WO2007033486A1

WO2007033486A1 - Foam finishing device

Info

Publication number: WO2007033486A1
Application number: PCT/CA2006/001563
Authority: WO
Inventors: Timothy J. Mcdonell; Patrick E. Mcdonell
Original assignee: Custom Foam Systems Ltd.
Priority date: 2005-09-23
Filing date: 2006-09-22
Publication date: 2007-03-29
Also published as: CA2623303C; US20120122379A1; CA2623303A1

Abstract

A hand-held device is used in finishing an elongated workpiece, such as molding, which has a profiled front surface, the profiled front surface including a specific contour in transverse cross-section. The device has a finishing portion and a gripping portion. The finishing portion is formed from an open-cell foam material and has a working surface that is transversely profiled to be complementary to at least the profiled front surface of the workpiece. The finishing portion is adapted to apply a liquid material, such as a paint, stain or protective coating, to the workpiece.

Description

FOAM FINISHING DEVICE

The present invention relates in general to apparatus for effecting the finishing of elongated profiled workpieces, and more particularly to devices especially adapted for the finishing of decorative moldings.

BACKGROUND TO THE INVENTION

In the construction and renovation of buildings, whether residential or commercial, it is common to complete each room with the application of elongated strips of molding along specific portions of a wall. Baseboard is applied to the bottom edge of each wall where it meets the floor. Shoe molding may be applied to the bottom edge of baseboard where it meets a solid floor (hardwood, vinyl, concrete, etc.)- Crown molding may be applied to the upper edge of a wall where it meets the ceiling. Casing may be applied around door and/or window openings. Chair rail may be applied to a wall part way up the vertical extent of a wall, running parallel to the floor. Bead board allows for panelling such as wainscoting to be installed underneath the bottom half thereof to finish a partial wall. Other types of decorative molding may be applied to a wall surface to define decorative areas.

Elongated strips of molding have much in common, in particular a rear surface, that is generally planar and will usually abut against a wall, floor or ceiling surface. Crown molding, which is generally angled relative to a wall and a ceiling will have a rear surface that includes angled corner edges that together generally form a 90° angle therebetween for abutment against both the ceiling and the adjacent wall. Each strip of molding will have upper and lower edge surfaces extending outwardly from the upper and lower edges of the rear surface, which edge surfaces will generally be contoured so as to curve into or mate with a front surface that is profiled to have a specific defined contour in transverse cross-section of the molding strip. The contour can be as simple as a planar surface as in door or window casing or a very complex arrangement of concave and/or convex curved sections and/or straight sections. It is interesting to note that while there are many manufacturers of moldings, the WMMPA (Wood Mould, Milling Profile Association) has defined the actual molding profiles so that a standard thereof exists. Thus a 3%" Colonial molding will have the same profile no matter which manufacturer provides the molding.

Moldings can be made from different materials, both natural and synthetic. Wood moldings can be formed from solid woods such as oak, pine or maple and will not have any joints therein. Moldings can also be made from shorter lengths of material, and thus include several joints over the length thereof. Finger-jointed pine moldings for example fall into that category. Such moldings generally are not pre-finished at the factory. It is up to the contractor or the homeowner to finish the molding with paint, stain and/or a varnish or urethane coating. Growing in popularity are factory-primed moldings, rapidly becoming the largest selling group of moldings.

Moldings made from medium density fiberboard (MDF) can be unfinished or provided with a coat of a primer paint. Generally MDF moldings will be painted rather than stained as they do not have any grain and would not be attractive with a stained finish. MDF moldings can also be prefinished with a paper or vinyl layer so that further finishing is not required.

There is also a trend to plastic extruded moldings that have the finish incorporated therein, although such moldings tend to be provided with a white colour finish, with either a gloss or a semi-gloss appearance.

Moldings formed from wood and MDF have in common the feature that additional finishing is required in order to obtain molding that is both attractive and long-lasting. With such moldings it is usually necessary to lightly sand the material so as to accept the finish material and to then apply the finish using a bristle brush or a foam pad. This is a labour intensive task as it is difficult to both apply a uniform coating of the finish material and to ensure that the material is applied to all areas of the surface to be finished. With moldings having a complex contour it is difficult to apply the coatings into all nooks and crannies of the contour. Furthermore, the finishing process can involve several applications of finish, whether stain, paint and/or protective urethane or varnish, with a light sanding between coats, thereby increasing the time required to finish the moldings. Usually the finishing is effected prior to attachment of the molding to the wall, floor or ceiling and thus there can be many lengths of molding lying around a work area in various stages of finishing, making it awkward for workers to effectively work in the area.

Even though the molding may have paint or stain applied thereto prior to installation it is usual to apply a final finish coat once the molding has been installed in its final location. It is difficult to apply the final finish coat without taking extra precautions to avoid inadvertent application of finish to surrounding material, such as a wall, carpet or floor. Many other construction materials require finishing in one form or another, including planking used for decks or fences or logs used in log home construction. Other types of profiled or contoured items requiring finishing include, but are not limited to, railings, banisters, hand holds and rail caps.

There is therefore a profound need for any device or process that will speed up the finishing of moldings and other profiled or contoured building materials and that will improve the end result, insofar as a uniform and attractive finish is concerned.

SUMMARY OF THE INVENTION

The present invention serves the purpose of improving the finishing of elongated workpieces, of any length, making the finishing task simpler and more effective that previously. In short, the present invention provides a device for use in the finishing of elongated workpieces which comprises a gripping portion and a finishing portion, the finishing portion being an open-cell foam material that has a transversely contoured working surface, the working surface having a transverse contour that is complementary to the transverse contour of the elongated workpiece to be finished. The finishing device of the present invention can be dipped into a liquid finish material, such as paint, stain, varnish, shellac or urethane, placed on the elongated workpiece at one end thereof with the contoured surface of the finishing portion mating with the contoured surface of the workpiece, and then slid along the workpiece so as to transfer the finish material from the device onto the surface of the workpiece. It only takes a single pass of the device along the workpiece to apply a smooth uniform coating of finish material to the workpiece, the length of coating applied only depending on the amount of coating originally held by the working surface of the device. If there is insufficient finish material carried initially by the device, it is again dipped into a reservoir of the finish material and then applied to the unfinished portion of the workpiece to complete the application process. It takes much less time to apply the finish material using the device of the present invention than to apply the finish using a brush. Furthermore there are no brush strokes associated with the present device and the end result is a more uniform finish than can be obtained with a brush application.

The device of the present invention is inexpensive to manufacture and thus is a disposable item, to be thrown away once a particular job is complete. A contractor or homeowner could obtain a complete set of finishing devices to encompass all of the different workpiece profiles that he works with, using them to apply paint, stain, urethane or varnish to the workpieces. If the workpiece requires cleaning using a liquid cleaner the device of the present invention can be used to apply the cleaner and it could also be used to wipe any excess cleaner from the surface of the workpiece, as required. A new, clean or unused device of the present invention could also be used to remove dust or debris from a workpiece prior to the finishing thereof.

The device of the present invention could also be manufactured with the profiled foam working surface thereof having been impregnated or overlaid with an abrasive substance such that the device could be used to effect a "sanding" or abrading operation on the workpiece before initial coating and/or between coatings.

Further details respecting the present invention will be realized from the description to be provided hereinbelow in association with the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Each of Figures IA through 8A shows an end view of the molding with which the particular finishing device is utilized.

Each of Figures IB through 8B shows a perspective view of the particular finishing device used with the particular molding profile.

Each of Figures 1C through 8C shows in transverse cross-section a molding having a specific profile abutting a surface and a finishing device of the present invention in contact therewith.

Figure 9 shows a finishing device that could be used with a workpiece of rectangular cross-section, as might be used for deck or fence construction.

Figure 10 shows a finishing device that could be used to apply finish material to an elongated log as used in a log home construction.

Figure 11 shows a representative finishing device having a particular form of gripping element secured thereto.

Figure 12 shows a finishing device adapted to function as a sanding block.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Each of Figures IA through 8A shows an end view of a particular molding profile, the profile pattern number as established by the WMMPA being shown thereon. Figures IA shows a casing 12; Figure 2A shows another casing 14; Figure 3A shows yet another casing 16; Figure 4A shows a baseboard 18; Figure 5A shows another baseboard 20; Figure 6A shows a chair rail 22; Figure 7A shows a bean board 24; and Figure 8A shows a crown molding 26. It is understood that these moldings are elongated, coming in lengths of 7, 8, 12, or 16 feet and that they can come in different widths albeit with the same general profile. Furthermore it is to be understood that the profiled moldings shown in these figures are representative of the available molding profiles and that other profiles are also available. Simple cove and quarter-round moldings, for example, have not been illustrated herein.

All of the illustrated moldings, as well as those not shown herein, have in common the feature of a specifically defined profile or contour that exists transversely across the piece, herein referenced as a workpiece. Generally speaking, each workpiece has a rearmost face 12a, 14a, 16a... 26a respectively. The rearmost face can be relatively flat, as with the workpieces 12, 14, 18, 20 and 22, perhaps having a longitudinally extending relief groove 28 therein; the face can be somewhat concave, as with the workpiece 16; the face can be stepped, as with the workpiece 24; or the face can have bevelled edge sections 30, 32 as with the workpiece 26. Each workpiece has what can be termed as upper and lower edge surfaces 12b, 12c; 14b, 14c..26b, 26c respectively which extend outwardly of the rear surface. Finally, each workpiece has a transversely extending profiled front surface 12d...26d respectively which can be as simple as the surface 18d shown in Figure 4A to the more complex profiles 22d and 26d of Figures 6A and 8A respectively. Each profile presents its own problems in the application of finishing material thereto, especially the complex profiles made up of combinations of convex, concave and/or straight portions. The more complex the profile the more difficult it is to apply the finishing material in a uniform manner so that there is no unwanted accumulation of material where, for example, a curved portion meets a straight portion, or so that there are no portions of the profile, as for example where a curved portion meets a straight portion, where there is insufficient material applied to the workpiece surface.

Figures IB through 8B illustrate a finishing device of the present invention which is especially adapted to apply a finish or cleansing liquid to an elongated workpiece of the associated "A" figure. Thus, in Figure IB there is shown a device 40a which has a finishing portion 42a and a gripping portion 44. The finishing portion 42a is preferably formed from an open cell foam material such as commonly available polyester foam, urethane foam, et cetera. Such a foam is capable of being worked and is also capable of absorbing liquid material, such as paint, stain, varnish, shellac, urethane, et cetera and of releasing the material with moderate pressure applied thereto. The finishing portion 42a has a working surface 46a that is transversely contoured to conform or to be complementary to the profiled front surface 12d of the workpiece 12 as well as to the upper and lower edge surfaces 12b, 12c of the workpiece. Preferably, the upper and lower edges of the finishing portion are bevelled or chamfered as shown at 47, establishing a "take away" surface or edge that angles outwardly from each end of the working surface 46 to the adjacent side wall of the finishing portion. Additionally, the edge defined by the juncture of each angled surface 47 with the working surface 46 is short of the full depth or height of the molding 12 shown in Figure IA. Thus, if the finishing device of Figure IB were laid on the workpiece of Figure IA with no pressure applied thereto the edge defined by the juncture of each angled surface 47 with the working surface 46 would be positioned above the rear surface 12a of the molding 12. In use, however, as seen in Figure 1C, a modest amount of pressure applied inwardly to cause liquid to ooze from the finishing portion 42a will bring the edges as defined closer to the wall 48 to effect the transfer of finish material to the full extent of the end surfaces 12b and 12c. Furthermore, by minimizing the possible contact between the finishing portion and the adjacent wall or substrate the possibility of finish material being inadvertently applied to the wall or substrate is minimized.

The gripping portion 44 may just simply be a designated portion of the applicator device 40a if the entire device is made of open cell foam. Alternatively, the gripping portion 44 may be a separate section of a more dense material, such as a closed cell foam material, that is adhered or fused to the finishing portion 42a. The gripping portion could even be a block of a solid material such as wood that is adhered to the finishing portion. It could even be a commercially available handle or grip. When a gripping portion that is more dense than the finishing portion is used the finishing portion is able to perform its function more effectively. A fairly rigid gripping portion could have a swivel with a threaded socket secured thereto for reception of the threaded end of an extension pole to enable the device to be used at a distance from the person applying the finish material. This would be most useful when attempting to finish crown molding, fencing or decking.

Figure 1C shows the finishing device 40a of the present invention applied to an elongated workpiece 12 of Figure IA, with the workpiece being affixed to a supporting surface 48 such as a wall. The close conformance of the working surface 46a of the device 40a relative to the profiled surfaces 12b, 12c and 12d of the workpiece is clearly seen in Figure 1C, there being little or no space between the mating or complementary surfaces. In operation the finishing portion 42a is dipped into the finishing liquid, e.g. stain, so that a volume of the finishing material is absorbed by the open cell finishing portion 42a. The device is then brought to the workpiece with the working surface 46a being moved into contact in conforming fashion to the profiled edge and front surfaces of the workpiece. With moderate pressure applied to the device via the gripping portion the device is slid or wiped along the length of the workpiece whereby the finishing material is transferred from the finishing portion to the profiled surfaces of the workpiece. The end result is a smooth even coating applied to the profiled surfaces. If the liquid material runs out before the full length of the workpiece has been coated, the finishing portion 42a of the device 40a is again dipped into the reservoir of finishing material and then the remaining unfinished section of the workpiece can be coated.

Because of the angled "take away" surfaces 47 there will be no contact between the finishing portion and the wall 48, meaning that no liquid finishing material will be inadvertently applied to the wall.

The only difference among the finishing devices 40b through 40h of Figures 2B through 8B respectively lies in the particular profile of the working surface 46b through 46h of each finishing portion 42b through 42h. In each case the profile of the working surface is complementary to the profile of the respective workpiece with which it is adapted to be used. Each such finishing device will have the angled "take away" surfaces 47b...47h respectively associated therewith. It is noted that in the embodiment of Figure 8B the angled surface 47h need not be markedly angled relative to the adjacent side wall of the finishing portion since the device 4Oh will be used at an angle to the wall and ceiling surfaces to which the crown molding is affixed. The gripping portion 44 will be the same as the gripping portion described for the exemplary embodiment of Figure IB.

Figure 9 shows a finishing device 50 that has a rectangular finishing portion 52, angled "take away" surfaces 57, a gripping portion 54 and a simple rectangular working surface 56 that is especially adapted to apply liquid material to an elongated workpiece that has a flat front surface, such as a length of lumber that might be used as a deck board or a fence board. The width of the working surface 56 would be complementary to the width of the lumber workpiece.

Figure 10 shows a finishing device 60 that has a generally rectangular finishing portion 62, angled "take away" surfaces 67, a gripping portion 64, and a generally arcuate working surface 66. Arcuate working surfaces of varying diameters could be provided so that the device 60 could be used with any type of transversely curved or profiled workpiece of essentially any diameter, ranging from small diameter lengths of dowling through to large diameter logs as might be used in log home construction.

Figure 11 shows a finishing device in which the gripping portion 70 is provided with a groove 72 extending into the body thereof from the outermost surface 74. The groove 72 provides a rest for a finger of the person using the device, giving the person greater control of the movement of the device and also permitting greater control of the application of inward pressure and hence the transfer of liquid finishing material to the workpiece. The gripping portion 70 can be used with any of the finishing devices illustrated in the drawings.

The device of the present invention is not limited to the application of liquid finishing material to a workpiece. Other types of liquid material can be applied to the workpiece and/or wiped therefrom. Cleansing liquids or paint removers are but two examples of liquid materials that can be applied to and/or wiped from a workpiece using the device of the invention.

The device of the invention is easy and inexpensive to manufacture. It is contemplated that the device would be a disposable item, offered inexpensively in the paint section of building supply and other such retail outlets. Sets of finishing devices covering the most popular molding profiles could be sold to consumers or contractors. Of course, the devices could be sold individually so that a consumer would not have to purchase finishing devices which he or she would not expect to use.

Since the finishing devices of the present invention are manufactured with profiled working surfaces that conform to the profiled surfaces of popular moldings, it would also be possible to impregnate or overlay the finishing portion of such devices with abrasive material whereby the device could be used as a sanding block, making it easy to smooth the profiled workpiece surface in a simple manner by drawing the block along the workpiece surface. Such an abrasive device could be used between coatings of urethane or varnish to prepare the workpiece to receive another finish coating.

Figure 12 shows an abrasive finishing device 80 having a finishing portion 82, angled "take away" surfaces 87, a gripping portion 84, a profiled working surface 86 and a an outer surface 88 of an abrasive material. For this embodiment the finishing portion 82 could be a polyester foam profiled as desired. A light weight isopolysaturate (glue) would be applied to the working surface 86 and then the abrasive material 88 would be applied to the coating surface. The abrasive could be, but need not be limited to, aluminium oxide. The coated device would then be cured and any non-adhered abrasive material would be recovered.

It is to be understood that the foregoing has presented the presently preferred embodiments of the present invention. It is also understood that a skilled individual would be able to suitably modify the applicator devices as disclosed herein without departing from the spirit of the present invention. Accordingly the protection to be afforded the invention is to be determined from the scope of the claims appended hereto.

Claims

1. A device for use in finishing an elongated workpiece having a profiled front surface, said profiled front surface including a specific contour in transverse cross- section, said device comprising a finishing portion and a gripping portion, said finishing portion being formed from an open cell foam material and having a working surface that is transversely profiled to be complementary to at least the profiled front surface of said workpiece, such that said finishing portion is adapted to apply a liquid material to said workpiece.

2. The device of claim 1 wherein said working surface of said finishing portion is profiled to be complementary to said profiled front surface and to upper and lower edge surfaces of said workpiece.

3. The device of claim 1 wherein said profiled working surface conforms to a standard profile established by the WMMPA (Wood Mould, Milling Profile Association) for elongated molding workpieces.

4. The device of claim 1 wherein said gripping portion is formed of a closed cell foam material and is adhered to said finishing portion.

5. The device of claim 4 wherein said gripping portion is provided with a longitudinally extending groove in an outermost surface thereof, said groove being adapted to receive a finger of a person using said device.

6. The device of any one of claims 1 to 5 wherein said finishing portion is capable of applying liquid material selected from the group of liquid materials comprising paints, stains, varnishes, urethanes, shellacs, and cleansing fluids.

7. A device for use in finishing an elongated workpiece having a profiled front surface, said profiled front surface including a specific contour in transverse cross- section, said device comprising a finishing portion and a gripping portion, said finishing portion being formed from an open cell foam material and having a working surface that is transversely profiled to be complementary to at least the profiled front surface of said workpiece, said working surface being coated with abrasive material such that said device can be used to abrade the profiled front surface of said workpiece.

8. The device of claim 7 wherein said working surface of said finishing portion is profiled to be complementary to said profiled front surface and to upper and lower edge surfaces of said workpiece.

9. The device of claim 7 wherein said profiled working surface conforms to a standard profile established by the WMMPA (Wood Mould, Milling Profile Association) for elongated molding workpieces.

10 The device of claim 7 wherein said gripping portion is formed of a closed cell foam material and is adhered to said finishing portion.

11. The device of claim 10 wherein said gripping portion is provided with a longitudinally extending groove in an outermost surface thereof, said groove being adapted to receive a finger of a person using said device.