So far the roller has often been dipped directly down into the paint or the glue in the tin, whereby at least a string of paint adheres to a part of the peripheral surface of the roller. Primarily this gives a very bad distribution of the paint or glue over the roller since the paint of the glue adheres as a usually narrow string axially on the roller, whereby the paint or glue does not become spread round the entire roller. The string of paint or glue weighs the roller down on the side carrying said string of paint, so that the string of paint becomes directed downwards and there is a risque that the paint drips. The paint or glue is, in this case, generally distributed over the actual surface in that the roller is moved forth and back over the surface intended to be covered with paint or glue, for instance the wall, the ceiling, the wallpaper etc. The relatively thick string of paint which is obtained when the roller is dipped in the paint tin also may cause the paint to splash if the roller is not handled with care when the paint is distributed over the entire surface of the roller. It is also usual that excess paint from the roller or from the handle thereof drips down and provides splashes and contamination of objects present underneath.

It is also known in case of painting with rollers to make use of a separate paint tray having an integral paint distribution surface, in which apparatus the paint is poured down in a tray bowl, whereupon the roller is dipped down in the paint or glue and is rolled forth and back on the paint distribution surface until the paint is evenly distributed over the roller. Said apparatus is disadvantageous, among other things, in that the paint has to be poured from the paint tin into the separate tray, and that excess paint, after the painting work is finished, has to be poured back into the paint tin. Also in this handling there is a risque of spilling and splashing, it

is cumbersome to hand the paint accordingly, and it is necessary to use a separate paint tray for each individual paint colour. The tray also generally has to be discarded after the painting work is finished.

There also has been suggested a paint distribution apparatus in the form of a separate paint distributor disc which, with one end thereof, can be dipped down into the paint in the tin to be supported against the bottom thereof, and in which the roller can be dipped down into the paint aside of said paint distributor disc and can be rolled up and down over the part of the paint distributor disc appearing above the paint surface. Also when using said apparatus there is a risk of dripping and splashing of paint, and it can be difficult to make use of such apparatus in fully filled up paint tins, since the part of the disc projecting above the paint surface is thereby too small. Further there are problems when the paint is nearly consumed since the roller thereby can not be dipped down in the paint between the distributor disc and the edges of the paint tin. Also in this case the paint distributor disc normally has to be discarded after the painting work has been finished.

It has been noted that it would be a great advantage if the paint or glue tin of the said type could be formed with a paint distribution apparatus formed so that, at the first use thereof, it is pushed down plainly (horizontally) in the tin into contact with the paint whereby the paint is pressed up through small bores in the paint distributor and which, in front of all, can be maintained in the tin after the painting work is finished, whereby said paint disc acts as a kind of lid preventing the paint in the tin, underneath said disc, to become dried. The little amount of paint which is remained on top of the disc may very well be allowed to dry thereby providing a skin of dry paint which can easily be torn off and be discarded when the paint tin is to be used for any forthcoming painting work, in particular since the paint feeding bores are thereby re-opened. Upon need the paint distribution disc can, of course, be removed in connection to a succeeding painting work and can be replaced by a new paint distribution disc.

Such an apparatus is shown for instance in the Swedish patent having

publication number 507.855. Said disclosed apparatus is in the form of a disc of a relatively hard material, like a wood fibre board (Masonite@), a plastic material, a metal plate or a similar material having an outer periphery which, to shape an size, substantially coincides with the inner of a conventional paint tin, and which is formed with a number of bores through which paint can be pressed up to the upper surface of the disc when a pressure is applied to the upper surface of the disc. The paint is thereby distributed over a roller which is moved forth and back on top of the disc in the paint tin, or the paint can be received on a paint brush from the paint which is present on the upper side of the disc.

The above mentioned paint distributor is smooth and convenient to use, but it may happen that the disc becomes pressed down underneath the surface of the paint, or that the disc, by time, absorbs so much water or solvent from the paint that it becomes so heavy that it even can sink down in the paint to the bottom of the tin. In some cases it may also be difficult to provide an even distribution of the paint on top of the paint distribution disc.

Therefore, the object of the present invention has been to solve the problem of providing a paint distribution disc, which to shape and size is adapted to the inner of a paint or glue tin, and which, at the first use thereof, can be pressed down against the upper surface of the paint in the paint tin, and which, after the painting work is finished, can be kept in the tin thereby preventing the paint underneath the paint distribution disc to become dried, and which is formed so that there is no risque that it is pressed down underneath the paint surface and sinks down into the paint, and which is formed with means for facilitating an even distribution of the paint over the upper surface of the paint distribution disc.

According to the invention the paint distribution disc is made of an inert material which can not absorb water or a solvent from the paint or glue, and which is, at the lower surface thereof, formed with air pockets or other pockets acting as floating cushions for the paint disc adapted to prevent the paint disc from sinking down into the paint. It is formed with several paint feeding bores extending from the upper surface of the disc down to a level corresponding to the bottom level of

the floating pockets, and through which bores paint is pressed up to the upper surface of the disc when a pressure is applied to the upper surface of the disc.

The floating pockets can be filled with air, or they can be filled with an inert floating material, for instance a cellular plastic material, which does not absorb paint, water or solvent from the paint or glue. The floating pockets provide raised portions in the disc having vertical side edges which act to strengthen and stabilize the paint distribution disc.

In a preferred embodiment of the invention the paint distribution disc is, at the upper surface thereof, formed with a pattern of projecting ribs between which the paint supply bores are provided. Said ribs act as carrier surfaces over which the roller is adapted to roll and which contribute to an additional stabilizing of the disc. The pattern of ribs form chambers on top of the disc, in which chambers a thin layer of paint can be collected. Between the ribs there is deposited a thin layer of paint (glue), so that said paint can be evenly distributed over the roller in an optionally thick layer, or from which the paint can be received by means of a paint brush. A strong pressure by the roller causes a relative large amount of paint to be pressed up, a slight pressure gives a correspondingly little amount of pressed up paint and a thin paint distribution over the roller. Thanks to the stabilizing provided by the downwardly projecting side edges of the floating cusions it is possible to press the roller against the upper surface of the disc without having said disc bulging down too much, and the floating cushions prevent the disc from being pressed down into the paint.

Also in said new embodiment of a paint distributor disc it is possible to have same remain on the paint surface after the painting work is finished, and the little amount of paint which is remained on top of the disc can be allowed to dry thereby forming a skin which can easily be torn off in connection to a renewed painting work using the same paint tin.

Now the invention is to be described more in detail with reference to the accompanying drawings, which disclose some embodiments of a paint distributor disc according to the invention. In the drawings figure 1 shows a top view of a first

embodiment of a paint distributor disc according to the invention designed for a circular paint tin. Figure 2 shows a vertical cross section following line 11-11 of figure 1. Figure 3 shows a paint distributor disc designed for an elongated tin. Figure 4 shows a pattern-punch adapted to provide a raised paint distribution pattern according to figure 3 on top of the distributor disc from the lower surface of the disc, in the illustrated case a square pattern. Figure 5 shows the paint distributor disc according to figure 3 pressed down against the paint for use in a paint tin and seen along line V-V of figure 3. Figure 6 shows the encircled portion of figure 5 in an enlarged scale. Figure 7 shows a further embodiment of a paint distributor disc for use in circular cylindric tins. Figure 8 shows the encircled portion of the slotted edges of figure 7 in an enlarged scale, and Figure 9 shows the same slotted portion after the disc has been pressed down in the tin. Figure 10 is a fragmentary view of a cross section along line X-X of figure 7. Figures 11,12 and 13 show three different stages of using the paint distributor disc according to the invention while comsuming the paint in the tin.

The paint distributor insert shown in figures 1 and 2 is designed for a circular tin and comprises a paint distributor disc 1 having a shape and size which substantially coincides with the inner of the tin 2 for which it is designed. The disc can be made of plastic, metal plate, some type of laminated cardboard material or any other relatively thin and ductile, but still stable material which is repellent to such liquids and chemicals which may be present in paint. The disc is made of an even disc blank in which side edges 3 have been punched or pressed down, so that the disc provides a supporting upper surface 4, whereas the downwardly projecting side edges 3, which are integral with the supporting upper surface 4 over stepped landings 5, provide an air cushion 6 at the lower side of the disc 1. The unit consisting of upper surface 4 and landings 5 forms a raised portion which stabilizes the paint distributor disc at the same time as forming the above mentioned air cushion 6. The air cushion is intended to form a supporting body for the disc on top of the paint 7 in the tin 2, so that the disc does not sink down into the paint. For supplying paint at the upper surface of the disc there are

a large number of through bores 8 which are provided submerged from the supporting upper surface 4 of the disc, and which are formed at the bottom of a cone having sides 9, and in which said bores 8, in the illustrated case, open substantially flush with the pressed down side edges 3.

The air cushion 6 at the lower side of the disc 1 can preferably be filled with some material which increases the floating capacity of the disc on the paint, especially an inert material 10 which does not absorb liquid of chemicals, for instance a cellular plastic material which fills out the entire air cushion down to the bottom plane at which the bore 8 opens and at which plane the pressed down side edges project radially outwards from the lower edge of the stepped landings 5. For adapting the outer edges of the side pieces 3 to the circular shape of the tin said side pieces 3 are formed with slots 11, so that the side edges can bow slightly upwards inside the tin 2. This is of importance, in particular since the tin is usually conically tapering in the direction downwards, so that the side edges bow more and more upwards the further down the disc 1 is pressed following the consumption of paint 7 in the tin. The slots 11 are provided at suitable places so that the intermediate slotted portions 12 place themselves partly overlapping on top of each other when the disc is pressed down at the same time as the side edges sealingly engage the inner surface of the tin 2 and, by a type of barb action, prevent the disc from unintentionally being displaced upwards in the tin.

For making it possible to provide an even distribution of paint which has been pressed up to the upper surface 4 of the disc through the bores 8,9, and for also increasing the supporting capacity for the roller 13 (see figures 8,9) against the upper surface 4 the disc 1 is formed with upwardly projecting ribs 14 provided in a suitable pattern. The ribs can be formed as a series of concentric rings (not shown in the drawings) or preferably as a type of square pattern, in which the paint supply bores 8,9 are preferably provided at the centre of each square 15.

The forming of pattern can be made by deep drawing of a heated flexible disc blank from the upper surface of the punch using vacuum from underneath a pattern forming punch. The square pattern as a whole can be arranged centred

over the supporting upper surface 4 of the disc. The ribs 14 preferably extend, over an extension 16, at least at some places as far as to the edge at the stepped landings 5 for stabilizing the square pattern at the upper surface 4 of the disc 1 so that it can counteract the force which is applied when the roller 13 is rolled over same without too much bulg down. The square pattern formed by the ribs 14 has two different functions, namely firstly to stiffen the disc 1 so that it can carry the roller, and secondly to provide a series of cavities which make it possible to evenly distribute the paint which is pressed up through the bores 8,9. The paint is distributed in a relatively even layer of paint in the cavities formed by the squares 15 and it thereby provides a relatively large surface for distributing paint over the entire roller, both longitudinally and peripherally over same. As mentioned above it is, of course, also possible to fill a paint brush with paint at the upper surface of the disc.

The depth of the air cushion 6 at the lower side of the disc 1 can be varied as desired and considering the floating capacity which is desired, which may vary depending on the type of material content of the tin. A low viscosity content and a large/wide tin may require a deeper air cushion than a high viscosity content and a tin having a relatively small cross section area. For water based paints of plastic type and for tins having a volume of between 4 and 10 litres a depth of 2-6 mm can be sufficient for the air cushions. The height of the ribs 14 also can be varied considering the content of the tin, but a rib height of 1-3 mm is sufficient and suitable for most paints.

In figure 3 is shown a paint distribution disc useful for an oval tin. Otherwise the disc is formed like the disc shown in figures 1 and 2. In figure 4 is shown a punch 17 by means of which the ribs 14,16 can be formed. This can be made in that an even disc is placed on top of a punch 17 having raised ribs, whereupon said disc is deep drawn in heated condition over the punch 17 using vacuum suction from underneath the punch 17. The bores 8,9 are preferably punched out and are shaped in a succeeding manufacturing step.

Figures 7-10 disclose an alternative embodiment of a paint distribution disc,

in which the pattern comprising the ribs 14 extend as far as to the outer periphery of the support surface 4 at several places, whereby the disc provides a very stiff support surface 4. The side edges are formed with several slotted portions 12 which are split from each other using obliquely extending slots 11a, as seen in figure 8 following the arrow VIII of figure 7. This enables the slotted portions 12 to slide overlapping on each other, as diagrammatically indicated in figure 9, when the disc is pressed down in a tin, especially in a conically tapering tin. In order to give the disc 1 an optimum floating capacity and stability the peripheral landing 5 of the support surface 4 ends at a level 18, see figure 10, which is lower than the bottom level 19 of the paint supply bores 8 and is ended by a channel 20 adjacent the side edges 3. For a tin containing 4-10 litres of paint or glue etc. a difference in levels 19-18 of about 1-2 mm is considered suitable. The upper end of the side edge 3 preferably is located on a slightly higher level than the upper surface of the paint in the square paint chambers 15. For facilitating the inserting and the removal of the paint disc in a tin the disc may be formed with a grab ear, see figure 7.

The paint distributor disc 1 is supplied in suitable dimensions and shapes adapted to different sizes and differently shaped tins. As dagrammatically illustrated in figures 11,12 and 13 the disc 1 is pressed down into contact with the surface of the paint 7 in the tin 2. The edges 3 of the disc 1 are sealingly engaging the inner surface of the tin. When the roller 13 is thereafter pressed against the ribs 14 at the upper surface of the disc paint is pressed up through the bores 8,9, and the paint is, by the action of the roller 13, distributed over the cavities which are formed by the squares 15 of the ribs 14, whereby the paint is distributed and spread in an even layer on the upper surface of the disc 1, and thereby also over the roller 13. The air cushions 6, eventually having a filling of a floating material 10, prevent the disc 1 from being pressed down or from sinking down into the paint. In figure 8 is shown the situation when the paint 7 in the tin 2 has been consumed to about 50%, and figure 9 shows that it is possible, by means of the apparatus according to the invention, to make use of/consume practically all paint

7 in the tin, as far down as to the bottom thereof.

When the painting work is finished the paint disc is left in the tin. Some paint thereby flows back through the bores 8,9. The tin may even be left without a lid, whereby the thin layer of paint which has been left at the upper surface of the disc 1 is allowed to dry forming a skin, which can easily be torn off in connection a renewed painting operation with paint from the same tin. When the paint skin has been torn off the repellent upper surface of the paint distributor disc 1 said disc is effectively made rid of paint, and the bores 8,9 are opened for renewed pressing up and distribution of paint at the upper surface of the disc.

REFERENCE NUMERALS 1 disc 2 tin 3 side edges 4 support surface 5 stepped landing 6 air cushion 7 paint 8 through bore 9 side 10 inert material 11 slot (11 a) 12 slotted portion 13 roller 14 rib 15 square 16 extended rib 17 punch 18 level (of 8) 19 level (of 20) 20 channel