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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the field of paint trays and the
like, and more particularly to an improved tray assembly which is
particularly suited for use as a painter's caddy.
2. Description of the Prior Art
Many forms of paint trays are, of course known.
However, upon information and belief, many known paint trays are limited by
a lack of universality of possible uses.
One example of a known form of paint tray, containing a metering roller, is
representatively shown in U.S. Pat. No. 3,648,322. However, this type of
tray construction appears to be limited practically to use with pad-type
paint applicators, and does not appear to be readily suited for use with
brush and roller-type applicators. Additionally, this known tray appears
to be difficult to hold while painting, and does not appear to facilitate
ready relocation of the tray, particularly when working on a ladder.
SUMMARY OF THE INVENTION
The present invention provides an improved tray assembly which is
particularly suited for use as a painter's caddy.
Broadly, the improved tray assembly includes: a tray having a bottom and a
pair of spaced side walls; mounting means on each of the side walls and
severally providing an opening spaced laterally from the tray's center of
gravity; a bail having two marginal end portions inserted into the
mounting means openings, the bail being pivotally mounted on the tray for
movement in one angular direction toward a raised position and for
movement in the opposite angular direction toward a lowered position; and
stop means mounted on the tray and arranged to engage a portion of the
bail when the bail is in its raised position to prevent further pivotal
movement of the bail relative to the tray in said one angular direction.
The preferred embodiment further includes abutment means mounted on the
tray and adapted to engage the bail when the bail is in its lowered
position to prevent further pivotal movement of the bail relative to the
tray in said opposite angular direction. The bail may include at least one
hook portion adapted to engage a rung or shelf of a ladder, and the
underside of the tray may be provided with a plurality of sawtooth-like
notches arranged to face the bail, when the bail is in its lowered
position, for use in capturing an object therebetween.
The improved tray may be further provided with a pair of trunnion bearings
mounted on the side walls and arranged to face one another, and the tray
assembly may include a roller having stub shafts extending axially beyond
its end faces. Preferably, each trunnion bearing has a narrowed entrance
portion, the width of which is slightly less than the diameter of the stub
shafts, so that the roller may be snapped into the trunnion bearings.
Accordingly, one general object of the present invention is to provide an
improved tray assembly which is adapted to many uses.
Another object is to provide an improved tray assembly which may
accommodate brush, roller and pad-type applicators.
Another object is to provide improved trunnion bearings for use in a tray
assembly, which bearings will prevent unintended separation of a roller
from a tray.
Still another object is to provide a universal paint tray which may be
rested on a plannar object, carried by the painter, or easily mounted on a
ladder.
These and other objects will become apparent from the foregoing and ongoing
specification, the drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view looking at the right rear corner of the
improved tray assembly, this view particularly showing the tray, bail and
roller, the stop means and the abutment means.
FIG. 2 is a fragmentary front elevation thereof.
FIG. 3 is a fragmentary vertical sectional view thereof, taken generally on
line 3--3 of FIG. 1, and showing the tray and roller in cross-section.
FIG. 4 is a fragmentary vertical sectional view thereof, taken generally on
line 4--4 of FIG. 1, and showing a trunnion support in elevation.
FIG. 5 is a fragmentary vertical sectional view thereof, taken generally on
line 5--5 of FIG. 1, and showing the right side mounting means and the
abutment means extending outwardly therefrom.
FIG. 6 is a fragmentary vertical sectional view thereof, taken generally on
line 6--6 of FIG. 5, and showing the mounting means, the abutment means, a
roller stub shaft journalled in the associated trunnion bearing, and also
showing a passageway in the intermediate wall.
FIG. 7 is a perspective view of the bail, and further showing, as a frame
of reference, three mutually perpendicular planes and lines of
intersection therebetween.
FIG. 8 is a right side elevation showing the improved tray assembly resting
on a suitable horizontal planar support, with the bail proximate its
lowered position.
FIG. 9 is a right side elevation of the tray assembly, with an operator
holding the bail in its raised position.
FIG. 10 is a right side elevation of the tray assembly mounted on the shelf
of a step ladder, with the bail proximate its lowered position.
FIG. 11 is a right side elevation of the tray assembly mounted on the top
rung of a step ladder, again with the bail proximate its lowered position.
FIG. 12 is a right side elevation of the tray assembly mounted on a ladder,
with the raised bail engaging one rung, and the support recess engaging
the next lower rung to provide a measure of fore and aft stability.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
At the outset, it should be clearly understood that like reference numerals
are intended to identify the same elements and/or structure consistently
throughout the several drawing figures, as such elements and/or structure
may be further described or explained by the entire written specification
of which this detailed description is an integral part.
Referring now to the drawings, and more particularly to FIG. 1 thereof, the
presently preferred embodiment of the improved tray assembly is generally
indicated at 20, and is particularly suited for use as a painter's caddy
or the like.
The improved tray assembly 20 is shown as broadly including a tray 21, a
roller 22 freely journalled on the tray, and a bail 23 which is uniquely
shaped to cooperate with portions or surfaces on the tray to increase the
adaptability of the tray assembly to multiple uses. Before proceeding, it
should be pointed out that the improved tray assembly may be used with
brush, roller or pad-type applicators for applying a liquid coating, such
as paint, to a suitable object.
Referring now to FIGS. 1-6, the tray 21 is shown as being a uniquely
configured member, preferably formed of a suitable plastic material, such
as high density polyethylene or the like. Tray 21 includes a rearward
trough portion 24, and a raised upwardly inclined shelf portion 25
extending forwardly therefrom. More specifically, the tray 21 has a pair
of spaced horizontally-elongated upwardly and outwardly inclined left and
right side walls 26, 28, and a pair of upwardly and outwardly inclined
front and rear walls 29, 30. In the preferred embodiment, walls 26-30 are
inclined outwardly with respect to the vertical at an acute included angle
on the order of about five degrees, although this exact angle is not
deemed critical and need not invariably obtain. As best shown in FIGS. 2
and 3, the bottom 31 of the trough portion 24 is shown as arcuately
joining the left, right and rear walls 26, 28, 30, and as tangentially
joining a lower arcuate portion 32 of a planar intermediate wall 33 which
extends upwardly and forwardly at a like angle of about five degrees to
provide an uppermost wiping lip 34 above the bottom 35 of the shelf
portion. Of course, this wiping lip 34 provides an edge across which an
applicator may be drawn to remove excess paint. The intermediate wall
lower arcuate portion 32 is preferably configured as a segment of a
cylinder generated about the axis of the trunnion bearings. The shelf
portion bottom 35 joins the left and right side walls 26, 28, and extends
forwardly and upwardly at an angle of about eight degrees with respect to
the horizontal, to join the lower margin of front wall 29. The left right,
front and rear tray walls 26, 28, 29, 30 are shown as terminating in an
uppermost out-turned permetrical common lip, collectively indicated at 36.
Referring now to FIGS. 1 and 6, the intermediate wall 33 is shown provided
with a pair of left and right passages 38, 39 which extend downwardly from
wiping lip 34 adjacent the left and right side walls 26, 28 to join the
shelf bottom 35. Moreover, the shelf bottom 35 is provided with a
plurality of rearwardly and laterally inclined ribs, severally indicated
at 40, which function to direct a flow of paint or the like on the shelf,
toward the passages 38, 39 so that it may flow back into the trough
portion 24.
Referring now to FIG. 7, the bail 23 is shown as being a
uniquely-configured wire-form member. The bail will be described with
reference to three mutually perpendicular planes A, B and C, which
intersect to define three mutually perpendicular lines x--x, y--y and
z--z, as schematically indicated in FIG. 7. Bail 23 is shown as having two
hooked marginal end portions 41, 41, arm portions 42, 42, leg portions 43,
43, arcuate transitional portions 44, 44, and a common cross-bar 45
provided with two U-shaped hook portions 46, 46. The central portion of
the cross-bar is surrounded by a tubular sleeve 48 which provides a
carrying handle and which may conceal a butt weld between two separate
wire sections, if this construction is employed. The bail is bent between
the various portions above described.
The hooked end portions 41, 41 and the arm portions 42, 42 are all
elongated in a common plane parallel to plane B. The arm portions 42, 42
extend away from the hooked end portions 41, 41 along lines parallel to
line z--z. The leg portions 43, 43 extend away from the arm portions along
lines parallel to line x--x. The arcuate transitional portions extend away
from the leg portions 43, 43 in planes parallel to plane A. The entire
cross-bar 45 including hook portions 46, 46 is arranged in a plane
parallel to plane C. Hence, cross bar 45 lies in a plane which is spaced
from, but preferably substantially parallel to, a plane including leg
portions 43, 43.
Referring now to FIGS. 1, 2 and 4-6, mounting means, severally indicated at
49, are shown as being mounted on each side wall proximate the trough
portion 24 and rearwardly of the tray's center of gravity. As best shown
in FIG. 6, each mounting means 49 includes an outer wall depending from
the outward margin of outturned flange 36 so as to be spaced from the
adjacent tray side wall. Specifically, each such outer wall includes a
rectangular vertical upper portion 50, and a rectangular vertical lower
portion 51 lapped on upper wall portion 50 and bonded thereto at 52. Each
outer wall portion 51 is provided with an opening 53 proximate bond 52 to
receive one of the bail hooked end portions 41. Moreover, each outer wall
is strengthened by fore and aft walls 54, 55 extending outwardly from the
adjacent side wall to join the outer wall. Hence, each mounting means 49
is mounted on a side wall to provide an opening, such as opening 53,
spaced laterally from the tray's center of gravity, to receive insertion
of one of the bail hooked end portions. While this construction is
preferred, it should be appreciated that the form of the mounting means is
not limited to that shown and described. Other forms of such mounting
means might also provide a wall spaced from the adjacent side wall.
Alternatively, in a simplified construction, the mounting means might
simply be a hole provided through the side wall itself. At any rate, the
function of the mounting means, in whatever structural form it may take,
is to provide an opening spaced laterally from the tray's center of
gravity.
Thus, the bail is adapted to be pivotally mounted on the tray for movement
in one angular direction (i.e., counterclockwise in FIG. 9) toward a
raised position (FIG. 9), and for movement in the opposite angular
direction (i.e., clockwise in FIG. 9) toward a lowered position (as
closely approached in FIG. 11).
The improved tray is shown as further including stop means, generally
indicated at 56, and arranged to engage a portion of the bail when the
bail is in the raised position to prevent further counterclockwise pivotal
movement of the bail relative to the tray. As best shown in FIGS. 1, 2 and
6, each stop means 56 may simply include a vertical plate-like member 58
extending outwardly from the adjacent side wall and provided with a notch
or recess or extending upwardly from its lower edge to receive the arm
portion of the bail. In the preferred embodiment, the upper edge of plate
58 is further secured to a tab 60 extending outwardly from perimetrical
flange 36.
The preferred embodiment is also shown as including abutment means,
generally indicated at 61, mounted on the tray and adapted to engage the
bail when the bail is in the lowered position (not completely shown) to
prevent further pivotal clockwise movement of the bail relative to the
tray. This abutment means 61 may simply include a vertical plate-like
member 62 extending laterally outwardly from mounting means plate portion
51 and adapted to engage the bail arm portion. The abutment means 61
functions to prevent the bail from hanging down beneath the tray if the
tray is grasped and lifted. Were such abutment means not provided, the
depending bail might interfere with a user's subsequent placement of the
tray on a suitable object, such as a table or floor.
Adverting now to FIGS. 2 and 3, the preferred form of tray 21 is further
shown as provided with a pair of laterally-spaced rearward skid-like
members, severally indicated at 62, reinforced by gusset plates 63, 63 and
provided with a pair of laterally-spaced plate-like supports severally
indicated at 64, similarly reinforced by gusset plates 65, 65. As best
shown in FIG. 3, each rearward skid-like member 62, 62 is mounted on the
tray bottom 31 and has a lower surface 66 inclined forwardly and upwardly
at an acute included angle of about three degrees so that when the tray
rests on a suitable horizontal planar support, trough portion bottom 31
will be slightly inclined to cause paint to flow towards roller 22.
Each forward support 64 has a semi-cylindrical recess 68 extending upwardly
from its lower surface, and has a forwardmost foot portion 69 aligned with
skid lower surface 66.
Moreover, the improved tray is preferably provided with tooth means,
generally indicated at 70, arranged on the tray bottom and defining at
least one, and preferably more, stepped notches 71, 71 arranged to face
toward the cross-bar 45 when the bail is in its lowered position, for a
purpose hereinafter explained.
Referring now to FIGS. 1, 3 and 4, the optional roller 22 is shown as being
a hollow blow-molded plastic member having a sealed chamber 72
therewithin. Roller 22 has an outer cylindrical surface 73 from which a
plurality of axially-elongated circumferential-spaced ribs 74 extend
outwardly. The particular configuration of the roller ribs is illustrative
only and is designed to facilitate ease in separation of the roller from
the mold halves after formation. This roller 22 also has annular vertical
left and right end faces 75, 76. A stub shaft 78 extends axially beyond
each roller end face and is shown as having a convex or rounded distal end
portion to minimize frictional contact with the trunnion bearings,
severally indicated at 79.
As best shown in FIG. 4, each trunnion bearing 79 includes a support
mounted on the adjacent side wall and extending upwardly from the tray
bottom. An upwardly-opening generally C-shaped recess extends downwardly
into the support 79 from its upper horizontal surface. Specifically, each
such trunnion bearing recess includes an uppermost narrowed entrance
portion 80 having a width slightly less than the diameter of the
associated stub shaft, and leading downwardly to larger substantially
cylindrical recess 77, which is slightly larger in diameter than the
diameter of the associated stub shaft. Hence, the roller may be initially
positioned such that its stub shafts are arranged above the trunnion
bearings, and then pressed downwardly to snap the stub shafts through
narrowed entrance portions 80 to enter the cylindrical recess therebelow.
This arrangement serves to prevent unintended separation of the roller
from its trunnion bearings, as might otherwise occur, for example, if the
roller were to float on a quantity of paint in trough portion 24.
One unique advantage of the improved tray assembly lies in the universality
of its application and use, as depicted in several environments shown in
FIGS. 8-13.
In FIG. 8, the tray assembly is shown as resting on a suitable horizontal
planar surface 81, such as a table, platform or floor. In this position,
the lower surfaces of the rearward skid-like members and the foot of the
forward support will rest on the surface so that the trough portion bottom
will be slightly forwardly and downwardly inclined, causing paint in the
trough to flow toward the roller. In this position, the bail cross-bar
will also rest on the support, just short of its fully lowered position.
Alternatively, the bail may be moved to its raised position so that the
tray may be carried, as shown in FIG. 9. Here, the location of the bail's
pivotal axis, coupled with the engagement between the stop means and the
bail arm portion, insures the stability of the depending tray regardless
of the quantity of paint in trough portion 24.
The improved tray assembly may also be mounted on the shelf 82 or top step
of a step ladder, as shown in FIGS. 10 and 11, respectively. In FIG. 10,
the bail cross-bar hook portions 46, 46 are shown as arranged beneath one
end of the shelf, with the shelf's other end being received in the
appropriate notch of the tooth means. In FIG. 10, it will be appreciated
that the tray abutment means will limit further substantial
counterclockwise pivotal movement of the tray relative to the shelf.
The application of the tray assembly to the top step of the step-ladder, as
shown in FIG. 11, is similar, except that the top step is shown as
engaging a different notch of the tooth means to allow for dimensional
variation between the width of the shelf and top step.
As shown in FIG. 12, the tray assembly may also be mounted on a ladder such
that the bail, in its raised position, will have its hook portions
engaging one rung, with the support recess engaging the next lower rung.
This is desirable since it affords the tray with a measure of fore and aft
stability, particularly when the painter draws his applicator across
wiping edge 34.
Of course, the invention contemplates that various modifications and
changes may be made. While it is presently preferred to form the tray
integrally, such construction need not invariably obtain, and the various
component tray parts may be formed as separate units subsequently
assembled together. While the disclosed tray assembly is shown as
including a roller journalled on trunnion bearings, it should be clearly
understood that this roller member is optional and may be omitted, if
desired.
Therefore, while the presently preferred embodiment of the improved tray
assembly has been shown and described, persons skilled in this art will
readily appreciate that various additional changes and modifications may
be made without departing from the spirit of the invention as defined in
the following claims.
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