Evolution of Product Design: The Roller Paint Brush

Evolution of Product Design: The Roller Paint Brush

Andrew Trick
Sinclair MET 1231.5
There are two competing claims for the inventor of the roller paint brush. In one
corner, an independent Canadian inventor Norman Breakey. In the other, Richard
Adams, an American engineer for Sherwin Williams.
Both gentleman developed an idea for a cylindrical brush to apply paint in the early
1940s. However, their motivations were quite different. Breakeys goal was to
streamline the painting process, while Adams was trying to overcome wartime
shortages. The Japanese blockade of mainland China had cut off the supply of hog
bristles which were the main material for paint brushes at the time.
Adams original design called for a sponge rubber roller to absorb, hold on too, and
deposit the paint. Breakey simply used a material recommended to him by his local
fabric salesman. It was a green velour, traditionally used to cover the insides of rail
coaches.
As an independent inventor, Breakey was unable to fund an initial production run.
Unable to secure investors, he did not patent his invention. Other companies heard
of the idea and produced their own variants, leaving Breakey far behind.
Adams, with Sherwin-Williams backing, filed a patent on February 2, 1942. In June
1945, Patent US 2378900 A was approved and claimed an invention that:
relates to a coating device or applicator of the roller type for applying
paint or other coating materials to various surfaces, and aims to provide an
improved and simplified construction for a device of this kind.
In the intervening 70 years, the form factor has remained essentially unchanged.
The figure below shows the original patent sketch; it should be very familiar to
anyone whos painted before.

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Figure 1: Sherwin Williams Co

While the general form has remained the same, several variants have developed.
These variants specialize the roller design to be better suited for certain tasks.
The most common brush is the traditional roller. These rollers can be mounted on
long handles for ceiling painting and other hard to reach areas. A relatively new
version is the hot dog roller (AkzoNobel, n.d.). It is a much smaller version of the
traditional roller that allows painting in small areas and tight corners.
As efficient as they are for wide open walls, it can be difficult to paint around trim
with the traditional roller. The pad roller was designed to bring roller efficiencies to
trim and other detail painting. These brushes are made of a highly absorbent pad
that rides along the wall on small wheels. The pad skims over the surface depositing
the paint without having to worry about splatter.
The brushes themselves have also diversified. Depending on the task and the
project, a painter can choose from a myriad of materials and roller styles. Some are
designed to hold the most amount of paint while others can form textures or
complex patterns.
Today youll find everyone from personal homeowners to large painting and
contracting companies using a paint roller. No matter the painting task its easy to
appreciate the rollers efficiency and quality.
References
AkzoNobel. What type of roller do I use? Retrieved August 23, 2016, from Dulux,
https://www.dulux.ca/diy/tips-tricks/tools-equipment/filler-shows-through-the-paint(8)
Sherwin-Williams. (n.d.). Retrieved August 23, 2016, from http://careers.sherwinwilliams.com/history/heritage/brushes

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Sherwin Williams Co,. "Coating Device". 1945: n. pag. Print.
Toronto Invents: The Paint Roller | culture | Torontoist. (2013). Retrieved August 23,
2016, from http://torontoist.com/2013/01/toronto-invents-the-paint-roller/

Improvement Suggestion
I enjoy house painting, but cannot stand to do the trim work. I try and paint as much
as I can with the roller. Inevitably Ill get to close to the ceiling or some other trim
piece and get paint where it shouldnt be. Before this project I hadnt heard of pad
rollers, and Im not sure Id spend the money for as little as Id use it. I need a
simple cheap tool to help me paint close to trim pieces with the paint roller I already
have.
I propose a foam wheel that I can stick to the edge of my roller with an adhesive
pad. The foam will provide a buffer between the ceiling/trim and my roller. The
width the of the foam will provide the minimum offset between the trim and brush.
It could be offered in various widths, but I think inch would be a good starting
point.

Figure 1: Complete Assembly

A: Foam Wheel
B: Adhesive Pad

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The ridge is very important as it is the dam between the trim and the paint coming
off the roller. These wheels must be cheap as they are meant to be disposable. As
soon as the wheel gets too much paint on it or the ridge allows paint through, tear it
off and put a new one on.