U.S. patent application number 11/809677 was filed with the patent office on 2008-12-04 for spackling tool and spackling pan.
Invention is credited to Edward C. Uva.
Application Number | 20080295435 11/809677 |
Document ID | / |
Family ID | 40086602 |
Filed Date | 2008-12-04 |
United States Patent
Application |
20080295435 |
Kind Code |
A1 |
Uva; Edward C. |
December 4, 2008 |
Spackling tool and spackling pan
Abstract
A spackling tool for applying spackling compound to sheetrock,
the spackling tool includes a handle with a curved slot defined
therein and a blade having a fixed edge secured in the curved slot
of the handle so as to form a non-planar surface. The blade has a
non-linear free edge disposed opposite its fixed edge. The
spackling tool may be used on either butt or tapered joints for
readily applying spackling compound over the taped joint and
removing any excess without disturbing the finished edge of applied
spackling compound. A spackling pan is also presented having at
least one non-linear free edge for accommodating spackling tools
having a non-planar blade with a non-linear free edge.
Inventors: |
Uva; Edward C.; (Burlington,
NJ) |
Correspondence
Address: |
Cheryl F. Cohen
2409 Church Road
Cherry Hill
NJ
08002
US
|
Family ID: |
40086602 |
Appl. No.: |
11/809677 |
Filed: |
June 1, 2007 |
Current U.S.
Class: |
52/514 |
Current CPC
Class: |
E04F 21/1652 20130101;
E04F 13/04 20130101; E04F 21/02 20130101; E04F 21/165 20130101 |
Class at
Publication: |
52/514 |
International
Class: |
E04G 23/02 20060101
E04G023/02 |
Claims
1. A spackling tool comprising: a handle having a curved slot
defined therein; and a blade having a fixed edge secured in the
curved slot of the handle so as to form a non-planar surface, the
blade having a non-linear free edge disposed opposite the fixed
edge.
2. The spackling tool in accordance with claim 1, wherein the free
edge is divided into a plurality of sections and terminating at
opposite ends in a curved corner.
3. The spackling tool in accordance with claim 2, wherein the free
edge comprises two substantially linear tab sections, wherein each
tab section is disposed inward of each curved corner.
4. The spackling tool in accordance with claim 3, wherein the free
edge comprises two non-linear intermediate sections, wherein each
intermediate section is disposed inward of each tab sections.
5. The spackling tool in accordance with claim 4, wherein each
intermediate section has a distance defined from substantially its
center relative to an axis defined by the tab sections of greater
than approximately 1/32 inch.
6. The spackling tool in accordance with claim 4, wherein the free
edge comprises a substantially linear central section disposed
between the intermediate sections, the central section being
substantially parallel with the tab sections.
7. The spackling tool in accordance with claim 3, wherein the blade
comprises two side edges, each side edge being divided into an
upper section proximate the curved corner and substantially
perpendicular to the respective tab section of the free edge; and a
lower section proximate the handle disposed at an angle relative to
the tab section of less than 90 degrees.
8. The spackling tool in accordance with claim 4, wherein the free
edge comprises a central section disposed between the tab sections,
the central section being displaced a predetermined distance
relative to an axis defined by the tab sections.
9. The spackling tool in accordance with claim 3, wherein the
central section is substantially linear and substantially parallel
to but separated a predetermined distance from an axis defined by
the tab sections.
10. The spackling tool in accordance with claim 1, wherein the slot
has two terminating ends at least one of which is open and sized
for receiving the blade therein.
11. The spackling tool in accordance with claim 1, wherein the slot
has a predetermined distance as measured radially inward from
substantially its center of length to an axis defined by its
terminating ends of the tab sections of greater than 0 but less
than approximately 1 inch.
12. A method for assembling a spackling tool including a handle
having a curved slot defined therein and a blade having a fixed
edge secured in the curved slot of the handle so as to form a
non-planar surface, the blade having a non-linear free edge
disposed opposite the fixed edge, the method comprising the steps
of: deforming the blade when it is substantially planar so that it
substantially conforms in shape to the curved slot defined in the
handle; and securing the blade in the handle.
13. The method in accordance with claim 12, wherein the deforming
step comprises sliding the substantially planar blade into one end
of the curved slot defined in the handle.
14. A spackling pan comprising: a bottom panel; and at least one
side panel having a non-linear free edge and an opposite fixed edge
secured to the bottom panel.
15. The spackling pan in accordance with claim 14, wherein the
non-linear free edge of the at least one side panel is divided into
a central convex section disposed between two concave sections.
16. The spackling pan in accordance with claim 14, further
comprising another side panel having a substantially linear free
edge and an opposite fixed edge secured to the bottom panel,
wherein each concave section is displaced a maximum predetermined
distance relative to the substantially linear free edge of greater
than 0 but less than approximately one inch, and at least a portion
of the central convex section is substantially equal in height
relative to the substantially linear free edge.
17. The spackling pan in accordance with claim 14, further
comprising another side panel having a substantially linear free
edge and an opposite fixed edge secured to the bottom panel.
18. A tool comprising: a single integral handle having a curved
slot defined therein; and a blade having a fixed edge secured in
the curved slot of the handle.
19. The tool in accordance with claim 18, wherein the fixed edge of
the blade is secured within the curved slot defined in the handle
via a friction fit without rivets, screws, adhesive or any other
separate component.
20. A kit comprising: a spackling tool comprising: a handle having
a curved slot defined therein; a blade having a fixed edge secured
in the curved slot of the handle so as to form a non-planar
surface, the blade having a non-linear free edge disposed opposite
the fixed edge; and a spackling pan comprising: a bottom panel; and
at least one side panel having a non-linear free edge and an
opposite fixed edge secured to the bottom panel.
21. The kit in accordance with claim 20, wherein the handle is a
single integral unit.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is directed to a spackling tool or
taping tool for applying spackling compound, mud, or joint compound
to abutting edges of sheetrock, wallboard or other substantially
planar surfaces. In particular, the present inventive spackling
tool allows experienced contractors and novice do-it-yourselfers
alike to apply spackling compound to a joint quickly and
efficiently with smooth clean professional results while readily
removing any excess spackling compound without disturbing the
finished edge.
[0003] 2. Description of Related Art
[0004] During construction sheetrock, wallboard or drywall is
secured to the wall studs. The edges of the sheetrock abut one
another to form a joint therebetween. Thereafter, a layer of mud,
spackling compound or joint compound is applied to the joint. A
strip of tape, generally paper or mesh, is then substantially
centered in the joint and the spackling tool is run over the
surface to set the tape in the joint while smoothing out the
spackling compound on each side of the tape with the spackling
tool. Once the mud dries setting the tape to the sheetrock,
thereafter spackling compound is applied to the top surface and
sides of the tape to form a mound the side edges of which are
feathered using the spackling tool to form a smooth finished
edge.
[0005] Heretofore conventional spackling tools for applying
spackling compound to a joint formed between abutting sheetrock
panels have been designed to have a two-dimensional planar blade
rectangular in shape forming a linear free edge with right angle
corners. Sheetrock may be manufactured with two different types of
edges, e.g., a tapered edge or a butt edge. The application of
spackling compound to butt joints and tapered joints formed between
abutting panels of sheetrock will now be described using a
conventional spackling tool having a planar blade, linear free edge
and right angle corners.
[0006] A tapered edge is just that, wherein the thickness of the
sheetrock toward its edge is tapered or convex. When tapered edges
of respective sheetrock panels are installed next to one another to
form a tapered joint 200 therebetween the abutting tapered edges of
the respective panels form a tapered joint recess 205 therebetween,
as shown in FIG. 2a. Spackling compound is applied to the tapered
joint 200 filling the joint recess 205. A strip of tape 210 is
substantially centered over the tapered joint 200 and set into the
spackling compound. Once dried, additional spackling compound is
applied in the tapered joint recess 205. The dragging of a
conventional spackling tool having a substantially planar blade
with a straight, linear free edge along the planar surface of the
sheetrock panels proximate the tapered joint recess 205 fills the
tapered joint recess 205 with spackling compound 215 whose formed
surface is substantially flush with the sheetrock panels, as shown
in FIG. 2b. Since the spackling compound shrinks as it dries, the
application of multiple applications of spackling compound may be
necessary to achieve the desired planar completed finish when dry.
Excess spackling compound 220 is forced out to the edges of the
spackling tool and must be cleaned with separate passes of the
blade on either side of the tapered joint without disturbing the
finished edge 230.
[0007] The other type of wallboard manufactured with a non-tapered
or butt edge is shown in FIGS. 1a and 1b. Spackling compound is
applied to the butt joint 100 formed between abutting butt edges. A
strip of tape 110 is then substantially centered in the joint 100
and the spackling tool is run over the surface to set the tape in
the joint while smoothing out the spackling compound on each side
of the tape with the spackling tool. Once the mud dries setting the
tape to the sheetrock, thereafter additional spackling compound is
applied to the tape 110 to form a mound 115 the side edges 130 of
which are feathered using the spackling tool to form a smooth
finished edge. With each repeated pass of the blade of the
conventional spackling tool spackling compound is pushed back and
forth in an attempt to feather out the edges 130 of the mound 115
while keeping the mound as flat as possible. Even experienced
contractors find this process to be time consuming since it
requires several passes of the blade. Excess spackle 120 is forced
to the outside of the blade, and when removed, disturbs the
finished edge 130 of the spackling compound mound 115 covering the
tape 110 and butt joint 100.
[0008] It is therefore desirable to develop an improved spackling
tool that solves the aforementioned problems associated with
conventional spackling tools while reducing application time and
thereby improving efficiency.
SUMMARY OF THE INVENTION
[0009] The present invention is directed to an improved spackling
tool and spackling pan that solves the aforementioned problems
associated with conventional spackling tools.
[0010] An object of the present invention is to provide a spackling
tool for readily achieving a relatively smooth surface of spackling
compound applied over a taped joint with minimum swipes of the
blade, while permitting the removal of any excess spackling
compound without disturbing the finished edge.
[0011] In particular, the present invention relates to a spackling
tool including a handle having a curved slot defined therein. A
blade having a fixed edge is secured in the curved slot of the
handle so as to form a non-planar surface. The blade has a
non-linear free edge disposed opposite the fixed edge.
[0012] Yet another aspect of the present invention is directed to a
method for manufacture of the spackling tool as described in the
preceding paragraph. During manufacture, a force is applied to a
substantially planar blade so that it substantially conforms in
shape to the curved slot defined in the handle. Specifically, the
substantially planar blade deforms to conform in shape to the
curved slot defined in the handle. Thereafter, the blade is secured
in the handle, for example, by friction fit, a releasable securing
mechanism or a non-releasable securing mechanism.
[0013] Another aspect the present invention relates to a spackling
pan having a bottom panel and at least one side panel having a
non-linear free edge and an opposite fixed edge secured to the
bottom panel.
BRIEF DESCRIPTION OF THE DRAWING
[0014] The foregoing and other features of the present invention
will be more readily apparent from the following detailed
description and drawings of illustrative embodiments of the
invention wherein like reference numbers refer to similar elements
throughout the several views and in which:
[0015] FIG. 1a is a side view of a prior art butt joint formed
between two abutting non-tapered, butt edges of sheetrock;
[0016] FIG. 1b is a side view of spackling compound applied to the
butt joint of FIG. 1a using a conventional spackling tool having a
planar blade and a straight free edge;
[0017] FIG. 1c is a side view of spackling compound applied to the
butt joint of FIG. 1a using a spackling tool having a non-planar
blade and a non-linear free edge in accordance with the present
invention;
[0018] FIG. 2a is a side view of a prior art tapered joint formed
between two abutting tapered edges of sheetrock;
[0019] FIG. 2b is a side view of spackling compound applied to the
tapered joint of FIG. 2a using a conventional spackling tool having
a planar blade and a straight free edge;
[0020] FIG. 2c is a side view of spackling compound applied to the
tapered joint of FIG. 2a using a spackling tool having a non-planar
blade and a non-linear free edge in accordance with the present
invention;
[0021] FIG. 3a is a front view of a first embodiment of the
spackling tool in accordance with the present invention having a
non-planar blade with a non-linear free edge;
[0022] FIG. 3b is a top view of the spackling tool of FIG. 3a;
[0023] FIG. 3c is a side view of the spackling tool of FIG. 3a;
[0024] FIG. 3d is a bottom view of the spackling tool of FIG.
3a;
[0025] FIG. 3e is a perspective view of the spackling tool of FIG.
3a;
[0026] FIG. 4a is a front view of another exemplary embodiment of
the spackling tool in accordance with the present invention having
a non-planar blade with a non-linear free edge;
[0027] FIG. 4b is a top view of the spackling tool of FIG. 4a;
[0028] FIG. 4c is a side view of the spackling tool of FIG. 4a;
[0029] FIG. 4d is a bottom view of the spackling tool of FIG.
4a;
[0030] FIG. 4e is a perspective view of the spackling tool of FIG.
4a;
[0031] FIG. 5a is a front view of a third embodiment of the
spackling tool in accordance with the present invention having a
non-planar blade with a non-linear free edge;
[0032] FIG. 5b is a top view of the spackling tool of FIG. 5a;
[0033] FIG. 5c is a side view of the spackling tool of FIG. 5a;
[0034] FIG. 5d is a bottom view of the spackling tool of FIG.
5a;
[0035] FIG. 5e is a perspective view of the spackling tool of FIG.
5a;
[0036] FIG. 6a is a front view of a spackling pan in accordance
with the present invention for use with a spackling tool in
accordance with the present invention having a non-planar blade and
a non-linear free edge;
[0037] FIG. 6b is a back view of the spackling pan of FIG. 6a;
[0038] FIG. 6c is a bottom view of the spackling pan of FIG.
6a;
[0039] FIG. 6d is a left side view of the spackling pan of FIG. 6a,
the right side view being a mirror image thereof;
[0040] FIG. 6e is a front perspective view of the spackling pan of
FIG. 6a; and
[0041] FIG. 6f is a top perspective view of the spackling pan of
FIG. 6a.
DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS OF THE
INVENTION
[0042] The present inventive spackling tool having a non-planar
blade with a non-linear free edge or top edge is more efficient and
faster than conventional spackling tools having a planar blade with
a linear or straight free edge while being suitable for use by both
experienced contractors and novice do-it-yourselfers alike.
[0043] A first embodiment of the spackling tool 300 in accordance
with the present invention is shown in FIGS. 3a-3e. This spackling
tool 300 is used to apply spackling compound to butt joints.
Spackling tool 300 has a handle 305, preferably an ergonomically
shaped handle made from wood, plastic, hard rubber or any other
rigid material. For ease of manufacture, the handle 305 may be
manufactured as a single integral unit. A blade 315 is used to
apply the spackling compound to the butt joints formed between
abutting panels of sheetrock. Blade 315 is made of a flexible
material, preferably metal, most preferably tempered spring blue
steel, tempered spring stainless steel, or some combination
thereof. To retain a predetermined amount of flexibility blade 315
is preferably in a range between approximately 0.015 gauge and
approximately 0.025 gauge. The blade 315 is received within a
crescent shaped or curved slot 350 defined in the handle 305. The
slot 350 defined in handle 305 forms a curve so that a distance D1
as measured from substantially the center of the length of the slot
350 to an axis defined by terminating ends 355 of blade 315 is
preferably greater than 0 but less than approximately 1 inch, most
preferably approximately 1/4 inch. The distance D1 remains
substantially constant irrespective of the length of the blade.
Slot 350, as shown in FIG. 3b, is open at one or both of its
terminating ends 355. In a preferred embodiment shown in FIGS.
3a-3e, a fixed end of blade 315 is releasably secured within slot
350 via a friction fit without the need for rivets, screws,
adhesive or any other separate securing mechanism. To minimize the
cost of manufacture, prior to assembly, the blade 315 is preferably
substantially planar. A force is applied to slide the blade 315
into the curved slot 350 through one of its open terminating ends
355 causing the blade 315 to deform or bend as it substantially
conforms to a curvature as defined by slot 350 while forming a
friction fit with the handle 305.
[0044] Other alternative releasable securing mechanisms such as a
nut and bolt may be used to releasably retain the blade 315 within
the slot 350 of the handle 305. Alternatively, blade 315, after
being assembled in the handle 305, may be permanently affixed
within the slot 350, for instance, using rivets, an adhesive
material or other non-releasable securing mechanism. Another option
that minimizes the cost of manufacture is to over form the handle.
This may be achieved by forming projections such as dimples, fins
or metal tabs on the handle that are received in complementary
shaped holes or recesses defined therethrough or in at least one
surface of the blade 315. During manufacture the molded projections
of the handle 305 are received in the complementary shaped holes or
recesses thereby securing the blade 315 within the handle 305
without the need for additional hardware.
[0045] In addition to its curved, non-planar shape, at least a
portion of the free or top edge of blade 315 of the spackling tool,
opposite its fixed end secured to the handle, is non-linear.
Referring to FIG. 3a, the free edge of blade 315 is divided into a
plurality of sections. Due to the curved, non-planar arrangement of
the blade 315, during use its corners, if at right angles, would
dig into the surface on which the spackling compound is to be
applied. To prevent or minimize destruction to the surface on which
the spackling compound is being applied, each corner 330, 330' is
curved.
[0046] Each section of the free or top edge of the blade 315 will
now be described starting from the respective corners 330, 330' and
extending inward towards its center. Tab sections 335, 335' of the
free edge of the blade are substantially linear and substantially
perpendicular to upper sections 325, 325', respectively, of a side
edge of the blade, described below in further detail. When the
spackling tool is in use tab sections 335, 335' of the free or top
edge are substantially flush with the surface on which the
spackling compound is applied thereby substantially removing any
excess spackling compound from the area of sheetrock beneath these
sections.
[0047] A central section 345 of the free or top edge is
substantially linear and substantially parallel to tab sections
335, 335' but separated by a predetermined distance D2, preferably
greater than approximately 1/32 inch, more preferably approximately
1/16 inch, and most preferably approximately 1/4 inch, from an axis
defined by tab sections 335, 335'. When the blade 315 is passed or
drawn over the tape, this central section 345 causes the spackling
compound to form a mound having a substantially flat contour. The
substantially linear configuration of this central section 345
minimizes or reduces possible mounding or rounding in the middle of
the finish applied spackling compound. Central section 345 extends
between inner edges of intermediate sections 340, 340' a distance
380.
[0048] Interposed between the central section 345 and each of the
respective tab sections 335, 335' is an intermediate section 340,
340', respectively. Unlike the tab sections and central sections,
intermediate sections 340, 340' of the free or top edge are
non-linear, preferably curved, and thus not parallel with either
the tab sections 335, 335' or central section 345. In the
embodiment shown in FIG. 3a, intermediate sections 340, 340' are
curved (concave) to taper the spackling compound away from the
outside edge of the tape used to cover the butt joint.
[0049] The total length of the free or top edge of blade 315
between the corners 330, 330' is defined by a distance 360. This
overall length 360 may be subdivided into three respective lengths
or distances: (i) distance 375 of intermediate section 340 as
defined between the inner edge of tab section 335 and the nearest
outer edge of central section 345; (ii) distance 380 of central
section 345 as defined between the outer edges of central section
345; and (iii) distance 375' of intermediate section 340' as
defined between the inner edge of tab section 335' and the nearest
outer edge of central section 345. An inner length 365 represents
the distance between the outer terminating ends of the intermediate
sections 340, 340' or the distance between the inner terminating
ends of the respective tab sections 335, 335'. This inner length
365 represents the length of finished spackling compound applied to
the work surface. It is contemplated and within the intended scope
of the present invention to vary the inner length 365 to
accommodate a wide variety of work surfaces. The outer terminating
ends of the tab sections 335, 335' produce the finished edge of the
applied spackling compound, whereas the tab sections 335, 335' wipe
substantially free and clean from spackling compound an area of the
sheetrock in which it comes into contact.
[0050] Each side edge of blade 315 is also divided into sections.
Specifically, each side edge comprises a lower section 320, 320'
proximate the handle 305 and an upper section 325, 325' proximate
the free or top edge of the blade 315. Lower sections 320, 320' of
the respective side edges of the blade 315 are tapered or angled
inwards towards the center of the blade. The tapering of lower
sections 320, 320' allows the blade 315 to flex to a substantially
near planar shape during use when pressed against the planar
surface to smooth out the spackling compound on a surface to which
it has been applied. Upper sections 325, 325' of the respective
side edges of the blade 315 are disposed substantially parallel to
one another and are substantially perpendicular to their respective
tab sections 335, 335'. These upper sections 325, 325' serve to
maintain the overall shape of the blade 315 while permitting a
sufficient amount of flexibility. In addition, upper sections 325,
325' prevent or minimize the corners 330, 330' from "flipping up"
as the blade 315 is substantially flattened out when pressure is
applied during use to smooth out the spackling compound.
[0051] The total length of each side edge of blade 315 between the
fixed edge of the blade secured to the handle and the corners 330,
330', respectively, is represented by a distance 385. Distance 385
is selected so that the blade 315 has a certain rigidity imparted
from the handle 305, while maintaining a certain amount of
flexibility when pressed against the surface on which the spackling
compound is being applied. This overall length 385 may be further
subdivided into two respective distances: (i) distance 390 of upper
section 325 is defined between the corner 330 and the inner edge of
lower section 320; and (ii) distance 395 of lower section 320 is
defined between the inner edge of upper section 325 and the outer
edge of lower section 320 mounted in handle 305.
[0052] By way of illustrative example, dimensions will be provided
for a spackling tool 300 having a blade 315 whose free or top edge
measures a distance 360 of approximately 10 inches. The table below
represents a preferred range of values, and a most preferred value
within each range for each structural feature: [0053] Overall
Length of Free Edge of Blade [Distance 360]: preferably
approximately 10 inches [0054] Length of each Tab Section 335, 335'
[Distance 370]: preferably in a range between approximately 1/4
inch-approximately 11/4 inch, most preferably approximately 3/8
inch [0055] Length of each Intermediate Section 340, 340' [Distance
375]: preferably in a range between approximately 21/4
inches-approximately 4 inches, most preferably approximately 33/8
inches [0056] Length of Central Section 345 [Distance 380]:
preferably in a range between approximately 1/2 inch-approximately
4 inches, most preferably approximately 21/2 inches [0057] Length
of Upper Section 325, 325' [Distance 390]: preferably in a range
between approximately 1/8 inch-approximately 2 inches, most
preferably approximately 3/4 inch [0058] Length of Lower Section
320, 320' [Distance 395]: preferably in a range between
approximately 17/8 inch-approximately 4 inches, most preferably
approximately 21/2 inches
[0059] It is, however, contemplated and within the intended scope
of the present invention to modify the length 360 of the free or
top edge of the blade 315, as desired, so that its length 360 is
greater than or less than 10 inches. When varying the length 360 of
the free edge of the blade 315 the distance 375 representing the
length of each intermediate section 340, 340' will also vary. In a
preferred embodiment, however, regardless of variations in length
360 of the blade the length of each tab section 335, 335' [distance
370] and the length of central section 345 [distance 380] will
remain substantially unchanged. It is also within the scope of the
invention to vary the length of the side edge [distance 385]
independently of the length of the free or top edge of the blade
315, as desired, which will vary the length of upper section 325,
325' [distance 390] and length of lower section 320, 320' [distance
395], accordingly.
[0060] Referring to FIG. 1c, during use tab sections 335, 335'
separate by a safe cleanable distance 125 the excess spackling
compound 120 forced out from the curved corners 330, 330' of the
blade from that of the finished edge 130 of spackling compound so
that any excess spackling compound may be readily removed without
disturbing the finished edge 130 of spackling compound.
[0061] During use the spackling compound is applied to the
spackling tool and applied to the butt joint. Curved intermediate
sections 340, 340' ensure that a tapered mound of spackling
compound is formed over the tape with minimum swipes. Tab sections
335, 335' glide substantially flush with the sheetrock surface on
which the spackling compound is applied thereby pushing any excess
spackling compound outward a predetermined distance clear of the
finished edge 130 of the tapered mound 115 of spackling compound
covering the taped butt joint. This predetermined substantially
clean portion 125 of the sheetrock between the excess spackling
compound 120 and the tapered finished edge 130 of the spackling
compound mound 115 covering the tape 110 permits the user to
readily remove any excess spackling compound 120 without disturbing
the finished edge 130.
[0062] FIGS. 4a-4e show an alternative example to that previously
shown in FIGS. 3a-3e, wherein central section 445 is substantially
parallel to and displaced a predetermined distance D3 relative to
an axis defined by tab sections 435, 435' of preferably
approximately 1/32 inch or greater.
[0063] Intermediate sections 440, 440' are non-linear, preferably
curved, and are separated a distance D4 defined from substantially
its center to an axis defined by tab sections 435, 435' preferably
greater than approximately 1/32 inch, more preferably approximately
1/16 inch, and most preferably approximately 1/4 inch. This
alternative embodiment minimizes the mound of spackling compound
while maximizing the distance between the finished edges 130 of the
spackling compound in FIG. 1c.
[0064] FIGS. 5a-5e show yet another embodiment of the spackling
tool in accordance with the present invention for use in applying
spackling compound to tapered joints. Spackling tool 500 differs
from that in the first embodiment shown in FIGS. 3a-3e along the
free or top edge of the blade. Intermediate sections 340, 340', as
shown in FIGS. 3a-3e, serve to taper the spackling compound away
from the outside edge of the tape covering a butt joint. When
applying spackling compound to a tapered joint forming a joint
recess there is no need to form a mound of spackling compound over
the taped joint. Accordingly, in FIGS. 5a-5e, intermediate sections
340, 340' have been eliminated whereby central section 545 extends
between the inner edges of the respective tab sections 535, 535' a
distance 565 preferably of approximately 2 inches to approximately
18 inches. The distance 565 will vary, as desired, depending on the
overall length of the blade. Central section 545 may be
substantially linear and substantially parallel with but separated
a predetermined distance D5 relative to an axis defined by tab
sections 535, 535', as shown in FIGS. 5a-5e. Distance D5 is
preferably greater than 0 but less than approximately 1/4 inch.
[0065] Alternatively, central section 545 may be non-linear,
preferably curved, and separated a maximum distance D5 from an axis
defined by tab sections 535, 535', wherein D5 is less than D2 in
FIGS. 3a-3e so as not to remove all the joint compound applied to
fill the joint recess 205 formed at the tapered joint. In a
preferred embodiment, D5 is preferably greater than 0 but less than
approximately 1/4 inch.
[0066] During use the spackling tool is dipped into the spackling
compound and then applied to the tapered joint. If the central
section 545 is substantially linear and substantially planar
relative to tab sections 535, 535' then the spackling compound will
fill the joint recess 205 formed by the tapered edges of the
abutting wallboard sheets so as to be substantially flush with the
planar surface of the sheetrock. In the alternative design in which
the central section 545 is curved then the spackling tool creates
over the tapered joint a mound of spackling compound protruding
slightly from the planar surface of the sheetrock. This extra mound
of spackling compound is advantageous to allot for some shrinkage
of the spackling compound when dried that otherwise would result in
a concave rather than substantially planar surface that is
substantially flush relative to the planar surface of the
sheetrock. Referring to FIG. 2c, tab sections 535, 535' separate
any excess spackle 220 from the inside clean finished edge 230 that
covers the tapered joint 200 and tape 210. As with the other
embodiment, the region 225 of the sheetrock in which the tab
sections 535, 535' come into contact are substantially free from
spackling compound thereby allowing any excess spackling compound
220 to be readily removed from the sheetrock without disturbing the
finished edge 230 of the spackling compound applied to the tapered
joint.
[0067] Due to its unique non-planar configuration it is desirable
to remove excess spackling compound or mud from the blade of the
spackling tool in accordance with the present invention using a
uniquely designed spackle or mud pan 600, as illustrated in FIGS.
6a-6f. Mud pan 600 may be made from any desired material such as
metal, plastic or even wood. Referring to FIGS. 6a-6f, mud pan 600
has two longitudinal side walls 605, 610, two lateral side walls
615, 620 and a bottom 665. The top of mud pan 600 is open to form a
cavity 645 therein for capturing the excess mud or spackling
compound when scraped off the blade of the spackling tool. Each
longitudinal side wall 605, 610 is of sufficient length to
accommodate the length of the free or top edge of the blade of the
spackling tool.
[0068] Longitudinal side wall 605 is substantially planar and has a
substantially straight, linear free edge 635 for scraping clean any
excess spackling compound from the surface of a conventional
spackling tool having a planar blade with a straight, non-linear
free edge. Opposing longitudinal side wall 610 is substantially
planar having a non-linear, preferably curved, free edge 625 for
scraping excess spackling compound from the blade surface of a
spackling tool in accordance with the present invention. Non-linear
free edge 625 is divided into three sections: a central convex
section 655 at least at a substantially central point is
substantially the same height relative to the bottom 665 as linear
free edge 635, wherein the central convex section is disposed
between two concave sections. A substantially central point of each
concave section being displaced a distance D6 relative to the
linear free edge 635. In a preferred embodiment, this distance D6
is preferably greater than 0 but less than approximately 1/4
inch.
[0069] The differently configured free edges 625, 635 of
longitudinal side walls 605, 610, respectively, allow the mud pan
in accordance with the present invention to be universally used
with conventional planar spackling blades having a straight, linear
free edge, as well as with non-planar spackling blades having a
curved, non-linear free edge in accordance with the present
invention. That is, linear free edge 635 is used to wipe clean a
conventional planar spackling blade having a linear free edge,
whereas the opposing curved, non-linear free edge 625 of the mud
pan is used to wipe clean the curved, non-planar spackling blade
having a non-linear free edge in accordance with the present
invention. Despite the advantages and universality of providing a
single mud pan having differently configured free edges, the linear
free edge may be eliminated altogether so that the mud pan has two
identical longitudinal sides 605, 610 each with a non-linear,
preferably curved, free edge 625. In this alternative configuration
another mud pan may be used to wipe clean conventional planar
spackling blades having a straight, linear free edge.
[0070] Thus, while there have been shown, described, and pointed
out fundamental novel features of the invention as applied to a
preferred embodiment thereof, it will be understood that various
omissions, substitutions, and changes in the form and details of
the devices illustrated, and in their operation, may be made by
those skilled in the art without departing from the spirit and
scope of the invention. For example, it is expressly intended that
all combinations of those elements and/or steps that perform
substantially the same function, in substantially the same way, to
achieve the same results be within the scope of the invention.
Substitutions of elements from one described embodiment to another
are also fully intended and contemplated. It is also to be
understood that the drawings are not necessarily drawn to scale,
but that they are merely conceptual in nature. It is the intention,
therefore, to be limited only as indicated by the scope of the
claims appended hereto.
[0071] Every issued patent, pending patent application,
publication, journal article, book or any other reference cited
herein is each incorporated by reference in their entirety.
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