Patent Application
20090277975
A texture sprayer assembly is used to apply texture materials, such as plasters, fillers and decorative materials to walls, ceilings and other surfaces. A texture sprayer assembly typically includes a pump and a hopper mounted on a cart. Texture materials are fed from the hopper to the pump. The output of the pump is connected to an application device by a hose.
Texture materials are available as a premixed mud or as a dry powder. The premixed mud may be added directly to the hopper, while the dry powder must be premixed with water before being added to the hopper. Prior to application, the texture material is mixed with a standard hand-held mixer in the hopper to create a uniform mixture. During the mixing process, a user inserts the hand-held mixer into the hopper. The user must support and direct the mixer during use. After mixing, the user must remove the mixer from the hopper.
A texture sprayer includes a mixer mount for mounting a mixer to a sprayer cart. The mixer mount includes a mixer clamp, a mixer bracket mount, a mixer bracket pivot and a mixer support assembly. The mixer clamp connects to the mixer bracket mount. The mixer bracket mount connects to the mixer bracket pivot at a pivot point so that the mixer bracket mount and the mixer clamp can pivot about the mixer bracket pivot. The mixer bracket pivot slidably engages in the mixer support assembly so that the distance between the mixer clamp and the mixer support mount may be adjusted. The mixer support assembly is capable of connecting to a sprayer cart.
Upper frame 24 is supported by lower frame 22. Upper frame 24 supports handle 42, bag assembly 44, hopper 18 and adjustable mixer bracket 20. Handle 42 extends to back side 26 of cart 12. By lifting up on handle 42 so that cart rest 40 is off the ground, the user places the weight of assembly 10 on wheels 38 and may roll assembly 10 on wheels 38.
Bag assembly 44 is connected to front side 28 of cart 12 and includes upright bag assembly support 46, rollers 48, bag roller handle 50 and bag support 52. Rollers 48 connect to upright bag assembly support 46. Bag roller handle 50 is connected to rollers 48 so that when handle 50 is turned, rollers 48 turn. Bag support 52 connects to upright bag assembly support 46 below rollers 48, and extends across hopper 18 to rest on adjustable mixer bracket 20.
Bag assembly 44 assists the user in emptying bags of premixed mud texture material. In use, a bag of premixed mud is placed on bag support 52. One end of the bag is opened, and the opposite end of the bag is fed through rollers 48. As the user turns bag roller handle 50, the bag is pulled through the rollers 48, which squeeze the premixed mud from the bag and into hopper 18.
Hopper 18 is located at front side 28 of cart 12 and is supported by upper frame 24. Hopper 18 holds texture material, such as plaster, fillers and decorative materials. Hopper 18 may be made of plastic and may be any shape. In one example, hopper 18 is an oblong.
A portion of hopper 18 extends above the top of upper frame 24 of cart 12, and a portion of hopper 18 extends below the top of upper frame 24, as is shown in
Hopper 18 has hopper outlet 54 connected to pump 14. Hopper 18 feeds the texture material to pump 14. Pump outlet 56 is connected to an application device by a hose (not shown) so that the texture material may be applied to walls, ceilings and other surfaces.
Adjustable mixer bracket 20 attaches to upper frame 24 by brackets 60, which are mechanically fastened to upper frame 24. In one example, brackets 60 are welded to upper frame 24. Mixer bracket 20 is located on the back side of hopper 18 and follows the perimeter of hopper 18. Mixer bracket 20 rigidly holds mixer 58 in hopper 18 to mix the texture material.
Clamping assembly 62 includes mixer clamp 66, mixer bracket mount 68, mixer bracket pivot 70, mixer bracket tube 72, bolts 74a, 84, 92a and 92b, washers 74b, 86, 88, 94a, and 94b and nuts 77c, 90, 96a and 96b. Nuts 77c, 96a and 96b are welded nuts. That is, for example, nuts 77c are welded to mixer bracket 68 so that only one wrench is necessary to tighten bolds 74a. nuts 96a and 96b function in a similar manner.
Mixer clamp 66 is mechanically fastened to mixer bracket mount 68, such as by bolts 74a through holes 74 and 75. Mixer bracket mount 68 is formed so that when mixer clamp 66 is attached, about a 2 inch (5.08 cm) diameter circular aperture is formed between mixer bracket mount 68 and mixer clamp 66. In use, sleeve 58c of mixer 58 is placed between mixer clamp 66 and mixer bracket mount 68. Sleeve 58c with a 2 inch diameter is standard on hand-held mixers. Therefore, a 2 inch (5.08 cm) diameter circular aperture allows mixer bracket 18 to be used with any standard hand-held mixer.
Mixer bracket mount 68 connects to mixer bracket pivot 70. Mixer bracket mount 68 is a U-shaped metal plate, having left side 68a, right side 68b and top 68c. Front left pivot slot 76a, front right pivot slot 76b, back left pivot hole 78a and back right pivot hole 78b are formed in mixer bracket mount 68.
Mixer bracket pivot 70 is also a U-shaped metal plate. Mixer bracket pivot 70 has left side 70a, right side 70b and bottom 70c. Front left pivot hole 80a, front right pivot hole 80b, back left pivot hole 82a and back right pivot hole 82b are formed in mixer bracket pivot 70.
Mixer bracket mount 68 and mixer bracket pivot 70 are connected in the back by pivot bolt 84, which extends through back pivot holes 78b, 82b, 82a and 78a. Mixer bracket mount 68 and mixer bracket pivot 70 are also connected in the front. On the left side, bolt 92a extends through front left pivot slot 76a of mixer bracket mount 68 and front left pivot hole 80a of mixer bracket pivot 70. Similarly on the right side, bolt 92b extends through front right pivot slot 76b and front right pivot hole 80b. Bolts 92a and 92b may be tightened at any location along pivot slots 76a and 76b, respectively. In this way, mixer bracket mount 68 pivots about pivot bolt 84. In one example, mixer bracket mount 68 can pivot between about 18 degrees and about 30 degrees from horizontal, giving a range of motion of about 12 degrees.
Pivoting mixer bracket mount 68 also pivots mixer clamp 66, and therefore pivots mixer 58, which is held by mixer clamp 66. Pivoting mixer 58 allows adjustable mixer bracket 20 to accommodate mixers with different length shafts. The pivoting also allows a user to adjust the location of blades 58e (and therefore the mixing) in hopper 18.
Mixer bracket tube 72 extends from mixer bracket pivot 70. Mixer bracket tube 72 may be a formed metal tube with a rectangular cross-section. Pin hole 98 is formed through mixer bracket tube 72 so that pin 100 may be inserted through pin hole 98 and locked in place with retainer 102.
Clamping assembly 62 slidably engages in support assembly 64. Support assembly 64 includes pockets 104L and 104R and rails 106a and 106b (referred to generally as pockets 104 and rails 106, respectively). Pockets 104 are formed metal tubes with a rectangular cross-section. Rails 106 are formed metal tubes or rods having a circular cross-section. Rails 106 extend between pocket 104L and 104R. Rails 106 provide support to pockets 104, and may be formed to mirror the shape of hopper 18.
Pockets 104L and 104R have pin holes 108L and 108R and holes 110L and 110R, respectively. Holes 110L and 110R connect pockets 104L and 104R to cart 12 so that support assembly 64 partially surrounds hopper 18, as shown in
Pockets 104 are formed so that the inner cross-sectional area of each pocket 104 is larger than the outer cross-sectional area of mixer bracket tube 72. As a result, mixer bracket tube 72 may be inserted into either pocket 104L or 104R. Mixer bracket tube 72 slidably engages in pockets 104, so that mixer bracket tube 72 may be removed from pocket 104 for storage, transportation, cleaning or to change pockets.
Having pockets 104L and 104R allows mixer bracket tube 72 (and therefore, mixer 58) to be placed at two alternative locations (left and right sides) on cart 12. This allows the user to place mixer 58 at the best location for a given application or according to the user's preference.
A series of pin holes 108L are formed in pocket 104L. Pin hole 98 in mixer bracket tube 72 is aligned with one pin hole 108L. Pin 100 is inserted through holes 98 and 108L. Pin 100 is held in place with retainer 102. The series of pin holes 108L allow mixer bracket tube 72 to be connected to pocket 104L at various locations along pocket 104L. This allows the distance between mixer clamp 74 (and mixer head 58a) and hopper 18 to be adjusted. This is also referred to as changing the height of clamp assembly 62. In one example, six pin holes 108L are formed in pocket 104L, with 0.45 inches (1.14 cm) center-to-center between the holes. Therefore, 2.25 inches (5.72 cm) of height adjustment is possible. Pocket 104R is constructed similarly.
Pin 100 and retainer 102 allow pin 100 to be inserted and removed without the use of tools. Therefore, it is quick and easy to connect and disconnect mixer bracket tube 72 and pockets 104, increasing the user's productivity.
Pin 100 may also be used as a stop for mixer bracket tube 72. For example, pin 100 may be inserted through pin hole 108L in pocket 104L, and then mixer bracket tube 72 may be inserted into pocket 104L so that mixer bracket tube 72 rests on pin 100. This arrangement also allows the height of mixer head 58a to be adjusted. Because mixer bracket tube 72 and pocket 104L are not securely fastened together, this arrangement is most useful when the texture sprayer assembly 10 is not being transported.
The adjustable height feature of adjustable mixer bracket 20 allows adjustable mixer bracket 20 to be used with different height hoppers. Depending on the capacity needed, different sized hoppers may be used in texture sprayer assembly 10. As explained above, a larger capacity hopper extends further above cart 12 than a smaller capacity hopper. Therefore, in order to hold mixer 58 in hopper 18, mixer clamp 74 must be farther away from cart 12 for a larger capacity hopper than for a smaller capacity hopper. That is, mixer bracket assembly 20 must be taller for a larger capacity hopper than for a smaller capacity hopper. The adjustable height of mixer bracket assembly 20 assures that mixer clamp 72 will be tall enough to clear the wall of hopper 18, and that mixer 58 may be placed at the desired location in hopper 18 regardless of what capacity hopper is used.
The adjustable height of mixer mounting bracket 20 also allows the user to adjust the location of blades 58e in hopper 18. By adjusting the location of blades 58e, the user can achieve uniform mixing in hopper 18.
Additionally, the adjustable height of mixer mounting bracket 20 allows adjustable mixer bracket 20 to accommodate mixers with different length shafts 58d. Mixers on the market today do not have a standardized shaft length 58d. For example, shaft length 58d may be about 25 inches (63.5 cm). The adjustable height of mixer mounting bracket 20 allows different mixers to be used in texture sprayer assembly 10.
Adjustable mixer bracket 20 prevents damage to hopper 18 and requires less operator attention during mixing. Previously, the user held and directed mixer 58 in hopper 18 during mixing. Typically blades 58e are metal while hopper 18 may be plastic. Therefore, hopper 18 may be damaged if contacted with blades 58e. Adjustable mixer bracket 20 rigidly holds mixer 58 in one place without operator attention, assuring that mixer 58 will not accidentally contact hopper 18.
Adjustable mixer bracket 20 allows the user to move away from hopper 18 or perform other tasks while mixer 58 is in hopper 18. Previously, mixer 58 was removed from hopper 18 when not in use. Adjustable mixer bracket 20 allows the user to leave mixer 58 in hopper 18, even the user is not present. Additionally, the user may move away from hopper 18 during mixing if mixer 58 has a lock-on feature. Thus, increasing the productivity of the user.
Adjustable mixer bracket 20 results in more uniform mixing. Adjustable mixer bracket 20 allows the user to adjust the height and angle of mixer 58 in hopper 18 to achieve optimum mixing. Further, adjustable mixer bracket 20 maintains mixer 58 in the optimum position. The user no longer has to personally physically maintain mixer 58 in the optimum position during the mixing process.
Additionally, the user may remove mixer 58 for storage or cleaning, and later re-insert mixer 58 without disturbing the adjusted height and angle positions. Similarly, the user may remove and re-insert clamping assembly 62 without disturbing the adjusted angle position.
Adjustable mixer bracket 20 holds standard hand-held mixer 58. Hand-held mixers have been standardized to include sleeve 58c below mixer head 58a. However, the length of shaft 58d may vary. Adjustable mixer bracket 20 accommodates a variety of shaft lengths by allowing the user to adjust the height and angle of mixer 58.
Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
