Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02902681 2015-09-01
APPARATUS AND METHOD FOR SMOOTHING DRYWALL MUD
Field
[0001] This invention relates to drywall finishing tools and methods for using
same, and
in particular to handheld tools for smoothing and blending drywall mud.
Background
[0002] Drywall (sometimes referred to as gypsum board, plasterboard,
wallboard, or other
names) is a commonly-used material in construction projects, particularly for
the
installation of interior walls and ceilings. Drywall sheets are typically
attached to studs
with screws, nails, or other fasteners, thereby forming a wall or ceiling
covering composed
of edge-adjacent drywall sheets. Seams between edge-adjacent drywall sheets
are typically
covered with tape, and corners between sheets may be covered with corner beads
(usually
metal and paper L-shaped structures). Tape, corner beads, countersunk screws,
and other
irregularities in the surface of the drywall are covered by a joint compound,
often referred
to as "mud".
[0003] Mud is often applied in multiple layers, with each layer given time to
dry (or cure)
and then sanded smooth before the next layer is applied. Sanding dried mud to
achieve a
substantially seamless, smooth surface which conceals underlying
irregularities is
generally a lengthy and labor-intensive process. For example, mud is commonly
sanded by
use of sandpaper, which can take a significant amount of time, require
significant physical
exertion, and result in significant quantities of airborne dust. The dried mud
is commonly
feathered (i.e. thinner towards the edges) so that it blends in with the
surrounding drywall
sheets. Correctly blending the mud often requires a certain degree of
experience, since
over-sanding an area is a common mistake and may result in damage to the
drywall and/or
a need to reapply mud.
[0004] Accordingly, there is a general desire for apparatus and methods for
smoothing
dried drywall mud.
Summary
[0005] An aspect of the present disclosure provides apparatus for smoothing
drywall mud.
The apparatus comprises a body having a support and a flexible blade assembly
engaged
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with the body. The blade assembly extends in a transverse direction and is
flexible in a
flexion direction orthogonal to the transverse direction. The blade assembly
has first and
second locations which are spaced apart in the transverse direction and which
are
substantially fixed in the flexion direction relative to the body. The
apparatus further
comprises a blade adjustment mechanism adjustably coupled between the support
and a
portion of the blade assembly located between the first and second locations
in the
transverse direction. The blade adjustment mechanism is adjustable to flex the
portion of
the blade assembly in the flexion direction.
[0006] In some embodiments, the blade adjustment mechanism comprises a
displacement
member that is movable relative to the support in the flexion direction and is
in contact
with the portion of the blade assembly. In some embodiments, the displacement
member is
movable, relative to the support, to a first position wherein contact between
the
displacement member and the portion of the blade assembly causes a first
deformation of
the portion of the blade assembly and to a second position wherein the contact
between the
displacement member and the portion of the blade assembly causes a second
deformation
of the portion of the blade assembly. In some embodiments, the flexion
direction is away
from the support.
[0007] In some embodiments, the apparatus comprises one or more blade biasing
mechanisms. Each blade biasing mechanism is anchored to the blade assembly and
biases
the blade assembly towards the support. In some embodiments, biasing the blade
assembly
towards the support comprises biasing the blade assembly in an opposing
direction
opposed to the flexion direction.
[0008] In some embodiments, at least one of the one or more blade biasing
mechanisms
comprises a rod extending through an aperture in the support. The rod has a
first end
anchored to the blade assembly and a second end opposite the first end. The
aperture in the
support is located between the first and second ends. The at least one of the
one or more
blade biasing mechanisms also comprises a head at the second end of the rod.
The head
has a width greater than a width of the rod. The at least one of the one or
more blade
biasing mechanisms also comprises a spring engaged between the head and the
support.
The spring biases the head away from the support.
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[0009] In some embodiments, the one or more blade biasing mechanisms comprise
a first
biasing mechanism and a second biasing mechanism. The first biasing mechanism
is
located transversely between the blade adjustment mechanism and the first
location. The
second biasing mechanism is located transversely between the blade adjustment
mechanism and the second location.
[00101 In some embodiments, the blade assembly is engageable with a plurality
of blades.
The plurality of blades comprise a first blade extending in the transverse
direction and a
second blade extending in the transverse direction and spaced apart from the
first blade in
the flexion direction. In some embodiments, the first blade comprises a rough
edge for
shaving drywall mud. The rough edge comprises one or more channels for the
passage of
excess drywall mud. The second blade comprises a smooth edge for smoothing
drywall
mud. The smooth edge is relatively smooth in comparison to the rough edge.
[0011] In some embodiments, the blade assembly comprises one or more
connectors. Each
of the one or more connectors is engageable with each of the plurality of
blades. The one
or more connectors are engageable with the plurality of blades at the first
and second
locations and at a third location of the blade assembly where the blade
displacement
member is coupled to the blade assembly. In some embodiments, the apparatus
comprises
one or more biasing mechanisms. Each biasing mechanism is anchored to a
connector of
the one or more connectors at a biasing location of the blade assembly. The
one or more
connectors are engageable with the plurality of blades at the one or more
biasing locations.
[0012] In some embodiments, the one or more connectors comprise a first
connector
engageable with the plurality of blades at the first location, a second
connector engageable
with the plurality of blades at the second location, and a third connector
engageable with
the plurality of blades at the third location. In some embodiments, the
apparatus comprises
a first biasing mechanism anchored to a first bias connector. The first bias
connector is
engageable with the plurality of blades at the first bias location. The
apparatus further
comprises a second bias mechanism anchored to a second bias connector. The
second bias
connector is engageable with the plurality of blades at a second bias
location. The first and
second bias mechanisms are configured to bias the plurality of blades towards
the support
at the corresponding first and second bias locations. In some embodiments, the
first
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biasing location is located transversely between the blade adjustment
mechanism and the
first location. The second biasing location is located transversely between
the blade
adjustment mechanism and the second location.
[0013] In some embodiments, the one or more connectors comprise a plurality of
rigid
connectors and the blade assembly comprises one or more relatively flexible
mounts
connecting the one or more connectors.
[0014] In some embodiments, the first connector is slidably anchored to the
body at the
first location. The first connector has an engagement member receivable by a
concavity
defined in the body and the concavity extends substantially in the transverse
direction. The
engagement member is slidable in the transverse direction while received by
the
concavity.
[0015] In some embodiments, the apparatus comprises a handle assembly for
engaging a
handle extending in a handle direction, one or more support arms connected to
the handle
assembly and extending from the handle assembly to the body, and a handle
biasing
mechanism connected to the handle assembly and extending from the handle
assembly to
the body. The body is rotatably connected to each of the one or more support
arms so that
the body is rotatable about an axis parallel to the transverse direction. The
handle biasing
mechanism biases the body towards a rotational position wherein, when one or
more
blades are engaged with the blade assembly and a handle is engaged by the
handle
assembly, the one or more blades are offset from the handle direction by an
offset angle.
[0016] In some embodiments, the displacement member comprises a screw
threadably
engaged with the support. The screw is rotatable to move in the flexion
direction relative
to the support.
[0017] An aspect of the present disclosure provides a method for smoothing
drywall mud
with a drywalling tool. The tool has a body, a flexible blade assembly
extending in a
transverse direction, and a blade adjustment mechanism adjustably coupled
between a
support of the body and a portion of the blade assembly. The flexible blade
assembly is
flexible in a flexion direction. The method comprises adjusting the blade
adjustment
mechanism to flex the portion of the blade assembly in the flexion direction,
thereby
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imparting a curvature to one or more blades of the blade assembly. The method
further
comprises positioning the one or more blades of the blade assembly against a
portion of
drywall mud. The method further comprises advancing the one or more blades
along the
portion of drywall mud to smooth the portion of drywall mud. The smoothed
portion of
drywall mud has a shape corresponding to the curvature of the one or more
blades.
[0018] In some embodiments, the blade adjustment mechanism comprises a
displacement
member that is in contact with the portion of the blade assembly. Flexing the
portion of the
blade assembly in the flexion direction comprises moving the displacement
member,
relative to the support, in the flexion direction from a first position to a
second position.
Contact between the displacement member and the portion of the blade assembly
causes a
deformation of the portion of the blade assembly. The method further comprises
retaining
the displacement member in the second position via engagement of the
displacement
member with the support.
[0019] In some embodiments, the displacement member is threadably engaged with
the
support and moving the displacement member comprises rotating the displacement
member to move in the flexion direction relative to the support. In some
embodiments, the
blade adjustment mechanism comprises a displacement member that is in contact
with the
portion of the blade assembly, the tool comprises a biasing mechanism anchored
to the
blade assembly, and flexing the portion of the blade assembly in the flexion
direction
comprises moving the displacement member, relative to the support, in an
opposing
direction from a first position to a second position. The opposing direction
opposes the
flexion direction. Flexing the portion of the blade assembly also comprises
biasing the
blade assembly towards the support in the opposing direction with the biasing
mechanism.
Bias exerted by the biasing mechanism on the portion of the blade assembly
causes a
deformation of the portion of the blade assembly.
[0020] In some embodiments, advancing the one or more blades along the portion
of
drywall mud comprises advancing the first blade along the portion of drywall
mud to
provide a rough finish to the portion of drywall mud and, after advancing the
first blade
along the portion of drywall mud, advancing the second blade along the portion
of drywall
mud to provide a smooth finish to the portion of drywall mud. The smooth
finish is
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relatively smooth in comparison to the rough finish. In some embodiments, the
method
comprises continuously smoothing a plurality of portions of drywall mud by
advancing the
first and second blades along the plurality of portions of drywall mud
substantially
simultaneously.
[0021] An aspect of the present disclosure provides another apparatus for
smoothing
drywall mud. The apparatus comprises a body, a flexible blade assembly movably
engaged with the body, and one or more blade biasing mechanisms. The blade
assembly
extends in a transverse direction and is flexible in a flexion direction
orthogonal to the
transverse direction. The blade assembly has first and second locations which
are spaced
apart in the transverse direction and which are substantially fixed in the
flexion direction
relative to the body. Each blade biasing mechanism is anchored to the blade
assembly and
biases the blade assembly in the flexion direction. In some embodiments, the
flexion
direction is away from the body.
[0022] In some embodiments, at least one of the one or more blade biasing
mechanisms
comprises a rod having a first end anchored to the blade assembly and a second
end
opposite the first end and a spring engaged between the blade assembly and the
body. The
second end is retained in a cavity defined by the body. The spring biases the
blade
assembly away from the body and is retained by the rod. In some embodiments,
the at
least one of the one or more blade biasing mechanisms comprises a head engaged
with the
second end of the rod. The head is retained by the cavity.
[0023] In some embodiments, the body is pivotably engaged with the blade
assembly and
the one or more blade biasing mechanisms do at least one of: oppose pivoting
movement
of the body toward the blade assembly and amplify pivoting movement of the
body toward
the blade assembly.
[0024] In some embodiments, the blade assembly comprises one or more
connectors. Each
of the one or more connectors is engageable with one or more blades. The one
or more
blades are flexible in the flexion direction while engaged with the one or
more connectors.
In some embodiments, the one or more blade biasing mechanisms comprise a first
biasing
mechanism and a second biasing mechanism. The first biasing mechanism has a
greater
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spring constant than the second biasing mechanism. In some embodiments, the
first blade
biasing mechanism is anchored to a first connector and the second blade
biasing
mechanism is anchored to a second connector. The first connector permits
relatively less
flexion of the one or more blades than the second connector. In some
embodiments, the
first blade biasing mechanism and first connector are located relatively
transversely
outwardly relative to the second blade biasing mechanism and second connector.
In some
embodiments, the one or more connectors comprise a plurality of rigid
connectors and the
blade assembly comprises one or more relatively flexible mounts connecting the
one or
more connectors.
[0025] Further aspects and example embodiments are illustrated in the
accompanying
drawings and/or described in the following description.
Brief Description of the Drawings
[0026] The accompanying drawings illustrate non-limiting example embodiments
of the
invention.
[0027] Figure lA is a first perspective view of an example drywalling tool
according to
the present disclosure.
[0028] Figure 1B is a second perspective view of the example drywalling tool
of Figure
IA showing the tool from a different angle than Figure IA.
[0029] Figure IC is a third perspective view of the example drywalling tool of
Figure IA
showing the tool from a different angle than Figures 18 and 1C.
[0030] Figure 2A is a plan view of the example drywalling tool of Figure IA.
[0031] Figure 2B is a plan view of the example drywalling tool of Figure IA
showing an
opposing side of the tool relative to Figure 2A.
[0032] Figure 3 is a side elevation view of the example drywalling tool of
Figure IA.
[0033] Figure 4A is a plan view of an example blade for the example drywalling
tool of
Figure lA having a relatively rough leading edge.
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[0034] Figure 4B is a plan view of an example blade for the example drywalling
tool of
Figure IA having a relatively smooth leading edge.
[0035] Figure 5A is a front elevation view of the example drywalling tool of
Figure IA
while the blades of the tool are unflexed.
[0036] Figure 5B is a front elevation view of the example drywalling tool of
Figure IA
while the blades of the tool are flexed in a first direction by a displacement
member.
[0037] Figure 5C is a front elevation view of the example drywalling tool of
Figure lA
while the blades of the tool are flexed in a second direction by biasing
mechanisms.
[0038] Figure 6 is a side elevation view of the example drywalling tool of
Figure IA while
being used to smooth dried drywall mud.
[0039] Figure 7 is a side elevation cross-sectional view corresponding to
Figure 6,
wherein the cross-section is taken through the displacement member.
[0040] Figure 8 is a perspective view of another example drywalling tool
according to the
present disclosure.
[0041] Figure 9 is a side elevation view of the example drywalling tool of
Figure 8.
[0042] Figure 10 is a cross-sectional view of the example drywalling tool of
Figure 8
taken along line B¨B of Figure 9.
[0043] Figure 11A is a front elevation view of the example drywalling tool of
Figure 8.
[0044] Figure 11B is a back elevation view of the example drywalling tool of
Figure 8.
[0045] Figure 12A is a plan view of the example drywalling tool of Figure 8.
[0046] Figure 12B is a plan view of the example drywalling tool of Figure 8,
showing an
opposing side relative to the view of Figure 12A.
Detailed Description
[0047] Throughout the following description, specific details are set forth in
order to
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provide a more thorough understanding of the invention. However, the invention
may be
practiced without these particulars. In other instances, well known elements
have not been
shown or described in detail to avoid unnecessarily obscuring the invention.
Accordingly,
the specification and drawings are to be regarded in an illustrative, rather
than a restrictive
sense.
[0048] Aspects of the present disclosure provide apparatus and methods for
smoothing
drywall mud (which may include blending and/or feathering drywall mud). The
apparatus
provides a drywalling tool having one or more flexible blades to be applied to
unfinished
dried drywall mud. The blades may be selectively flexed by moving a
displacement
member relative to the body of the tool. The blades may be biased against the
displacement member by biasing mechanisms. The tool may receive multiple
blades,
including a relatively rough-edged blade for a first pass across the drywall
mud and a
relatively smooth-edged blade for subsequent pass across the drywall mud. The
blades
may be kept in place with connectors which may be flexibly connected to allow
for
flexion.
[0049] Figures 1A, 1B and 1C (collectively and individually, "Figure 1"),
Figures 2A and
2B (collectively and individually, "Figure 2") and Figure 3 provide several
views of an
example drywalling tool 1. Drywalling tool 1 has a body 2 which engages a
blade
assembly 10. In the depicted embodiment, body 2 comprises a blade assembly
connector 4
for engaging blade assembly 10 and a frame 6 to which various other elements
of tool 1
(such as guide 56 and handle assembly 40, discussed below) are connected. In
some
embodiments, blade assembly connector 4 and frame 6 are integrally formed. In
other
embodiments, blade assembly connector 4 and frame 6 are permanently or
removably
attached. In still other embodiments, frame 6 may be omitted and other
elements of tool 1
(if any) may connect directly or indirectly to blade assembly connector 4
and/or to other
components of body 2. Body 2 may be made of suitably rigid metal, plastic,
wood, other
materials and/or combinations thereof.
[0050] Blade assembly 10 comprises one or more blades 14. Blade assembly 10
may be
permanently or releasably connected to body 2. For example, blade assembly 10
may
comprise a cartridge insertable into or otherwise releasably connectable to
blade assembly
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connector 4. As another example, blade assembly 10 may be integrally formed
with body
2.
[0051] The example blade assembly 10 shown in Figure 1 receives one or more
blades 14,
which are releasably connectable to and separately formed from blade assembly
10. In
some embodiments, blades 14 are integrally formed with and/or otherwise
fixedly attached
to blade assembly 10. For example, blades 14 may be fixedly attached to blade
assembly
by interlocking bolts and apertures. Blade assembly 10 may be provided with a
full
complement of blades 14 (e.g. three blades 14 in the case of the Figure 1
embodiment, but
any suitable number of blades in other embodiments). However, blade assembly
10 may
additionally or alternatively be provided with a number of blades 14 which is
less than a
full complement of blades 14. In some cases, blade assembly 10 may be provided
without
blades 14. In these cases (i.e. wherever blade assembly 10 comprises fewer
than a full
complement of blades 14), blade assembly 10 may receive one or more blades 14
to
provide a full complement.
[0052] In at least the example embodiment of Figure 1, blades 14 may be
received and
held in place by blade assembly 10 during use of tool 1, and may be
subsequently removed
and/or replaced. Removal and/or replacement of blades 14 may be due to wear,
in
response to a user's needs, and/or for other reasons. For example, as will be
discussed in
greater detail below, blades 14 may be provided with a variety of types of
leading edges
15, and different leading edges may be preferable in different circumstances.
A blade 14
with a relatively rough leading edge 15 may be used on a rough portion of
drywall mud
and/or to provide relatively coarse smoothing, and may be swapped out for a
different
blade 14 with a relatively smoother leading edge 15 when finishing a smoother
portion of
drywall mud and/or to provide relatively fine smoothing.
[0053] In some embodiments, blade assembly 10 houses a plurality of blades 14.
For
example, blade assembly 10 may house blades 14a, 14b, and 14c (referred to
collectively
and individually herein as blades 14), as shown in Figures 1, 2, and 3. In
some
embodiments, blades 14 are substantially identical. In some embodiments, one
or more of
the blades 14 are different than other blades 14. In some embodiments, blades
14 are
removable, replaceable and/or interchangeable.
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[0054] For example, blade 14a may have a serrated, irregular, or otherwise non-
smooth
leading edge 15a suitable for shaving rough portions of drywall mud and/or to
provide a
relatively coarse smoothing. An example of such a blade 14a is shown in Figure
4A. As is
discussed in greater detail below, as tool 1 is drawn across a portion of
drywall mud, blade
I4a may be the first to pass across the portion of drywall mud, thereby
shaving the portion
of drywall mud down to a rough finish (e.g. relatively coarse smoothing
action). Rough-
edged blades such as blade 14a are generally more effective at shaving
unfinished drywall
mud than smooth-edged blades, as excess drywall mud is permitted to pass
through
channels 11, thereby permitting the leading edge 15a to penetrate more deeply
into the
drywall mud (and/or with relatively less force) than a smooth-edged blade. In
some
embodiments, blades 14 are arranged so that blade 14a leaves behind no more
than 1 mm
of excess drywall to be shaved by blade 14b (and/or other blades, such as
blade 14c).
Rough-edged blades such as blade 14a also tend to generate less fine
particulate matter
than sandpaper. Consequently, relative to smoothing drywall mud with
sandpaper, the use
of tool 1 to smooth drywall mud may result in the generation of less airborne
particulate
drywall mud.
[0055] In some embodiments, blades 14b and 14c may have leading edges 15b and
15c,
respectively, which may be relatively smooth in comparison to leading edge 15a
of blade
14a. In some embodiments, blades 14b and 14c differ; for example, the leading
edge 15b
of blade 14b may be rougher than leading edge 15c and, optionally, smoother
then leading
edge 15a. In some embodiments, blades 14b and 14c are substantially identical
(e.g. blade
14c may be substantially identical to blade 14b shown in Fig. 4B). Smooth-
edged blades
such as blades 14b and 14c may be used to provide a smooth finish to partially-
finished
drywall mud, such as drywall mud initially shaved by blade 14a. Providing
multiple
smooth-edged blades 14b and 14c be convenient in some circumstances, as
multiple
passes are sometimes desirable to effectively smooth a portion of drywall mud.
[0056] In some embodiments, corners 13 of blades 14 are rounded for safety,
comfort,
and/or to reduce the likelihood or severity of blades 14 digging into (and
potentially
damaging) drywall during use of tool 1. In some embodiments, blades 14 may be
of
different lengths (as measured between the leading edge and the opposing
edge); for
instance, blade 14a may have a shorter length than blade 14b, which may in
turn have a
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shorter length in blade 14c, thereby allowing blades 14 to collectively
provide an interface
with drywall mud which is sloped relative to body 2. Alternatively, or in
addition, blades
14 may be set at different locations in blade assembly 10 so that some blades
14 protrude
further beyond body 2 than other blades 14.
[0057] In some embodiments, one or more of blades 14 may comprise an aperture
19
(shown in dashed lines) through which a rod, screw, or like member may pass to
anchor
blades 14 to connector 12. For example, connectors 12 may comprise apertures
(not
shown) corresponding to apertures 19 and a screw may pass through connectors
12 and
blades 14 via the apertures in connectors 12 and blades 14. For example, the
screw (not
shown) may be anchored to connector 12c and pass through blades 14a, 14b, and
14c and
connectors 12a and 12b.
[0058] In some embodiments, blade assembly 10 comprises one or more connectors
12
which connect (i.e. receive, are affixed to, hold in place, and/or otherwise
house) blades 14
to blade assembly 10. Blade assembly 10 may, for example, comprise a single
connector
which runs along all or part of the width (as measured between transverse edge
17a, 17b,
or 17c and the opposing transverse edge) of a blade 14. Blade assembly 10 may,
for
example, comprise a plurality of connectors which connect blades 14 in a
plurality of
locations, e.g. transversely spaced-apart locations as illustrated in Figures
1, 2, and 3 by
connectors 12a, 12b, 12c, 12d, 12e (referred to collectively and individually
herein as
connectors 12).
[0059] Each connector 12 may connect one or more blades 14. For example, in an
embodiment with blades 14a, 14b, and 14c, one or more connectors 12 may each
connect
each of blades 14a, 14b, and 14c (e.g. as shown in the embodiment of Figures
1, 2, and 3).
Alternatively, or in addition, one or more connectors 12 may each connect a
single blade
12 or a subset of the one or more blades 12. Connectors 12 may comprise any
suitable
material, such as rubber, plastic, foam, metal (e.g. aluminum), wood, and/or
other
materials.
[0060] In embodiments with a plurality of connectors 12, connectors 12 may be
connected
to one another by one or more mounts 16. For example, mounts 16 may comprise a
rod
12
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which passes through apertures 18 in connectors 12 (as shown in Figures 2A and
7),
and/or may comprise a plurality of rods, each affixed to a connector 12 at one
or more
ends. As another example, mounts 16 may comprise all or a portion of body 2,
in which
case connectors 12 may each be connected to body 2 (e.g. as integrally-formed
parts of
body 2, or as separately-formed elements engaged with body 2). Mounts 16 may
be any
suitable shape or structure for connecting the connectors 12 of blade assembly
10 to each
other.
[0061] In some embodiments, blades 14 are flexible. Blade assembly 10 may also
be
flexible and may hold blades 14 to permit flexion of blades 14. For example,
as shown in
Figure 5A, blades 14 may extend in transverse directions 24 and flex in
flexion directions
22. Blade assembly 10 may provide a plurality of connectors 12 spaced apart in
transverse
directions 24 and permitting certain connectors 12 (e.g. 12c) to move in
flexion directions
22 while other connectors 12 (e.g. 12a, 12e) do not move in flexion directions
22, move
relatively less in flexion directions 22, and/or move in a direction 22
opposing the
movement of the certain connectors 12. Figure 5B shows an example scenario
wherein
blades 12 are deformed in flexion direction 22A away from a support 20 and
Figure 5C an
example scenario wherein blades 14 are flexed such that at least central
portions of blades
14 are deformed in flexion direction 22B toward support 20. Figures 5A, 5B,
and 5C are
collectively and individually referred to herein as Figure 5.
[0062] In some embodiments having a plurality of connectors 12, mounts 16 may
be
flexible in at least flexion directions 22. For example, mounts 16 may
comprise one or
more flexible rods connecting connectors 12. Thus, flexion of blades 14 may be
accompanied by a corresponding displacement of connectors 12 which is matched
by
flexion in mounts 16. Mounts 16 may be flexible between two points spaced
apart in the
transverse directions 24 and substantially fixed in flexion directions 22 at
those points. For
example, mounts 16 may connect to connectors 12a and 12e, each of which may be
attached to body 2 and substantially fixed in flexion directions 22 (as
discussed in greater
detail below). In embodiments with flexible mounts 16, mounts 16 may be made
of any
suitable material, such as flexible plastic, wood, metal, cord, and/or other
materials,
including non-flexible materials arranged in a flexible structure (e.g. linked
chains or the
like).
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[0063] In some embodiments, tool 1 comprises an adjustment mechanism 30 for
flexing
one or more blades 14. In the embodiment illustrated in Figure 5, adjustment
mechanism
30 comprises displacement member 30. Displacement member 30 is moveable in
directions 22 relative to support 20. Movement of displacement member 30
relative to
support 20 may thus change the force experienced by one or more blades 14, and
many
correspondingly change the corresponding reaction force experienced by support
20.
Blades 14 may be relatively more deformable than support 20, and so blades 14
may
deform away from support 20 (i.e. in direction 22A) and/or toward support 20
(i.e. in
direction 22B). In this sense, support 20 may be considered to be an anchor,
and
movement of displacement member 30 relative to support 20 may increase and/or
decrease
flexion of one or more blades 14 in direction 22.
[0064] Figure 5B shows an example scenario where displacement member 30 has
been
moved in direction 22A and is pressed against connector 12c, thereby pushing
connector
12c away from support 20 and flexing at least a central portion of blades 14
(along with
mounts 16 and connectors 12b, 12c, and 12d) away from support 20. Displacement
member 30 may be selectively moved to flex blades 14 and/or blade assembly 10
to a
greater or lesser degree (e.g. by advancing or retracting displacement member
30).
[0065] In some embodiments, a plurality of adjustment mechanisms 30 (e.g.
displacement
members 30) are provided, thereby providing a user with more options in the
flexion of
blades 14. For example, displacement members 30 may be positioned at suitable
locations
to apply force in directions 22 to connectors 12a, 12c, and 12e (and/or at
other locations,
including at other connectors 12 and other transverse locations relative to
blades 14),
allowing a user to provide different curvatures to different portions of
blades 14. In some
such embodiments, connectors 12a and 12e are permitted to move and/or deform
in
flexion directions 22 to accommodate the plurality of displacement members 30.
[0066] In the illustrated embodiment, displacement member 30 and support 20
are
threaded to facilitate the movement of displacement member 30 relative to
support 20 in
directions 22 by suitable threaded rotation of displacement member 30. For
example,
displacement member 30 may be threadably engaged with support 20 via a
threaded
aperture 32 in support 20. For example, displacement member 30 may comprise a
threaded
14
CA 02902681 2015-09-01
screw with a head operable to be engaged by a screwdriver, a user's fingers,
or other
means for driving a displacement member 30.
[0067] Adjustment mechanism 30 (e.g. displacement member 30) may comprise any
suitable means for flexing one or more blades 14 and/or blade assembly 10 in
directions
22 relative to support 20. For example, adjustment mechanism 30 may comprise a
telescoping rod, piezoelectric stack, ratcheted jack, and/or any other
adjustable mechanism
for displacing a portion of (and thereby flexing) one or more blades 14.
[0068] In some embodiments, tool 1 comprises a biasing mechanism 34 for
flexing blades
14. Biasing mechanism 34 biases one or more blades 14 in flexion direction 22.
For
example, biasing mechanism 34 may bias one or more blades 14 in direction 22B
towards
support 20, so that (absent a countervailing force from adjustment mechanism
30) one or
more blades 14 flex in direction 22B towards support 20. Thus, biasing
mechanism 34 and
adjustment mechanism 30 may cooperate to permit flexion both toward and away
from
support 20 (i.e. in directions 22A, 22B), according to the operation of
adjustment
mechanism 30. For example, biasing mechanism 34 may flex one or more blades 14
towards displacement member 30 so that retracting displacement member 30 (e.g.
moving
displacement member 30 in direction 22B) permits further flexion by biasing
mechanism
34 in direction 22B towards support 20. Displacement member 30 may overcome
the
biasing force of biasing mechanism 34 by moving in direction 22A.
[0069] An example of a biasing mechanism 34 is shown in Figure 5. In the
embodiment
shown in Figure 5, biasing mechanism 34 comprises a rod 38 passing through
support 20
and connecting at an end to a connector 12 (and in particular, in this
example, to one of
connectors 12b and 12d). Biasing mechanism 34 has a head 39 at an opposing
end. A
spring 36 is provided around rod 38 and bears on support 20 and head 39 to
bias head 39
away from support 20 in direction 22B. Head 39 has a circumference greater
than spring
36, and may comprise a disk, ball, cross, or other suitable shape for
retaining spring 36.
When head 39 is biased in direction 22B away from support 20, rod 38 connected
to
connector 12 pulls connector 12 and a corresponding portion of blade 14 in
direction 22B
toward support 20. In this manner, biasing mechanism 34 acts to bias
corresponding
portions of one or more blades 14 (and/or blade assembly 10) in direction 22B
towards
CA 02902681 2015-09-01
support 20.
[0070] In the depicted embodiment, two biasing mechanisms 34 are provided,
connecting
to connectors 12b and 12d at corresponding transversely spaced apart locations
and
corresponding transversely spaced apart portions of blades 14 and/or blade
assembly 10.
In the illustrated embodiment, each of these locations is located transversely
outwardly
from the location of adjustment mechanism 30. In some embodiments, a greater
or lesser
number of biasing mechanisms 34 are provided, and/or biasing mechanisms 34 may
be
provided in different locations. For example, a biasing mechanism 34 may be
provided at
the same location in transverse directions 24 as adjustment mechanism 30 (e.g.
appearing
to be behind or in front of adjustment mechanism 30 in the Figure 5 view) and
connect to
connector 12c.
[0071] Biasing mechanism(s) 34 may also, or alternatively, be provided on an
opposing
side of blade assembly 10. For example, a biasing mechanism 34 may be provided
at a
side of connector 12c opposing adjustment mechanism 30 and thus bias connector
12c in
direction 22B towards adjustment mechanism 30 and/or support 20. Such a
biasing
mechanism 34 may, for example, comprise a spring mounted to body 2 and/or to a
second
support (not shown) parallel to support 20. Such biasing mechanisms 34 may
alternatively,
or additionally, be provided at other locations, such as at the locations of
connectors 12b,
12d and/or other locations on blades 14 directly.
[0072] Biasing mechanism 34 may comprise any suitable means for flexing blades
14
and/or blade assembly 10 (and/or a corresponding portion thereof) in direction
22B
towards support 20 by biasing all or part of blade assembly 10 and/or blades
14. For
example, biasing mechanism 34 may comprise a spring, an elastic connector
between
blade assembly 10 and support 20, and/or any other mechanism for biasing and
thereby
flexing blade assembly 10 and/or blades 14 and/or corresponding portions
thereof.
[0073] In some embodiments, adjustment mechanism 30 is operable to flex blades
14
(and/or a corresponding portion thereof) in direction 22B towards support 20
without, or
in addition to, the biasing action of biasing mechanism 34. For example,
adjustment
mechanism 30 may be affixed to connector 12c so that, as adjustment mechanism
30 is
16
CA 02902681 2015-09-01
retracted in direction 22B towards support 20, connector 12c is drawn in
direction 22B
towards support 20, thereby causing a corresponding flexion in blades 14
(and/or a
corresponding portion thereof) in direction 22B towards support 20. In other
embodiments, displacement member is not affixed to connector 12c, e.g. to
allow blades
14 to flex further in direction 22A during use of tool 1.
[0074] As blades 14 flex in direction 22, the total dimension of blades 14 in
transverse
directions 24 will variously expand and contract. In some embodiments,
connectors 12a
and 12e move in transverse directions 24 so as to be positioned closer
together as the
flexion of blades 14 increases and further apart as the flexion of blades 14
decreases. For
example, connectors 12a and 12e may be movably mounted to body 2 so that
connectors
12a and 12e may move in transverse directions 24 as blades 14 flex, while
(optionally)
keeping connectors 12a and 12e substantially fixed in the flexion direction
22. In some
embodiments, one or more connectors 12 may be deformable, and in particular
may be
deformed in a manner corresponding to the deformation of one or more blades
14.
[0075] For example, as shown in Figure IC, one or both of connectors 12a and
12e may
comprise a protrusion 52 which is received in a corresponding aperture or
recess of body
2, such as aperture 50. Aperture 50 may be elongated in transverse directions
24 and have
a width in flexion directions 22 substantially corresponding to a width of
protrusion 52.
Thus, protrusion 52 may slide transversely into or out of aperture 50 in
transverse
directions 24 while remaining substantially fixed in flexion directions 22.
[0076] Body 2, blade assembly 10, blades 14 and various other elements
described above
may be used in a variety of drywall mud-smoothing tools, ranging from small
handheld
tools to large industrial or machine-mounted tools. The present disclosure
presents an
exemplary handheld tool 1, described in greater detail below, but it will be
understood that
the present disclosure is not limited to the illustrated tool 1.
[0077] Figures 1-3 and 5-7 depict a tool 1 having a body 2 connected to a
handle assembly
40. Handle assembly 40 receives and/or comprises a handle 46 (an example of
which is
shown in Figure 1) to be held by a user during use of tool 1. In the depicted
embodiment,
handle assembly 40 comprises a body defining an aperture 48. Aperture 48 may,
for
17
CA 02902681 2015-09-01
example, be threaded and suitable for receiving a threaded end of handle 46.
In some
embodiments, handle 46 and handle assembly 40 are integrally formed, so that
handle
assembly 40 is shaped to be held by a user's hand. In some embodiments, handle
assembly
40 is operable as a handle (e.g. handle assembly 40 may be shaped to be held
by a user's
hand) and also provides an aperture 48 for receiving a handle 46; thus, for
example, handle
assembly 40 may be used as a handle when a longer handle is not needed, and a
longer
handle 46 (e.g. a pole) may be used when needed or desired.
[0078] Handle assembly 40 may connect to body 2 via one or more support arms
42. For
example, support arms 42 may extend from handle assembly 40 to frame 6 (see
Figure 1).
Support arms 42 may connect to body 2 at one or more transverse locations on
body 2
and/or continuously across a transverse dimension of body 2 to distribute
force applied at
handle 46 across body 2, thereby allowing force applied to handle assembly 40
to
distribute transversely across blades 14. In the embodiment depicted in Figure
1, two
support arms 42 are provided which connect with body 2 at a plurality of
transversely
spaced-apart locations. In some embodiments, one or more wedge-shaped support
arms 42
are provided, each support arm widening from a narrow transverse width at
handle
assembly 40 to a wider transverse width at body 2, thereby distributing force
across body
2.
[0079] In some embodiments, handle assembly 40 is pivotably connected to body
2. For
the sake of convenience, body 2 will be referred to as being pivotable
relative to handle
assembly 40, although it will be understood that handle assembly 40 can be
equivalently
understood to pivotable relative to body 2. Body 2 may pivot in any of several
directions.
For example, body 2 may pivot about a transverse axis parallel to transverse
directions 24
(e.g. so that, as body 2 pivots, leading edges of blades 14 move in roughly
flexion
direction 22). Figures 1-3 depict an example embodiment with this type of
pivoting, as
discussed further below. Body 2 may also, or alternatively, pivot about an
axis parallel to
flexion direction 22. For example, handle assembly 40 may connect to body 2
via a swivel
joint, about which body 2 may pivot.
[0080] In the example embodiment of Figures 1-3, support arms 42 comprise
transversely-
oriented axles 60 (i.e. axles oriented parallel to directions 24) received by
apertures 62 in
18
CA 02902681 2015-09-01
body 2. Body 2 may be pivotable about axles 60, and in particular may be
pivotable about
an axis 64 extending substantially in transverse directions 24 between axles
60.
[0081] A biasing mechanism 44 may be provided between handle assembly 40 and
body 2
to bias body 2 towards a particular position relative to handle assembly 40
(e.g. away from
handle assembly 40). Providing such a bias may help maintain a suitable angle
between
blades 14 and drywall mud during use of tool 1 while still permitting some
flexibility in
the position of body 2 relative to handle 46, which may be desirable in
certain
circumstances. For example, if tool 1 is being drawn across a particularly
uneven portion
of drywall mud, biasing mechanism 44 may, in some circumstances, assist in
enabling
blades 14 to travel in a less-uneven path than would be followed if body 2
were rigidly
attached to handle assembly 40.
[0082] Biasing mechanism 44 may bias body 2 so that the angle e at which
blades 14
extend relative to handle assembly 40 and/or handle 46 (see, e.g., Fig. 3) is
kept within a
range under typical usage conditions and/or at rest. In some embodiments,
biasing
mechanism 44 may bias body 2 to maintain angle e in the range of 20 to 60 .
For
example, biasing mechanism 44 may bias body 2 towards a position where angle 8
is
22.5 . Referring to Fig.7, such an angle may enable guides 56 to make contact
with
drywall 110 while still permitting a separation between drywall 110 and blades
14. It will
be understood that, in some embodiments, certain exertions of force and/or
extreme
conditions may cause angle 8 to leave the range promoted by biasing mechanism
44
temporarily.
[0083] Biasing mechanism 44 may comprise any suitable means for biasing body 2
towards a particular position or range of positions relative to handle
assembly 40. For
example, biasing mechanism 44 may comprise a spring, a resilient connector
between
handle assembly 40 and body 2, and/or any other mechanism for biasing body 2
relative to
handle assembly 40.
[0084] In some embodiments, tool 1 provides a guide 56 for guiding body 2
along drywall
during use. Guide 56 may assist in maintaining registration between leading
edges 15 and
a portion of drywall mud during use of tool 1, may space body 2 away from the
drywall
19
CA 02902681 2015-09-01
and/or drywall mud during use of tool 1, and/or may assist the user in
smoothly moving
body 2 along the drywall and/or drywall mud. Tool 1 may comprise any number of
guides
56, but in some embodiments tool 1 comprises at least two guides 56 ¨ a first
guide 56
proximate to one transverse side of body 2 and a second guide 56 proximate to
an
opposing transverse side of guide 56. The guides 56 may be spaced apart
sufficiently in
transverse directions 24 (e.g. 15 cm to 60 inches, or 6 inches to 24 inches,
in various
embodiments) to allow a typical expanse of drywall mud to fit between them; in
such
embodiments, guides 56 may be adapted to smoothly slide, roll, or otherwise
move along
drywall while blades 14 smooth the drywall mud applied to the drywall between
the
guides 56.
[0085] In some embodiments, the position of guide 56 is adjustable in
protrusion
directions 26 (shown in Figure 3) relative to body 2 and/or blades 14. A user
may adjust
such guides 56 to protrude past leading edges 15 in protrusion direction 26,
retract behind
leading edges 15 of blades 14 in protrusion direction 26, and/or remain flush
with leading
edges 15 in protrusion direction 26. Different degrees of adjustment may be
desirable
depending, for example, on the depth that the user desires blades 14 to shave
drywall mud.
Retraction of guide 56 may cause body 2 to be positioned closer to the
drywall, thereby
assisting blades 14 in penetrating deeper (and thereby shaving deeper) into
the drywall
mud during use.
[0086] In one non-limiting example embodiment, guide 56 may comprise a wheel
mounted to frame 6. Guide 56 may protrude beyond body 2 in protrusion
direction 26B so
that, when leading edges 15 are each positioned against a portion of drywall
mud (such as
drywall mud 100 applied to drywall 110 in Figure 6), guide 56 is suitably
positioned to
support body 2 against the drywall and/or drywall mud. An example of such an
arrangement is shown in Figure 6.
[0087] Guide 56 may comprise a wheel, a flat surface (e.g. defined by body 2)
for sliding
along a portion of drywall, and/or any other suitable structure which assists
with
maintaining registration between leading edges 15 and drywall mud during use
of tool 1.
[0088] In some embodiments, the position of one or more blades 14 is
adjustable in
CA 02902681 2015-09-01
protrusion directions 26. For example, one or more adjustment mechanisms (such
as
displacement member 30) may be anchored to body 2 and extend towards blade
assembly
in protrusion direction 26B. Moving these adjustment mechanisms (not shown) in
protrusion direction 26B may cause blades 14 to protrude further beyond guide
56, thereby
allowing relatively deeper shaving of drywall mud, substantially as discussed
above.
Moving these adjustment mechanisms (not shown) in protrusion direction 26A may
cause
blades 14 to protrude less far beyond guide 56, and/or even retract behind
guide 56 in
protrusion direction 26A, thereby allowing relatively shallower shaving of
drywall mud. In
some embodiments, one or more blades 14 are selectively adjustable in
protrusion
directions 26 independently of one or more other blades 14; for example, rough-
edged
blade 14a may be advanced so that leading edge 15a protrudes beyond leading
edges 15b
and/or 15c in protrusion direction 26B.
[0089] Figures 6 and 7 illustrate a method for smoothing dried drywall mud
according to
the present disclosure. Tool 1 may be positioned against drywall 110 so that
the one or
more blades 14 abut drywall mud 100. Tool 1 may then be advanced along drywall
110 in
advancement direction 120 (e.g. by a user applying force to handle 46). The
user applies
force to handle 46, which causes blades 14 to pass across a portion of drywall
mud 100
with sufficient force to at least partially smooth drywall mud 100. Each
successive pass of
a blade 14 across a portion of drywall mud 100 may further smooth the portion
of drywall
mud 100.
[0090] In embodiments with multiple blades 14, this process may be expedited.
For
example, a rough-edged blade 14a may advance along an unfinished drywall mud
portion
102, thereby shaving excess drywall mud and transforming unfinished drywall
mud
portion 102 into rough drywall mud portion 104. Rough-edged blade 14a may
comprise
one or more channels 11 through which excess drywall mud may pass as
unfinished
drywall mud portion 102 is shaved. As tool 1 is drawn across drywall 110,
smooth-edged
blade 14b may be subsequently drawn across rough drywall mud portion 104,
thereby
further smoothing portion 104. Additional blades, such as smooth-edged blade
14c, maybe
be subsequently drawn across rough drywall mud portion 104, thereby smoothing
portion
104 even further. Such smoothing may transform rough drywall mud portion 104
to a
relatively smoothed drywall mud portion 106. Thus, a plurality of adjacent
unfinished
21
CA 02902681 2015-09-01
drywall mud portions 102 may be smoothed into relatively smoothed drywall mud
portions 106 by simultaneously advancing the several blades 14 along portions
of drywall
mud 100.
[0091] In some embodiments, blades 14 may be flexed to permit the smoothed
portion
106 to possess some curvature. For example, when smoothing drywall mud on top
of a
tape seam, the corner, counter-sunk screw, and/or the like, it may be
desirable for the
drywall mud to have increased thickness in that location (while still
appearing smooth) to
conceal the underlying feature, whereas it may be desirable for drywall mud
away from
the feature to be concealed to have decreased thickness to blend with the
surrounding
drywall 100. In some circumstances, this may be accomplished by flexing blades
14 in the
appropriate direction prior to smoothing drywall mud 100. As another example,
it may be
desirable to provide a particular curvature to drywall mud 100 when smoothing
a curved
portion of drywall 110.
[0092] As discussed above, flexion may be accomplished by adjusting adjustment
mechanism 30 (e.g. displacement member 30) to press against blade assembly 10
and/or
blades 14, thereby selectively flexing corresponding portions of blades 14.
Alternatively,
or in addition, blades 14 may be flexed by a biasing mechanism 34 (optionally
mediated to
a countervailing force exerted by an adjustment mechanism 30). Once flexed,
the one or
more blades 14 may be positioned against a portion of drywall mud 100 and
advanced
along the drywall mud to engage in a smoothing action substantially as
described above.
[0093] Figures 8-10, 11 A and 11B (collectively and individually "Figure 11"),
and 12A
and 12B (collectively and individually "Figure 12") show another example
drywalling tool
200. Throughout Figures 8-12, like reference numerals refer to like features
of Figures 1-
7; for example, blade assembly 210 corresponds generally to blade assembly 10,
although
like-numbered features may comprise various differences as described in
greater detail
herein. For convenience, drywall tool 200 is generally described with
reference to the
same directions 22, 24, 26 as were described in connection with Figures 1-7.
[0094] Drywall tool 200 comprises a body 202 coupled to a frame 206. Body 202
may be
shaped to be held by a user (and thus may function as a handle). A blade
assembly 210 is
22
CA 02902681 2015-09-01
coupled to frame 206 and retains one or more blades 14 having leading edges
15. Blade
assembly 210 comprises one or more connectors 212 for retaining blades 14 and,
in some
embodiments, one or more biasing mechanisms 234 for flexing blades 14. In the
depicted
embodiment, blade assembly 210 retains one blade 14, although it will be
appreciated that
blade assembly 210 may retain a plurality of blades 14 (e.g. as described
above).
[0095] Biasing mechanisms 234 bias one or more blades 14 in flexion direction
22. In
some embodiments (including the depicted embodiment of Figures 8-12), biasing
mechanisms 234 bias blade 14 in flexion direction 22A toward body 202. In some
embodiments, biasing mechanisms 234 do not flex blade 14 when at rest; that
is, when
blade 14 is substantially unflexed (and is not being flexed in flexion
direction 22B by a
countervailing force), biasing mechanisms 234 do not exert any significant
force on blade
14 in direction 22A.
[0096] In some embodiments (including the depicted embodiment of Figures 8-
12),
adjustment mechanism 30 is omitted, and biasing mechanisms 234 provide tension
which
partially counteracts flexion of blade 14 in flexion direction 22B caused by
(for example)
drywall mud being smoothed by blade 14. By maintaining such tension, biasing
mechanisms 234 may enable blade 14 to more effectively smooth drywall mud
(relative to
an unbiased blade which flexes away from such drywall mud more easily) while
still
providing some flexibility of blade 14 in flexion directions 22.
[0097] Biasing mechanisms 234 may be of any suitable construction, as
described above.
In some embodiments, biasing mechanisms 234 comprise rods 238, springs 236,
and
(optionally) heads 239. Such biasing mechanisms 234 are best shown in Figures
9 and 10.
Figure 9 is a side elevation view of drywalling tool 200, and Figure 10 is a
cross-sectional
view of drywalling tool 200 taken along line B¨B of Figure 9. In some
embodiments,
rods 238 connect to blade assembly 210 (e.g. to connectors 212) and heads 239
are
retained in cavities 219 of body 202. Springs 236 may be retained between
connectors 212
and an internal surface of cavity 219, thereby biasing body 202 and connectors
212 against
each other. Springs 236 may be further retained by rods 238.
[0098] In some embodiments, head 239 abuts an internal surface of cavity 219
when body
23
CA 02902681 2015-09-01
202 is moved close to connectors 212, thereby preventing body 202 from moving
nearer to
connectors 212. In some embodiments, head 239 is retained in cavity 219 so
that, when
body 202 is moved away from connectors 212, head 239 prevents at least a
portion of
body 202 from moving beyond head 239, thereby preventing body 202 from moving
further away from connectors 212. For example, head 239 may abut against a
support 220
of body 202. Head 239 does not necessarily retain spring 239 in such
embodiments, as that
function may be provided by body 202 and/or other elements of drywalling tool
200.
[0099] In the depicted embodiment, thirteen biasing mechanisms 234 are
provided,
connecting to a corresponding number of connectors 212. Any suitable number of
biasing
mechanisms 234 may be provided. In some embodiments, a sufficient number of
biasing
mechanisms 234 are provided so that each biasing mechanism 234 is spaced apart
from
adjacent biasing mechanisms 234 by at most 2.5 cm (approximately 1 inch). In
some
embodiments, some biasing mechanisms 234 provide less biasing force than other
biasing
mechanisms 234. For example (and as shown in the depicted embodiment),
transversely
outermost biasing mechanisms 234b provide greater biasing force (e.g. by
providing
springs 236 with a greater spring constant) than transversely inward biasing
mechanisms
234a.
[0100] Transversely inward biasing mechanisms 234a may connect to transversely
inward
connectors 212a and transversely outermost biasing mechanisms 234b may connect
to
transversely outermost connectors 212b. In some embodiments, transversely
outermost
biasing mechanisms 234b retain blade 14 relatively more securely than
transversely
inward biasing mechanisms 234a. For example, transversely outermost biasing
mechanisms 234b may prevent the portions of blade 14 which they retain from
bending
(e.g. to prevent the edges of blade 14 from gouging drywall during use). In
some
embodiments, transversely outermost biasing mechanisms 234b are fixedly
attached to
frame 206 (e.g. by fasteners 208). In some embodiments, transversely outermost
biasing
mechanisms 234b are longer in transverse directions 24 than transversely
inward biasing
mechanisms 234a.
[0101] In some embodiments, connectors 212 may be connected to one another by
one or
more mounts 216. For example, mounts 216 may comprise a rod which passes
through
24
CA 02902681 2015-09-01
apertures 218 in connectors 212, and/or may comprise a plurality of rods, each
affixed to a
connector 212 at one or more ends. Alternatively, or in addition, mounts 216
may be
otherwise constructed, as described above. Mounts 216 may be any suitable
shape or
structure for connecting the connectors 12 of blade assembly 10 to each other.
[0102] In some embodiments, body 202 is pivotably connected to frame 206. For
example
(as shown in the depicted embodiment), body 202 may be connected to frame 206
by a
hinge 260 or other forms of pivotal joint. Body 202 may pivot about hinge 260.
Biasing
mechanisms 234 may bias such pivoting movement so that pivoting in an angular
direction
corresponding to when body 202 moves toward connectors 212 is opposed by
biasing
mechanism 234 and pivoting in an angular direction corresponding to when body
202
moves away from connectors 212 is amplified by biasing mechanisms 234. It will
be
understood that, if body 202 is pulled away from connectors 212 beyond a
neutral position
of biasing mechanisms 234, this opposition/amplification relationship may be
reversed.
Such opposition and/or amplification force may be overcome by the application
of force
against body 202 by a user.
[0103] In some embodiments, drywalling tool 200 provides a guide 256. As
described
above with reference to guide 56, guide 256 may comprise a wheel mounted to
frame 206,
a flat surface (e.g. defined by frame 206, body 202, and/or blade assembly
210) for sliding
along a portion of drywall, and/or any other suitable structure which assists
with
maintaining registration between leading edges 15 and drywall mud during use
of tool
200. In at least the depicted embodiment, an outermost edge of guide 256 is
substantially
parallel with leading edge 15 in flexion direction 22.
[0104] Figures 11 and 12 show additional views of drywalling tool 200, for
greater clarity.
Figure 11A shows a front elevation view of drywalling tool 200, whereas Figure
11B
shows a rear elevation view (i.e. from an opposing side to the view of Figure
11A) of
drywalling tool 200. Figures 12A and 12B show plan views of opposing sides of
drywalling tool 200; for convenience, Figure 12A may be considered to provide
a "top"
view, and Figure 12B may be considered to provide a "bottom" view (although,
as
described below, "top" and "bottom" do not limit the orientations of
drywalling tool 200).
CA 02902681 2015-09-01
[0105] As shown (for example) in Figures 11B and 12B, in some embodiments, one
or
more connectors 212 may be fastened to blade 14 by fasteners 208. For example,
transversely outermost connectors 212b may be fastened to blade 14 by
fasteners 208. One
or more transversely inward connectors 212a may also, or alternatively, be
fastened to
blade 14 by one or more fasteners 208. In at least the depicted embodiment,
blade 14 is
fastened to connectors 212 at at least three locations ¨ two transversely
outward locations
and one transversely central location. Fastener 208 may comprise, for example,
a screw,
post, clamp, and/or other fastening mechanism.
[0106] Drywalling tool 200 may be used substantially similarly to drywalling
tool 1 ¨
namely, drywalling tool 200 may be applied against drywalling mud (e.g.
drywalling mud
100) and advanced along such drywalling mud to smooth it. In operation, a user
applies
force to body 202 to move drywalling tool 200 in an advancement direction
(e.g.
advancement direction 120). This force causes blade 14 to pass across a
portion of drywall
mud with sufficient force to at least partially smooth the drywall mud.
[0107] In some embodiments, including the depicted embodiment, a user may
apply force
against body 200 in flexion directions 22, thereby causing pivoting movement
of body 202
relative to blade 14. Such movement may cause flexion of blade 14 in flexion
direction
22A. However, in circumstances where drywalling mud is applying force against
blade 14
to cause flexion in flexion direction 22B, force applied by a user in flexion
direction 22A
may counteract the force of the drywalling mud and thus may serve to reduce
the flexion
of blade 14 (and increase the force exerted by blade 14 against the drywalling
mud). A
user may selectively increase or decrease the force applied against blades 14
by
correspondingly increasing or decreasing the force applied against body 202 in
flexion
direction 22A (without necessarily adjusting the force exerted in the
advancement
direction).
Interpretation of Terms
[0108] Unless the context clearly requires otherwise, throughout the
description and the
claims:
= "comprise", "comprising", and the like are to be construed in an
inclusive sense, as
26
CA 02902681 2015-09-01
opposed to an exclusive or exhaustive sense; that is to say, in the sense of
"including, but not limited to";
= "connected", "coupled", or any variant thereof, means any connection or
coupling,
either direct or indirect, between two or more elements; the coupling or
connection
between the elements can be physical, logical, or a combination thereof;
elements
which are integrally formed may be considered to be connected or coupled;
= "herein", "above", "below", and words of similar import, when used to
describe
this specification, shall refer to this specification as a whole, and not to
any
particular portions of this specification;
= "or", in reference to a list of two or more items, covers all of the
following
interpretations of the word: any of the items in the list, all of the items in
the list,
and any combination of the items in the list;
= the plural forms "blades", "mounts", and "directions" are used at various
points in
place of the term "one or more blades", "one or more mounts", and "one or both
directions", respectively, and accordingly include the meaning of the singular
forms "blade", "mount", and "direction", respectively (and vice-versa);
= the singular forms "a", "an", and "the" also include the meaning of any
appropriate
plural forms.
[0109] Words that indicate directions such as "vertical", "transverse",
"horizontal",
"upward", "downward", "forward", "backward", "inward", "outward", "vertical",
"transverse", "left", "right", "front", "back", "top", "bottom", "below",
"above", "under",
and the like, used in this description and any accompanying claims (where
present),
depend on the specific orientation of the apparatus described and illustrated.
The subject
matter described herein may assume various alternative orientations.
Accordingly, these
directional terms are not strictly defined and should not be interpreted
narrowly.
[0110] Specific examples of systems, methods and apparatus have been described
herein
for purposes of illustration. These are only examples. The technology provided
herein
can be applied to systems other than the example systems described above. Many
27
CA 02902681 2015-09-01
alterations, modifications, additions, omissions, and permutations are
possible within the
practice of this invention. This invention includes variations on described
embodiments
that would be apparent to the skilled addressee, including variations obtained
by:
replacing features, elements and/or acts with equivalent features, elements
and/or acts;
mixing and matching of features, elements and/or acts from different
embodiments;
combining features, elements and/or acts from embodiments as described herein
with
features, elements and/or acts of other technology; and/or omitting combining
features,
elements and/or acts from described embodiments.
[0111] It is therefore intended that the following appended claims and claims
hereafter
introduced are interpreted to include all such modifications, permutations,
additions,
omissions, and sub-combinations as may reasonably be inferred. The scope of
the claims
should not be limited by the preferred embodiments set forth in the examples,
but should
be given the broadest interpretation consistent with the description as a
whole.
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