Note: Descriptions are shown in the official language in which they were submitted.
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MAGNETIC INSULATOR PAD FOR CONTAINER
FIELD OF THE INVENTION
This invention relates to an insulator pad for containers
holding materials such as workable cement and drywall jointing
compounds, and more specifically to a magnetic insulator pad for
removable attachment to a container.
Joint compound containers, commonly known as "mud
pans,' are well known in the art by dry wall finishers when joining
previously installed wallboard and the joints therebetween. Generally,
the mud pan is trapezoidal in shape and comprises a flat bottom, two
sloping sidewalls extending upwardly and laterally from the bottom,
and two similarly sloping end walls terminating in a planar upper edge.
Current mud pans are generally not shaped to fit a
worker's hand and accordingly, the mud pan is difficult for the worker
to hold when filled with the joint compound, especially for lengthy
working periods. In addition, current mud pans generally have a high
polished surface finish that causes the pan to become slippery,
especially when wet, and prevents the worker from maintaining a
secure grip on the pan. Also, because the worker routinely rotates the
pan in a "flipping" action to repeatedly mix the pan contents and
prevent the joint compound from settling and hardening, the
slipperiness of the pan can cause the worker to lose his grip and drop
the pan. Current mud pans also tend to "sweat" when the cooler
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temperature joint compound is placed inside of the pan, further adding
25 to the slipperiness of the pan.
Another problem with current mud pans is that the
operational life of the pan can be significantly shortened if the pan is
dropped due to uneven weight distribution when flipping the pan, the
slipperiness of the pan or general hand fat]gue of the worker. The
30 severity of damage to the pan can escalate based on numerous
factors such as the height and angle of the drop in combination with
the weight of the joint compound contained within the pan.
To try and resolve this problem, insulating pads have
been developed that are secured to the mud pan to provide a more
35 comfortable and cold temperature resistant platform for the worker's
hand. In U.S. Patent Number 6,575,328 to Foraker, an insulating pad
is provided that is removably secured to the mud pan by magnetic
sheets. Specifically, in Foraker, the insulating pad includes a
magnetic material layer attached by adhesive to a foam rubber layer.
40 The magnetic material layer is segmented into three spaced sections
to enable the pad to bend to conform to the bottom and sidewalls of
the mud pan.
However, a problem found in Foraker is that the
adhesive attaching the magnetic and foam layers weakens over time
45 under normal working conditions, causing the magnetic layer to peel
away from the foam layer and preventing proper attachment to the
pan, requiring replacement of the pad. Another problem in Foraker is
that because of the thickness of the insulator pad relative to the
magnets, the magnets and adhesive may not be strong enough to
50 securely retain the pad to the mud pan. Also, in Foraker, because of
the thickness of the insulator pad, it is rather bulky and can be difficult
to store when not in use. Further, the insulator pad in Foraker is
preferably manufactured from Neoprene rubber and provides poor
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traction for the user's hand, causing the pad to become slippery or
55 difficult to handle after continued use. In addition, in Foraker, the
sides of the insulator pad extend to almost the upper peripheral edge
of the mud pan sidewalls, and accordingly the pad can interfere if joint
compound spills over onto the sides of the mud pan and the worker
must use a taping knife to remove the joint compound. Also, such
60 interference can damage the insulator pad when the worker uses the
taping knife to scrape the joint compound back into the mud pan.
Accordingly, there is a need for an improved magnetic
insulator pad that increases the operational life of the mud pan and
prevents dropping and the corresponding damage to the mud pan.
65 There is a further need for an improved insulator pad for a mud pan
that prevents the magnets from tearing away from the pad and
provides a secure yet removable attachment to the mud pan. There is
also a need for an improved insulator pad for a mud pan that is thick
enough to provide temperature insulation between the joint compound
70 and/or the pan and the worker's hand, but thin enough to provide a
secure attachment to the pan that is comfortable to the user. Further,
there is a need for an improved insulator pad that is easy to store
when not in use. Finally, there is a need for an improved insulator pad
that does not interfere with the taping knife or the mud pan when the
75 worker is cleaning the side of the pan while applying the joint
compound.
BRIEF DESCRIPTION OF THE INVENTION
The above-listed objects are met or exceeded by the
80 present invention that is configured for increasing the operational life
of the mud pan by preventing damage to the mud pan caused by
inadvertent dropping. The present insulator pad for a container
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includes at least one magnet that is more securely adhered to the
insulator pad than a conventional pad. The present insulator pad is
85 also thinner than a conventional pad and provides a secure
attachment to the container while preventing relative temperature
transfer between the container and/or the joint compound and the
worker's hand. Further, the present insulator pad is easy to store
when not in use and is less bulky than a prior insulator pad. Also, the
90 present insulator pad includes a more positive gripping surface that
prevents the worker's hand from slipping after continued work. Finally,
the present insulator pad is arranged on the container to prevent
interference with the taping knife during use.
More specifically, an insulator pad for a container
95 includes a flexible body having a first surface and a second, opposite
surface for contacting the container, the second surface including at
least one recessed portion, at least one magnet associated with and
disposed in the at least one recessed portion for removably securing
the body to the container, and at least one hinge provided on the body,
100 wherein the at least one hinge is configured for allowing the body to
bend to conform to a shape of the container.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE
DRAWINGS
FIG. 1 is a perspective view of the present insulator pad
attached to a container;
FIG. 1a is an end view of the present insulator pad
attached to the container;
FIG. 2 is an overhead plan view of the insulator pad of
FIG. 1 shown in a flattened position;
FIG. 3 is a bottom view of the insulator pad of FIG. 2;
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FIG. 4 is a fragmentary cross-section taken along the
line 4-4 of FIG. 3 and in the direction indicated;
FIG. 4a is a fragmentary enlarged portion of the
encircled portion of FIG. 4;
FIG. 5 is an overhead plan view of an altemate
embodiment of the insulator pad of FIG. 2; and
FIG. 6 is an overhead plan view of the insulator pad of
FIG. 3 in a folded configuration.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGs. 1-3, an insulator pad for a
container is provided and generally designated 10. The insulator pad
105 10 is constructed and arranged for attachment to a container 12,
typically a mud pan, however other containers are contemplated.
Included on the pad 10 is a flexible body 14 having a first, outer
surface 16 and a second, opposite surface 18 for contacting the
container 12. As known in the art, the container 12 includes two
110 opposing sidewall surfaces 20 and two opposing endwall surfaces 21
joined together at a bottom surface 22 to form a generally trapezoidal
container having preferably rounded corners 24, however other
configurations are contemplated.
Preferably, the body 14 is manufactured from silicone to
115 provide a durable and resilient body that can also insulate a worker's
hand from relative extreme temperatures of the container and/or its
contents. Specifically, it is contemplated that the silicone body
insulates against both hot and cold temperatures. For example,
because joint compound is generally cold in temperature and can
120 cause the container to become cold, the silicone body 14 is configured
for providing insulation to the worker's hand from the cold temperature.
Also, when the container 12 is stored in the worker's vehicle or left
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outside on an extremely hot day, the container can become too hot for
the worker to comfortably handle. Accordingly, it is contemplated that
125 the silicone body 14 also insulates the worker's hand from extremely
hot temperatures. Further still, the silicone body 14 is configured for
preventing transfer of the heat from the worker's hand through the
container and to the joint compound, causing the compound to
prematurely set.
130 Preferably still, the body 14 is manufactured from
silicone provided by DC Dongjue Silicone Group Co. Ltd. (model no.
NE-5140) in Nan Jin, China. It is contemplated that manufacturing the
body 14 from silicone will provide a thinner and more temperature
resistant insulator pad than the prior art pad, allowing the worker to
135 more comfortably hold the pad 10 for longer periods of time. It is
further contemplated that the silicone body 14 provides a more durable
pad than the prior art pad, increasing the operational life of the pad
and preventing dropping of the pan and the resulting damage. Also, it
is contemplated that the silicone body 14 is more flexible than the prior
140 art insulating pad, and that because of its thin profile, can be folded as
shown in FIG. 6 and easily transported in the worker's pocket.
Further, it is contemplated that the silicone body 14 provides a
relatively positive gripping surface, preventing dropping of the pan and
increasing user comfort. However, it is recognized that other materials
145 with similar durability and temperature-resistant properties may be
suitable, as known in the art.
The body 14 is preferably integral, disk shaped and
generally planar, with an approximate 8-inch (20.32cm) diameter, as
shown in FIGs. 1-3. However, it is appreciated that other shapes and
150 sizes may be suitable, as will be described in further detail below.
Regardless of its shape, the body 14 is preferably approximately .04-
.12 inches (1-3mm) thick with a weight of approximately 3-6 ounces
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(.09-.17kg). More preferably, the body 14 is approximately .09 inches
(2.4mm) thick with a weight of 4.9 ounces (.14kg), which is less than
155 1/3 the thickness and about 2/3 the weight of the insulating pad in
Foraker. It is contemplated that this construction provides a more
flexible, durable and comfortable pad than that disclosed in Foraker.
As shown in FIG. 2, the first, outer surface 16 includes a
first panel 26a, a second panel 26b and a third panel 26c. The first
160 and second panels 26a, 26b are preferably semi-circular in shape and
located at opposite ends of the first surface 16. Preferably still, the
third panel 26c is generally centrally located on the first surface 16 and
is generally rectangular in shape. However, it is contemplated that
altemate configurations may be appropriate, depending on the
165 application.
When the pad 10 is secured to the container 12, the first
and second panels 26a, 26b, only cover approximately 1/3 of the
corresponding sidewall 20, although other dimensions may be
suitable. It is contemplated that because of the shape of the body 14
170 and the panels 26a, 26b with respect to that of the sidewalls 20, the
pad 10 will not extend near the container edge and as such wili not
interfere with the taping knife if joint compound spills onto the
container sidewalls. Thus, the worker is able to more easily scrape
the compound back into the pan 12.
175 To prevent slippage during continued use of the
insulating pad 10 releasably affixed to the container 12, the first, outer
surface 16 is preferably textured to provide a more secure gripping
surface for the worker's hand. Gripping is further enhanced by the first
and second panels 26a, 26b preferably including a plurality of ribs 28.
180 As seen in FIG. 2, the ribs 28 are generally rectangular in shape,
although it is recognized that other shapes may be suitable. It is
contemplated that providing a textured surface and the ribs 28 also
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increases user comfort because there is less slippage between the
user's hand and the first surface 16.
185 Referring to FIGs. 3 and 4, the insulator pad 10 further
includes a first magnet 30a, a second magnet 30b and a third magnet
30c associated with and disposed on the body second surface 18 for
removably securing the pad to the container 12. Preferably, the
magnets 30a-30c are manufactured by DC Dongguan Maghard
190 Flexible Magnet Co., Ltd. (Model Nos. 0602-0001-00 and 0602-0002-
00) in Dong Guan, China. Preferably sfill, the magnets 30a-30c are
approximately .04-.12 inches (1-3mm) thick, and most preferably are
approximately .06 inches (1.4mm) thick, although it is appreciated that
other thicknesses may be appropriate, depending on the application.
195 It is further preferred that comers of the magnets 30a-30c include
radiused comers 31 (FIG. 3), enabling a more secure adhesion to the
body second surface 18. The magnets 30a-30c are preferably flexible
sheets, enabling bending of the pad 10 and increasing the durability
and flexibility of the pad.
200 As shown in FIGs. 3 and 4, the body second surface 18
includes recessed portions 32a, 32b, and 32c corresponding to the
panels 26a, 26b and 26c. The recessed portions 32a-32c are
constructed and arranged for receiving and securely retaining
corresponding magnets 30a, 30b and 30c. Further, by providing the
205 recessed portions 32a-32c, it is contemplated that the thickness of the
body 14 is significantly reduced, reducing the weight of the pad 10 and
increasing its flexibility. It is contemplated that the body 14 is only
thick enough to provide a positive gripping surface, to insulate the
worker's hand from cold temperatures, and to securely hold the
210 magnet. Accordingly, in the pad 10, use of excess or unnecessary
material is avoided.
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Preferably, the first and second magnets 30a, 30b are
generally semi-circular in shape and are arranged at opposing outer
edges of the body 14. Preferably still, the third magnet 30c is
215 generally rectangular in shape and is generally centrally arranged on
the body 14. It is contemplated that the recessed portions 32a-32c are
shaped to correspond with the magnets 30a-30c, respectively.
However, it is recognized that other configurations of the magnets
30a-30c may be appropriate.
220 Preferably and as seen in FIG. 4, the body 14 is no more
than twice as thick as the magnets 30a, 30b and 30c. It is
contemplated that this construction provides insulation to the worker's
hand, structural support to the magnets 30a-30c, and prevents
bulkiness or excessive weight of the pad 10.
225 To secure the magnets 30a-30c into their respective
recessed portions 32a-32c, an adhesive process is preferably used.
Specifically, and as depicted in FIG. 4a, a surface active treatment
(not shown), such as that manufactured by Yih Chou Engineering Co.
Ltd. (model no. SP-616) in Guang Zhou, China, is applied to the
230 recessed portions 32a-32c. The surface active treatment is configured
for neutralizing the silicone body's mold release agent. A strip of
double-sided tape 34, such as that manufactured by Sekisui (model
no. 5760, www.sekisui.com.hk), in Osaka, Japan, shaped to fit within
each of the recessed portions 32a-32c, is then placed over the treated
235 recessed portion. Finally, the magnets 30a-30c are placed over their
respective strips of tape 34, and pressure is applied. It is
contemplated that by applying the surface active treatment to the
silicone body 14, the silicone's mold release agent is neutralized,
providing a more secure bond between the body and the adhesive,
240 preventing the magnets 30a-30c from tearing away from the recessed
portions 32a-32c, and increasing the usage life of the insulating pad
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10. However, it is appreciated that other adhesion processes may be
suitable, depending on the application. It is also appreciated that the
above-described adhesion process may be suitable for other
245 applications not limited to the drywall field, such as the housewares
industry for silicone products (i.e., for oven mitts) and the automotive
industry (i.e., for magnetic silicone fender covers).
As shown in FIGs. 2 and 3, the insulator pad 10 further
includes a pair of hinges 36a, 36b separating the third magnet 30c
250 from each of the first and second magnets 30a, 30b, respectively.
Preferably and as seen in FIG. 4, upon insertion of each of the
magnets 30a, 30b, and 30c into the corresponding recessed portion
32a, 32b and 32c, a magnet gripping surface 38 of each of the
magnets is oriented coplanar with a hinge gripping surface 40 of each
255 of the hinges 36a, 36b. It is contemplated that this arrangement
provides an even gripping surface and a more secure attachment to
the container sidewalls 20 and the bottom 22.
Each of the hinges 36a, 36b is preferably a flexible web
including a plurality of cutouts 42 arranged generally in spaced parallel
260 relationship to each other. It is contemplated that by providing the
hinges 36a, 36b as a flexible web, the insulator pad 10 can be used on
different sizes of mud pans 12 without the need to purchase a new
pad. The cutouts 42 are preferably oval in shape and permit flexible
adjustment of the body 14 along the hinges 36a, 36b to allow
265 attachment of the pad 10 to differing sizes of containers/mud pans.
However, it is recognized that other cutout configurations may be
suitable, depending on the application.
Referring now to FIGs. 3 and 4, each of the hinges 36a,
36b includes two rows of ridges 44a, 44b projecting from the body
270 second surface 18 and arranged generally parallel to each other.
Preferably, the first row of ridges 44a is constructed and arranged for
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gripping the pan bottom 22, and the second row of ridges 44b is
constructed and arranged for gripping the pan sidewa1120. The first
and second rows of ridges 44a, 44b are preferably arranged generally
275 perpendicular to the cutouts 42, although it is appreciated that other
configurations may be appropriate. Preferably still, the first and
second rows of ridges 44a, 44b are located within an area defined by
axial ends of the cutouts 42.
Best shown in FIG. 4, the first and second rows of ridges
280 44a, 44b are preferably arranged at an approximately equal height to
ensure consistent gripping of the container sidewalls 20 and bottom
22. The first and second rows of ridges 44a, 44b each preferably have
a generally pointed distal end 46 for gripping the container 12,
although it is contemplated that other configurations may be suitable,
285 depending on the application. Further, the first row of ridges 44a and
the second row of ridges 44b form a trough 48 therebetween.
Preferably, the trough 48 is constructed and arranged for bending and
accommodating the corresponding container corners 24 (See FIG.
1 A).
290 An alternate embodiment of the insulator pad is
illustrated in FIG. 5 and is generally designated 50. Shared
components of the pad 10 and the pad 50 are designated with
identical reference numbers. The pad 50 includes a body 52 having a
first, outer surface 54 and a second surface 56 configured for
295 contacting the container 12. The body 52 is preferably oval in shape
with rounded ends 58 and straight edges 60 connecting the ends.
Similar to the pad 10, the outer surface 54 of the pad 50 includes a
first panel 62a, a second panel 62b and a third panel 62c, where the
first and second panels are arranged at opposite ends of the pad and
300 the third panel is generally centrally located on the pad. The first and
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second panels 62a, 62b include the ribs 28, providing a positive
gripping surface for the worker's hand.
The pad 50 further includes the hinges 36a, 36b, each of
which are arranged to separate the third panel 62c from the first and
305 second panels 62a, 62b. The construction of the second surface 56 is
the same as that of the second surface 18, except that the magnets
and corresponding recessed portions (not shown) are shaped to
conform with the shape of the panels 62a-62c. It is contemplated that
when secured to the container 12, the pad 50 does not extend as high
310 up the sidewalls 20 as the pad 10, further preventing the pad from
interfering if joint compound spills onto the sidewalls and the worker
must use a taping knife to remove the compound.
To use the insulator pad 10 with the container 12, the
worker aligns a longitudinal axis "L" of the third magnet 30c with a
315 longitudinal axis "R" of the container bottom 22 (FIG. 1). The worker
then secures the insulator pad 10 to the container 12 by pressing the
third magnet 30c to the container boftom, and bending the pad 10 at
hinges 36a, 36b, such that the first and second magnets 30a, 30b are
secured to corresponding container sidewalls 20. After use, the pad
320 10 can be easily removed. It is contemplated that when the pad 10 is
not in use on the container 12, it can be easily stored by folding the
pad at hinges 36a, 36b such that the first and second magnets 30a,
30b overlap each other and are arranged on top of the third magnet
30c (FIG. 6). In this configuration, the magnets 30a-30c are
325 magnetically attached to each other and the pad 10 is flat enough to fit
within the worker's pocket. This is a contemplated advantage over
current insulator pads, which can be bulky and difficult to store when
not in use.
While a particular embodiment of a magnetic insulator
330 pad for a container has been shown and described, it will be
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appreciated by those skilled in the art that changes and modifications
may be made thereto without departing from the invention in its
broader aspects and as set forth in the following claims.
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