U.S. patent application number 10/339677 was filed with the patent office on 2003-12-04 for reusable masking device for sprayable bed liner.
This patent application is currently assigned to NISSAN TECHNICAL CENTER NORTH AMERICA, INC.. Invention is credited to Bradley, Blaine, Cuyler, Brian B., Dumbleton, Richard, Womack, Darren.
Application Number | 20030224198 10/339677 |
Document ID | / |
Family ID | 29586598 |
Filed Date | 2003-12-04 |
United States Patent
Application |
20030224198 |
Kind Code |
A1 |
Cuyler, Brian B. ; et
al. |
December 4, 2003 |
Reusable masking device for sprayable bed liner
Abstract
A masking device is provided with a plug including at least one
protruding portion, wherein the protruding portion is adapted to
engage at least one of an orifice and a deformation in a
substrate.
Inventors: |
Cuyler, Brian B.; (Oxford,
MI) ; Womack, Darren; (Windsor, CA) ;
Dumbleton, Richard; (Northville, MI) ; Bradley,
Blaine; (Madison, MS) |
Correspondence
Address: |
FOLEY AND LARDNER
SUITE 500
3000 K STREET NW
WASHINGTON
DC
20007
US
|
Assignee: |
NISSAN TECHNICAL CENTER NORTH
AMERICA, INC.
NISSAN NORTH AMERICA, INC.
|
Family ID: |
29586598 |
Appl. No.: |
10/339677 |
Filed: |
January 10, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60346889 |
Jan 11, 2002 |
|
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Current U.S.
Class: |
428/577 |
Current CPC
Class: |
B05B 12/26 20180201;
Y10T 428/12229 20150115 |
Class at
Publication: |
428/577 |
International
Class: |
B21F 001/00 |
Claims
What is claimed is:
1. A masking device, comprising: a plug including at least one
protruding portion, wherein said protruding portion is adapted to
engage at least one of an orifice and a deformation in a
substrate.
2. The masking device according to claim 1, wherein said plug
includes a magnetic insert, and wherein said substrate comprises a
metal, said magnetic insert functioning to magnetically hold said
masking device on said metal substrate.
3. The magnetic device according to claim 1, wherein said plug
comprises a magnetic material.
4. The masking device according to claim 1, further comprising a
material having a surface energy less than about 50 dynes/cm
applied to at least a portion of said plug.
5. The masking device according to claim 4, wherein said material
comprises Teflon.
6. The masking device according to claim 1, further comprising a
plurality of plugs, each plug including a protruding portion
adapted to engage at least one of an orifice and a deformation in a
substrate.
7. The masking device according to claim 1, further comprising a
material having a surface energy less than about 37 dynes/cm
applied to at least a portion of said plug.
8. The masking device according to claim 1, further comprising a
material having a surface energy less than about 30 dynes/cm
applied to at least a portion of said plug.
9. The masking device according to claim 1, further comprising a
material having a surface energy less than about 20 dynes/cm
applied to at least a portion of said plug.
10. The masking device according to claim 1, wherein said plug is
configured to overhang a portion of said substrate so as to create
a tapered edge of a material sprayed on said substrate.
11. A truck bed, comprising: a bed; at least one bushing adjacent
to said bed; and a coating applied over said bed, wherein said
coating is applied such that said coating retains said bushing
adjacent to said bed.
12. The truck bed according to claim 11, wherein said coating
comprises a sprayed polyurethane bed liner.
13. The truck bed according to claim 11, wherein said bushing
includes an elongated section adjacent to an upper edge of a
channel in said bed.
14. A method of manufacturing a truck bed liner, comprising the
steps of: positioning at least one masking plug having a protruding
portion into an orifice of said truck bed; applying a bed liner
material onto said truck bed; and removing said at least one
masking plug.
15. The method of manufacturing a truck bed liner according to
claim 14, wherein said at least one masking plug comprises a
magnetic material, said magnetic material magnetically holding said
at least one masking plug adjacent to said truck bed.
16. The method of manufacturing a truck bed liner according to
claim 14, further comprising a step of positioning at least one
bushing adjacent to said masking plug prior to the step of
positioning at least one masking plug having a protruding portion
into an orifice of said truck bed, said masking plug magnetically
holding said bushing on said masking plug.
17. The method of manufacturing a truck bed liner according to
claim 14, further comprising a step of removing said masking
plug.
18. A truck including a bed liner manufactured by the method
according to claim 14.
19. A masking device, comprising: a plug adapted to cover at least
one of an orifice and a deformation in a substrate; and a clip
coupled to said plug, said clip being adapted to releasably retain
said plug on said substrate.
20. The masking device according to claim 19, wherein said plug and
said clip are separate components.
21. The masking device according to claim 19, wherein said plug and
said clip are formed as an integral component.
22. The masking device according to claim 19, further comprising a
material having a surface energy less than about 50 dynes/cm
applied to at least a portion of said plug.
23. The masking device according to claim 22, wherein said material
comprises Teflon.
24. The masking device according to claim 19, further comprising a
material having a surface energy less than about 37 dynes/cm
applied to at least a portion of said plug.
25. The masking device according to claim 19, further comprising a
material having a surface energy less than about 30 dynes/cm
applied to at least a portion of said plug.
26. The masking device according to claim 19, further comprising a
material having a surface energy less than about 20 dynes/cm
applied to at least a portion of said plug.
27. The masking device according to claim 19, wherein said plug is
configured to overhang a portion of said substrate so as to create
a tapered edge of a material sprayed on said substrate.
28. A masking device, comprising: a base portion adapted to cover
an area of a substrate; and a key lock adapted to releasably lock
said base portion to said substrate.
29. The masking device according to claim 28, further comprising:
at least one guide leg coupled to said base portion, said at least
one guide leg being adapted to engage at least one guide hole
within said substrate so as to position said base portion on said
substrate.
30. The masking device according to claim 28, further comprising:
at least one spacer coupled to a bottom surface of said base
portion so as to create a gap between said bottom surface of said
base portion and a top surface of said substrate.
31. The masking device according to claim 28, further comprising: a
shield having a profile of sufficient area so as to shield a
rotating portion of said key lock from sprayed material.
32. The masking device according to claim 29, further comprising a
material having a surface energy less than about 50 dynes/cm
applied to at least a portion of said base portion.
33. The masking device according to claim 32, wherein said material
comprises Teflon.
34. The masking device according to claim 29, further comprising a
material having a surface energy less than about 37 dynes/cm
applied to at least a portion of said base portion.
35. The masking device according to claim 29, further comprising a
material having a surface energy less than about 30 dynes/cm
applied to at least a portion of said base portion.
36. The masking device according to claim 29, further comprising a
material having a surface energy less than about 20 dynes/cm
applied to at least a portion of said base portion.
37. A masking device, comprising: means for masking at least one of
an orifice and a depression formed on a substrate; and means for
releasably positioning said means for masking on said
substrate.
38. The masking device according to claim 37, further comprising:
means for spacing said means for masking from a top surface of said
substrate.
39. The masking device according to claim 37, further comprising:
means for preventing sprayed material from adhering to said means
for masking.
40. The masking device according to claim 37, further comprising:
means for rotatably locking said means for masking on said
substrate.
41. A masking device for masking a region on a substrate,
comprising: a plug including at least one protruding portion,
wherein said plug is configured to overhang a portion of said
substrate so as to create a tapered edge of a material sprayed on
said substrate.
Description
CORRESPONDING RELATED APPLICATIONS
[0001] The Applicants claim the benefit of and priority to U.S.
Provisional Patent Application No. 60/346,889 filed on Jan. 11,
2002, the entire contents of which are incorporated by reference
herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] A. Field of the Invention
[0003] The invention relates generally to vehicle bed liners, more
particularly, to sprayable bed liners and methods of manufacturing
the same.
[0004] B. Description of the Related Art
[0005] As a way to protect pickup truck beds, a sprayable, rapidly
curing, polymer coating is applied to the painted or e-coated
surface. See, for example, U.S. Pat. Nos. 5,925,466 and 5,814,398
which are incorporated by reference herein in their entirety. These
sprayed on linings provide several advantages over the widely used
preformed plastic liners. The preformed plastic linings generally
do not form a tight seal between the truck bed and the liner, which
allows water and dirt to intrude in between the liner and the bed.
Water and dirt buildup can eventually lead to abrasion of the paint
and corrosion of the truck bed. Sprayed on liners (e.g., polymer
coatings) adhere to the surface of the truck bed, effectively
sealing it from water and dirt. Rapid curing sprayed on liners
allow the product to be sprayed on vertical and other
non-horizontal surfaces. Areas that do not require the sprayed on
liner, or must not have any build up of the sprayed on liner (e.g.,
cab rear glass window, tie downs, etc.), however, require trimming
or masking those areas to prevent the sprayed on liner from
adhering to those surfaces.
[0006] Trimming of the cured product is difficult and time
consuming. Trimming with a sharp blade or similar device can score
through the paint or e-coat applied to the pickup bed. Scoring
allows moisture to be in contact with the bare metal substrate
which would be a prime site for corrosion to begin. Furthermore, as
sprayed on liner materials tend to cure to a hard tough coating,
trimming generally must be performed before the sprayed on liner
fully cures.
[0007] Masking off areas to prevent the sprayed on liner from
adhering to those surfaces also has its difficulties. At least
partially due to the fast curing nature of sprayed on liners, if
masking tape is removed too long after the bed liner is sprayed,
the cured layer on top of the tape will effectively prevent it from
being removed. If the masking tape is removed before the material
is fully cured, a jagged appearance along the edge of the sprayed
on liner can result.
[0008] One solution to this problem is to mask with edge trimming
tape. See, for example, U.S. Pat. No. 6,025,045 which is
incorporated by reference herein in its entirety. Edge trimming
tape contains a wire which, when pulled up through a semi-cured
material, cuts the material and leaves a clean edge. Edge trimming
tape works well for long, straight, and semi-straight areas, but
holes and odd shapes are problematic due to their shape and size.
Also, because the edge trimming tape needs to be pulled up before
the sprayable bed liner is fully cured, there is a finite period of
time that the de-masking can take place. If the edge trimming tape
is left until the coating is fully cured, the removal of the tape
is difficult if not impossible.
[0009] Moreover, to provide clean edges for a desirable appearance,
trimming with a blade, conventional masking, and masking with edge
trimming tape, all need to be done shortly after the material is
sprayed (i.e., prior to substantial curing).
[0010] To date, substantially all of the sprayable bed liners have
been done by after market shops. Companies such as Rhino
Linings.RTM. spray bed liners one truck bed at a time, with the
masking, spraying and de-masking taking several hours. Using this
process in an original equipment manufacturer (OEM) manufacturing
plant, however, is not feasible due to the considerable amount of
time and labor required. Thus, to apply a sprayable bed liner in an
automobile manufacturing plant, a need exists for a method of
masking or trimming that is fast to apply, flexible enough to be
able to be removed after curing, and leaves a good appearance.
[0011] The present invention is directed to overcoming or at least
reducing the effects of one or more of the problems set forth above
and other problems in the prior art.
SUMMARY OF THE INVENTION
[0012] According to one embodiment of the present invention, a
masking device is provided with a plug including at least one
protruding portion, wherein the protruding portion is adapted to
engage at least one of an orifice and a deformation in a
substrate.
[0013] According to another embodiment of the present invention, a
truck bed is provided with a bed, at least one bushing adjacent to
the bed, and a coating applied over the bed, wherein the coating is
applied such that the coating retains the bushing adjacent to the
bed.
[0014] According to another embodiment of the present invention, a
method of manufacturing a truck bed liner is provided. The method
comprises the steps of positioning at least one masking plug having
a protruding portion into an orifice of the truck bed, applying a
bed liner material onto the truck bed, and removing the at least
one masking plug.
[0015] According to another embodiment of the present invention, a
masking device is provided with a plug adapted to cover at least
one of an orifice and a deformation in a substrate, and a clip
coupled to the plug, the clip being adapted to releasably retain
the plug on the substrate.
[0016] According to another embodiment of the present invention, a
masking device is provided with a base portion adapted to cover an
area of a substrate, and a key lock adapted to releasably lock the
base portion to the substrate.
[0017] According to another embodiment of the present invention, a
masking device is provided with means for masking at least one of
an orifice and a depression formed on a substrate, and means for
releasably positioning the means for masking on the substrate.
[0018] According to another embodiment of the present invention, a
masking device for masking a region on a substrate is provided with
a plug including at least one protruding portion, wherein the plug
is configured to overhang a portion of the substrate so as to
create a tapered edge of a material sprayed on the substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIGS. 1A-1D are views of a masking device according to one
embodiment of the present invention.
[0020] FIG. 2 is a perspective view of a masking device according
to another embodiment of the present invention.
[0021] FIG. 3 is a cross sectional view of a masking device
positioned on a sheet metal according to another embodiment of the
present invention.
[0022] FIG. 4 is a cross sectional view of a masking device and a
bushing retained by a bed liner material, with a portion of the
masking device enlarged in FIGS. 4A-4C, according to another
embodiment of the present invention.
[0023] FIG. 5 is a perspective view of a masking device including a
plurality of masking plugs according to another embodiment of the
present invention.
[0024] FIG. 6 is a perspective view of a masking device including a
plurality of protruding portions according to another embodiment of
the present invention.
[0025] FIG. 7 is a cross sectional view of a masking device
according to another embodiment of the present invention.
[0026] FIG. 8 is a side view of a masking device according to
another embodiment of the present invention.
[0027] FIGS. 9A and 9B are views of a masking device according to
another embodiment of the present invention.
[0028] FIGS. 10A-10C are views of a masking device according to
another embodiment of the present invention.
[0029] FIGS. 11A and 11B are views of a clip to be used with the
masking device of FIGS. 10A-10C according to another embodiment of
the present invention.
[0030] FIGS. 12A-12C are views of a masking device according to
another embodiment of the present invention.
[0031] FIGS. 13A-13C are views of a clip to be used with the
masking device of FIGS. 12A-12C according to another embodiment of
the present invention.
[0032] FIGS. 14A-14C are views of a masking device according to
another embodiment of the present invention.
[0033] FIGS. 15A-15C are views of a wide bodied masking device
according to another embodiment of the present invention.
DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS
[0034] Reference will now be made in detail to presently preferred
embodiments of the invention. Wherever possible, the same reference
numbers will be used throughout the drawings to refer to the same
or like parts.
[0035] According to one aspect of the present invention, as a way
to mask channels, holes and other areas of a vehicle, to which a
sprayable bed liner material is to be applied, a fast, reusable,
and effective method has been developed. The method employs a
magnetic material covered with Teflon, or other low surface energy
material. The shape of the piece is such that it can be located
easily before the material is sprayed, and removed after, revealing
a clean surface with no bed liner material. The low surface energy
of the Teflon, or similar material, does not allow the sprayable
bed liner to wet then bond to it, thus making removal of the
masking plug easy. A magnetic core of the masking plug keeps it
fixed in position during the spraying of the bed liner material.
Because the design does not allow the sprayable material to overlap
onto it, it can be removed after the material has cured.
[0036] A first embodiment of the present invention is shown in the
views of FIG. 1 (i.e., FIGS. 1A-1D). According to this first
embodiment, a masking device 100 comprises a masking plug 10 and a
protruding portion 30 for locating the masking plug 10 on a
substrate (not shown) such as a metal truck bed. As would be
readily apparent to one skilled in the art after reading this
disclosure, the masking plug 10 can take on any number of shapes or
designs (e.g., plug 410 in FIG. 4, plug 810 in FIG. 7, plug 910 in
FIG. 8, etc.), thereby facilitating the use for masking complex
shaped areas which could not be done easily with conventional
techniques.
[0037] Preferably, the masking plug 10 comprises and/or is coated
with a material having a substantially low surface energy. The
masking plug 10 can be made from a wax, chrome plating on a metal
substrate, polyurethane, rubber, or other materials as would be
readily apparent to one skilled in the art. Teflon, polypropylene,
polyester, polystyrene, polycarbonate, nylon, PVC, ABS,
polyethylene, fluoropolymers, and other materials with a surface
energy preferably less than about 50 dynes/cm could be used to coat
the masking plug 10. More preferably, the coating material has a
surface energy in the range of about 18 dynes/cm to about 37
dynes/cm. Most preferably, the coating material has a surface
energy in the range of about 18 dynes/cm to about 30 dynes/cm. The
table below lists several plausible low surface energy materials
suitable for the present invention. These materials are provided
for explanation only, and are not limiting on the scope of the
invention.
1 Material Substrate's dynes/cm Kapton .RTM. (Polymide) 50 Phenolic
47 Nylon 46 Alkyd Enamel 45 Polyester 43 Epoxy Paint 43
Polyurethane Paint 43 ABS 42 Polycarbonate 42 PVC (Polyvinyl
Chloride) 39 Noryl .RTM. 38 Acrylic 38 Polane .RTM. Paint 38 PVA 37
Polystyrene 36 Acetal 36 EVA 33 Polyethylene 31 Polypropylene 29
Tedlar .RTM. 28 Teflon .RTM. 18
[0038] Preferably, the masking plug 10 comprises a rubber material
coated with Teflon. As would be readily apparent to one skilled in
the art, the masking plug 10 may be substantially coated on all
surfaces, or may be coated on only some of the surfaces depending
on the application. Thus, for example, masking plug 10 may only
require a coating on top surface 10A and side surface 10B, with a
substantially coating free bottom surface 10C (FIG. 1D).
[0039] The masking plug 10 further comprises a magnetic material
20. Preferably, the magnetic material 20 comprises a magnetic
insert, such as a conventional magnet (FIG. 1B). Alternatively, the
magnetic material 20 may be dispersed throughout the masking plug
10, or the masking device 100 may comprise a magnet coated with a
material having a substantially low surface energy, thereby
obviating a need for a separate magnetic material 20.
[0040] According to this first embodiment, the masking device 100
can be positioned on a substrate by aligning the protruding portion
30 with a deformation or orifice on the substrate. Preferably, the
substrate comprises a metal material, such that the magnetic
material 20 of the masking device 100 magnetically holds the
masking device 100 on the substrate. A coating (e.g., a sprayable
polyurethane bed liner) can then be applied to the substrate
without applying any substantial amount of the coating in the
deformation or orifice of the substrate effectively masked by the
masking device 100. The masking device 100 can later be quickly and
easily removed by simply applying enough force to overcome the
magnetic hold, preferably after the applied coating has at least
partially cured.
[0041] A masking device 100 according to this first embodiment thus
has the advantage of being relatively easy to locate/apply on a
substrate, and relatively easy to remove from the substrate after
applying a coating to the substrate. Excess substrate coating can
be easily removed from the masking plug 10 due, in part, to the
material having a substantially low surface energy, thereby
improving the reusability of the masking plug 10. Specifically, the
low surface energy does not allow the coating to wet then bond to
it, thus making removal of excess substrate coating relatively
easy. The substantial prevention of wetting then bonding also
improves removability of the masking plug 10 from the deformation
or orifice by substantially preventing the masking plug 10 from
being held in place by the applied coating. The improved
removability of the masking plug 10 also advantageously leaves a
substantially clean and predictable edge after being removed. A
masking device 100 according to this first embodiment can also be
removed after cure.
[0042] A second embodiment of the present invention is shown in the
perspective view of FIG. 2. According to this second embodiment, a
masking device 200 comprises a masking plug 210 and a plurality of
protruding portions 230 for locating the masking plug 210 on a
substrate with a plurality of orifices/depressions/etc. (not
shown). Preferably, the masking device 200 includes a magnetic
material and/or a material having a substantially low surface
energy (not shown) as previously described with reference to FIG.
1.
[0043] As would be readily apparent to one skilled in the art after
reading this disclosure, other configurations of masking plug 210
are also possible as shown, by way of example, in FIG. 5 and FIG.
6. As shown in FIG. 5, masking device 500 comprises a plurality of
individual masking plugs 510 each including a protruding portion
530 for engaging an orifice 590 in a substrate. As similarly shown
in FIG. 6, masking device 600 comprises a single base portion 610
with a plurality of protruding portions 630 for engaging a
plurality of orifices 690 in a substrate. Depending on the
particular orifice configuration, the plurality of protruding
regions 530/630 may obviate the need for a magnetic insert to
effectively hold the mask 500/600 on the substrate during
application of a coating. Moreover, the plurality of protruding
regions 530/630 facilitate masking of a plurality of holes
simultaneously. Preferably, the bed liner material would then be
sprayed below the top of the masking device 500/600 to minimize
material buildup. As would be readily apparent to one skilled in
the art, other variations and combinations thereof are plausible in
view of the teachings of the present invention.
[0044] According to this second embodiment, the masking device 200
effectively masks a plurality of deformations or orifices in a
substrate via the plurality of protruding portions 230. Thus, in
addition to the aforementioned advantages of the first embodiment,
a masking device 200 according to this second embodiment also
provides a simple and low cost device for masking a plurality of
deformations or orifices. Moreover, the masking device 200 further
provides masking along an elongated region in the shape of the
bottom surface of masking plug 210, such as along a substantially
rectangular section (e.g., a channel or track) of a truck bed.
[0045] A third embodiment of the present invention is shown in the
cross sectional view of FIG. 3. According to this third embodiment,
masking device 300 is shown comprising a masking plug 310 including
a magnetic material 320. As shown, a protruding portion 330 of the
masking plug 310 protrudes into an orifice of sheet metal 350. The
masking device 300 substantially prevents bed liner material 340
from entering the orifice of sheet metal 350. The orifice thus may
be kept open so that, for example, a fastener can engage a weld nut
360. A masking device 300 according to this third embodiment has
all of the aforementioned advantages of the first embodiment.
[0046] A fourth embodiment of the present invention is shown in the
cross sectional view of FIG. 4. Masking device 400 comprises a
masking plug 410 including a protruding portion 430 for engaging an
orifice or deformation in bed sheet metal 450. Preferably, the
masking device 400 includes a magnetic material 420 for
magnetically holding the masking device 400 on the bed sheet metal
450 during application of a bed liner material 440.
[0047] A masking device 400 according to this fourth embodiment has
all of the advantages as described above with respect to FIG. 3 by
keeping the orifice open for a fastener to engage weld nut
460/etc., and also provides for retaining a bushing 480 on the bed
sheet metal 450 via the applied bed liner material 440. The masking
plug 410 will be removed after the bed liner material 440 has
cured. The bed liner material 440 effectively holds the bushing 480
on the bed sheet metal 450 via the overlap region 405. Alternative
bushing/overlap configurations are shown in FIG. 4B and FIG. 4C.
Moreover, the bushing 480 may comprise an elongated metal strip
along a central groove, wherein the bed liner material 440 retains
the elongated metal strip on the bed sheet material 450 along a
central track. Thus, a masking device 400 according to this fourth
embodiment has all of the advantages described above with respect
to FIG. 3 and further provides a simple and inexpensive means for
holding a bushing on a bed sheet metal 450.
[0048] A fifth embodiment of the present invention is shown in the
cross sectional view of FIG. 7. A masking device 800 according to
this fifth embodiment is similar to the masking device 300 of FIG.
3, but includes a pointed masking plug 810. More specifically, the
masking plug 810 shown may comprise a cone shaped masking plug
(i.e., having a substantially circular base portion with narrowing
to a tip as shown), a pyramid shaped masking plug (e.g., a three,
four, five . . . sided pyramid), etc. As shown, the edge portion on
the bottom of the masking plug 810 provides a "shadowed" area 880
(roughly corresponding in size to that of bushing 480 in FIG. 4)
when the bed liner material 840 is being sprayed. This allows the
material 840 to taper gradually from the full film thickness to a
minimal (or zero) thickness. This gradual taper is beneficial in
that it is less likely to lift at the interface between the
material 840 and bed sheet metal 850. Also, because this tapered
edge is formed without touching any portion of the masking device
800, when the masking device 800 is removed it will not lift the
edge of the cured bed liner 840 from the surface of the bed 850,
which reduces the possibility of delamination.
[0049] Also, as shown, the plug 810 may include a separate or
integral magnetic portion 820 for magnetically attaching to the bed
sheet metal 850, the plug 810 may include a magnetic insert as
similarly shown in the masking device 300 of FIG. 3, or the plug
may be free of a magnetic material (e.g., when used to plug a
substantially horizontal surface). The protruding portion 830 then
protrudes into the orifice from the bottom surface of the plug 810
or magnetic portion 820 (if provided).
[0050] A sixth embodiment of the present invention is shown in the
cross sectional view of FIG. 8. A masking device 900 according to
this sixth embodiment is similar to the masking device 800 of FIG.
7, but includes a "mushroom" shaped masking plug 910. As shown, the
plug 910 may include a tapered portion 920 (preferably magnetic) on
a bottom portion of the plug 910. The protruding portion 930 then
protrudes into the orifice from the bottom surface of the tapered
portion 920.
[0051] A masking device 900 according to this sixth embodiment
provides many of the advantages of the masking device 800, and may
be easier to grasp for removal from the orifice due, in part, to
the mushroom shape.
[0052] A seventh embodiment of the present invention is shown in
the views of FIGS. 9A and 9B. A masking device 1000 according to
this seventh embodiment includes a handle 1090 to facilitate easier
removal of the masking device 1000 from an orifice. The handle 1090
may comprise a rectangular shape as shown in the top down view
(FIG. 9B), or may comprise other shapes such as hexagonal, etc. The
handle 1090 may be fixedly coupled to the plug 1010 as shown; e.g.,
by shaft 1095 or the like.
[0053] It should be appreciated that other aspects of the masking
device 1090 are similar to those of previous embodiments. Hence,
masking device 1090 may include a magnetic portion 1020, and a
protruding portion 1030 as previously described. It should further
be appreciated that other embodiments of the present invention may
include a handle 1090 (preferably with shaft 1095) as in this
seventh embodiment, if desired.
[0054] An eighth embodiment of the present invention is shown in
the cross sectional views of FIGS. 10 and 11. A masking device 1100
according to this eighth embodiment preferably comprises a plug
1110 (FIG. 10) and separate clip 1115 (FIG. 11) coupled thereto.
More specifically, as shown in FIG. 10, the plug 1110 preferably
includes a channel 1125 (e.g., a bore or hole in plug 1110) adapted
to receive the clip 1115, with one or more locking notches 1135
(e.g., for receiving a locking screw or the like). Alternatively,
the plug 1110 and clip 1115 may be formed as one integral unit.
[0055] According to this eighth embodiment, the clip 1115 (FIG. 11)
is adapted to clip into an orifice to temporarily "lock" the plug
1110 in place. Hence, the clip 1115 preferably comprises a pliable
material, such as tempered/polished spring steel about 1.58 mm
thick and about 4.76 mm wide. The clip 1115 and plug 1110
configuration of this eighth embodiment provide an alternate means
for temporarily attaching to the bed sheet metal during a spraying
operation without use of a magnetic insert or an interference fit
between a protrusion and the orifice walls.
[0056] A ninth embodiment of the present invention is shown in the
cross sectional view of FIGS. 12 and 13. A masking device 1200
according to this ninth embodiment preferably comprises a plug 1210
(FIG. 12) and a clip 1215 (FIG. 13) coupled thereto, similar to the
plug 1110 and clip 1115 of FIGS. 10 and 11. More specifically, as
shown in FIG. 12, the plug 1210 preferably includes a channel 1225
(e.g., a bore or hole within the plug 1210) adapted to receive the
clip 1215 (FIG. 13), with one or more locking notches 1235 (e.g.,
for receiving a locking screw or the like).
[0057] Operation of the masking device 1200 is similar to that of
masking device 1100, though the Figs. indicate variations thereon
including, for example, a different sized plug 1210 and clip
1215.
[0058] A tenth embodiment of the present invention is shown in the
cross sectional views of FIGS. 14. A masking device 1300 according
to this tenth embodiment preferably comprises a plug 1310 (FIG. 14)
and a clip (not shown) coupled thereto, similar to the plug 1110 of
FIG. 10. More specifically, as shown, the plug 1310 preferably
includes a channel 1325 (e.g., a bore or hole in plug 1310) adapted
to receive the clip, with one or more locking notches 1335 (e.g.,
for receiving a locking screw or the like).
[0059] The clip according to this tenth embodiment preferably
comprises a pass through quick-release pin (also known as faspins).
Known quick-release pins typically comprises a self-locking pin
with a spring-loaded ball that retracks when you push or pull the
pin. Due to the configuration of known quick-release pins, the
channel 1325 of masking device 1300 is depicted passing entirely
therethrough in FIG. 14.
[0060] Operation of the masking device 1300 is similar to that of
masking device 1100, though the Figs. indicate variations thereon
including, for example, a different sized plug 1310.
[0061] An eleventh embodiment of the present invention is shown in
the views of FIG. 15. A masking device 1500 according to this
eleventh embodiment preferably comprises a base portion 1510 (e.g.,
a metal plate) having a shape adapted to fit over a region to be
masked. By way of example, the base portion 1510 shown is square
shaped to mask a substantially square region on a base substrate
(not shown). Hence, the base portion 1510 may take on alternative
shapes (e.g., square, ovular, octagonal, etc.) depending on the
particular region to be masked.
[0062] The masking device 1500 also includes a rotatable key lock
1520 adapted to lock the base portion 1510 to the substrate. The
rotatable key lock 1520 includes a base portion 1521 adapted to
rotate beneath the substrate so as to lock the masking device 1500
down on the substrate (and thus provide a locking surface
underneath the substrate), a handle 1523 for rotating the base
portion 1521, and a shaft 1525 coupling the base portion 1521 to
the handle 1523. Preferably, the rotatable key lock 1520 also
includes a shield 1527 for shielding a rotating portion of the
rotatable key lock 1520 from sprayed bed liner material, such that
the rotating portion is not contaminated with sprayed bed liner
material.
[0063] In addition, the masking device 1500 may include one or more
guide legs 1530 adapted to engage corresponding pre-drilled holes
in the substrate such that the guide legs 1530 position the masking
device 1500 on the substrate. The guide legs 1530 are shown in the
bottom view of FIG. 16A and side views of FIGS. 16B and 16C
projecting downward from the base portion 1510. It should be
appreciated that the guide legs 1530 may be an integral part of the
base portion 1510, or may be separable components (e.g., screw on
legs) that can be changed depending on the particular guide hole
dimensions to be interfaced with.
[0064] The masking device 1500 may also include one or more spacers
1540 for creating a gap between a bottom surface of the base
portion 1510 and a top surface of the substrate on which the bed
liner is to be sprayed. This creates a similar tapered edge as
discussed in reference to the masking device 800.
[0065] In operation, the masking device 1500 is placed over a hole
(with or without guide holes for guide legs 1530) into which the
key lock 1520 is placed. The key lock 1520 is then rotated to lock
the masking device 1500 down onto the substrate. Once the area is
sprayed, the masking device 1500 can be easily removed by simply
rotating the key lock 1520 into a release position.
[0066] This masking device 1500 thus has advantages similar to
those of previously described embodiments, and also provides for a
larger masking area. Hence, the area around an orifice can be kept
free of bed liner material for attaching (e.g., by welding)
additional components, such as, tool boxes, etc.
[0067] Thus, sprayable bed liners and methods of manufacturing the
same have been described according to various aspects of the
present invention. Moreover, an improved masking device can be
achieved by combining the teachings of various embodiments of the
present invention.
[0068] The foregoing description of preferred embodiments of the
invention has been presented for purposes of illustration and
description. It is not intended to be exhaustive or to limit the
invention to the precise form disclosed, and modifications and
variations are possible in light of the above teachings or may be
acquired from practice of the invention. The embodiments were
chosen and described in order to explain the principles of the
invention and its practical application and to enable one skilled
in the art to utilize the invention in various embodiments and with
various modifications as are suited to the particular use
contemplated. It is intended that the scope of the invention be
defined by the claims appended hereto, and their equivalents.
* * * * *