is depressed, allowing a metered amount of texture material to be dispensed to the brush chamber  19  within the casing  18  and upon the circular brush  40 . As the brush  40  turns, the bristles are bent back upon the flick plate  38 . When the bristles are released from the flick plate  38 , droplets of material are flung upon the desired surface, creating a texture pattern. 
   While the main materials used for the preferred embodiment are rigid plastics, it is contemplated that a variety of other materials may be used as well. Any and all materials deemed of an equal or superior nature, for any parts, may be substituted. Parts requiring added durability and strength, such as bushings, bearings, gears, and shafts, shall be fashioned of materials suited to those requirements. Attachments may be made by, but are not limited to, the use of plastic or metal welds, uni-body construction and the use of screws, or similar devices. The preferred manufacturing method for major components, such as the hopper  20  and main body casing  18 , is injection molding. However, it is contemplated that any other manufacturing techniques deemed preferable may be employed. 
   The hopper  20 , which contains the hopper chamber  23  within, may be attached to the main body casing  18  to form one solid unit. The hopper  20  is located above and to the side of the casing  18  in a position that allows gravity to act upon the contents within hopper chamber  23 , causing the contents to be directed towards the casing  18 . The hopper  20  may have an irregular shape, such as being wider at the top than at the bottom. It may also have a rectangular straight sided top with a securely fitting rectangular lid  22  upon it. 
   The main body casing  18  is substantially cylindrical in shape. In a preferred embodiment, casing  18  is a one-sided cylinder, having an open side, such as the right side shown in  FIG. 2 . The interior circumference and width of the casing  18  are only slightly more than the circumference and width of the circular brush  40 . The cylinder wall  70  is defined by the circumference and width of the casing  18 . The brush  40  and casing area are a close tight fit, but do not bind with one another. Casing  18  may comprise an outlet notch or opening  67  existing through the cylinder wall  70 . The opening  67  allows the texture material to exit the brush chamber  19  after the bristles or tines of the brush  40  are bent back and released from the flick plate  38 . Although the opening  67  in  FIGS. 1-5  comprises an angled notch, it is contemplated that a variety of shapes may be employed, including, but not limited to, other concave shapes and convex shapes (such as a continuation of the casing&#39;s cylindrical shape). Holes may be present in the casing&#39;s side to accept bushings  32 , gear shaft  33  and driveshaft  50 . A splatter lip  68  is shown at the top of notch  67 , preventing the unwanted splatter of texture material on an undesired location. 
   An inlet slot  48  is present at the back of cylinder wall  70 , allowing for the texture material to flow from the hopper  20  to the brush chamber  19 . The slot  48  may extend substantially the width of cylinder wall  70 . 
   A primary handle  26  is present. The handle  26  is attached to the hopper  20  and main casing  18 . The handle  26  is hollow, allowing for internal components. An arm rest  28  may be attached to the hopper  20  or the handle  26 . The arm rest  28  may be hollow in the middle and concave at the end to comfortably accept the operator&#39;s forearm. 
   An inlet control tab  49 , shown in  FIG. 4 , is attached to the flow control trigger  24  located within primary handle  26 . The tab  49  extends across the width and breadth of inlet slot  48 . A trigger return spring  25  exists behind trigger  24 . 
   A removable cover  44  may enclose the entire open side of the casing  18 , such as the right side in  FIG. 2 . The outlet notch  67  may continue through the removable cover  44 . The cover  44  may be attached by the use of wing nuts (not shown) or any like device to hard points located on the casing  18 . A raised ring  47  may be located on the interior of the cover  44 . The ring  47  fits snugly inside casing  18 . Holes are present in cover  44  to accept bushing  32  and driveshaft  50 . 
   The rotating brush  40  slides onto keyed driveshaft  50 . As seen in  FIG. 5 , the driveshaft  50  passes through the left side of casing  18  and bushing  32 , then continues through a gear cover  30  and bushing  32 . A gear  34  is attached to driveshaft  50  in a fixed position. The gear  34  is meshed with a like gear  34  positioned directly under the first gear. This second gear is keyed to gear shaft  33 . The gear shaft passes through holes in casing  18  and gear cover  30 . Bushings  32  may be employed at either end. The shaft  33  extends out gear cover  30  side and allows the attachment of a hand crank  42  (shown in  FIG. 1 ), a variable speed drill (not shown) and similar devices. The gear cover  30  is attached securely to casing  18 . 
   A flick plate  38  and a flick plate bracket  36  are located on the exterior and towards the bottom portion of opening  67 , on the opposite side of the casing  18  from the hopper  20  and inlet slot  48 . The bracket  36  may be comprised of two pieces attached to one another and to casing  18 , as seen in  FIG. 4 . The flick plate  38  is located atop the bracket and may be removably secured with wing nuts, set screws, or any other securing means known in the art. 
   The desired texture material, likely drywall texture compound, is deposited into the hopper chamber  23  within hopper  20 . The hopper  20  is of an irregular shape and is located in a high position relative to the main casing  18 . The location serves to provide maximum force of gravity upon the texture material inside the hopper  20  in order to facilitate delivery of the texture material to brush chamber  19 . This position also allows the use of a texture flow control device at the hoppers bottom. The hopper lid  22  is set securely in place upon hopper  20 , sealing the texture material within. 
   The applicator may be grasped by the primary handle  26  with the operator&#39;s left hand. The operator&#39;s forearm rests comfortably against the concave arm rest  28 . The operator&#39;s right hand may then hold the hand crank  42 , substituted variable speed drill or like device. The crank handle  42  is easily removed for this purpose, and a suitable end provided on the gear shaft  33  to accept the drill or like device. The use of a variable speed device as a power source provides a convenient, consistent and highly controllable way to power the device. 
   As viewed from the left side in  FIGS. 1 and 4 , a clockwise turning is imparted to gear shaft  33 . When gear shaft  33  is turned, force is imparted to gear  34  located within gear cover  30 . The cover  30  protects and holds the gears  34 , their respective shafts  33  and  50 , and bushings  32  in a locked stable position. The gear  34  located on gear shaft  33  turns a similar gear located directly above it. This second gear  34 , also in a keyed fixed position, turns driveshaft  50 . The driveshaft  50  is keyed holding the circular brush  40  in a fixed position. When viewed from the left side, the circular brush  40  turns in a counter clockwise direction. When the hand crank  42  turns gear shaft  33  in a clockwise direction, which is more comfortable for most people, the rotating brush  40  fixed upon shaft  50  is caused to turn in a counter clockwise direction. The turning of the circular brush  40  in this direction allows the texture droplets to be expelled in an upward direction. As the bristles or tines of the rotating brush  40  are bent back against the flick plate  38  and released, the texture material is flung in an upward trajectory upon the desired surface since the bristles or tines of the rotating brush  40  are being released from a lower position to a higher position. This upward movement helps counteract gravity, which tends to causes the texture droplets to sag. Upward movement mitigates this problem and also facilitates the coverage of ceiling areas. Lower areas can still be covered easily by tipping the applicator forward. 
   After reaching the desired rotation speed, the flow control trigger  24 , located within the primary handle  26 , is depressed by the operator. As the trigger  24  is pulled back, the inlet control tab  49  is in turn pulled back. The control tab  49 , located under hopper  20 , extends the breadth and width of the inlet slot  48 , effectively sealing the hopper chamber  23  from the brush chamber  19  when in the closed position. The inlet slot  48  may extend the width of the cylinder wall  70 . As the control tab  49  is pulled back, an even bead of texture material is deposited onto the surface width of the circular brush  40 . The more the trigger  24  is depressed, the more material is allowed to enter. When the trigger  24  is released, a trigger return spring  25  located behind the trigger  24  returns the trigger  24  to the original closed position or to any spot in-between the open and closed position. Trigger  24  and control tab  49  provide the advantage of allowing the operator to conveniently and accurately control the amount of texture material being dispensed. 
   The circular brush  40  slides down upon the keyed drive shaft  50 . As the circular brush  40  rotates and picks up material, it interacts with flick plate  38 . As the bristles or tines are bent back upon the flick plate  38 , tension is produced. When the bristles are released, the collected medium present on the bristles is flung out in the pointed direction, and deposited upon the desired surface. The flick plate  38  and flick plate bracket  36  are located at the bottom and exterior of casing  18 . The bracket  36  is securely attached to cylinder wall  70 . The bracket  36  provides an angled mounting platform for the flick plate  38 . The flick plate  38  may have the substantially the same width as the width of the brush chamber  19  and extend into the brush chamber  19  to the desired depth. The flick plate  38  is adjustable, allowing for removal and replacement. The flick plate  38  may comprise a slot that allows the plate to slide in and out. The flick plates  38  may be secured by the use of wing nuts or like devices. 
   The circular brush  40  is accessed through the removable cover  44 . The cover  44  may be removed by the removal of cover fasteners, which may be wing nuts or a variety of other securing means. Removing the cover  44  allows for easy access and replacement of the circular brush  40 , with others of different configurations. The removable cover  44  also makes the cleaning of the applicator easier. The cover  44  may have a raised ring  47  located on the interior of the cover surface. The ring  47  fits snugly inside the cylinder wall  70  of casing  18 . This centers the cover  44  and provides a good seal, solving any possible leakage problem. 
   Various modifications are possible with the embodiments so far described. Many components may be simplified, altered or even eliminated. Rigid plastics and aluminum are the primary envisioned materials. However, it is contemplated that a variety of other materials may be used as well. Any material deemed suitable may be employed. The hopper lid  22  may be altered or eliminated. The hopper  20  may be modified to any shape or size desired, so long as it promotes the flow of the texture material from the hopper chamber  23  to the brush chamber  19 . The arm rest  28  may be eliminated. The double gears  34  and gear cover  30  can be eliminated for the simplicity of a direct drive. 
   Referring to  FIG. 10 , a variety of flick plates may be used interchangeably. Plates with different patterns are provided to assist in the application of custom patterns. The different plate shapes cause the bristles on the circular brush  40  to be pushed in various directions, causing different patterns to emerge. 
   Referring to  FIG. 9 , the main body casing and removable cover can be constructed separate from the hopper and primary handle. They would in essence form a circular cartridge  84 . The cartridge assembly  84  would fix into a saddle  86  constructed as part of the hopper. The cartridge  84  would have the ability to rotate within the saddle  86 . Rotating the cartridge  84  moves the flick plate to a higher or lower position, thereby changing the trajectory of the expelled texture material. This rotating configuration allows for easier coverage of ceiling areas. The cartridge  84  may be held in place by the use of a removable pin  88  located on saddle  86  and extending through one of a series of holes  90  on the side of cartridge  84 , as seen in  FIG. 9 . As cartridge  84  is rotated, the pin  88  would line up with a different hole  90 , thereby allowing for different secured positions. Although not shown, the cartridge  84  may also be held in place by the use of a removable pin  88  located on cartridge  84  and extending through one of a series of holes  90  on the side of saddle  86 . 
   In  FIGS. 6 and 7 , a second embodiment of the applicator is presented. This applicator is designed to address the requirements of an applicator suited to larger jobs and to the application of custom texture patterns. For this purpose a number of modifications to the first embodiment have been made. 
   For efficiently covering large areas, an applicator utilizing a circular brush with a larger diameter and wider face is useful. With a wider face and larger diameter, large surface areas can be covered efficiently. The wider face and larger diameter also allow for more diverse bristle patterns, making the application of custom patterns more effective. 
   For comfort and stamina, the weight of the applicator may be reduced. The hopper on the first embodiment may be omitted. A remote location for the texture compound container may be used in its place. The container must be capable of holding a large amount of material, yet must also be portable. 
   Many of the features of the first embodiment are present in the second embodiment. The differences and additions are discussed below. 
     FIGS. 6 and 7  show a second embodiment of a texturing applicator according to the present invention. The power source utilized for this embodiment is a small motor  58 . The motor  58  may be located and attached between the primary handle  26  and the main body casing  18 . A standard belt pulley  54  may be affixed upon the motor&#39;s drive shaft. A second pulley  54  attaches to the main driveshaft  50 , which in turn rotates the circular brush  40 . A drive belt  62  is provided and exists in a taut position between both pulleys  54 . A belt cover  60  may be affixed to main casing  18 , protecting the belt  62  and pulleys  54  within. 
   The motor  58  may utilize a standard variable speed control mechanism  66  located in a secondary handle  52 . The rotation speed can be easily set and manipulated by setting the speed control  66  to the desired speed. A power cord  64  may be located along side supply line  56 . The secondary handle  52  is provided to add stability and support to the applicator, making it easier on the user to manipulate. The applicator is supplied with texture compound under pressure by a supply line  56 . In order to control the flow through the supply line  56  to the brush chamber  19 , an inline gate valve  72  is located in the primary handle  26 . Depression of the flow control trigger  24  adjusts the flow rate through the line  56 . 
   As seen in  FIG. 8 , the supply line  56 , a pressure capable hose of suitable diameter, is connected to the bottom of supply tank  74 . The tank  74  provides texture material to the brush chamber  19  through supply line  56 . A gate valve  76  is provided at the tanks outlet point. The tank  74  may be made of aluminum and is preferably fitted with a pressure tight twist on lid  78 . A pressure gauge  80  is present on the lid  78 . An air inlet fitting  82  may also be present on the lid  78 . A high pressure hose attached to a standard small compressor (not shown) may be hooked up to the inlet fitting  82 , putting a constant even pressure on the tank&#39;s contents. 
   Other variations possible with this second embodiment include fitting the supply tank  74  with wheels and/or handles for portability. Although the flick plate  36  and flick plate bracket  38  in  FIGS. 6 and 7  are mounted on the upper portion of the hopper casing  18 , they can also be mounted in the lower position, such as in the first embodiment  FIGS. 1-5 . 
   Thus it should be apparent to the reader that some old technology surrounded by new innovations has resulted in an applicator of superior versatility and effectiveness in the application of existing texture patterns and new custom patterns. It should be apparent that an applicator has been provided that is simple in operation, easy to manufacture, light weight, and portable. 
   It should also be apparent that an applicator has been provided that can be built to different scales, that is capable of handling large or small jobs, that can produce a multitude of patterns, that utilizes re-moveable and varied flick plate and circular brush configurations, and that can utilize a hopper or supply tank. 
   While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention.