Magnetic insulator pad for container

[0001] This invention relates to an insulator pad for containers holding materials such as workable cement and drywall jointing compounds, and more specifically to a magnetic insulator pad for removable attachment to a container.

[0002] Joint compound containers, commonly known as “mud pans,” are well known in the art by dry wall finishers when joining previously installed wallboard and the joints therebetween. Generally, the mud pan is trapezoidal in shape and comprises a flat bottom, two sloping sidewalls extending upwardly and laterally from the bottom, and two similarly sloping end walls terminating in a planar upper edge.

[0003] Current mud pans are generally not shaped to fit a worker's hand and accordingly, the mud pan is difficult for the worker to hold when filled with the joint compound, especially for lengthy working periods. In addition, current mud pans generally have a high polished surface finish that causes the pan to become slippery, especially when wet, and prevents the worker from maintaining a secure grip on the pan. Also, because the worker routinely rotates the pan in a “flipping” action to repeatedly mix the pan contents and prevent the joint compound from settling and hardening, the slipperiness of the pan can cause the worker to lose his grip and drop the pan. Current mud pans also tend to “sweat” when the cooler temperature joint compound is placed inside of the pan, further adding to the slipperiness of the pan.

[0004] Another problem with current mud pans is that the operational life of the pan can be significantly shortened if the pan is dropped due to uneven weight distribution when flipping the pan, the slipperiness of the pan or general hand fatigue of the worker. The severity of damage to the pan can escalate based on numerous factors such as the height and angle of the drop in combination with the weight of the joint compound contained within the pan.

[0005] To try and resolve this problem, insulating pads have been developed that are secured to the mud pan to provide a more comfortable and cold temperature resistant platform for the worker's hand. In U.S. Pat. No. 6,575,328 to Foraker, an insulating pad is provided that is removably secured to the mud pan by magnetic sheets. Specifically, in Foraker, the insulating pad includes a magnetic material layer attached by adhesive to a foam rubber layer. The magnetic material layer is segmented into three spaced sections to enable the pad to bend to conform to the bottom and sidewalls of the mud pan.

[0006] However, a problem found in Foraker is that the adhesive attaching the magnetic and foam layers weakens over time under normal working conditions, causing the magnetic layer to peel away from the foam layer and preventing proper attachment to the pan, requiring replacement of the pad. Another problem in Foraker is that because of the thickness of the insulator pad relative to the magnets, the magnets and adhesive may not be strong enough to securely retain the pad to the mud pan. Also, in Foraker, because of the thickness of the insulator pad, it is rather bulky and can be difficult to store when not in use. Further, the insulator pad in Foraker is preferably manufactured from Neoprene rubber and provides poor traction for the user's hand, causing the pad to become slippery or difficult to handle after continued use. In addition, in Foraker, the sides of the insulator pad extend to almost the upper peripheral edge of the mud pan sidewalls, and accordingly the pad can interfere if joint compound spills over onto the sides of the mud pan and the worker must use a taping knife to remove the joint compound. Also, such interference can damage the insulator pad when the worker uses the taping knife to scrape the joint compound back into the mud pan.

[0007] Accordingly, there is a need for an improved magnetic insulator pad that increases the operational life of the mud pan and prevents dropping and the corresponding damage to the mud pan. There is a further need for an improved insulator pad for a mud pan that prevents the magnets from tearing away from the pad and provides a secure yet removable attachment to the mud pan. There is also a need for an improved insulator pad for a mud pan that is thick enough to provide temperature insulation between the joint compound and/or the pan and the worker's hand, but thin enough to provide a secure attachment to the pan that is comfortable to the user. Further, there is a need for an improved insulator pad that is easy to store when not in use. Finally, there is a need for an improved insulator pad that does not interfere with the taping knife or the mud pan when the worker is cleaning the side of the pan while applying the joint compound.

[0008] The above-listed objects are met or exceeded by the present invention that is configured for increasing the operational life of the mud pan by preventing damage to the mud pan caused by inadvertent dropping. The present insulator pad for a container includes at least one magnet that is more securely adhered to the insulator pad than a conventional pad. The present insulator pad is also thinner than a conventional pad and provides a secure attachment to the container while preventing relative temperature transfer between the container and/or the joint compound and the worker's hand. Further, the present insulator pad is easy to store when not in use and is less bulky than a prior insulator pad. Also, the present insulator pad includes a more positive gripping surface that prevents the worker's hand from slipping after continued work. Finally, the present insulator pad is arranged on the container to prevent interference with the taping knife during use.

[0009] More specifically, an insulator pad for a container includes a flexible body having a first surface and a second, opposite surface for contacting the container, the second surface including at least one recessed portion, at least one magnet associated with and disposed in the at least one recessed portion for removably securing the body to the container, and at least one hinge provided on the body, wherein the at least one hinge is configured for allowing the body to bend to conform to a shape of the container.

[0018] Referring now to FIGS. 1-3, an insulator pad for a container is provided and generally designated 10. The insulator pad 10 is constructed and arranged for attachment to a container 12, typically a mud pan, however other containers are contemplated. Included on the pad 10 is a flexible body 14 having a first, outer surface 16 and a second, opposite surface 18 for contacting the container 12. As known in the art, the container 12 includes two opposing sidewall surfaces 20 and two opposing endwall surfaces 21 joined together at a bottom surface 22 to form a generally trapezoidal container having preferably rounded corners 24, however other configurations are contemplated.

[0019] Preferably, the body 14 is manufactured from silicone to provide a durable and resilient body that can also insulate a worker's hand from relative extreme temperatures of the container and/or its contents. Specifically, it is contemplated that the silicone body insulates against both hot and cold temperatures. For example, because joint compound is generally cold in temperature and can cause the container to become cold, the silicone body 14 is configured for providing insulation to the worker's hand from the cold temperature. Also, when the container 12 is stored in the worker's vehicle or left outside on an extremely hot day, the container can become too hot for the worker to comfortably handle. Accordingly, it is contemplated that the silicone body 14 also insulates the worker's hand from extremely hot temperatures. Further still, the silicone body 14 is configured for preventing transfer of the heat from the worker's hand through the container and to the joint compound, causing the compound to prematurely set.

[0020] Preferably still, the body 14 is manufactured from silicone provided by DC Dongjue Silicone Group Co. Ltd. (model no. NE-5140) in Nan Jin, China. It is contemplated that manufacturing the body 14 from silicone will provide a thinner and more temperature resistant insulator pad than the prior art pad, allowing the worker to more comfortably hold the pad 10 for longer periods of time. It is further contemplated that the silicone body 14 provides a more durable pad than the prior art pad, increasing the operational life of the pad and preventing dropping of the pan and the resulting damage. Also, it is contemplated that the silicone body 14 is more flexible than the prior art insulating pad, and that because of its thin profile, can be folded as shown in FIG. 6 and easily transported in the worker's pocket. Further, it is contemplated that the silicone body 14 provides a relatively positive gripping surface, preventing dropping of the pan and increasing user comfort. However, it is recognized that other materials with similar durability and temperature-resistant properties may be suitable, as known in the art.

[0021] The body 14 is preferably integral, disk shaped and generally planar, with an approximate 8-inch (20.32 cm) diameter, as shown in FIGS. 1-3. However, it is appreciated that other shapes and sizes may be suitable, as will be described in further detail below. Regardless of its shape, the body 14 is preferably approximately 0.04-0.12 inches (1-3 mm) thick with a weight of approximately 3-6 ounces (0.09-0.17 kg). More preferably, the body 14 is approximately 0.09 inches (2.4 mm) thick with a weight of 4.9 ounces (0.14 kg), which is less than ⅓ the thickness and about ⅔ the weight of the insulating pad in Foraker. It is contemplated that this construction provides a more flexible, durable and comfortable pad than that disclosed in Foraker.

[0022] As shown in FIG. 2, the first, outer surface 16 includes a first panel 26a, a second panel 26b and a third panel 26c. The first and second panels 26a, 26b are preferably semi-circular in shape and located at opposite ends of the first surface 16. Preferably still, the third panel 26c is generally centrally located on the first surface 16 and is generally rectangular in shape. However, it is contemplated that alternate configurations may be appropriate, depending on the application.

[0023] When the pad 10 is secured to the container 12, the first and second panels 26a, 26b, only cover approximately ⅓ of the corresponding sidewall 20, although other dimensions may be suitable. It is contemplated that because of the shape of the body 14 and the panels 26a, 26b with respect to that of the sidewalls 20, the pad 10 will not extend near the container edge and as such will not interfere with the taping knife if joint compound spills onto the container sidewalls. Thus, the worker is able to more easily scrape the compound back into the pan 12.

[0024] To prevent slippage during continued use of the insulating pad 10 releasably affixed to the container 12, the first, outer surface 16 is preferably textured to provide a more secure gripping surface for the worker's hand. Gripping is further enhanced by the first and second panels 26a, 26b preferably including a plurality of ribs 28. As seen in FIG. 2, the ribs 28 are generally rectangular in shape, although it is recognized that other shapes may be suitable. It is contemplated that providing a textured surface and the ribs 28 also increases user comfort because there is less slippage between the user's hand and the first surface 16.

[0025] Referring to FIGS. 3 and 4, the insulator pad 10 further includes a first magnet 30a, a second magnet 30b and a third magnet 30c associated with and disposed on the body second surface 18 for removably securing the pad to the container 12. Preferably, the magnets 30a-30c are manufactured by DC Dongguan Maghard Flexible Magnet Co., Ltd. (Model Nos. 0602-0001-00 and 0602-0002-00) in Dong Guan, China. Preferably still, the magnets 30a-30c are approximately 0.04-0.12 inches (1-3 mm) thick, and most preferably are approximately 0.06 inches (1.4 mm) thick, although it is appreciated that other thicknesses may be appropriate, depending on the application. It is further preferred that corners of the magnets 30a-30c include radiused corners 31 (FIG. 3), enabling a more secure adhesion to the body second surface 18. The magnets 30a-30c are preferably flexible sheets, enabling bending of the pad 10 and increasing the durability and flexibility of the pad.

[0026] As shown in FIGS. 3 and 4, the body second surface 18 includes recessed portions 32a, 32b, and 32c corresponding to the panels 26a, 26b and 26c. The recessed portions 32a-32c are constructed and arranged for receiving and securely retaining corresponding magnets 30a, 30b and 30c. Further, by providing the recessed portions 32a-32c, it is contemplated that the thickness of the body 14 is significantly reduced, reducing the weight of the pad 10 and increasing its flexibility. It is contemplated that the body 14 is only thick enough to provide a positive gripping surface, to insulate the worker's hand from cold temperatures, and to securely hold the magnet. Accordingly, in the pad 10, use of excess or unnecessary material is avoided.

[0027] Preferably, the first and second magnets 30a, 30b are generally semi-circular in shape and are arranged at opposing outer edges of the body 14. Preferably still, the third magnet 30c is generally rectangular in shape and is generally centrally arranged on the body 14. It is contemplated that the recessed portions 32a-32c are shaped to correspond with the magnets 30a-30c, respectively. However, it is recognized that other configurations of the magnets 30a-30c may be appropriate.

[0028] Preferably and as seen in FIG. 4, the body 14 is no more than twice as thick as the magnets 30a, 30b and 30c. It is contemplated that this construction provides insulation to the worker's hand, structural support to the magnets 30a-30c, and prevents bulkiness or excessive weight of the pad 10.

[0029] To secure the magnets 30a-30c into their respective recessed portions 32a-32c, an adhesive process is preferably used. Specifically, and as depicted in FIG. 4a, a surface active treatment (not shown), such as that manufactured by Yih Chou Engineering Co. Ltd. (model no. SP-616) in Guang Zhou, China, is applied to the recessed portions 32a-32c. The surface active treatment is configured for neutralizing the silicone body's mold release agent. A strip of double-sided tape 34, such as that manufactured by Sekisui (model no. 5760, www.sekisui.com.hk), in Osaka, Japan, shaped to fit within each of the recessed portions 32a-32c, is then placed over the treated recessed portion. Finally, the magnets 30a-30c are placed over their respective strips of tape 34, and pressure is applied. It is contemplated that by applying the surface active treatment to the silicone body 14, the silicone's mold release agent is neutralized, providing a more secure bond between the body and the adhesive, preventing the magnets 30a-30c from tearing away from the recessed portions 32a-32c, and increasing the usage life of the insulating pad 10. However, it is appreciated that other adhesion processes may be suitable, depending on the application. It is also appreciated that the above-described adhesion process may be suitable for other applications not limited to the drywall field, such as the housewares industry for silicone products (i.e., for oven mitts) and the automotive industry (i.e., for magnetic silicone fender covers).

[0030] As shown in FIGS. 2 and 3, the insulator pad 10 further includes a pair of hinges 36a, 36b separating the third magnet 30c from each of the first and second magnets 30a, 30b, respectively. Preferably and as seen in FIG. 4, upon insertion of each of the magnets 30a, 30b, and 30c into the corresponding recessed portion 32a, 32b and 32c, a magnet gripping surface 38 of each of the magnets is oriented coplanar with a hinge gripping surface 40 of each of the hinges 36a, 36b. It is contemplated that this arrangement provides an even gripping surface and a more secure attachment to the container sidewalls 20 and the bottom 22.

[0031] Each of the hinges 36a, 36b is preferably a flexible web including a plurality of cutouts 42 arranged generally in spaced parallel relationship to each other. It is contemplated that by providing the hinges 36a, 36b as a flexible web, the insulator pad 10 can be used on different sizes of mud pans 12 without the need to purchase a new pad. The cutouts 42 are preferably oval in shape and permit flexible adjustment of the body 14 along the hinges 36a, 36b to allow attachment of the pad 10 to differing sizes of containers/mud pans. However, it is recognized that other cutout configurations may be suitable, depending on the application.

[0032] Referring now to FIGS. 3 and 4, each of the hinges 36a, 36b includes two rows of ridges 44a, 44b projecting from the body second surface 18 and arranged generally parallel to each other. Preferably, the first row of ridges 44a is constructed and arranged for gripping the pan bottom 22, and the second row of ridges 44b is constructed and arranged for gripping the pan sidewall 20. The first and second rows of ridges 44a, 44b are preferably arranged generally perpendicular to the cutouts 42, although it is appreciated that other configurations may be appropriate. Preferably still, the first and second rows of ridges 44a, 44b are located within an area defined by axial ends of the cutouts 42.

[0033] Best shown in FIG. 4, the first and second rows of ridges 44a, 44b are preferably arranged at an approximately equal height to ensure consistent gripping of the container sidewalls 20 and bottom 22. The first and second rows of ridges 44a, 44b each preferably have a generally pointed distal end 46 for gripping the container 12, although it is contemplated that other configurations may be suitable, depending on the application. Further, the first row of ridges 44a and the second row of ridges 44b form a trough 48 therebetween. Preferably, the trough 48 is constructed and arranged for bending and accommodating the corresponding container corners 24 (See FIG. 1A).

[0034] An alternate embodiment of the insulator pad is illustrated in FIG. 5 and is generally designated 50. Shared components of the pad 10 and the pad 50 are designated with identical reference numbers. The pad 50 includes a body 52 having a first, outer surface 54 and a second surface 56 configured for contacting the container 12. The body 52 is preferably oval in shape with rounded ends 58 and straight edges 60 connecting the ends. Similar to the pad 10, the outer surface 54 of the pad 50 includes a first panel 62a, a second panel 62b and a third panel 62c, where the first and second panels are arranged at opposite ends of the pad and the third panel is generally centrally located on the pad. The first and second panels 62a, 62b include the ribs 28, providing a positive gripping surface for the worker's hand.

[0035] The pad 50 further includes the hinges 36a, 36b, each of which are arranged to separate the third panel 62c from the first and second panels 62a, 62b. The construction of the second surface 56 is the same as that of the second surface 18, except that the magnets and corresponding recessed portions (not shown) are shaped to conform with the shape of the panels 62a-62c. It is contemplated that when secured to the container 12, the pad 50 does not extend as high up the sidewalls 20 as the pad 10, further preventing the pad from interfering if joint compound spills onto the sidewalls and the worker must use a taping knife to remove the compound.

[0036] To use the insulator pad 10 with the container 12, the worker aligns a longitudinal axis “L” of the third magnet 30c with a longitudinal axis “R” of the container bottom 22 (FIG. 1). The worker then secures the insulator pad 10 to the container 12 by pressing the third magnet 30c to the container bottom, and bending the pad 10 at hinges 36a, 36b, such that the first and second magnets 30a, 30b are secured to corresponding container sidewalls 20. After use, the pad 10 can be easily removed. It is contemplated that when the pad 10 is not in use on the container 12, it can be easily stored by folding the pad at hinges 36a, 36b such that the first and second magnets 30a, 30b overlap each other and are arranged on top of the third magnet 30c (FIG. 6). In this configuration, the magnets 30a-30c are magnetically attached to each other and the pad 10 is flat enough to fit within the worker's pocket. This is a contemplated advantage over current insulator pads, which can be bulky and difficult to store when not in use.

[0037] While a particular embodiment of a magnetic insulator pad for a container has been shown and described, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.