U.S. patent application number 12/131484 was filed with the patent office on 2009-12-03 for apparatus for applying filler material and method of using same.
Invention is credited to Gene Keohan.
Application Number | 20090293414 12/131484 |
Document ID | / |
Family ID | 41378032 |
Filed Date | 2009-12-03 |
United States Patent
Application |
20090293414 |
Kind Code |
A1 |
Keohan; Gene |
December 3, 2009 |
APPARATUS FOR APPLYING FILLER MATERIAL AND METHOD OF USING SAME
Abstract
A nozzle for applying filler material within a groove is
provided that includes a plate member, an orifice through the plate
member, a guide member for engaging the groove, and a pliable
attachment. The orifice is in communication with a supply of the
filler material. The guide member protrudes from the plate member
and has a width less than the groove. The pliable attachment has a
channel with an angled portion for directing the filler material
into the groove. The nozzle may also be used independent from the
attachment.
Inventors: |
Keohan; Gene; (Kansas City,
MO) |
Correspondence
Address: |
HUSCH BLACKWELL SANDERS LLP
4801 Main Street, Suite 1000
KANSAS CITY
MO
64112
US
|
Family ID: |
41378032 |
Appl. No.: |
12/131484 |
Filed: |
June 2, 2008 |
Current U.S.
Class: |
52/742.16 |
Current CPC
Class: |
E04F 21/1652 20130101;
E04F 21/165 20130101 |
Class at
Publication: |
52/742.16 |
International
Class: |
E04G 23/02 20060101
E04G023/02 |
Claims
1. An apparatus for applying filler material within a groove, said
apparatus comprising: a plate member having a leading edge; an
orifice through said plate member, said orifice in communication
with a supply of said filler material; a guide member for engaging
said groove protruding proximate said plate leading edge and having
a width less than said groove; and a channel in communication with
said orifice having an angled portion for directing said filler
material into said groove.
2. The apparatus of claim 1, further comprising a pliable
attachment having a leading edge, a trailing edge, and a cavity in
communication with said orifice wherein said channel is part of
said pliable attachment.
3. The apparatus of claim 1, further comprising a tubular portion
configured to be in communication with a supply of said filler
material and said orifice.
4. The apparatus of claim 1, wherein said apparatus further
comprises a device capable of conveying said filler material.
5. The apparatus of claim 3, wherein said tubular portion is
configured for detachably coupling with a device capable of
conveying said filler material.
6. The apparatus of claim 5, wherein said tubular portion is
configured for pivotally coupling with said device.
7. The apparatus of claim 2, wherein said plate and pliable
attachment have a width greater than said groove.
8. The apparatus of claim 7, wherein said pliable attachment is
adapted for coming into substantially sealing contact with a
surface on either side of said groove.
9. The apparatus of claim 7, wherein said orifice is at least as
wide as said groove.
10. The apparatus of claim 7, wherein said pliable attachment
leading edge is beveled to aid its movement over a surface on
either side of said groove.
11. The apparatus of claim 7, wherein said pliable attachment
leading edge is rounded to aid its movement over a surface on
either side of said groove.
12. The apparatus of claim 2, wherein said pliable attachment
includes a slot proximate its leading edge for receiving said guide
member.
13. The apparatus of claim 2, wherein said channel is located
proximate said pliable attachment trailing edge.
14. The apparatus of claim 2, wherein said cavity is tapered for
directing said filler material into said groove.
15. The apparatus of claim 1, wherein said channel has tapered
portion for directing said filler material into said groove.
16. The apparatus of claim 1, further comprising at least two
channels for directing said filler material into at least two said
grooves.
17. The apparatus of claim 1, wherein said orifice and said channel
are at least as wide as said groove.
18. The apparatus of claim 1, wherein said channel has a width
between about 0.125 inches and 0.75 inches.
19. The apparatus of claim 16, wherein said channels have a width
between about 0.125 inches and 0.75 inches and are spaced out on
centers between about 0.625 inches and 5.0 inches.
20. The apparatus of claim 2, wherein said pliable attachment is
constructed of a material selected from the group consisting of
polypropylene, polyethylene, Neoprene, vulcanized rubber, and
combinations thereof.
21. The apparatus of claim 1, wherein said filler material is a
material selected from the group consisting of grout, mortar,
sealant, caulking, cement, concrete, and combinations thereof.
22. An apparatus for distributing flowable materials within the
space between two tiles, said apparatus comprising: a tubular
portion configured to be in communication with a supply of said
filler material; a plate with a width greater than said space
adapted for contacting a surface on either side of said space and
having a leading edge; an orifice through said plate that is in
communication with said tubular portion; a guide member configured
to fit within said space; and a supple attachment having a cavity
in communication with said orifice wherein said cavity includes a
channel with an angled portion for directing said filler material
into said space.
23. A nozzle for applying grout between tiles of the like
comprising: a tube configured to be removably mounted to and in
communication with a device for feeding said grout; a plate member
having a width greater than a distance between said tiles and a
leading edge; an orifice through said plate member in communication
with said tube for distributing said grout in between said tiles;
and a guide member for engaging a space between said tiles, said
guide member protruding proximate said plate leading edge and
having a width less the distance between said tiles.
24. The apparatus of claim 23, wherein said orifice has an angled
portion for directing said filler material in between said
tiles.
25. A method for applying filler material between tiles or the like
comprising the steps of: providing a nozzle in communication with a
supply of filler material, said nozzle including a plate member
with an orifice for distributing filler material between said tiles
and a guide member protruding from said plate member; placing said
nozzle plate on said tiles with said guide member located between
said tiles; causing filler material to be supplied to said nozzle
and distributed from said nozzle orifice to a space between said
tiles; moving said nozzle in a direction in order to continue the
distribution of filler material between said tiles.
26. The method of claim 25, wherein said orifice has an angled
portion for directing said filler material in between said tiles.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None.
BACKGROUND OF THE INVENTION
[0002] Billions of square feet of tile are installed in the United
States every year. It is very common to tile floors, walls,
bathtubs, showers, counters, backsplashes and swimming pools in
both residential and nonresidential settings. According to one
estimate, approximately 2.7 billion square feet of tile were
installed in the United States in 2006.
[0003] Normally, after tiles have been installed and have had a
chance to set up, a filler material, such as a grout, is applied to
the void spaces between the tiles. In doing so, a quantity of grout
is first placed on or around the tiles. A grout float or trowel is
then used to spread and disperse the grout into the void spaces
between the tiles. When spreading and dispersing the grout, the
grout float is typically moved back and forth in diagonal sweeping
motions in order to work the grout into the void spaces between the
tiles. In order to effectively force the grout into the void
spaces, the grout float is held at an angle with respect to the
tiles. Once the void spaces are completely filled with grout, the
excess grout can be scraped from the tiles using the side of the
grout float. This is often a time consuming and messy process and
can take a large toll on the grout applicator's knees and back.
[0004] Accordingly, a need exists for a device that can be used to
apply filler materials to the void spaces between tiles and the
like in a quicker and cleaner fashion. A need further exists for a
device that can be used to apply filler materials wherein the
applicator does not have to hunch down on his or her hands and
knees. Additionally, a need exists for a method in which filler
materials can be applied in a quicker and cleaner fashion and that
does not require the applicator to hunch down on his or her hands
and knees, thereby preventing pain or injury.
SUMMARY OF THE INVENTION
[0005] One embodiment of the present invention is directed to an
apparatus for applying filler material within a groove that
includes a plate member, an orifice through the plate member, a
guide member for engaging the groove, and a pliable attachment. The
orifice is in communication with a supply of the filler material.
The guide member protrudes from the plate member and has a width
less than the groove. The pliable attachment has a channel with an
angled portion for directing the filler material into the
groove.
[0006] Another embodiment of the present invention is directed to
an apparatus for distributing flowable materials within the space
between two tiles that includes a tubular portion, a plate, an
orifice through the plate, a guide member, and a supple attachment.
The tubular portion is in communication with a supply of the filler
material. The plate has a width greater than the space between the
tiles and is adapted for contacting a surface on either side of the
space. The orifice is in communication with the tubular portion and
the guide member is configured to fit within the space between the
tiles. The supple attachment has a cavity in communication with the
orifice. The cavity includes a channel with an angled portion for
directing the filler material into the space.
[0007] A further embodiment of the present invention is directed to
a nozzle for applying grout between tiles that includes a tube, a
plate member, an orifice through the plate member, and a guide
member. The tube is configured to be removably mounted to and in
communication with a device for feeding the grout. The plate member
has a width greater than the distance between the tiles. The
orifice is in communication with the tube for distributing the
grout in between the tiles. The guide member protrudes from the
plate member and is configured for engaging a space between the
tiles.
[0008] The present invention is also directed to a method for
applying filler material between tiles comprising the steps of
providing a nozzle in communication with a supply of filler
material, placing the nozzle on the tiles, causing the filler
material to be supplied to the nozzle and distributed from the
nozzle to a space between the tiles, and moving the nozzle in a
direction in order to continue the distribution of the filler
material between the tiles. The nozzle includes a plate member with
an orifice for distributing the filler material between the tiles
and a guide member protruding from the plate member.
[0009] Certain embodiments of the invention are outlined above in
order that the detailed description thereof may be better
understood, and in order that the present contributions to the art
may be better appreciated. In this respect, it is to be understood
that the invention is not limited in its application to the details
of construction and to the arrangements of the components set forth
in the following description or illustrated in the drawings. The
invention is capable of embodiments in addition to those described
and of being practiced and carried out in various ways. Also, it is
to be understood that the phraseology and terminology employed
herein, as well as the abstract, are for the purpose of description
and should not be regarded as limiting.
[0010] As such, those skilled in the art will appreciate that the
conception upon which this disclosure is based may readily be
utilized as a basis for the designing of other structures, methods
and systems for carrying out the several purposes of the present
invention. It is important, therefore, that the claims be regarded
as including such equivalent constructions insofar as they do not
depart from the spirit and scope of the present invention. Though
some features of the invention may be claimed in dependency, each
feature has merit when used independently.
DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0011] Further features of the present invention will become
apparent to those skilled in the art to which the present invention
relates from reading the following description with reference to
the accompanying drawings, in which:
[0012] FIG. 1 is an exploded bottom perspective view of a nozzle
with an attachment having a tapered cavity and parallel-walled
channel in accordance with one embodiment of the present
invention;
[0013] FIG. 2 is an assembled bottom perspective view of a nozzle
with an attachment having a tapered cavity and parallel-walled
channel in accordance with one embodiment of the present
invention;
[0014] FIG. 3 is an exploded bottom perspective view of a nozzle
with an attachment having a parallel-walled chamber and tapered
channel in accordance with one embodiment of the present
invention;
[0015] FIG. 4 is an assembled bottom perspective view of a nozzle
with an attachment having a parallel-walled chamber and tapered
channel in accordance with one embodiment of the present
invention;
[0016] FIG. 5 is an exploded bottom perspective view of a nozzle
with an attachment having multiple channels;
[0017] FIG. 6 is an assembled bottom perspective view of a nozzle
with an attachment having multiple channels;
[0018] FIG. 7 is an exploded side perspective view of a machine for
applying filler materials into spaces between tiles; and
[0019] FIG. 8 is an assembled side perspective view of a machine
for applying filler materials into spaces between tiles.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The invention will now be described with reference to the
drawing figures, in which like reference numerals refer to like
parts throughout. For purposes of clarity in illustrating the
characteristics of the present invention, proportional
relationships of the elements have not necessarily been maintained
in the drawing figures.
[0021] One embodiment of the present invention is directed to a
nozzle 10 for applying filler material (not shown) into at least
one void space or groove (not shown) between tiles (not shown) or
the like. As will be discussed in further detail hereinbelow, the
nozzle 10 is configured to be in substantially fluid communication
with a supply of filler material for distributing the filler
material into the void spaces or grooves between tiles. In use, the
nozzle 10 is configured to be pushed or pulled in a direction
represented by arrow A.
[0022] As illustrated in FIG. 1, the nozzle 10 includes a
substantially solid back plate 12 and an attachment 14. The back
plate 12 can be constructed from a plastic such as polyethylene,
polypropylene, acrylonitrile butadiene styrene (ABS), polyvinyl
chloride (PVC), urethane, and combinations thereof. The back plate
12 can also be constructed from a cast, forged, or shaped metal,
such as aluminum, steel, an alloy, and combinations thereof. In
this embodiment, the back plate 12 includes a plate member 16, a
tubular member 18, and a guide member 20. In the embodiment shown
in FIGS. 1-2 and in most tiling applications wherein the tiles are
being installed on a generally flat floor or wall, the plate member
16 is generally flat or planar, but it will be appreciated by one
skilled in the art that the plate member 16 can have any suitable
shape or form suitable for use in the particular application for
which the nozzle 10 is to be used. In certain embodiments, the
plate member 16 has a width greater than the width of the spaces or
grooves between the tiles.
[0023] The plate member 16 includes a leading or front edge 24 and
a trailing or back edge 26 and further includes a first surface 17,
an opposing second surface 19, and an orifice 22 defined
therethrough. In certain embodiments, orifice 22 is generally
rectangular in shape as shown in FIGS. 1-4 or, in other embodiments
such as those shown in FIGS. 5-6, orifice 22 is generally circular.
However, it will be appreciated that orifice 22 may have virtually
any suitable shape including, but not limited to, square,
triangular, oval, and the like. In certain embodiments, the orifice
22 is disposed directly adjacent the guide member 20 has a width,
w.sub.o that can be less than, equal to, or greater than the width
of the space or groove between the tiles. While FIG. 1 shows the
orifice 22 as having a generally rectangular shape, it will be
appreciated by one skilled in the art that the orifice 22 can take
on other shapes or forms, so long as filler material is allowed to
pass through the orifice 22.
[0024] The tubular member 18 includes a generally cylindrical
sidewall 25 having a substantially hollow interior, a first end 21
and a second end 23. Sidewall 25 may include an aperture 28
configured to receive a fastener therethrough such as a set screw,
pin, bolt, hair pin clip, or spring-loaded push button, and the
like for coupling nozzle 10 to a supply of filler material as
discussed in detail hereinbelow. As shown in FIG. 1, the tubular
member second end 23 is operably coupled to and extends outwardly
from the plate member first surface 17 such that the hollow
interior of sidewall 25 is in fluid communication with orifice 22.
The tubular member 18 can also be adjustably connected to the plate
member 16 using, for example, an elbow joint (not shown) or the
like disposed between the plate member first surface 17 and the
tubular member second end 23 thereby allowing for greater
flexibility in adjusting an angle .alpha. at which the tubular
member 18 extends outwardly from the plate member 16.
Alternatively, the tubular member 18 can be pivotably connected to
the first surface 17 of plate member 16 using a pivot joint (not
shown) or the like disposed between first surface 17 and second end
23. In this embodiment, the pivot joint includes an axis
approximately perpendicular to the plate member 16 or an axis
approximately longitudinal to the tubular member 18.
[0025] The angle .alpha. at which the tubular member 18 extends
outwardly from the plate member 16 can vary from embodiment to
embodiment. For example, in certain embodiments, .alpha. is between
about 90 degrees and 135 degrees, and more preferably between about
115 degrees and 125 degrees. In other embodiments, .alpha. is
preferably between about 45 degrees and 90 degrees.
[0026] As illustrated in FIG. 1, the guide member 20 protrudes
outwardly from the second surface 19 of the plate member 16
proximate the plate member's leading edge 24. The guide member 20
is configured to engage the space or groove between the tiles. The
guide member 20 has a width w.sub.g that is less than the width of
the space or groove between the tiles. The width of the space or
groove between the tiles can vary from application to application,
depending upon the type and size of tile used and further depending
upon the preferences of the person for whom the tile is being
installed. Usually, the width of the spaces or grooves is between
0.0625 inches and 1.0 inch, and most often between 0.125 inches and
0.5 inches.
[0027] The guide member 20 also has a length, l.sub.g. That length,
l.sub.g, is great enough so that the guide member 20 extends past
surface 44 of the attachment 14, but not so great that it comes
into contact with the flooring or wall on which the tiles are
installed. Thus, for most tiling applications, l.sub.g is not
normally greater than the combination of the thicknesses of the
attachment 14 and the tiles. The guide member 20 may include
beveled edges 34 to aid in the movement of the nozzle 10.
[0028] As shown in FIG. 1, the attachment 14 includes a chamber or
cavity 50, a slot 62, and at least one channel 56. The attachment
14 can be constructed of a pliable or flexible material. For
example, the attachment 14 may be constructed from a plastic
foam-like material such as polypropylene or polyethylene. The
attachment 14 may also be constructed from a rubber foamlike
material such as Neoprene or vulcanized rubber. The attachment 14
may also be made of combinations of these materials or any other
material suitable for use in the present invention.
[0029] A first surface 42 of attachment 14 is configured to be
removably coupled or, alternatively, affixed to the front surface
19 of the plate member 16. As shown in FIGS. 1-2, when coupled or
affixed, the attachment first surface 42 is matingly engaged with
the plate member second surface 19 such that the cavity 50 is in
communication with the orifice 22. The attachment 14 and plate
member 16 can be coupled or affixed by use of an adhesive,
interlocking members, fasteners or any other fastening methods now
known or hereafter developed. As illustrated in FIGS. 1 and 2, the
cavity 50 has a tapered configuration such that it decreases in
width from front to back. As the width of the cavity 50 decreases,
from front to back, the cross-sectional area of the cavity 50 also
decreases from front to back toward channel 56. This decrease in
cross-sectional area, coupled with the constant flow of filler
material, causes the filler material to increase in velocity as it
travels from front to back in the cavity 50. The increase in
velocity of the filler material aids in forcing the filler material
into the spaces or grooves between the tiles.
[0030] The attachment 14 also includes at least one channel 56
having a pair of substantially parallel sidewalls 52 so that
channel 56 has a substantially uniform width, w.sub.c, from front
to back. Like the orifice 22, the channel's 56 width, w.sub.c, can
be less than, equal to, or greater than the width of the spaces or
grooves between the tiles. The channel 56 can also include a wall
58 that further directs the filler material into the spaces or
grooves. The wall 58 is sloped from front to back. In addition to
directing the filler material into the space or groove, the sloped
wall 56 translates to the channel 56 having a decreasing
cross-sectional area from front to back. Like the cavity 50, this
decrease in cross-sectional area causes the filler material to
increase in velocity as it travels from front to back in the
channel 50 and, therefore, aids in forcing the filler material into
the spaces or grooves.
[0031] The attachment 14 further includes a contacting surface 44.
In use, this surface 44 comes into substantially sealing contact
with the tiles. This substantially sealing contact prevents the
filler material from escaping via the front, back, or sides of the
attachment 14. While coming into substantially sealing contact with
the tiles, the contacting surface 44 also allows the nozzle 10 to
slide on the tiles when it is pushed or pulled. The contacting
surface 44 also wipes excess filler material from the tiles,
thereby significantly reducing the amount of clean up time and
effort required. In one embodiment, the attachment 14 extends
around the guide member 20. In such an embodiment, the attachment
14 includes a slot 62 for receiving the guide member 20. The
attachment 14 can also have a beveled portion 64 proximate its
leading edge 46 to aid the movement of the nozzle over uneven
surfaces.
[0032] In one embodiment, the nozzle 10 does not include an
attachment 14. Rather, it only includes the solid back plate 12. In
such a case, the solid back plate 12 can further include a channel,
like the channel 56 described above. The solid back plate 12 may
also include a cavity, like the cavity 50 described above. Like the
channel 56 and cavity 50 described above, the channel and cavity
that can be included in the solid back plate 12 would aid in
forcing the filler material into the spaces or grooves.
[0033] FIGS. 3 and 4 illustrate another embodiment of the nozzle
10. As shown, the cavity 50 has sidewalls 54 that are substantially
parallel with one another, giving it a substantially uniform width
and cross-sectional area from front to back. As with the other
embodiments, the cavity 50 can have a width that is less than,
equal to, or greater than the width of the space or groove between
the tiles.
[0034] In the embodiment shown in FIGS. 3 and 4, the channel
sidewalls 52 are converging, giving the channel 56 a tapered
configuration. The channel 56 decreases in width, w.sub.c, from
front to back. Again, this decrease in width, w.sub.c, translates
into a decrease in cross-sectional area causing the filler material
to increase in velocity as it travels from front to back and aids
in forcing the filler material into the spaces or grooves between
the tiles. As shown in FIGS. 3 and 4, the channel 56 also includes
a wall 58 that further directs the filler material into the groove
or space. Again, this wall 58 is sloped from front to back, thus
causing a decrease in cross-sectional area of the channel 56 from
front to back and an increase in the velocity of the filler
material.
[0035] In the embodiment shown in FIGS. 3 and 4, the guide member
20 protrudes from the plate member 16 from a location behind the
leading or front edge 24. While the guide member 20 is shown
protruding directly adjacent the orifice 22, it need not protrude
directly adjacent the orifice 22, and can protrude in any area in
front of the orifice 22. This embodiment also demonstrates a
longer, narrower orifice 22. Again, like other embodiments, the
orifice 22 can have a width, w.sub.o, that is less than, equal to,
or greater than the width of the spaces or grooves between the
tiles. Furthermore, this embodiment includes apertures 28 in the
tubular member 18 for receiving a fastening device, such as a
circlip 38, retaining ring, retaining pin, or snap ring, among
others.
[0036] One variation of the nozzle 10 shown in FIGS. 3 and 4 does
not include an attachment 14. Rather, it just includes the solid
back plate 12. In such a case, the solid back plate 12 can further
include a channel, like the channel 56 described above. The channel
56 can be attached to and in direct communication with the orifice
22. Like the channel 56 described above, the channel that can be
included in the solid back plate 12 would aid in forcing the filler
material into the spaces or grooves.
[0037] FIGS. 5 and 6 illustrate yet another embodiment of the
nozzle 10. As shown, the attachment 14 in this embodiment includes
multiple channels 56. These multiple channels 56 can be configured
to simultaneously distribute filler material into multiple spaces
or groves that are substantially parallel to one another. Thus,
rather than distributing filler material into only one space or
groove at a time, this embodiment can distribute it into multiple
spaces or grooves. While this embodiment can be used for tiles of
any width, it is most often used for tiles having narrower widths.
As illustrated in FIGS. 5 and 6, the channels 56 can also include
walls 58 that further direct the filler material into the spaces or
grooves. The walls 58 are sloped from front to back and aid in
forcing the filler material into the spaces or grooves, as
discussed with the other embodiments above.
[0038] Like the other embodiments, the width of the channels,
w.sub.c, can be less than, equal to, or greater than the width of
the spaces or grooves between the tiles. The distance, d.sub.c,
between the centers of the channels is determined by the width of
the tiles. The distance, d.sub.c, between the centers of the
channels is normally equal to the width of the tiles plus the width
of the spaces or grooves between the tiles. For example, if the
tiles were 1.0 inch wide with 0.25 inch spacings between them, then
the distance, d.sub.c, would be 1.25 inches. The distance, d.sub.c,
is usually between 0.625 inches and 5.0 inches
[0039] While the embodiment in FIGS. 5 and 6 shows the attachment
14 having five channels 56, the attachment 14 may include more than
five or less than five channels.
[0040] As shown, the cavity 50 includes a wall 51 having an orifice
53. In order to help the filler material be more evenly distributed
to all of the channels 56, the orifice 53 has a tongue portion 55.
Even though a tongue portion 55 is shown in FIGS. 5 and 6, it will
be appreciated by one skilled in the art that other configurations
and shapes can be used to help the filler material be more evenly
distributed to all of the channels 56. The attachment 14 can also
have a rounded portion 66 proximate its leading edge 46 to aid the
movement of the nozzle over uneven surfaces.
[0041] As set forth above, the orifice 22 in the plate member 16
can be of a variety of shapes, so long as filler material is
allowed to pass through the orifice 22. As shown in FIG. 5, the
orifice 22 is a substantially circular shape. The diameter of the
circular-shaped orifice 22 can be less than, equal to, or greater
than the width of the spaces or grooves between the tiles.
[0042] As further shown in FIG. 5, .beta. represents the angle at
which the tubular member 18 is connected to the plate member 16.
Again, the nozzle 10 can be configured to be pushed by the user
along the tiles or pulled by the user along the tiles. In cases
where the nozzle 10 is pushed, .beta. will normally be between
about 90 degrees and 135 degrees, and most preferably be between
about 95 degrees and 105 degrees. In cases where the nozzle 10 is
pulled, .beta. will normally be between about 45 degrees and 90
degrees. As illustrated in FIGS. 5 and 6, the guide member 20 can
have a rounded edge 36 to aid in the movement of the nozzle. Again,
the nozzle 10 can also be configured such that the angle at which
the tubular 18 member is connected to the plate member 16 can be
adjusted through, for example, an elbowjoint. Additionally, the
tubular member 18 can have the ability to pivot or swivel with
respect to the plate member 16 on an axis approximately
perpendicular to the plate member 16 or an axis approximately
longitudinal with the tubular member 18. The tubular member 18 can
have apertures 30 configured for receiving a fastening device, such
as a circlip 38
[0043] One variation of the nozzle 10 shown in FIGS. 5 and 6 does
not include an attachment 14. Rather, it just includes the solid
back plate 12. In such a case, the solid back plate 12 can further
include channels, like channels 56 described above. The solid back
plate 12 may also include a cavity 50. To help the filler material
be more evenly distributed to all of the channels 56, the orifice
22 in the solid back plate 12 may have a tongue portion similar to
the tongue portion 55 described above.
[0044] As mentioned above, in use, the nozzle 10 normally receives
filler material from a feeding device. That feeding device can be a
handheld machine 68, like the one shown in FIGS. 7 and 8, or can be
a larger, stand-alone machine (not shown) to which the tubular
member 18 of the nozzle 10 is connected via a hose. In use, the
tubular member 18 normally receives filler material from a feeding
back plate and passes the filler material on though the orifice 18.
As will be discussed in further detail below, the feeding device
can be a handheld machine 68, like the one shown in FIGS. 7 and 8,
or can be a larger, stand-alone machine (not shown) to which the
tubular member 18 is connected to via a hose.
[0045] The handheld machine 68 illustrated in FIGS. 7 and 8 is
configured to distribute filler material to the nozzle 10. The
machine 68 and nozzle 10 can be configured such that they can apply
filler material between tiles installed on a substantially
horizontal surface (e.g. floor), a substantially vertical surface
(e.g. wall), or an overhead surface (e.g. ceiling).
[0046] Once it is prepared, the filler material is placed into the
hopper 98. The hopper 98 can have an outlet 100 that is rotatably
attached to the inlet neck 92 of the chamber 90. The position in
which the hopper 98 is attached to the chamber 90 depends upon
angle at which the machine 68 is being used. For example, if the
machine 68 is being used to apply filler material between tiles
installed on a horizontal floor, the hopper 98 would be attached to
the chamber 90 in a position similar to the one seen in FIGS. 7 and
8. If the machine 68 is being used to apply filler material between
tiles on a vertical wall or an overhead ceiling, the hopper 98
would likely be attached in a position that is approximately 180
degrees offset from the one seen in FIGS. 7 and 8. For other
applications, it may be desirable that the hopper 98 be attached at
another angle. For example, if the machine 68 is being used to
apply filler material between tiles that are set on a vertical wall
at a 45 degree diagonal, the user may wish to attach the hopper 98
in a position that is approximately 135 degrees offset from the one
seen in FIGS. 7 and 8.
[0047] In one embodiment, the filler material is fed into the
chamber 90 by gravity. In such an embodiment, the auger 84 can also
help pull the filler material into the chamber 90. However, in
other embodiments, the filler material is fed into the chamber 90
with the assistance of a rotating paddle, an additional auger, a
vibrating rod, or a plunger located within the hopper 98. Though
the hopper 98 shown in FIGS. 7 and 8 is bell-shaped, this need not
be the case. The hopper 98 can take almost any shape, so long as it
allows filler material to be fed into the chamber 90. Furthermore,
the hopper can be replaced with a hose that is in communication
with a supply of filler material.
[0048] Once in the chamber 90, the filler material is fed to the
nozzle 10 by an auger 84. The auger 84 includes spiral or helical
flighting 88 wrapped around a shaft 86. As shown in FIG. 7, the
auger 84 is tapered such that the diameter of flighting 88 becomes
decreasingly smaller as it progresses towards the nozzle 10.
[0049] Depending upon factors, such as the type, viscosity, and
desired flow rate of the filler material used, different types of
augers 84 can be substituted in and out of the machine 68. For
example, an auger 84 can be used that has relief cuts or holes
formed into the flighting 88. An auger 84 can also be used that has
more or less flights 89 per unit length. Furthermore, an auger 84
having an increased or reduced flighting 88 pitch can be used.
Additionally, in substitute of a tapered auger 88, as shown in FIG.
7, the machine 68 can be configured to use a stepped auger. Such a
configuration can take place by changing out the chamber 90. Rather
than having a gradual decrease in the diameter of the flighting 88
like the tapered auger 84 shown in FIG. 7, the stepped auger has
flighting with a substantially uniform diameter at one end and
flighting with a substantially uniform smaller diameter at the
other end. An auger 84 combining the features of a tapered auger 84
and a stepped auger can also be used.
[0050] Again, the filler material is transferred from the hopper
98, through the chamber 90, and then to the nozzle 10. The nozzle
10 can be rotatably and detachably coupled to an output neck 94 of
the chamber 90. As discussed above, the nozzle 10 may be attached
using a fastener such as a set screw, a circlip 38, a retaining
ring, a retaining pin, or a snap ring. These fasteners can engage
an indented groove 96 formed around the output neck 94. This
engagement can keep the nozzle 10 coupled to the chamber 90, while
still giving it the ability to pivot or rotate.
[0051] The auger 84 is driven by a motor 80. The motor 80 can be
coupled to the auger 84 via a gear reduction unit 82. As
demonstrated in FIG. 8, the motor 80 and the gear reduction unit 82
are contained inside of a housing 78. The motor 80 may be of a type
that produces a generally high-speed, low-torque output. The motor
80 may be capable of being powered by a DC power source, such as a
battery, or by an AC power source, such as a 110V wall outlet.
Additionally, the motor 80 may be capable of producing variable
speeds.
[0052] The gear reduction unit 82 converts the high-speed,
low-torque output from the motor into a lower-speed, higher-torque
output that drives the auger 84. The gear reduction unit 82 may use
a variety of types of gears, including planetary gears, spur gears,
helical gears, and worm gears. The gear reduction unit 82 can also
include at least two gearing ratios, such as a high and a low In
such a case, one gearing ratio creates an output that is of a lower
speed and higher torque than the other ratio. A user may select
between the gearing ratios by flipping a switch.
[0053] The variable speed motor 80, the multiple gearing ratios,
and the interchangeability of auger 84 allow a user to precisely
adjust the output flow of the filler material from the machine 68.
For example, the user may wish to increase the output flow of the
filler material in cases where the spaces or grooves between tiles
are larger or deeper or in cases where the user desires to move the
nozzle 10 at a faster speed. Conversely, the user may wish to
decrease the output flow of the filler material in cases where the
spaces or grooves between tiles are smaller or shallower or in
cases where the user desires to move the nozzle 10 at a slower
speed. Such adjustments may be made by adjusting the speed of the
motor 80, the gearing ratio, and/or changing the auger 84. A guide
recommending certain motor 80 speed, gearing ratio, and auger 84
combinations may be provided with the machine 68. Such a guide sets
forth the combinations that are best for applying certain filler
materials to certain sized spaces or grooves at certain speeds.
[0054] Again, the motor 80 can be powered by a DC power source,
such as a battery, or by an AC power source, such as a 110V wall
out outlet. When the motor 80 is powered by a battery, that battery
may be one of many types, including a lithium ion battery. Though
not shown in the drawings, the battery can be attached to the
machine 68 at the handle portion 70. More specifically, the battery
may be at least partially received by the grip section 72 of the
handle portion 70. The trigger 74, when pulled, connects the power
supply with the motor 80. Thus, when the user desires filler
material to be fed from the nozzle 10, he or she will pull the
trigger 74 in order to power the motor 80 and therefore turn the
auger 84.
[0055] As illustrated in FIGS. 7 and 8, the machine 68 includes a
removable extension portion 76. The extension portion 76 is used to
connect the handle portion 70 to the motor and gear reduction
housing 78. In some applications, the extension portion 76 may be
desirable. When a user is applying filler material to a floor, the
user may wish to use the extension portion 76. This allows the user
to stand while applying the filler material to the floor. In such a
case the user would walk behind the machine 68, pushing it in a
forward direction. If the nozzle 10 was configured to be pull
rather than pushed, as discussed above, the user would walk in
front of the machine 68, pulling it a forward direction.
[0056] In other instances, such as when the user is applying filler
material to a wall or counter top, the user may wish to use the
machine 68 without the extension portion 76. In such a case, the
handle portion 70 is directly connected to the motor and gear
reduction housing 78. Again, depending on the nozzle 10
configuration, the machine 68 may either be pushed or pulled.
[0057] When the extension 76 is either removed or added, the
electrical wires connecting the switch 74 to the motor 80 are
disconnected, and then reconnected once the extension 76 is removed
or added. Alternatively, the extension 76 may include a slot
running the length of the extension 76 or have the ability to be
separated into two lengthwise pieces, thus eliminating the need to
disconnect and reconnect the wires.
[0058] As mentioned above, the nozzle 10 may also receive filler
material from a larger, stand-alone machine (not shown) to which
the tubular member 18 of the nozzle 10 is connected via a hose. In
such a case, the larger, stand-alone machine would feed filler
material to the nozzle 10 by using an auger system similar to the
one utilized by the machine 68 or by pressurizing the filler
material with a pump. This embodiment could include a valve
proximate the nozzle 10 that the user would open or close depending
on whether he or she wanted filler material to be distributed from
the nozzle 10. This valve could be controlled by the user through
the push of a button, the turn of a knob, or the squeeze of a
trigger, for example.
[0059] Attention will now be drawn to the filler material. As
mentioned above, the filler material can include, but is not
limited to, grout, mortar, sealant, caulking, cement, concrete, and
combinations thereof. Suitable filler material can include, but is
not limited to, grout, mortar, sealant, caulking, cement, concrete,
and combinations thereof. Because the filler material is directed
through the machine 68 and nozzle 10, it is often desirable to
decrease the viscosity of the filler material. While water can be
used to decrease the viscosity of the filler material, water also
reduces the strength of the filler material.
[0060] Instead of water, a plasticizer or water reducer can be
used. Plasticizers decrease the viscosity without weakening the
strength of the filler material. Some plasticizers cause the filler
material particles to have a negative charge, thereby leading the
particles to repel one another. Other plasticizers decrease the
viscosity through steric stabilization. Examples of plasticizers
that can be used in the filler material include polycarboxylate,
citric acid, formaldehyde, lignosulfonate, zinc salts, borates,
phosphates, chlorides, amines and their derivatives, polymeric
compounds such as cellulose, ethers, melamines and their
derivatives, and naphthalene, among others. In general, any
augmentation or chemical additive, organic or inorganic that will
reduce the amount of water required to achieve a certain viscosity
appropriate for the flow through the machine can be used. Depending
on the type of filler material and plasticizer used, the filler
material/plasticizer mixture may contain between about 0.001
percent and 5.0 percent plasticizer by mass. In other words, for
every 100 grams of filler material, approximately 0.001 to 5.0
grams of plasticizer may be added.
[0061] For example, a common bag of tile grout may be composed of
approximately 25 percent cement and 75 percent sand. In one
embodiment, polycarboxylate may be mixed with the grout. In such a
case, the amount of polycarboxylate added to the mixture may be 0.2
percent of the mass of the concrete. Thus, for every 100 grams of
concrete (or every 400 grams of tile grout), 0.2 grams of
polycarboxylate is added to the mixture.
[0062] Attention will now be drawn to a method for applying the
filler material between tiles and the like. In use, the first step
is to provide a nozzle 10 as described above. The nozzle 10 should
be in substantially fluid communication with a supply of filler
material. The next step is to place the nozzle 10 on the tiles or
the like such that the plate member second surface 19 is in contact
with the tiles. The guide member 20 should be located in the space
between the tiles. Next, the user causes filler material to be
supplied to the nozzle 10. The filler material is distributed from
the nozzle orifice 22 to the spaced between the tiles. Finally, the
user causes the nozzle 10 to be moved in a direction in order to
continue distribution of the filler material between the tiles.
[0063] From the foregoing, it may be seen that the nozzle of the
present invention is particularly well suited for the proposed
usages thereof. Furthermore, since certain changes may be made in
the above invention without departing from the scope hereof, it is
intended that all matter contained in the above description or
shown in the accompanying drawing be interpreted as illustrative
and not in a limiting sense. It is also to be understood that the
following claims are to cover certain generic and specific features
described herein.
* * * * *