VISCOUS MATERIAL AND METHOD THEREOF

BACKGROUND OF THE INVENTION

The present invention concerns an article for applying and spreading viscous material, and in particular concerns a recloseable tube and cap adapted with an integral spreader for spreading viscous material dispensed from the tube.

Typically, when spreading viscous materials like adhesives and spackling compounds, one must scoop the material from containers using a "putty knife" or other thin flat spreading tool. Inevitably, the ridge along the top edge of the container becomes partially filled with dried compound, thereby preventing an airtight seal when the lid is replaced. Also, the compound near the top of the container partially dries and clots, and thus develops an unworkable and/or unacceptable consistency. Aside from problems with the material itself, the putty knife may be misplaced or dirty, or may have the wrong stiffness/flexibility for spreading the particular viscous material being used. Still further, scooping material from a container with a putty knife requires two hands, one for the putty knife and one for the container, making it difficult for the repair person to do other tasks, such as to hold onto a ladder for balance during the application process or to wipe up misapplied material.

Viscous materials can also be applied by using a tube to dispense the viscous material, and subsequently spreading the viscous material with an applicator tool. While this method is "neater" than the aforementioned procedure, it still requires two hands - one for squirting the material and one for spreading the material. Also, a clean applicator tool having the desired size, shape and preferred stiffness/flexibility must be obtained.

Skilled workers who apply viscous materials as part of their job prefer articles and tools that can be adapted to particular jobs and to the worker's particular preferences. In particular, when applying viscous materials, workers desire spreader blades having a desired amount of flexibility/stiffness, a desired width and shape, and a cleanable and durable blade. Nonetheless, the workers also prefer to use disposable containers of viscous material to avoid the mess and inefficiencies of having to load viscous material into a gun or applicator.

Thus, an article and method solving the aforementioned problems is desired.

SUMMARY OF THE INVENTION

In one aspect, the present invention includes an article for dispensing and

spreading viscous material having a blade configured to spread viscous material, and a tube-engaging member having an attachment flange for attaching to and supporting the blade. The tube-engaging member is configured to operably engage a tube filled with the viscous material and includes a supply tube extending to the blade for communicating the viscous material squeezed from the tube to the blade for spreading by the blade.

In another aspect, the present invention includes an article for dispensing and spreading viscous material including a one-piece tube having a body defining a chamber for holding a viscous material and a blade-defining end having a relatively wide and flat profile. The blade-defining end includes a supply tube extending from the body to the blade-defining end for supplying material from the chamber to a location proximate an edge of the blade-defining end.

These and other features and advantages of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims and appended drawings. BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a perspective view of an article embodying the present invention including a cap having an integral blade attached to a tube, the tube being shown in phantom;

Fig. 1A is a side view of the article shown in Fig. 1 in use; Figs. 2-6 are front, side, rear, top and bottom views of the cap shown in Fig. 1;

Fig. 7 is a cross-sectional view taken along the lines VII- VII in Fig. 2.;

Fig. 8 is a side view including an edge guard positioned on the blade of the cap shown in Fig. 2;

Fig. 9 is a perspective of the cap including the edge guard shown in Fig. 8; Fig. 9 A is a fragmentary rear view of a modified cap having a serrated blade edge;

Fig. 10 is a perspective view of a modified cap including a blade embodying the present invention;

Figs. 11-14 are front, side, top and bottom views of the blade shown in Fig. 10, the blade being shown in the closed position;

Figs. 15-17 are front, side and top views of the cap shown in Fig. 10, the blade being shown in the folded position;

Fig. 18 is a front view of a flexible tube embodying the present invention

including a dispensing remote end modified to include an integral blade;

Figs. 19-21 are side, top and bottom views of the tube shown in Fig. 18;

Fig. 22 is a front view of a modified flexible tube embodying the present invention; Figs. 23-24 are plan and side views of another modified flexible tube embodying the present invention;

Figs. 25-26 are fragmentary top and bottom views of the modified tube shown in

Fig. 23;

Fig. 27 is a plan view of a tube-supporting-and-engaging putty knife; and Fig. 28 is a cross sectional view of the putty knife shown in Fig. 27 including the tube-engaging connector.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

For purposes of description herein, the terms "upper, " "lower, " "right," "left, "

"rear, " "front, " "vertical, " "horizontal, " and derivatives thereof shall relate to the invention as oriented in Fig. 1, the front of the tube being toward the left. However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and methods 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 be considered as limiting, unless the claims expressly state otherwise.

An article 30 (Figs. 1 and 3) embodying the present invention includes a tube 32 made of a resilient material for holding viscous material 33, and a cap 34 threadably engaged with a dispensing end 36 of tube 32. Cap 34 includes a blade 38 and material defining a passageway 40 for communicating viscous material in tube 32 from a dispensing outlet 42 in dispensing end 36 to a dispensing point proximate an edge 44 on blade 38. By dispensing the viscous material proximate blade edge 44, the viscous material can be conveniently applied and spread with a continuous motion without the need to change hands or manipulate a separate tool such as a putty knife.

Tube 32 is made of a resilient material that can be squeezed to dispense the viscous material held in the chamber defined inside of tube 32. Such tubes and resilient materials are generally known in the art, and are of the type commonly used for

toothpaste and moisturizing cremes. The sidewalls of tube 32 define a generally continuous transition from a dispensing remote end 48, which is substantially flat and closed, to the dispensing end 36, which is generally cylindrically-shaped. An externally threaded nipple 50 extends longitudinally from dispensing end 36 and defines the dispensing outlet 42 (Fig. 1A).

Cap 34 is a one piece molded member and includes a cylindrically-shaped body 52 that is internally threaded to mateably releasably engage threaded tube nipple 50. A disk- shaped wall 54 forms the end of body 52 and a spreader or flat blade 38 extends longitudinally from disk-shaped wall 54. Body 52 defines a longitudinal center line 56, and blade 38 is offset from center line 56 (Fig. 3). This offset position facilitates use of the blade 38 since the sides of tube 32 are positioned farther away from the worksurface 31 being repaired (Fig. 1A). Three ribs 58, 60 and 62 (Fig. 1) extend generally longitudinally along the "back" side of blade 38 from body 52 toward the blade edge 44. The number and shape of ribs 58, 60 and 62 can be customized to create a preferred flexibility/stiffness in blade 38 given the viscosity of the viscous material 33 being spread. Also, an operator can place his or her fingers on or between ribs 58, 60 and 62 for better control when manipulating blade 38. The surface and thickness of blade 38 can also be customized to an optimal surface smoothness, slipperiness (i.e., resistiveness to adhesion by the viscous material), and size for the viscosity of the material being applied. For example, a higher viscosity material would likely require a stiffer blade 38. Ribs 58, 60 and 62 terminate short of edge 44, and a series of bumps 64 are located between the ends of the ribs and edge 44, the bumps forming a line generally parallel edge 44.

The center rib 60 is enlarged over ribs 58 and 62, and is somewhat deeper than it is wide for mechanical advantage so that an optimally stiff section is formed in the center of blade 38. Further, rib 60 is hollow, and defines the oval-shaped passageway 40. A secondary outlet 66 extends through blade 38 at the outer end of passageway 40. Viscous material 33 (Fig. 1A) squeezed from tube 32 passes through passageway 40 and secondary outlet 66 and is deposited onto the "front" side 68 of blade 38 near blade edge 44. "Front" side 68 of blade 38 is flat, and thus suitable for scraping/spreading the dispensed viscous material into a desired flat film covering a worksurface. The flatness of front side 68 also facilitates cleaning side 68. Notably, edge 44 can include serrations 45 (Fig. 9A) or can be "U" shaped or "V" shaped such as to facilitate caulking a window pane or a bathtub.

An edge guard 70 (Figs. 8-9) is shaped to be releasably clipped onto blade 38 to protect edge 44 and to cover secondary outlet 66. Edge guard 70 is U-shaped and is formed from sheet metal, plastic or other structural material. Edge guard 70 includes a first leg 72 which is generally flat and long enough to sealingly cover secondary outlet 66. The free end 74 of first leg 72 is radiused for aesthetics and for ease of grasping. Edge guard 70 further includes a second leg 76 opposite first leg 72 which has a plurality of undulations 78. Undulations 78 are configured to frictionally engage bumps 64 to retain edge guard 70 on blade 38. First and second legs 72 and 76 are connected by a resilient section 78 that biases legs 72 and 76 together but allows flexible movement therebetween. Edge guard 70 can be snapped into place on blade 38 from a longitudinal direction (over the front edge 44) or from a lateral direction (parallel front edge 44). Notably, edge guard 70 can be used as an auxiliary device to clean flat side 68, such as by scraping radiused edge 74 across blade front edge 44.

Additional articles 30A, 30B and 30C embodying the present invention are shown in Figs. 10-17, Figs. 18-21 and Fig. 22, respectively. To reduce redundant discussion, identical or comparable features are identified by using identical numbers as were used in describing article 30, but with the addition of letters "A," "B," and "C," respectively.

Cap 34A (Figs. 10-17) includes a body 52A, a pivotable tip 80A, and a blade 38A integrally connected to pivotable tip 80 A. Tip 80 A is rotationally mounted in body 52 A by axle 81A. Specifically, axle 81A engages a receptacle 83A in cap 34A configured to rotationally support tip 80A proximate dispensing outlet 42 A. Axle 81 A and receptacle 83 A are generally known in the art. However, tip 80 A defines a passageway 82 A operably connected to passageway 40 A on blade 38 A. Tip passageway 82 A is aligned with dispensing outlet 42 A on tube 32 A when pivoted to an extended position (Figs. 10- 14), but is misaligned with dispensing outlet 42 A when tip 80A is pivoted to the folded position (Figs. 15-17). Thus, tube dispensing outlet 42A is closed when tip 80A is in the folded position and the viscous material within tube 32 A will not dry out. Notably, blade 38 A includes a single reinforcement rib 60 A and also blade 38 A is tapered to a relatively thin tip along edge 44 A. Thus, blade 38 A is somewhat more flexible than blade 38. Accordingly, a lower viscosity material is likely to be used in article 30A.

Tube 32B (Figs. 18-21) includes an enlarged flattened section 84B at the dispenser remote end 48B forming a blade 38B and a blade edge 44B. Enlarged flattened section

84B is formed by thermally sealing opposing sidewalls of tube 32B together. The

enlarged flattened section 84B extends about an inch or so inwardly from the blade edge 44B on dispensing remote end 48B; however it is noted that section 84B can be substantially any size or shape desired. The inner marginal edge 86B of flattened section 84B is arcuately-shaped to define an area for comfortably receiving a person's thumb or forefmgers. Cap 34B is threadably retained on the dispensing end 36B of tube 32B. Cap 34B includes a pivotable tip 80B for closing dispensing outlet 42B. By thermally bonding the tube sidewalls together to form enlarged flattened section 84B, the stiffness of section 84B is increased above the thickness of a single, unsupported wall of tube 32B so that section 84B is stiff enough to readily spread viscous materials having the viscosity of spackling compounds or caulking compounds. It is noted that a stiffening board or reinforcement ribs can be added to further stiffen section 84B if necessary or desired. However, it is noted that as a practical matter, some flexibility of enlarged flattened section 84B is usually desired.

Tube 32C (Fig. 22) is substantially identical to tube 32B except that tube 32C includes a blade edge 44C having serrations 88C. The serrated edge 44C allows viscous material to be spread with a desired material distribution while the edge 44C is moved across a worksurface. Afterwards, the flat side 68C of enlarged flattened section 84C can be used to smooth the viscous material. Alternatively, the serrated edge 44C can be used to leave a pattern in the dispensed viscous material. Notably, the ribs defining serrations 88C can be any size, length, shape or profile (such as "V" shaped, "U" shaped or rectangularly-shaped) to facilitate the application process.

In operation, viscous material is applied by manually squeezing or otherwise dispensing the viscous material from the tube 32 (or 32 A, 32B or 32C), and by spreading the dispensed viscous material or otherwise working the viscous material to a desired smooth pattern on the worksurface while continuously holding the tube in the worker's hand. Thus, the task of spreading the viscous material can be accomplished by using a single hand while the repair person's other hand remains free for other purposes, such as for hanging onto a ladder. Still further, the disclosed articles are "self contained", and no separate tools or containers are required. A one-piece article 30D (Figs. 23-26) includes a viscous material holding tube

32D and a molded-in blade-forming end section 38D. The blade-forming end 38D includes a molded-in passageway 40D for communicating viscous material from within tube 32D to outlet 66D proximate blade edge 44D, and further includes stiffening ribs

58D and 62D. A blade-edge-covering edge guard 70D is configured to snap onto blade edge 44D and cover passageway outlet 66D. Blade-forming end section 38D can be molded relatively thick to provide stiffness to the blade-forming end 38D, or a metal insert can be insert-molded into blade end section 38D for stiffness. Tube dispensing- remote end 48D is molded open so that viscous material can be injected therein from the dispensing-remote end 48D, after which the dispensing-remote end 48D is thermally sealed or otherwise closed so that the viscous material can be forced through passageway 40D as the tube 32D is squeezed. The article 30D conveniently holds material in a substantially closed contained manner such that the material does not tend to dry out. Further, article 30D can be conveniently disposed of in an environmentally safe manner when empty.

A tube-supporting-and-engaging article 100 (Figs. 27-28) includes a metal blade 101, and a molded plastic tube-supporting shell 102 having an adapter section 103 that interconnects the blade 101 to the shell 102 structurally. Adapter section 103 also operably interconnects a tube 104 positioned in the shell 102 to the blade 101. Tube- supporting shell 102 includes a semi-cylindrically-shaped receptor 104 having a transverse wall 105 at one end and an open end 106 at its other end. Receptor 104 is shaped to mateably receive the tube 104. Transverse wall 105 includes a centrally located hole 107. A tubular connector 108 (Fig. 28) extends from transverse wall 105 into receptor 104. Tubular connector 108 includes depressions 109 forming a connecting structure for mateably receiving and sealingly engaging ridges on the outlet end 110 of tube 104. Depressions 109 can be in the form of a single ring (as shown) or can be various configurations such as threads, twist-lock connecting arrangements, and the like. The illustrated depressions 109 allows for quick disconnection of an empty tube 104 and for quick snap-attach reconnection of a new full tube 104 to article 100. A second tubular connector 111 extends from transverse wall 105 in a direction opposite tubular connector 108. Second tubular connector 111 includes radially extending rings 112 on its exterior surface, and a flexible supply tube 113 includes a cylindrical wall-shaped to securely frictionally sealingly engage rings 112. Flexible supply tube 113 is L-shaped and includes an axially extending leg 114 and a laterally extending leg 115. Axially extending leg 114 includes a series of ring-shaped accordion-like depressions or ripples 116 that allow axially extending leg 114 to flex. This accommodates flexing of blade 101, yet allows a continuous supply of viscous material to be provided to blade 101. A flange 117 extends

from transverse wall 105 axially. Flange 117 is generally stiff but resiliency flexible. Flange 117 extends a distance shorter than axially extending leg 114 of supply tube 113, and includes a series of countersunk holes 119 across its width.

Blade 101 comprises a sheet metal part selected for its desired level of flexibility. Notably, workers often want different blade stiffnesses/flexibilities depending upon the viscosity of the material being spread and the particular idiosyncrasies/preferences of the worker, particularly skilled workers who have developed abilities to apply materials quickly and efficiently. Blade 101 includes a spreading edge 120 and a flange-engaging end 121 opposite spreading edge 120. Flange-engaging end 121 includes a series of holes 122 corresponding to countersunk holes 119, and screws 123 extend through countersunk holes 119 and threadably engage holes 122 to securing blade 101 to adapter 103. Thus, different blades can be secured to shell 102. For example, the blades can be different widths, such as 3" or 4" blades, or the blades can include differently shaped spreading edges, such as a planar blade with straight edge, a planar blade with serrated edge, and/or a non-planar blade. The laterally extending leg 114 of supply tube 113 extends through a hole 124 in blade 101. Laterally extending leg 114 includes a lipped end 125 that retains leg 114 in hole 124. However, it is contemplated that a number of different configurations can be used to retain leg 114 in hole 124, such as a U-clip, a snap-in-place connector formed on leg 114 including angled barbs, and other shapes. A blade-edge guard 126 can be used to cover outlet 127 of supply tube 113, or a piece of tape adhered to blade 101 or plug positioned in outlet 127 can be used.

To use article 100, a blade 101 having a desired shape, width, and stiffness is connected to shell 100, and a flexible supply tube 113 is connected from receptor 104 to blade 101. A tube 104 having a particular viscous material therein is snap attached or otherwise operably connected to article 100. The viscous material is squeezed from tube 104 through supply tube 113 and applied to a substrate adjacent blade edge 120. Notably, as a worker applies material, blade 101 will be flexed to various positions. However, the supply tube 113 also flexes allowing a continuous supply or "as-needed" supply of viscous material to be provided to blade 101 for trowelling. In the foregoing description, it will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed herein. Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise.