Method for forming variable paint applicators

Abstract

A method for forming a plurality of distinct paint applicators having a common exterior head configuration and distinct paint applying medium configurations includes forming a plurality of handles and forming a plurality of paint carrying units. Each handle formed includes a head having an exterior configuration and an interior having a mouth and head thickness between the exterior configuration and the mouth. Each paint carrying unit includes at least one paint applying medium coupled to a mounting portion that is disposed within an interior of one of the plurality of handles. The mounting portion has a mounting portion exterior configuration and a mounting portion thickness between the mounting portion exterior configuration and the paint applying medium. To form the plurality of distinct paint applicators, the configuration of the paint applying medium is varied while at least one of the head thickness and the mounting portion thickness is also varied.

What is claimed is:  
     
         1 . A plurality of paint applicators comprising: 
 a first applicator including: 
 a first handle having an exterior configuration; and  
 a first paint applying medium coupled to the first handle, the first paint applying medium having a first medium configuration with a first width and a first thickness; and  
   a second applicator including: 
 a second handle having the same exterior configuration; and  
 a second paint applying medium coupled to the second handle, the second paint applying medium having a second medium configuration having a second width and a second thickness different than the first width and the first thickness, respectively.  
   
     
     
         2 . The paint applicators of  claim 1 , wherein the first handle has a first interior cavity having a first interior configuration receiving the first paint applying medium, and wherein the second handle has a second internal cavity having a second internal configuration different from the first internal configuration and receiving the second paint applying medium.  
     
     
         3 . The applicators of  claim 2 , wherein the second internal configuration includes at least one projection.  
     
     
         4 . The applicators of  claim 3 , wherein the second internal configuration includes a plurality of projections arranged so as to reduce an effective internal dimension of the second internal cavity.  
     
     
         5 . The applicators of  claim 2 , wherein the first handle has a first head thickness extending between the exterior configuration of the first handle and the first interior cavity and wherein the second handle has a second thickness extending between the exterior configuration of the second handle and the second internal cavity, wherein the second thickness is different than the first thickness.  
     
     
         6 . The applicators of  claim 1 , wherein the first paint applying medium is coupled to a first mounting portion having a first configuration and wherein the second paint applying medium is coupled to a second mounting portion having a second configuration different than the first configuration.  
     
     
         7 . The applicators of  claim 6 , wherein the first handle and the second handle include internal cavities having same internal cavity configurations and wherein the internal cavities of the first and second handles receive the first and second mounting portions, respectively.  
     
     
         8 . The applicators of  claim 6 , wherein the first mounting portion and the second mounting portion include similarly configured openings that receive portions of the first and second handles, respectively.  
     
     
         9 . The paint applicators of  claim 6 , wherein the first mounting portion and the second mounting portion comprise ferrules.  
     
     
         10 . A plurality of paint applicators comprising: 
 a first applicator including: 
 a first handle having an exterior configuration and a first interior cavity having a first interior configuration; and  
 a first paint applying medium coupled to the first handle, the first paint applying medium having a first medium configuration; and  
   a second applicator including: 
 a second handle having the same exterior configuration and a second interior cavity having a second interior configuration different than the first interior configuration; and  
 a second paint applying medium coupled to the second handle, the second paint applying medium having a second medium configuration different than the first medium configuration.  
   
     
     
         11 . The paint applicators of  claim 10 , wherein the second interior configuration includes at least one projection extending into the second internal cavity so as to reduce an effective size of the second internal cavity.  
     
     
         12 . The applicators of  claim 10 , wherein the first handle has a first head thickness between the exterior configuration and the first interior cavity and wherein the second handle has a second thickness extending between the exterior configuration and the second internal cavity, wherein the second thickness is different than the first thickness.  
     
     
         13 . A plurality of paint applicators comprising: 
 a first applicator including: 
 a first handle having an exterior configuration; and  
 a first paint applying medium having a first configuration and being coupled to a first mounting portion, the first mounting portion having a first sized dimension; and  
   a second applicator including: 
 a second handle having the same exterior configuration; and  
 a second paint applying medium having a second configuration and being coupled to a second mounting portion, the second mounting portion having a second sized dimension different from the first sized dimension.  
   
     
     
         14 . The paint applicators of  claim 13 , wherein the first handle and the second handle include interior cavities which at least partially receive the first mounting portion and the second mounting portion, respectively.  
     
     
         15 . The paint applicators of  claim 13 , wherein the first mounting portion and the second mounting portion include first and second openings, respectively, wherein the first and second openings are similarly configured and wherein the first and second openings receive the first handle and the second handle, respectively.  
     
     
         16 . The paint applicators of  claim 13 , wherein the first mounting portion and the second mounting portion comprise ferrules.  
     
     
         17 . A paint applicator comprising: 
 a handle having an internal cavity including at least one inwardly extending projection;    at least one paint applying medium; and    a mounting portion coupled to the at least one paint applying medium, the mounting portion received within the interior cavity, wherein the at least one projection engages the mounting portion.    
     
     
         18 . The paint applicator of  claim 17 , wherein the applicator has a greater longitudinal length and wherein the at least one projection extends along a longitudinal axis.  
     
     
         19 . A method for forming a plurality of distinct paint applicators having a common exterior head configuration and distinct paint applying medium configurations, the method comprising: 
 forming a plurality of handles, each handle including a head having an exterior configuration, an interior having a mouth, and a head thickness therebetween;    forming a plurality of paint carrying units, each unit including at least one paint applying medium coupled to a mounting portion and disposed within an interior of one of the plurality of handles, the mounting portion having a mounting portion exterior configuration and a mounting portion thickness between the mounting portion exterior configuration and the paint applying medium; and    varying a configuration of the paint applying medium while varying at least one of the head thickness and the mounting portion thickness to form a plurality of distinct paint applicators having a common exterior head configuration and distinct paint applying medium configurations.    
     
     
         20 . The method of  claim 19  including the step of varying the head thickness.  
     
     
         21 . The method of  claim 20  including: 
 providing a mold having an internal cavity configured to form a handle having an exterior configuration;  
 inserting one of a plurality of differently sized inserts into the cavity, wherein the inserts are configured to form the interior; and  
 supplying handle forming material between the mold and the insert, wherein the differently sized inserts vary the head thickness to allow the head to accommodate variously configured paint applying mediums.  
 
     
     
         22 . The method of  claim 21 , wherein at least one of the plurality of differently configured inserts is configured to form at least one projection extending into the interior of the handle.  
     
     
         23 . The method of  claim 22 , wherein at least one of the plurality of differently configured inserts is configured to form at least one projection extending into the interior of the handle along a major longitudinal axis.  
     
     
         24 . The method of  claim 19  including the step of varying the mounting portion thickness.  
     
     
         25 . The method of  claim 19 , wherein the paint applying medium comprises a plurality of bristles.