BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The following detailed description of the present invention can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:
FIG. 1 shows a cartridge according to an aspect of the present invention, and connection of the cartridge to an EHD spray device;
FIG. 2 shows a perspective cutaway view of the cartridge of FIG. 1 with a cap placed adjacent a distal end of the cartridge;
FIG. 3 shows a side cutaway view of the cartridge of FIG. 1 with the wetted lead screw, piston, seal and frame removed;
FIG. 4 shows the use of a stop-cock valve as an alternate embodiment for selective closure of the cartridge;
FIG. 5A shows a first perspective view of the connection of the wetted lead screw to the driver of a sprayer handle;
FIG. 5B shows a second perspective view of the connection of the wetted lead screw to the driver of a sprayer handle;
FIG. 5C shows a perspective view of an alternative embodiment of a hub for the wetted lead screw;
FIG. 5D shows a perspective view of an alternative embodiment of the driver that could be coupled to the hub of FIG. 5C;
FIG. 6 shows the frame that is used to support the wetted lead screw in the cartridge;
FIG. 7A shows a perspective view of the piston and seal of FIG. 1;
FIG. 7B shows a reversed side cutaway view of the piston and seal of FIG. 7A, presently shown without a retaining ring;
FIGS. 8A through 8C show various embodiments of the engagement of the wetted lead screw and the seal;
FIG. 9 shows an alternate embodiment of the seal;
FIG. 10 shows a nozzle cover that can be resiliently snapped onto the cartridge of FIG. 2;
FIGS. 11A and 11B show top and elevation views, respectively, of the manifold;
FIG. 12 shows a view of an alternate embodiment of a handle used to connect to a cartridge;
FIG. 13 shows a converter that can be situated within the handle of FIG. 1 or 12;
FIG. 14 shows a side elevation view of the handle of FIG. 12 connecting to a notional cartridge;
FIG. 15 shows an alternate embodiment of the handle, now angled relative to the cartridge to which it is connected;
FIG. 16 shows a perspective view of the attachment of yet another handle embodiment to a cartridge; and
FIG. 17 shows a rear perspective view of the handle of FIG. 16, with a ring with which to hang the handle is deployed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIGS. 1 and 13, a sprayer 10 includes a handle 26, a cartridge interface 29 and fluid-containing cartridge 20. An array of nozzles 22 are situated beneath cartridge 20, and are in fluid communication therewith to dispense a fluid. The handle 26 is used to house a power supply 12, a converter (also referred to as an electronics or circuit board) 14, a motor 16, a drive mechanism 18 and driver 19, and a high voltage multiplier 30 (also referred to as a voltage multiplier circuit). In the present context, the term “high voltage” and its variants is used to represent increases in voltage over that provided by the power supply 12 due to the operation of the voltage multiplier 30, rather than as indicia of a particular voltage level. By way of example, for a voltage measured at the output of the power supply 12 of six volts, a voltage of thousands of volts measured at the output of the voltage multiplier 30 would constitute a high voltage. The power supply 12 may comprise a portable, on-board voltage supply, such as through a set of batteries, for example four AA batteries, which may or may not be rechargeable. As shown with particularity in FIG. 13, converter 14 includes a processor 15, transformer 17 and potting material 31, the last to encase the multiplier 30 to provide insulation for the high voltage emanating therefrom. The converter 14 acts to step up the voltage from the power supply 12 to a higher level in order that it may (among other things) power the multiplier 30. The multiplier 30, in turn, converts the voltage from the converter 14 to a level suitable for comminuting a liquid contained within the cartridge 20 with EHD forces. The multiplier 30 may be configured as a flyback oscillator circuit as understood by those skilled in the art. In an exemplary form, converter 14 (with transformer 17 and multiplier 30) can take an input voltage of between four and six DC volts and convert that to between twenty thousand and thirty thousand DC volts. An electrical connection (not shown) between the multiplier 30 and the nozzles 22 enables a necessary charge to be formed on the latter such that when fluid passes therethrough, it is comminuted. Cartridge 20 includes generally opposing ends: a proximal end 20A that is adjacent to and cooperative with the cartridge interface 29, and a distal end 20B through which the fluid to be dispensed flows. The interior 20C of cartridge 20 defines a fluid chamber between the proximal and distal ends 20A, 20B. Cartridge 20 is preferably disposable and not reusable.
Referring to FIGS. 2 and 3, cutaway views showing the cartridge with (FIG. 2) and without (FIG. 3) internal componentry is shown. The cartridge 20 and the cartridge interface 29 are adapted to enable the cartridge 20 to attach and detach quickly, easily, and without spillage of contained liquid. The inside (fluid-containing) portion of cartridge 20 is bounded at its proximal and distal ends 20A, 20B by a piston 50 and a septum 24, and radially by the inner wall 20C such that a fluid chamber is defined. Septum 24 forms a closure barrier at the distal end 20B of cartridge 20, and can be punctured by a needle 85 formed into discharge tube 80 that makes up a part of cap 100. Needle 85 may be configured as a syringe needle, while septum 24 is made from a material (such as rubber) that substantially self-seals. To promote the piercing of septum 24 by needle 85, cap 100 needs to be snapped fully in place. As will be noted, the cap 100 in FIG. 2 is not snapped fully in place, such that needle 85 has not poked a hole in septum 24, whereas in FIG. 3, cap 100 is shown snapped fully in place such that needle 85 pierces septum 24 to produce the aperture 25 that enables the flow of liquid from the fluid chamber to the header 90.
Fluid that is forced out of cartridge 20 passes through discharge tube 80 and into manifold 90, where a series of channels (shown and described in more detail below) distribute the fluid to the nozzles 22. To promote EHD operation, high voltage from handle 26 is imparted to at least one of the manifold 90 and nozzles 22 so that an adjacent charge field to act upon the fluid. An electrical connection 99 is used to establish electrical continuity between the power source 12 and associated voltage multiplying components situated on converter 14.
Piston 50 is mounted onto a wetted lead screw 40. While the screw 40 can be made from any suitable structural material, in a preferred embodiment it is made of plastic. Threads on both cooperate with each other such that upon rotation of screw 40, piston 50 progresses from the proximal end 20A to the distal end 20B. While the direction of travel of the piston 50 towards the distal end 20B as described above is preferred, it is not intended to limit the scope of the invention described herein. As such, it will be appreciated by those skilled in the art that the cartridge 20 may be designed so that the wetted lead screw 40 drives the piston 50 from the distal end 20B towards the proximal end 20A of the fluid chamber. A relatively snug fit between the outer periphery of the piston 50 and the inner wall 20C prevents the piston 50 from sympathetically turning with the lead screw 40. It will be understood by those skilled in the art that other anti-rotation features may be employed, such as an axial key and slot arrangement formed in the piston and cartridge inner wall, or by forming the inner wall and piston with complementary oval or other non-axisymmetric shape. While it is preferable that the piston not rotate in relation to the inner wall 20C, in some applications the piston may rotate slightly in relation to the bore wall, but at a rate slower than the lead screw. The construction of piston 50 is such that it acts like a plunger in that it pushes fluid situated on its downstream portion out of a container, vessel or chamber to which the plunger is attached. Retaining ring 55 may be disposed substantially about the periphery of piston 50 to promote rigidity and shape retention. Cartridge 20 may optionally include a window, or be made of a transparent or translucent material (none of which are shown) to provide a visual dose cue to indicate the volume of fluid or number of doses remaining. Other indicia, such as an auditory application cue (not shown) through timed sounds linked to volume dispensing rate could also be used.
A seal 70 is situated between an axial bore 52 formed in the piston 50 and the threads of screw 40. As with the piston 50, seal 70 may include threads on its inner bore so that the seal 70 can cooperate with the rotational movement of screw 40. In order to maximize its sealing feature, seal 70 is preferably made from a softer material than that of the screw 40 or piston 50. This results in a more compliant form that can better maintain small gaps between the seal 70 and the threads of the screw 40, thereby reducing the possibility of backwards leakage along the screw 40. Examples of seal material can be a silicone-based or plastic-based structure. In one form, the seal 70 can be integrally manufactured into piston 50 to ensure a leak-free connection.
For best sealing properties, the seal 70 is manufactured or molded to match the thread design of the wetted lead screw 40. As shown in FIGS. 8A through 8C, by way of example and not limitation, these may be cut threads, rolled threads, squared threads, sinusoidal threads or other thread designs. Unified lead threads are preferred for ease of manufacture of the seal 70. With reference to FIGS. 7A and 7B, this structure may be produced by separately manufacturing or molding the seal 70 for insertion into piston 50, or by molding the seal 70 in place in the cavity of the piston 50, which is preferred.
The seal designs of FIGS. 8A through 8C can be augmented with a self-actuating sleeve formed as a projecting portion of seal 70, shown for example in FIG. 9. Such a configuration extends into the fluid chamber along the wetted lead screw 40, so that as the pressure of the fluid in the fluid chamber increases, the seal 70 compresses more tightly against the lead screw 40 to increase sealing pressure against leakage. The sealing pressure of the sleeve may be enhanced by producing the sleeve with a slight inward taper, provided the taper is not sufficient to block the travel of the wetted lead screw 40. The length, taper and flexibility of the sleeve will control the sealing pressure thus applied by the seal material as it is stretched over the wetted lead screw 40. The sleeve design is not preferred, as the added friction draws more power and tends to add cost to the cartridge and sprayer by requiring stronger parts, and a larger motor. Modifications of the spraying device 10 for electrospraying would include a larger motor 16 to generate higher pressures, corresponding strength in the fluid chamber and piston 50, as well as to smaller apertures or related orifices.
In another alternative design (not shown), seal 70 may be made without a thread design manufactured or molded therein. In this form, seal 70 may be formed from a relatively soft elastomer sleeve that could engage the threads of lead screw 40. The compliant nature of the sleeve would allow the sleeve to work its way into the threads as the lead screw 40 repeatedly passes over the sleeve. In such a design, the threads of the wetted lead screw 40 may be very fine, for applications where shorter travel per revolution of the wetted lead screw 40 is desired. The material of seal 70 is softer than that of the wetted lead screw 40 and piston 50, so that seal 70 is squeezed into the threads of the wetted lead screw 40 to seal against leakage. Again, this further alternative design is not preferred, as the sleeve compression on the fine threads adds friction and more revolutions are required per inch of travel for the wetted lead screw 40, all of which draws more power and tends to add cost to the cartridge and sprayer by requiring stronger parts and a larger motor.
Referring again to FIG. 2, and further in conjunction with FIGS. 5A through 5D and 6, screw 40 extends from one end of the fluid chamber to the other. Referring with particularity to FIGS. 2, 5A and 5B, a proximal end of screw 40 fans out to define a hub 42, while at its distal end, screw 40 preferably has a ball end supported in a socket. Connectors to the ball and socket arrangement, such as conical and other like connectors known in the art may be used. Alternatively, the screw 40 may be cantilevered, supported at the one end and by the piston 50 and frame 60. To keep screw 40 radially centered in the fluid chamber and aligned with the driver 19, hub 42 is mounted to a frame 60. Referring with particularity to FIG. 6 in conjunction with FIG. 2, frame 60 assumes a spider-like (i.e., hub-and-spoke) shape with a ring 62 defining a central race 65, and a plurality of radially-extending legs 63 that terminate in feet 64. In this way, ring 62 acts as a hub, while the individual legs 63 act as spokes that connect the hub to the inner wall 20C of the fluid chamber. The central race 65 of frame 60 is configured to rest upon the corresponding race 45 formed in hub 42 (discussed in more detail below). Their cooperative nature allows them to act as a bearing such that screw 40 can rotate relative to the frame 60. Preferably, the frame 60 is made from a relatively rigid material, such as metal. The legs 63 are axially canted, while the feet 64 are additionally canted; this gives the frame 60 spring-like qualities to promote insertability into the fluid chamber of cartridge 20. By having the legs 63 and feet 64 be backwardly-biased, the frame 60 inhibits backward movement of the screw 40, as any attempt to push the frame 60 rearward (i.e., toward the proximal end) will cause feet 64 to splay radially outward, thereby digging into the relatively soft inner wall 20 and inhibiting additional movement.
Various rotational couplings between the driver 19 and wetted lead screw 40 are shown. Drive mechanism 18 (shown in FIG. 1) and driver 19 form a coupling at the end of a shaft on motor 16, and can rotate about the generally elongate axis L of the sprayer 10. Referring with particularity to FIGS. 5A and 5B, hub 42 includes an anterior surface 43, posterior ridge 44 and race 45. The end of hub 42 forms a multicompartmented female portion 46 that engages the male projection of driver 19. The structure of hub 42, with its race 45 that is of a smaller radial dimension than the axially adjacent anterior surface 43 and posterior ridge 44, is such that the central race 65 of frame 60 (shown in FIG. 6) can be made to fit onto the race 45 of hub 42 by snap-fit or similar connection. The drive mechanism 18 and driver 19 convey rotational motion from the motor 16 to the lead screw 40, and as may be appreciated by those skilled in the art, can also include various gearing and belt arrangements, as well as a linear drive motor arrangements to impart the necessary rotational motion. Referring with particularity to FIGS. 5C and 5D, an alternate embodiment of hub 142 includes an anterior surface 143, posterior ridge 144 and race 145. Unlike the hub 42 of FIG. 5A, hub 142 includes a male projection 146 having angled or angled arcuate surfaces 146D (in addition to generally square surfaces 146C). A complementary female fitting in the driver 119 defines an inner periphery (such as in the form of a race) that has gear-like teeth disposed about an inner periphery of such race. The top surfaces 119D of the teeth are also angled or angled arcuate surfaces. When male projection 146 from hub 142 is inserted into the female fitting of driver 119 so that the surfaces 146D and 119D contact, these surfaces deflect to cause the cartridge 20 to automatically adjust by slight rotation or similar clocking motion for proper connection. This provides a self-adjusting feature for the handle 26 and cartridge 20. In one form, the clocking motion is typically no more than approximately fifteen degrees.
In one form, a bayonet-type attachment 110 may be employed, as well as a keyed slot 120 to ensure proper alignment between the cartridge 20 and the handle 26 of sprayer 10. Such an attachment ensures quick connection and removal. The bayonet-type attachment 110 may be disposed on both sides of cartridge 20, so long as both can be engaged or disengaged simultaneously by relative rotation in one direction or the other between the cartridge 20 and handle 26. An example of such connection can be seen in FIGS. 2, 3, 16 and 17. Alternatively, a twist-type attachment (not shown) with a positive or friction lock, a spring mounted pin and hole arrangement (not shown), or other means for positively connecting the cartridge to the handle would be suitable. A further feature of the mechanical interface is that the surface 61B is a load bearing surface which transfers the operational forces acting upon the lead screw 40 of the cartridge 20 to the handle 26 when it is assembled to the handle 26. Surface 61B contacts surface 61A of the frame 60 (as shown in FIG. 6) to this end to minimize the load applied to the drive mechanism 18 and driver 19 and related internal components in the handle. The cartridge 20 and handle 26 are preferably detachable, so that cartridge 20 may be disposable (or refillable), or so that one cartridge may be exchanged for another having a different fluid. The handle interface 29 thus includes both mechanical and electrical interfaces.
Referring next to FIG. 12, in one form, the handle 26 can be ergonomically designed to minimize leverage on the hand, wrist, and/or forearm of a user. An on/off switch 26A is used to provide power to the cartridge 20. When switch 26A is in the “on” position, a light-emitting diode (LED) 26B lights up to indicate operational status. The switch 26A may control, singly or in combination, activation of indicators (such as LED 26B), the motor 16, and the multiplier 30. An activation switch 26C is placed just ahead of seating surface 26D such that unless activation switch 26C is depressed (such as by the presence of a cartridge 20 placed against the seating surface 26D at the location designated as interface 29), connection between the high voltage coming from the multiplier 30 to contact 26E (which electrically connects to connector 99 of manifold 90) is not made, thereby preventing open exposure of a “hot” lead from the handle 26. Trigger 26F is to give the user control over the supply of electricity to the motor 16. In an alternate form, activation may be provided by trigger 26F on the grip, instead of by the on/off switch 26A. In yet another form, the grip itself, minus the trigger, could be used to activate the sprayer 10.
Additional ergonomic features of the handle are shown in FIGS. 14 through 17. The internal components are placed, along with weights as needed, to effect such a balance. In a preferred embodiment, the handle 26 is weighted with the power supply 12, converter 14, motor 16, drive mechanism 18 (all as shown in FIG. 1) and, optionally, weights (not shown), so that when the handle 26 is attached to the cartridge 20, the center of balance of the spraying device thus formed is preferably located in the grip. Alternatively, the center of balance may move from outside the grip into the grip, or fdrom inside the grip to outside the grip, as the fluid is dispensed. Regardless, as the fluid chamber within the cartridge 20 is emptied, the center of balance shifts slightly along the grip, maintaining ease of operation throughout the life of the cartridge 20. As shown in FIG. 13, the handle 26 may be generally aligned with the cartridge 20, or as shown in FIG. 14, an angle may be formed between the handle 26 and the cartridge 20. This angle may be a rigid connection, or may be formed by an articulable joint (not shown) on the sprayer 10 that enables the angle between the cartridge 20 and the handle 26. The joint may comprise a spring-loaded mechanism, friction lock, or other comparable adjusting mechanism. In addition, in a further optional feature of the device, after connection of the cartridge 20 to the handle 26, the cartridge 20 may further be rotated along its longitudinal axis, preferably to pre-set angles from one to forty five degrees, and more preferably approximately fifteen to thirty degrees, as may be desired by the user, by rotating an interface 23 between the cartridge and handle. The rotation may be provided by a joint (not shown) comprising opposing discs having knobs and detents, spring loaded mechanisms, friction locks, or other comparable adjusting mechanism. Regardless of the configuration used, the desired result is improved manipulative control over the sprayer, more even application, and reduced fatigue for the user.
For best operation, the sprayer 10 should be referenced between the user and the target during EHD spraying. The handle 26 preferably comprises a conductive material suitable for making electrical contact between the sprayer 10 and the user. The material may be, for example, a metal, conductive rubber, plastic, or other polymer. The material for the handle 26 may also comprise a soft-touch material to provide tactile contact between the user and the sprayer 10. As shown in the embodiment illustrated in FIG. 1, the power supply 12 may comprise a power supply pack positioned in the front of the handle 26. In an alternate embodiment, such as that shown in FIGS. 14 through 17, the power supply and associated electronics may be positioned in the rear of handle 26. As discussed above, balance and ergonomic weight distribution is an important consideration for the sprayer 10. In addition to ergonomic considerations, the sprayer 10 may also be designed so that such balance that favors causing the sprayer to strike the ground at the rear (i.e., butt) end of the handle 26 to minimize the potential for damage to the nozzles 22.
Referring next to FIGS. 11A and 11B in conjunction with FIG. 1, fluid disposed in the fluid chamber of cartridge 20 flows through needle 85 into the manifold 90 which distributes it to the nozzles 22 (shown presently in an alternate, non-tapered construction). In one embodiment, the manifold 90, includes distribution channels 91. The array of nozzles 22 is typically linear, typically between four and seven inches in length, but may be in other forms, such as (but not limited to) circular or otherwise curved. As discussed above, in a preferred embodiment, the manifold 90 and nozzles 22 are preferably made from an electrically conductive plastic. In one form, the material has a surface resistivity between 102 and 1014 ohms per square, and a volume resistivity of between 102 and 1014 ohms per centimeter. As mentioned above, suitable base polymer materials may include ABS, HDPE, polypropylene and polycarbonate, all of which can have additives known in the art added to them to make them conductive.
Referring next to FIG. 10, a nozzle cover 28 may also optionally be provided to prevent exposure and possible damage to nozzles 22 when the sprayer 10 is not in use. The cover 28 includes resilient tangs 28A that are designed to clip onto the cartridge 20 to cover and protect the nozzles 22 during storage, advantageously applying slight force generally in the range of 0.5 to 4 pounds, and more preferably 1.5 to 2.5 pounds, across the tips of the nozzles 22. The cover 28 is designed to clip onto the cartridge surface opposite the nozzles during spraying, or can be configured with a hinge element to flip away from the nozzles.
Referring next to FIG. 4, an alternative preferred means for dispensing fluid from the cartridge 20 to the nozzles 22 is shown. A valve device, such as a stop-cock 200, is shown. Unlike the configuration depicted in FIGS. 2 and 3, which included septum 24 being pierced by needle 85 to produce an aperture 25 in the distal end 20B of cartridge 20, the present embodiment utilizes a rotating handle 202 that selectively engages valve 206. The stationary part 204 of stop-cock 200 remains fixed to a complementary neck 21 on cartridge 20 by snap-fit, friction or related connection, and acts as a housing through which discharge tube 80 passes.
While certain representative embodiments and details have been shown for purposes of illustrating the invention, it will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention, which is defined in the appended claims.
Patent Application
20080083845
