System and method for cleaning both the interior and the exterior of drywall tools

Abstract

A system for cleaning both the exterior and the interior of drywall tools uses a standard bucket, a metal frame, and a set of brushes. The brushes are rigidly mounted to the frame, and the brush/frame assembly is placed inside the bucket. The system also has a foot-actuated pump having a supply hose that mounts to the bucket and a delivery hose that mounts to a tool to be cleaned. The system is used to clean both the exterior surfaces of the soiled tool and its interior chambers. The bucket is filled with water and the delivery hose is attached to an inlet port of the tool. The tool is lowered into the bucket and scrubbed against the brushes to clean the exterior of the tool. Simultaneously, the pump is actuated by the user to force water through the tool to clean compound out of its interior chambers.

Description

BACKGROUND OF THE INVENTION

[0001] 1. Technical Field

[0002] The present invention relates in general to an improved tool cleaning system, and in particular to an integrated system and method for simultaneously cleaning both the interior and the exterior of drywall tools.

[0003] 2. Description of the Related Art

[0004] Drywall has become the dominant material in the production of interior building partitions. Interior building partitions typically comprise a studwall of vertical support members or studs that are spaced apart from each other in a parallel arrangement. The studs are used to support preformed panels or wallboards that are usually attached to the studwall with fasteners. A joint exists between adjacent ones of the abutted wallboards. In order to provide a continuous flat surface appearance to the wall, it is necessary to apply a finish to the joint between the adjacent panels.

[0005] Finishing typically requires the build-up of multiple layers of a mastic material or joint compound that is commonly referred to as mud. Mud is a paste-like substance that is formed by mixing a powdery compound with water. The blending of the joint compound into the panel surface forms the desired flat and contiguous wall surface. The build-up of mud in the joint area or “floating” comprises the application of a first layer of mud and the embedding of a wallboard tape such as paper or fiberglass tape in the first layer. Finally, one or two more layers of mud are applied on top of the first layer/tape to complete the joint. The finishing of the joints is a time consuming and labor intensive process, it is generally necessary to wait 24 hours between each application of mud in order to allow each layer to dry. In addition, it is generally necessary to sand the joint area so as to produce a finish that matches the remainder of the wallboards.

[0006] Because of the messiness associated with drywall compound and the need for drying time between applications, the drywall tools used to apply mud and tape must be cleaned frequently. In addition, the mechanized components of the tools should be thoroughly cleaned to maintain them in a properly functioning condition. However, as the ambient operating temperature of the surrounding environment increases and, thus, the compound drying conditions improve, the time intervals between these tool cleaning operations must be shortened. Consequently, even more frequent cleaning of the tools is required for proper function.

[0007] In the prior art, the clean-up of drywall tools is typically accomplished by the rudimentary method of manually scrubbing the exterior of the tool with a hand brush and then rinsing the tool in a bucket of water. The interior of the tool can be cleaned by using a smaller or narrower brush for scrubbing the inner chambers of the tool, and then flushing the interior of the tool with water from the bucket or a garden hose. Although these prior art methods are somewhat effective, they are inefficient and consume a significant amount of productivity for drywall workers. Thus, a faster, more efficient cleaning system for drywall tools that would decrease operator downtime and make more time available for production would be desirable.

SUMMARY OF THE INVENTION

[0008] One embodiment of the present invention comprises a system for cleaning both the exterior and the interior of drywall tools. The system uses a standard 5-gallon bucket, a metal frame, and a set of brushes. The brushes are rigidly mounted to the frame, and the brush/frame assembly is placed inside the bucket. The system also has a foot-actuated pump having a supply hose that mounts to the bucket and a delivery hose that mounts to a tool to be cleaned.

[0009] In operation, the system is used to clean both the exterior surfaces of the soiled tool and its interior chambers. The bucket is filled with water and the delivery hose is attached to an inlet port of the tool. The tool is lowered into the bucket and scrubbed against the brushes to clean the exterior of the tool. Simultaneously, the pump is actuated by the user to force water through the tool to clean compound out of its interior chambers. Thus, the tool is cleaned inside and outside in one efficient operation. The delivery hose is disconnected from the tool, which is then ready for use or storage.

[0010] The foregoing and other objects and advantages of the present invention will be apparent to those skilled in the art, in view of the following detailed description of the preferred embodiment of the present invention, taken in conjunction with the appended claims and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] So that the manner in which the features, advantages and objects of the invention, as well as others which will become apparent, are attained and can be understood in more detail, more particular description of the invention briefly summarized above may be had by reference to the embodiment thereof which is illustrated in the appended drawings, which drawings form a part of this specification. It is to be noted, however, that the drawings illustrate only a preferred embodiment of the invention and are therefore not to be considered limiting of its scope as the invention may admit to other equally effective embodiments.

[0012] FIG. 1 is an isometric view of a bucket utilized by the system of the present invention.

[0013] FIG. 2 is an isometric view of a support frame utilized by the system of the present invention.

[0014] FIG. 3 is an isometric view of a brush utilized by the system of the present invention.

[0015] FIG. 4 is an isometric view of a set of the brushes of FIG. 3 mounted to the support frame of FIG. 2.

[0016] FIG. 5 is a top view of the support frame and brush assembly of FIG. 4.

[0017] FIG. 6 is an isometric view of a pump assembly utilized by the system of the present invention.

[0018] FIG. 7 is a sectional side view of a fitting utilized by the pump assembly of FIG. 6.

[0019] FIG. 8 is an isometric view of one version of the pump assembly of FIG. 6 mounted to the bucket of FIG. 1.

[0020] FIG. 9 is a partially-sectioned, isometric view of a preferred embodiment of a system for cleaning drywall tools and is constructed in accordance with the present invention.

[0021] FIG. 10 is an isometric view of the system of FIG. 9 in operation.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0022] Referring to FIG. 1, a bucket 11 utilized by the system of the present invention is shown. Bucket 11 is a conventional cylindrical pail with an open top and an optional handle, and preferably comprises a 5-gallon capacity. FIG. 2 illustrates a rigid support frame 13 utilized by the system of the present invention. Support frame 13 is preferably formed from flat metallic strap stock, but may be formed from other rigid materials as well.

[0023] In the version shown, support frame 13 includes a pair of parallel, annular bands 15, 17 that are joined to each other by two pair of vertically-oriented straps 19, 21. Bands 15, 17 and straps 19, 21 are preferably welded together, but may be joined by other means as well. Straps 19 are shorter in length than straps 21, and only extend between bands 15, 17. Straps 21 also extend between bands 15, 17, but also include a hanger extension 23 that extends vertically above band 15. A snap-like hook 25 is formed at the upper end of each hanger extension 23.

[0024] Referring now to FIGS. 3-5, the system of the present invention also utilizes a plurality of brushes 31. Each brush 31 includes a mounting portion 33 with bristles 35 protruding therefrom. At least one of the brushes 31 is also equipped with generally C-shaped clips 37 that are mounted along the side edge of mounting portion 33. As shown in FIGS. 4 and 5, one version of the present invention utilizes four of the brushes 31 with the backs of their respective mounting portions 33 mounted to the interior surfaces of support frame 13 to form a frame and brush assembly 41.

[0025] Each brush 31 is vertically aligned with and is secured to one of the straps 19, 21 and both bands 15, 17 with a pair of screws 39 or other fastening means. Brushes 31 are arranged in a substantially orthogonal arrangement such that all of the bristles 35 extend radially inward toward the center of the generally cylindrical frame and brush assembly 41. However, as shown in FIG. 5, there is still some open space between the bristles 35 of opposite ones of the brushes 31.

[0026] FIG. 6 illustrates a pump assembly 51 utilized by the system of the present invention. In the version shown, pump assembly 51 includes a manually-actuated pump 53, preferably a foot pump, having a base 55 and a pump actuator 57. Pump 53 also may comprise an automated pump, such as an electric pump. Pump assembly 51 also has an intake hose 59, one end of which is fluidically interconnected to a suction port (not shown) in base 55. The opposite end 61 of intake hose 59 is provided for immersion in a cleaning fluid, as will be described below.

[0027] Pump assembly 51 also has a delivery hose 63 with one end fluidically interconnected to a pressure port (not shown) in base 55. The opposite end 65 of delivery hose 63 includes a fitting 67. Fitting 67 may comprise a multi-jet nozzle or other fluid dispensing means, but preferably comprises the fitting 67 of FIG. 7. Fitting 67 has a small end 69 for insertion into end 65 of delivery hose 67, a large end 71 for connection to a tool, and an O-ring 73 for sealing to the tool, as will be described below. As shown in FIG. 8, one version of pump assembly 51 is mounted to bucket 11 by installing intake hose 59 and delivery hose 67 through the sidewall of bucket 11. However, this configuration is not the preferred embodiment.

[0028] Referring now to FIG. 9, a preferred embodiment of the present invention is illustrated as an assembled cleaning system 75 for cleaning drywall tools and other types of tools. System 75 includes bucket 11 of FIG. 1, frame and brush assembly 41 of FIG. 4, and pump assembly 51 of FIG. 6.

[0029] Frame and brush assembly 41 is placed inside bucket 11 and should be relatively closely received by the interior of bucket 11. the two hooks 25 at the upper end of support frame 13 snap onto the upper rim of bucket 11 at its open end to firmly secure support frame 13 to bucket 11. The lower end of frame and brush assembly 41 should be located at or near the bottom of bucket I1. The intake hose 59 of pump assembly 51 is secured to clips 37 on one of the brushes 31, as shown, such that end 61 is located below the lower one of the clips 37. Clips 37 firmly but removably retain intake hose 59 in bucket 11. Pump 53 is located adjacent to bucket 11 and delivery hose 63 is ready to be connected to a tool 81 (schematically illustrated in phantom).

[0030] In operation (FIG. 10), system 75 is prepared for use by filling bucket 11 with a cleaning fluid 83, such as water, such that the fluid level is located above and covers brushes 31 (see FIG. 9). The soiled tool 81 that is to be cleaned typically has a drywall compound tube or other intake port for receiving the compound. Fitting 67 on delivery hose 63 is secured to the intake port for fluid interconnection, and the user begins to actuate pump 53, preferably by moving actuator 57 with his or her foot. Pump assembly 51 draws fluid 83 out of bucket 11 through intake hose 59 and circulates fluid 83 through delivery hose 63 into the soiled tool 81. Pumping fluid 83 through tool 81 flushes and cleanses the interior chambers of tool 81 as fluid 83 is expelled through a compound outlet port in tool 81. This process may be performed directly above bucket 11 so that the discharged fluid drains back into bucket 11.

[0031] One advantage of the present invention is that the foregoing process of cleaning the interior of tool 81 may be simultaneously performed while the exterior of tool 81 is being cleaned. The exterior of tool 81 is cleaned by lowering the soiled portion of tool 81 into bucket 11 such that it is submerged in fluid 83. When the submerged tool 81 is moved vertically in an up-and-down motion and rotated in a circular motion back-and-forth, the entire exterior of the submerged tool 81 is cleansed. Since the level of fluid 83 is located above brushes 31, splashing and sloshing of fluid 83 is greatly reduced. After tool 81 has been cleaned both inside and out, delivery hose 63 is disconnected from tool 81, which may then be returned to use or left to dry.

[0032] The present invention has many advantages. This cleaning system is capable of simultaneously cleaning both the exterior and the interior of drywall tools. The apparatus is highly mobile and can be located adjacent to a filling bucket and used as necessary. The apparatus itself also is easily cleaned since the brush assembly can be removed from the bucket so that the bucket can be emptied and the brushes cleaned. The components of the system have multiple uses between cleaning since the bucket acts as a reservoir for the compound which will settle to the bottom. The present invention is also easy to use since all operations can be accomplished while standing in an upright position.

[0033] The cleaning system of the present invention significantly increases efficiency over prior art systems and methods. The present invention not only cleans tools, but it also reduces the physical movements required to accomplish the work. The result is an increase in efficiency over the rudimentary methods currently used. Another feature of the present invention is that it is readily adaptable to work in conjunction with traditional or standard tools such as box tools, tubular mud wipe down units, hawks, and pans.

[0034] While the invention has been shown or described in only some of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to various changes without departing from the scope of the invention.

Claims

1. A system for cleaning an interior and an exterior of a tool, comprising:

a bucket;

a support frame mounted inside the bucket;

a brush mounted to the support frame inside the bucket;

a pump assembly having a pump, an intake hose having one end that is adapted to be located inside the bucket, and a delivery hose having one end that is adapted to be connected to the tool; and wherein

when the bucket contains a cleaning fluid, the system is adapted to clean both the interior and the exterior of the tool when said one end of the intake hose is submerged in the cleaning fluid, said one end of the delivery hose is connected to the tool, the pump is actuated to circulate the cleaning fluid through the tool such that the interior of the tool is flushed, and the exterior of the tool is scrubbed with the brush.

2. The system of claim 1 wherein the system simultaneously cleans both the interior and the exterior of the tool.

3. The system of claim 1 wherein the brush comprises a plurality of brushes having bristles that radiate toward a center of the bucket.

4. The system of claim 1 wherein the support frame is suspended from a rim of the bucket located at an open upper end of the bucket.

5. The system of claim 1 wherein the pump of the pump assembly is manually-actuated.

6. The system of claim 1 wherein the support frame comprises a generally cylindrical form of flat metallic straps and bands.

7. A system for simultaneously cleaning an interior and an exterior of a tool, comprising:

a bucket having an open upper end and a rim;

a support frame having a generally cylindrical form of flat metallic straps and bands located inside the bucket and suspended from the rim of the bucket;

a set of brushes mounted to the support frame inside the bucket and having bristles that radiate toward a center of the bucket;

a pump assembly having a pump, an intake hose having one end that is adapted to be located inside the bucket, and a delivery hose having one end that is adapted to be connected to the tool; and wherein

when the bucket is filled with a cleaning fluid, the system is adapted to clean both the interior and the exterior of the tool when said one end of the intake hose is submerged in the cleaning fluid, said one end of the delivery hose is connected to the tool, the pump is actuated to circulate the cleaning fluid through the tool such that the interior of the tool is flushed, and the exterior of the tool is scrubbed with the brushes.

8. The system of claim 7 wherein at least one of the brushes has clips for securing the intake hose inside the bucket.

9. The system of claim 7 wherein the pump of the pump assembly is manually-actuated.

10. The system of claim 7 wherein the pump of the pump assembly is actuated by a foot of a user.

11. The system of claim 7, further comprising a fitting having one end inserted into the delivery hose and an opposite end that is adapted to be secured to the tool.

12. The system of claim 7 wherein the support frame is rigidly suspended from the rim of the bucket on a set of snap hooks.

13. A method of cleaning both an interior and an exterior of a tool, comprising the steps of:

(a) providing a bucket, a support frame, a brush, and a pump assembly;

(b) mounting the brush to the support frame;

(c) locating the support frame inside the bucket such that the brush is also located inside the bucket;

(d) placing a cleaning fluid inside the bucket;

(e) submerging one end of an intake hose of the pump assembly in the cleaning fluid;

(f) connecting one end of a delivery hose to the tool;

(g) actuating the pump assembly to circulate the cleaning fluid through the intake hose, the pump, the delivery hose, and the tool;

(h) cleaning the interior of the tool by pumping the cleaning fluid through the interior of the tool; and

(i) cleaning the exterior of the tool by scrubbing the exterior of the tool with the brush.

14. The method of claim 13 wherein steps (h) and (i) are performed simultaneously.

15. The method of claim 13 wherein step (c) comprises suspending the support frame from a rim of the bucket located at an open upper end of the bucket.

16. The method of claim 13 wherein step (g) comprises manually actuating the pump.