GB2338503A

GB2338503A - Filling and grouting device

Info

Publication number: GB2338503A
Application number: GB9914125A
Authority: GB
Inventors: Nigel Anthony Chute
Original assignee: Individual
Current assignee: Individual
Priority date: 1998-06-20
Filing date: 1999-06-18
Publication date: 1999-12-22
Anticipated expiration: 2019-06-18
Also published as: GB2338503B; GB9914125D0; GB9813394D0; GB2338502A

Abstract

A filling and grouting device for use in home improvements and interior decoration projects. Said device consists substantially of a rigid handle (205) bonded to a flexible work head (207), wherein said handle provides means for applying a compressive load on any filling or grouting (401) materials via a work head, and is simultaneously dragged along the surface of said filling materials. Said compressive load is spread across the surface of the said flexible work head and causes the filling materials to be smooothly and evenly rendered.

Description

CHU-POS-GI3 2338503 1 Manually Operable Tool The present invention relates

to a manually operable toot configured to work a mass of filter material into a gap between two pieces.

A hand held applicator tool adapted to work a mass of filler material into a gap to form a seal between two pieces is described in United States patent number 5 675 860. The tool includes a handle having attached thereto a tapered head defined by tapered lateral side edges thereof which co operate to define a tip as well as a working surface. The tool may have further working tips each having a different radius of curvature so as to seal a gap having at least two different bead.widths.

The hand held applicator described in this prior patent publication is fabricated from a relatively hard material and is directed at producing beadings having particular widths. It is primarily directed at experienced fillers and grouters who would know approximately how much filling material to apply such that there is relatively little excess material when a bead of the appropriate dimensions is required. The device does not facilitate general purpose filling and grouting operations which, particularly when being performed by amateurs and do it yourself enthusiasts, often results in fingertips being used in order to ensure the grouting or filler is placed in the most appropriate location.

It can be seen that the relatively hard plastic material results in physical properties which are different from those provided by a soft fingertip. The device itself has no give, therefore all of the movement must be provided by means of the filling material itself moving which in turn may result in undesirable artefacts being introduced.

A tool for spreading soft malleable material is described in United CHU-PO5-GI3 M 1 1 2 States patent number 4 211 501. A spreading tool is shown having a relatively hard core and an elastomeric covering at the end of said core. The elastomeric coverings are sufficiently soft to make an effective seal with angular surfaces at the corner where the material is being spread.

Thermosetting elastomers are identified as being preferable, having a durometer hardness in a range from 20 to 70 Shore A. Specific examples are given as silicone rubber, chloreprene, nitrile and polyisoprene. It is stated that the eleastomeric covering should be sufficiently thick to be soft for sealing purposes and a thickness of one eighth of an inch (3 millimetres) is identified as being preferable. Furthermore, it is stated that the radius of the working edge at the tip may be about one quarter of an inch (6 millimetres).

The device shown in this prior patent publication is directed at a substantially similar application to that shown in the previously described patent publication and again shows examples of grouting being applied along a right angled edge. The device would not have general purpose application and again experiments would suggest that the amateur or DIY enthusiast would be forced to make use of his or her fingertip in certain situations. The device shown in the '501 patent is relatively flat and therefore only presents a curvilinear surface in one dimension. The elastomeric material is primarily provided to give a degree of sealing and thereby presents a beading cavity, of the type provided in a hard material in the '806 patent by means of deformation.

Shore A is a method of assessing hardness for relatively soft materials in which the depth of penetration of an indentor is measured under specified conditions. Experiments have shown that when emulating a fingertip, a hardness in the range of 10 to 15 Shore A is preferable therefore 'the hardness specified in the 501 patent would tend to be harder than a fingertip CHU-PM-GB n- ' r- 3 and as such would not provide the preferred interaction. When confronted with this problem, a designer may be tempted to replace the material of the '501 patent with a softer material thereby giving the preferred characteristics.

A known problem with soft materials is that they tend not to provide a smooth gliding interaction. Typically, soft materials, such a rubber, result in the soft filler material being dragged away from its required location. Thus, if the material being used is too soft, it will provide the required level of deformation but as the material is being located at one region the filler material will tend to be dragged away from its preferred location at another region. Clearly, such a fabrication would be unsuitable for the intended application.

According to a first aspect of the present invention, there is provided a manually operable tool configured to work a mass of filler material into a gap between two pieces, comprising a rigid handle, a flexibly deformable work head attached to said handle, wherein said work head is constructed as a two component composite, in which said first component facilitates flexing of the head under pressure, said second component presents a smooth interaction with said filler, and said work head provides a substantially continuous curvilinear work surface. ' In a preferred embodiment a flexibly rigid spline extends from said handle and said flexibly deformable work head is attached to the handle by means of said spUne. Preferably said flexibly deformable work head is convex in shape and has a profile substantially similar to a human fingertip. Furthermore said second component takes the form of a slip agent configured to be released from the surface of said deformable work head.

According to a second aspect of the present invention, there is provided a manually operable tool configured to work a mass of filler material CHU-POS-GI3 1 1 k 4 into a gap between two pieces, comprising a rigid handle, a flexibly deformable work head attached to said handle, wherein said work head provides a substantially continuous curvilinear work surface and said tool is constructed as a three component composite, in which said first component facilitates flexing of said head under pressure, said second component facilitates a smooth interaction between said head and said filler, and said third component facilitates a manual application of pressure to said head.

According to a third aspect of the present invention, there is provided a manually operable tool, comprising a rigid handle and a flexibly deformable work head attached to said handle, wherein said work head provides a substantially continuous curvilinear work surface and a line exists between any two defined points on said work surface, such that said line (a) is the shortest line on said surface between said two defined points, and (b) is curved at every point on said line.

According to a fourth aspect of the present invention, there is provided a method of manufacturing a manually operable tool comprising a rigid handle and a flexibly deformable work head attached to said handle, in which said work head provides a substantially continuous curvilinear work surface, wherein said handle and said work head are injection moulded together by a process of two-shot moulding.

According to a fifth aspect of the present invention, there is provided method of manufacturing a manually operable tool configured to work a mass of filler material into a gap between two pieces, comprising the steps of forming a rigid handle, forming a flexibly deformable work head as a two component composite, with a substantially continuous curvilinear work surface, and attaching said work head to said handle, wherein said first component is configured to facilitate flexing of said head under pressure, and CHU-POS-GI3 said second component is configured to present a smooth interaction with said filler.

The invention will now be described by way of example only, with reference to the accompanying drawings, in which:

Figure 1 shows a two shot injection moulding machine having one injection moulding unit to produce a handle and another injection moulding unit to produce a work head, Figure 2A shows a moulding tool configured to produce a handle and a work head on the machine shown in Figure 1 and Figure 2B shows the moulding tool of Figure 2A in an alternative configuration; Figure 3 shows a handle and work head injection moulded in the moulding tool shown in Figure 2; Figure 4 shows the handle and work head shown in Figure 3 being used as a filling and grouting device; Figure 5A shows a close up -of the work head shown in Figure 4, Figure 58 shows an enlarged view of the work head shown in Figure 4, and Figure 5C shows a close up of the work head shown in Figure 4 in an alternative view; Figure 6 shows a close up of the work head in a further use of the filling and grouting device shown in Figure 4; Figure 7 shows a close up of the work head in a further use of the filling and grouting device shown in Figure 4; Figure 8 shows a second embodiment of a filling a grouting device; Figure 9 shows a third embodiment of a filling a grouting device; Figure 10 shows a fourth embodiment of a filling and grouting device; Figure 11 provides a cross-sectional view of the device shown in Figure 3; CHU-POS-GB I- 1-, U 6 Figure 12 provides a cross-sectional view of a device of the type shown in Figure 8; Figure 13 provides a cross-sectional view of the device shown in Figure 10; Figure 14 summarises diagrammatically the three part composite structure, defined by each of the embodiments shown in Figures 11, 12 and 13; and Figure 15 provides an enlarged view of the front, side and bottom elevations of work head of the tool in Figure 3.

An injection moulding machine 101 is shown in Figure 1, configured to operate a two-component injection moulding system, otherwise known as two-shot injection moulding. The machine 101 is provided with an injection unit 102 which works horizontally through the fixed mounting platen 103.

The machine 101 is further provided with another injection unit.104 which is located vertically above the mould area 105 in alignment with the position of a parting line on the mould. Injection unit 102 is loaded with granules of a thermoplastic eiastomer material to produce the work head of a grouting and filling device, and injection unit 104 is loaded with granules of polypropylene to produce the handle of a filling and grouting device.

Figure 2(i) shows an injection moulding tool 201 configured to operate in the machine 101 shown in Figure 1. Injection moulding tool 201 is provided with at least two cavities 202 and 203 configured to produce a filling and grouting device. Preferably, cavity 202 is duplicated four times in moulding tool 201, and cavity 203 is likewise duplicated four times on said moulding tool. Tool 201 is mounted on a rotary platen 204. By injection with the vertical injection unit 104 shown in Figure 1, pre-moulded handles 205 are produced. At the same time the horizontal injection moulding unit 102 CHU-PM-GB 7 shown in Figure 1 injects the pre-moulded handles 206 of the previous operation cycle with the second component, the work head 207. When the mould 201 opens, the sprues 208 and 209 of both injection moulded parts are ejected along with the completed part 206. The pre-moulded handles 205 remain on the mould core.

In Figure 2(ii) the rotary platen 204 is swivelled by 180 degrees, thus causing the moulding tool 201 to rotate by the same extent. The premoulded handles 205 are now in a finishing position; in the second set of cavities 202 the first parts, the handles, can be injected again. After a new ejection, the mould 201 turns, is re-closed and the new operation cycle commences. One operation cycle takes approximately thirty seconds to complete.

Figure 3 shows the handle 205 moulded in combination with the work head 207, as shown in Figure 2(i) and 2(ii), to produce the finished filling and grouting device 206. The plan view shows a handle 205 moulded in polypropylene having a shape substantially similar to a paint brush handle. Such a shape, known as a beavertail, is known to have suitable properties of handling and ergonomics for a device used in decorating applications. Furthermore, it is envisaged that such a shape will render the device sufficiently similar in appearance to said paintbrushes as to greatly assist its visual integration into existing ranges of decorating products. The handle 205 is provided with a hole 301 for purposes of hanging for storage. The polypropylene contains a blowing agent, whose function is to enable the moulding of the substantially thick sections of material necessary to confer the desired handling properties. The blowing agent is derived from talc and contributes to an overall stiffening of the handle 205.

Towards the end of the handle where the work head 207 is located is CHU-PO5-GB 1 8 provided a spline 302 which extends two-thirds of the way into said work head. The spline can also be seen on the view in section. A purpose ofthe spline is to provide means for transmitting the compression exerted by a hand grip through handle 205 into the flexible work head 207, so that the work head is squashed down and around a gap to be filled and the surfaces immediately adjacent to said gap. A further purpose of the spline 302 is to provide an increased area of contact between the surfaces of the polypropylene in the handle 205 and the thermoplastic elastomer in the work head 207, in order to optimise the bonding between the two elements.

The choice of a thermoplastic elastomer for the work head is explained by a combination of properties in this material suitable for the present application. Thermoplastic elastomers have the appearance and ability to be deformed, in a similar manner to rubbers, together with the processing characteristics of thermoplastics. Preferably, the thermoplastic elastom used to manufacture the work head 207 is proprietary product Evoprene G 936' supplied by Laporte Alpha-Gary Limited. This material is 1;i le highly fle;i le, having a hardness of only ten Shore A. It will therefore compress extremely readily and spread evenly over a gap to be filled without the need for excessive force being appliedetWthe handl e 205.

'Evoprene G 936' is based on Shell Chemicals 'Krati' SEBS' (styrene ethylene-butylene-styrene) block copolymer. This material is olefin-based, like polypropylene, which results in a strong bond at the polymer level between the tw o materials when moulded in combination (as Figures 1 and 2). The work head 207 will therefore resist any shear or peel forces at the bonding faces with the handle 205 and the spline 302. Such forces might otherwise cause the two elements to separate under working loads, thus allowing dirt and moisture into the resulting gaps and compromising the CHU-POS-GE3 1 9 overall functionality of the device.

The shape of the work head 207 is substantially similar to that of a human fingertip. Such a shape is defined by a plurality of curves which create a substantially convex, smooth and irregular surface 303. This shape has been found to work effectively in the wide variety of applications where the filling and grouting device is used.

Figure 4 shows a filling and grouting device being used for a home improvement task. In this application, the operator has introduced a run of filling material 401 between a bath and an adjacent wall, upon which is a plurality of tiles 403. The operator grips the handle 205 of a filling and grouting device and applies downward pressure on the filler 401 in the direction of arrow 404, whilst at the same time pulling the device in the direction of arrow 405.

Figure 5(i) illustrates a close-up sectional view of the work head 207 of the filling and grouting device shown in Figure 4. An effect of the application of work head 207 simultaneously in the direction of arrows 404 and 405 is the compression and smoothing down of filler 401 to produce the desired finish 501.

It is known that materials including the filler 401 are substantially particles based in a solution of water. Such materials produce an abrasive action upon a work head 207 of a filling and grouting device, which can lead to wear of said work head. In order to reduce this effect, a quantity of an ingredient known as a slip agent is added to the thermoplastic ela stomer used to make the work head.

Slip agents are usually added to thermoplastic materials to assist with de-moulding problems in the injection moulding cycle of the kind illustrated in Figures 1 and 2, wherein the slip agent can cause a moulding CHU-PO5-GB 1 1 1 to be more easily removed from the moulding tool. In the present application, a slip agent is added to the material used to mould the work head 207 to render its surface 303 slippery. This property enables the work head to be drawn over filler and adjacent surfaces more easily and causing less wear on said work head. Preferably, said thermoplastic elastomer is kT m_ Evopren- tn- 936' and said slip agent is one percent crodamide. Said slip agent is a wax-based material and its most familiar application is to be found in lipsticks and cosmetics. The advantage in the present application is that the wax repels water. Because said filling materials are substantially water-based, the respective surfaces of said filler 503 and the work head 303 tend to repel each other. An effect of this is to reduce wear on the working surface 303 of work head 207. A further effect is that finished filler surface 501 is substantially smooth and even.

In a preferred embodiment, the working surface 303 of work head 207 is provided with a fine texture, as shown in Figure 5(ii). In this view a magnified section of working surface 303 is shown, wherein an arrangement of peaks 504 and troughs 505 in said texture can be seen.

When the filling and grouting device is dragged across the filler 401, particles of said filler mixed with water are collected in said troughs 505.

This creates a further barrier between the work head 207 and the filler 401 which functions as a bearing between the two respective surfaces.' An effect of this is that wear on the' work head 207 is further reduced.

Preferably, said texture is fine and is expressed as 27-33 VD1.

Figure 5(iii) illustrates the work head 207 shown in Figure 5(i) from a different angle. The operation shown in Figure 5(i) comprises the application and smoothing of filler in a position between a bath edge 402 and the adjacent wall 403, which is also illustrated in Figure 4. The profile of CHU-PO5-GB -I- 1_--- 11 the join is substantially right angular and having a blend radius at its inner corner. Upon application of the filling and grouting device, the surface 303 of the work head 207 assumes a substantially dght angular profile, due to the flexibility of said work head. The surface of the filler 503 is thus also provided with said substantially right-angular profile. Such a result is made possible because the work tip is flexible not only in one plane, but in any number of planes, and all at the same time.

Figure 6 shows the filling and grouting device being used to finish a gap in which the adjacent surfaces 601 are aligned with one another. Upon application of the filling and grouting device, the surface 303 of the work head 207 assumes a substantially level profile, due to the flexibility of said work head. The surface of the filler 602 is thus also provided with said substantially level profile.

Figure 7 shows the filling and grouting device being used to finish a gap in which the adjacent surfaces 701 are irregular and unevenly disposed. Upon application of the filling and grouting device, the surface 303 of the work head 207 assumes a substantially irregular profile, due to the flexibility of said work head. The surface of the filler 702 is thus also provided with said substantially irregular profile.

Figure 8 shows a second embodiment of the present invention. The second embodiment of the filling and grouting device has a handle 801 'and a work head 802. The handle is provided with a spline 803 whose position when viewed in sectional side elevation is in the centre of the work head 802. The spline 803 is further provided with a hole 804 which confers additional mechanical locking properties on a bond between said handle 801 and said work head 802, wherein said work head is manufactured from either a thermoplastic elastomer or a self-skinning flexible polyurethane CHU-POS-GB 1 12 foam.

Figure 9 shows a third embodiment of the present invention. The third embodiment of the filling and grouting device has a handle 901 and a work head 902. Bonding means are provided by a metal ferrule 903, wherein said ferrule is wrapped and pinned around the joint between the handle and the work head. Said work head is manufactured from either a thermoplastic elastomer, a self-skinning flexible polyurethane foam, a natural rubber or a silicone rubber. Said ferrule is substantially similar to the means used for bonding paintbrush bristles to their handles. Said handle is manufactured from polypropylene, polyethylene or similar plastics material, or from wood.

Figure 10 shows a fourth embodiment of the present invention. The fourth embodiment of the filling and grouting device has a handle 1001 and a work head 1002. The handle is provided with a spline 1003 whose position when viewed in sectional side elevation is near the centre of the work head 1002. The work head 1002 is manufactured from a silicone rubber and is provided with a cavity 1004 inside. The work head is fixed to the handle 1001 by pushing onto the spline 1003. Said spline is provided with a locking rim 1005 which engages with a groove 1006 on the inner surface of the work head. The cavity 1004 is substantially larger than the spline 1003 which fits inside it. After assembly therefore, a void 1007 is created. Said void 1007 is defined as a deflection chamber; when the filling and grouting tool is used as shown in Figures 4 to 7 the work head partially collapses under compression into said deflection chamber. This enables the surface of the work head 1008 to assume the profile of the surfaces adjacent to the filler so as to produce a smooth and even finish on said filler.

CHU-PO5-GB 1 13 The work head 1002 may be pulled off the spline 1003 and replaced when required, for example when said work head is worn out. Because in this embodiment the handle and work head are manufactured separately, the handle may be readily recycled, wherein said handle is manufactured from polypropylene, polyethylene or other suitable material.

An enlarged view of the work head of the device shown in Figure 3, is provided in Figure 11. The rigid handle 205 and the spline 302, are moulded as a single component frorp Polypropylene. The work head 207, is WPM moulded substantially from Evoprene G 936 in combination with the handle and therefore a strong bond exists at the interflce 1101. As previously described with reference to Figure 4, the Evopreri'MY'- 936, contains the slip agent crodamide at the one percent level. The crodamide, shown diagrammatically as dots, is blended into the Evoprene so that it is present throughout the bulk of the work head. Therefore, as the work head becomes worn with use, a supply of crodamide remains present at the surface 303.

A three part composite structure, therefore, exists within the filling and grouting device shown in Figure 11. The handle and spline comprises the first component of the three and its rigid structure enables a compressive force to be applied to the work head. The thermoplastic work head comprises the second component and its soft, flexible structure allows it to deform to the desired shape when in use. The third component is the crodamide which allows the work head to slide freely over the filling or grouting material and the adjacent surfaces.

An enlarged view of a work head of a device of the type shown in Figure 8, is provided in Figure 12. The work head 1201 is attached to a rigid handle 1202 and rigid spline 1203 which are moulded as a single unit from CHU-PO5-GB 1 14 polypropylene. The work head is moulded from polyurethane foam, such that it surrounds the spline 1203 and extends through a hole 1204 in said spline. The hole thus provides a key-way to mechanically lock the work head onto the spline. This is important since the polyurethane foam does not tend to form a bond with the polypropylene handle and spline.

The work head is moulded using a water blown polyester based polyurethane system. Water is chosen in preference to other blowing agents for environmental reasons. In manufacture the handle and spline are fitted into a mould which is filled with the polyurethane foam system. After the mould is closed the polyurethane foam system undergoes a reaction which produces an aerated structure and cures the polyurethane. The structure subsequently produced is a very soft aerated core 1205 and a hard skin 1206 formed where the system touches the walls of the mould. The skin 1206 is smooth, since it has a profile defined by the mould, and in addition it is hard, having a Shore A hardness of sixty to seventy.

A three part composite structure, therefore, exists within the device described with reference to Figure 12. The first component is again the rigid handle and spline which enables a compressive force to be applied to the work head. The second component is the soft aerated core of the work head, having a structure which allows the work head to deform to the desired shape when in use. The third component is the hard skin of the work head which provides a smooth slippery surface, allowing the work head to slide freely over the filling or grouting material and the adjacent surfaces when in use.

An enlarged view of the work head of the device shown in Figure 10, is provided in Figure 13. The rigid handle 1001 and the spline 1003, are moulded as a single component and are configured to accept a snap on CHU-POS-GB silicone rubber work head 1002. The grade of silicone rubber used for moulding the work head is Harboro reference KP 109. This provides a more slippery surface than that of natural rubber.

The specified silicone rubber has a Shore A hardness of forty-seven to fifty-seven and so is harder than other materials herein described for use as work heads. However, as previously described with reference to Figure 10, the work head 1002, contains a deflection chamber 1007, which allows a deformable portion 1301 of the work head to deflect and deform as is required in use.

It should be understood that other silicone rubbers may be used to that specified and that liquid silicone based, addition cure rubbers generally provide the surface properties and low degree of hardness which is desired.

Indeed, with the advancement of silicone rubber technology, new silicone rubbers having lower hardness and a lower surface friction may be developed. A preferable alternative to Harboro KIP 109 may therefore become available.

Once again, a three part composite structure, exists within the device described with reference to Figure 13. The first component is the rigid handle and spline, which enables a compressive force to be applied to the work head. The second component is the deflection chamber within the work head which allows the surface of the work head to flex and assume the required profile. The third component is the silicone rubber work head itself. This provides a smooth, relatively hard and slippery surface, and so allows the work head to slide easily over the filling material and adjacent surfaces during use.

The three part composite structure, defined by each of the embodiments shown in Figures 11, 12 and 13, is summarised CHU-POS-GB q 16 diagrammatically in Figure 14. Firstly, in each case, the device contains a rigid handle and spline. Secondly, each device contains a component within the work head which facilitates flexing of the head. This was represented in Figure 11 by the soft thermoplastic work head; in Figure 12 by the soft aerated core and in Figure 13 by the deflection chamber. Finally each device contains a component within the work head which provides a smooth interface with the filler. This was represented in Figure 11 by the crodamide; in Figure 12 by the hard skin and in Figure 13 by the relatively hard silicone work head. The front, side and bottom elevations of the tool in Figure 3, have been

enlarged to provide a detailed view of the work head in Figure 15. The radii of curvature at points 1501 to 1506 on the work surface are critically dependent upon the point's location. In between such points the surface is configured to be completely smooth with one radius blending into the next Therefore, if a line is drawn anywhere on the work surface, such that it is the shortest line between two points, the line will be continuous and curved at every point. For the purposes of this specification, the word curved' means, 'has a non-zero, finite radius of curvature'.

The smooth curved lines of the work surface are an essential feature to the operation of the tool. The work surface is configured to provide a smaller radius of curvature, namely 6.5 millimetres, (as viewed in a bottom elevation 1607) neighbouring a point 1501 and to provide a much larger radius of curvature, namely 11 millimetres, (as viewed in a front elevation 1508) neighbouring a point 1502. Furthermore, in between the points 1501 and 1502, intermediate values of radius of curvature exist. Therefore, by adjustment of the angle of the handle to the surface of the filler, a smoothly varying radius of curvature may be presented to the filler.

CHU-PO5-GB 17 In addition, at points such as the point 1503, the radius of curvature (as viewed in the front elevation 1508) is 5 millimetres and the radius of curvature about the point 1501 (as viewed in a side elevation 1509) is 3.5 millimetres. Intermediate radii of curvature exist between points such as 1501 and 1503. Therefore by rotating the tool about an axis 1510, smaller radii of curvature may be presented to the filler. Moreover, the radius of curvature presented to the filler may be simultaneously adjusted by rotating the tool and varying the angle between the handle and the filler.

r I,- - CHU-PO5-GB k 18

Claims

1. A manually operable tool configured to work a mass of filler material into a gap between two pieces, comprising a rigid handle, a flexibly deformable work head attached to said handle, wherein said work head is constructed as a two component composite, in which said first component facilitates flexing of said head under pressure, said second component presents a smooth interaction with said filler, and said work head provides a substantially continuous curvilinear work surface.

2. A tool according to claim 1, wherein a flexibly rigid spline extends from said handle and said flexibly deformable work head is attached to said handle by means of said spline.

3. A tool according to claim 1 or claim 2, wherein said flexibly deformabie work head is convex in shape and has a profile substantially similar to a human fingertip.

4. A manually operable tool according to any of claims 1 to 3, wherein said first component and said second component are configured together in a single moulding operation.

5. A manually operable tool according to any of claims 1 to 4, wherein said curvilinear work surface has a fine textured finish.

CHU-POS-GI3 19

6. A manually operable tool according to any of claims 1 to 5, wherein said work head is configured to be detachable from said handle.

7. A manually operable tool according to any of claims 1 to 6, wherein said second component takes the form of a slip agent configured to be released from said work surface.

8. A manually operable tool according to any of claims 1 to 7, wherein said first component is substantially formed from thermoplastic elastomer material.

f

9. A manually operable tool according to claim 8, wherein said thermoplastic elastomer is Evoprene G 936.

10. A manually operable tool according to any of claims 1 to 6, wherein said second component takes the form of a smooth hard outer layer.

11. A manually operable tool according to any of claims 1 to 6 or claim 10, wherein said first component takes the form of a foam material.

12. A manually operable tool according to any of claims 1 to 6, wherein said second component is flexibly deformable and hollow.

13. A manually operable tool according to any of claims 1 to 6 or to claim 12, wherein said first component is an air-filled void.

14. A manually operable tool configured to work a mass of filler CHU-POS-GI3 r_.

material into a gap between two pieces, comprising a rigid handle, a flexibly deformable work head attached to said handle, wherein said work head provides a substantially continuous curvilinear work surface and said tool is constructed as a three component composite, in which said first component facilitates flexing of said head under pressure, said second component facilitates a smooth interaction between said head and said filler, and said third component facilitates a manual application of pressure to said head.

15. A tool according to claim 14, wherein a flexibly rigid spline extends from said handle and said flexibly deformable work head is attached to said handle by means of said spline.

16. A tool according to claim 14 or claim 15, wherein said flexibly deformable work head is convex in shape and has a profile substantially similar to a human fingertip.

17. A manually operable tool according to any of claims 14 to 16, wherein said first component and said second component are configured together in a single moulding operation.

18. A manually operable tool according to any of claims 14 to 17, wherein said curvilinear work surface has a fine textured finish.

19. A manually operable tool according to any of claims 14 to 18, wherein said work head is configured to be detachable from said handle.

CI-JU-POS-GB 21

20. A manually operable tool according to any of claims 14 to 19, wherein said second component takes the form of a slip agent configured to be released from said work surface.

21. A manually operable tool according to any of claims 14 to 20, wherein said first component is substantially formed from thermoplastic elastomer material.

22. A manually operable tool according to claim 21, wherein said thermoplastic elastomer is Evoprene G 936.

23. A manually operable tool according to any of claims 14 to 19, wherein said second component takes the form of a smooth hard outer layer.

24. A manually operable tool according to any of claims 14 to 19 or claim 23, wherein said first component takes the form of a foam material.

25. A manually operable tool according to any of claims 14 to 19, wherein said second component is hollow.

26. A manually operable tool according to any of claims 14 to 19 or claim 25, wherein said first component is an air-filled void.

27. A manually operable tool configured to work a mass of filler material, comprising a rigid handle and a flexibly deformable work head attached to said handle, wherein sa"id work head provides a substantially CHU-POS-GB 22 continuous curvilinear work surface and a line exists between any two defined points on said work surface, such that said line (a) is the shortest line on said surface between said two defined points, and (b) is curved at every point on said line.

28. A manually operable tool according to claim 27, wherein a flexibly rigid spline extends from said handle and said flexibly deformable work head is attached to said handle by means of said spline.

29. A tool according to claim 27 or claim 28, wherein said flexibly deformable work head is convex in shape and has a profile substantially similar to a human fingertip.

30. A tool according to any of claims 27 to 29, wherein said work surface includes a plurality of radii of curvature and the radii of curvature presented to said filler is manually adjustable.

31. A tool according to any & claims 27 to 30, wherein said flexibly deformable work head is a thermoplastic elastomer material.

32. A tool according to any of claims 27 to 31, wherein said thermoplastic elastomer material is Evoprene G 936.

33. A tool according to any of claims 27 to 30, wherein said flexibly deformable work head is a silicon rubber material.

CHU-POS-GI3

34. A method of manufacturing a manually operable tool comprising a rigid handle and a flexibly deformable work head attached to said handle, in which said work head provides a substantially continuous curvilinear work surface, wherein said handle and said work head are injection moulded together by a process of two-shot moulding.

35. A method of manufacturing a manually operable tool according to claim 34, wherein a flexibly rigid spline is formed as an extension to said handle and said flexibly deformable work head is attached to said handle by means of said spline.

36. A method of manufacturing a tool according to claim 34 or claim 35, wherein said flexibly deformable work head is configured to be convex in shape and have a profile substantially similar to a human fingertip.

37. A method of manufacturing a tool according to any of claims 34 to 36, wherein said flexibly deformable work head is made from a thermoplastic elastomer material.

38. A method of manufacturing a tool according to claim 37, wherein said thermoplastic elastomer material is Evaprene G 936.

39. A method of manufacturing a tool according to any of claims 34 to 38, wherein said tool is configured for the purpose of filling or grouting.

40. A method of manufacturing a manually operable tool configured to work a mass of filler material into a gap between two pieces, comprising CHU-PM-GB 1 I 1 I 24 the steps of forming a rigid handle, forming a flexibly deformable work head as a two component composhe, with a substantially continuous curvilinear work surface, and attaching said work head to said handle, wherein said first component is configured to facilitate flexing of said head under pressure, and said second component is configured to present a smooth interaction with said filler.

41. A method of manufacturing a manually operable tool according to claim 40, wherein a flexibly rigid spline is attached to said handle and said work head is attached to said handle by means of said spline.

42. A method of manufacturing a manually operable tool according to claim 40 or claim 41, wherein said work head is configured to be convex with a profile substantially similar to a human fingertip.

43. A method of manufacturing a manually operable tool according to any of claims 40 to 42, wherein said first component and said second component are formed together in a single moulding operation.

44. A method of manufacturing a manually operable toot according to any of claims 40 to 43, wherein said curvilinear work surface is configured with a fine textured finish.

45. A method of manufacturing a manually operable tool according to any of claims 40 to 44, wherein said second component is a slip agent and CHU-PO5-GB said work head is configured to release said slip agent dudng use.

46. A method of manufacturiing a manually operable tool according to any of claims 40 to 45, wherein said first component is substantially formed from a thermoplastic elastomer material.

47. A method of manufactufing a manually operable tool according to claim 46, wherein said thermoplastic elastomer material is Evoprene G 936.

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48. A method of manufactudrig a manually operable tool according to any of claims 40 to 44, wherein said second component is formed as a smooth hard outer layer.

49. A method of manufacturing a manually operable tool according to any of claims 40 to 44 or claim 48, wherein said first component is formed as a foam-like material.

50. A method of manufacturing a manually operable tool according to any of claims 40 to 44, wherein said second component is configured to be hollow.

51. A manually operable tool substantially as herein described with reference to any of the accompanying figures.

52. A method of manufacturing a manually operable tool substantially as herein described with reference to any of the accompanying CHU-PO5-GB 1' 26 figures.