Patent Grant
10456801
The present disclosure relates to material sprayers. More particularly, the present disclosure relates to a slidable engagement of a pump with a material sprayer.
Material sprayers are used to spray fluid to build up and/or cover surfaces such as walls and ceilings, with the fluid drying in place to form a solid material. The sprayed fluids are typically viscous and can include plaster, aggregate (e.g., polystyrene or vermiculite), wall and ceiling texture materials, joint compounds, surfacing materials, acrylic materials, textured elastomeric materials, and coating materials (e.g., anti-skid floor coating materials). Material for the sprayer is typically supplied in bags or buckets, mixed with water if necessary, fed into the sprayer, placed under pressure by a pump of the sprayer, and then sprayed from a gun or other outlet.
A pump for use with a material sprayer includes a cylinder, a piston disposed in the cylinder, a pump head attached to the piston, first and second check valves, and an elbow connected to the cylinder. The cylinder and the piston are coaxial with a pump axis of the pump. The pump head is configured to make a mechanical connection with the reciprocating drive mechanism so as to allow the reciprocating drive mechanism to reciprocate the piston along the pump axis. The elbow includes a first end, a second end, and an inner fluid channel. The first end is configured to make a fluid connection with the hopper. The second end is configured to be fixed with respect to the cylinder. The inner fluid channel extends from the first end to the second end and bends between the first end and the second end. The pump head and the first end of the elbow are configured to make both a mechanical connection and a fluid connection with a single linear motion of the pump.
A pump assembly for a material sprayer with a hopper and a reciprocating drive mechanism includes a pump and an elbow. The pump is configured to pressurize a fluid and is mechanically attached to the reciprocating drive mechanism and fluidly attached to the hopper. The pump includes a cylinder, a piston disposed in and slideably engaged with the cylinder, and a pump axis. The piston includes a pump head connected to the reciprocating drive mechanism. The cylinder and the piston are coaxial with the pump axis such that the piston reciprocates along the pump axis. The piston is connected to the reciprocating drive mechanism such that the piston is coaxial with and is driven by the reciprocating drive mechanism to reciprocate along the pump axis. The elbow is a bent tube configured to transport a fluid therethrough and fluidly connects the pump to the hopper. The elbow includes a first end, a second end, and a bend portion. The first end is fluidly connected to a port of the hopper. The second end of the elbow is attached to the pump on a first end of the pump opposite from the reciprocating drive mechanism. The bend portion extends between the first and second ends of the elbow. The pump assembly is configured to be attached to or detached from the hopper and the reciprocating drive mechanism with a single linear motion of the pump assembly relative to the hopper and the reciprocating drive mechanism.
A method of installing a pump assembly onto a material sprayer with a hopper and a reciprocating drive mechanism includes inserting a first end of an elbow of the pump assembly into a port of the hopper. The pump assembly includes a pump and an elbow. The pump includes a cylinder and a piston disposed in and slideably engaged with the cylinder. The piston includes a piston head. The cylinder and the piston are coaxial with the pump axis. The elbow includes the first end, a second end, and a bend portion. The second end of the elbow is attached to the pump on a first end of the pump opposite from the reciprocating drive mechanism. The bend portion of the elbow extends between the first and second ends of the elbow. The piston head is inserted into a slot of a collar of the reciprocating drive mechanism. A dynamic mechanical connection is formed between the pump and the reciprocating drive mechanism. A fluidic connection is formed between the pump and the port of the hopper.
Material sprayer 10 is a modular unit that can be maneuvered around a jobsite as needed. Frame 12 is disposed throughout material sprayer 10 and is connected to the various elements of material sprayer 10 such as wheels 14, hopper 16, pump 22, and reciprocating drive mechanism 24. Wheels 14 are mounted to frame 12 via an axle. Hopper 16 is mounted to a portion of frame 12. Port 18 is disposed on a gravitational bottom portion of hopper 16 (towards the bottom of
Material sprayer 10 is configured to spray a pressurized fluid onto a surface. Frame 12 holds together and supports all of the elements of material sprayer 10. Wheels 14 rotate enabling material sprayer 10 to be moved around to new locations. Hopper 16 contains material within hopper 16. During operation of material sprayer 10, hopper 16 guides the material within hopper 16 in a downward direction to port 18. Port 18 transports the fluid from hopper 16 to assembly pump 26. Fitting 20 forms a fluidic seal between portions of port 18 and pump assembly 26. Hose 22 transports the pressurized fluid away from pump assembly 26 to a spray handle or other fluidic outlet. Reciprocating drive mechanism 24 is driven to cause pump assembly 26 to create a pressure within pump assembly 26. Pump assembly 26 pressurizes the fluid received from hopper 16 and delivers the pressurized fluid to hose 22.
Pump 28 a mechanical device that creates pressure to move a fluid. In this non-limiting embodiment, pump 28 is a double displacement pump that makes use of two check valves to control the flow of fluid during operation (see e.g.,
Pump mount frame 36 is a structural framework of solid material. Door 38 is a removable barrier of solid material. Clamps 40 and 46 are over center cam clamps, or alternatively are sanitary clamps. Clamp 42 is a sanitary clamp. Clamp 44 is a hand release clamp with a handle. In other non-limiting embodiments, any of clamps 40, 42, 44, and/or 46 can be an over center cam clamp, a sanitary clamp, or another type of releasable or non-releasable clamp. Angle θ is an angle between pump axis AP and direction G of gravity.
A first end of fitting 20 is attached to port 18 of the hopper by clamp 40. A second end of fitting 20 is attached to first end 34A of elbow 34 by clamp 46. Pump 28 is fluidly connected to elbow 34. First end 28A of pump 28 is physically connected and attached to second end 34B of elbow 34 via clamp 42. Second end 28B of pump 28 is physically connected and attached to pump mount frame 36 via clamp 44. Cylinder 30 is attached and connected to second end 34C of elbow 34 and to pump mount frame 36. Cylinder 30 surrounds and encases a piston. Lower section 32 is connected and attached to cylinder 30 and to second end 34C of elbow 34.
Elbow 34 is fluidly connected to port 18 of hopper 16 and to pump 28. The inner fluid channel of elbow 34 extends from first end 34A to second end 34C and bends between first end 34A and second end 34C. First end 34A of elbow 34 is connected and attached to port 18 of hopper 16 via fitting 20 and clamps 40 and 46. Bend portion 34B of elbow 34 is connected to and located between first and second ends 34A and 34C of elbow 34. In this non-limiting embodiment, bend portion 34B includes a bend of approximately 90 degrees. Second end 34C of elbow 34 is connected and attached to first end 28A of pump 28.
Pump mount frame 36 is rigidly attached directly or indirectly to frame 12 of material sprayer 10. Door 38 is detachably affixed to pump mount frame 36. Clamp 40 is clamped onto and around portions of fitting 20 and port 18. Clamp 42 is clamped onto and around portions of second end 34C of elbow 34 and first end 28A of pump 28. Clamp 44 is clamped onto and around portions of second end 28B of pump 28 and pump frame mount 36. Clamp 46 is clamped onto and around portions of fitting 20 and first end 34A of elbow 34. In this non-limiting embodiment, angle θ between pump axis AP and direction G of gravity is approximately 45 degrees. In other non-limiting embodiments, angle θ between pump axis AP and direction G of gravity can be approximately 15 to 65 degrees.
Fitting 20 allows for small adjustments and misalignments in the positioning of hopper 16 and elbow 34 (and pump 28 as attached to elbow 34). Pump 28 pressurizes fluid received from port 18 of hopper 16 and delivers the pressurized fluid to hose 22 (not shown in
Clamp 42 attaches and forms a sealing interface between portions of second end 34C of elbow 34 and first end 28A of pump 28. Clamp 44 attaches and forms a sealing interface between portions of second end 28B of pump 28 and pump frame mount 36. Clamp 46 attaches and forms a sealing interface between portions of fitting 20 and first end 34A of elbow 34. Clamp 46 is tightened over fitting 20 to secure and seal fitting 20 about elbow 34 to affix fitting 20 and elbow 34 together and to prevent any leakage of fluid at the interface between fitting 20 and elbow 34.
Angling pump axis AP of pump assembly 26 relative to gravity (or relative to the ground) allows for hopper 16 and pump 28 to be low to the ground to maximize compactness of material sprayer 10 and for a lower a center of mass of material sprayer 10 for increased stability, both aspects of which are useful for transporting material sprayer 10 around a jobsite. Angling pump axis AP of pump assembly 26 relative to gravity (or relative to the ground) also removes the necessity for the use of springs in check valves within pump 28 due to the ball elements of the check valves being able to seat due to the vertical component of gravity. Being able to use pump 28 without springs removes complications associated with the use of springs in check valves such as leakages, blockages, and failure of the spring(s).
Centerline axis AC is an axis passing through a center-point of first end 34A of elbow 34. Connector 48 is a device configured to connect or attach two elements together. Piston 50 is an elongated rod including features at opposite ends. In one non-limiting embodiment, a material of piston 50 can include metal. First check valve 52 and second check valve 56 are fluidic valves with balls and seats. Output port 54 is a fluidic outlet. Intake 58 is a fluidic inlet. Annular flange 60 and annular flange 66 are ring-shaped protrusions of solid material. Annular protrusion 62 is an annular extension of solid material. Packing ring stack 64 is a stack of seal rings. In other non-limiting embodiments, packing ring stack 64 can include a single seal or bushing in place of a stack of rings. O-ring 68 is a gasket. Head 70 is a distal end of piston 50. Collar 72 is a ring or band of solid material. Connecting arm 74 is an elongated piece of solid material. Slot 76 is an aperture or slit.
In this non-limiting embodiment, centerline axis AC of first end 34A is oriented at approximately 90 degrees from pump axis AP. Connector 48 connects hose 22 to output port 54 of pump 28 with a threaded interface. Piston 50 is disposed in and is in slidable engagement with cylinder 30. Piston 50 is mounted to collar 72 via head 70 of piston 50. Piston 50 is coaxial (e.g., axially aligned) with pump axis AP such that piston 50 reciprocates along pump axis AP. Piston 50 and cylinder 30 are coaxial with pump axis AP. First check valve 52 is housed within lower section 32. Output port 54 is formed in a portion of cylinder 30 of pump 28. Output port 54 is fluidly connected to cylinder 30 and to hose 22 via connector 48. Second check valve 56 is housed within the bottom end of piston 50. In another non-limiting embodiment, second check valve 56 can be mounted onto cylinder 30 (and not on piston 50) as part of output port 54 for pump 28. Intake 58 is formed by annular protrusion 62 in lower section 32 of pump 28 and is fluidly connected to elbow 34.
Annular flanges 60 and 66 are complementally to fit flush against one another. As shown, annular flanges 60 and 66 fit within clamp 42. Annular protrusion 62 is formed by part of lower section 32 and defines a portion of the opening of intake 58 of pump 28. Annular protrusion 62 extends beyond (e.g., below) annular flange 60. Annular protrusion 62 fits inside elbow 34. Packing ring stack 64 is disposed directly between piston 50 and cylinder 30. O-ring 68 is positioned between annular flanges 60 and 66. Head 70 is located at the second end of piston 50. With piston assembly 26 engaged with reciprocating drive mechanism 24, head 70 of piston 50 is disposed or accepted within slot 76 of collar 72. Head 70 of piston 50 attaches to collar 72 of reciprocating drive mechanism 24.
Collar 72 cradles underneath head 70 of piston 50. Connecting arm 74 is physically connected to collar 72 and is mounted within a portion of pump mount frame 36. Slot 76 is disposed in a portion of collar 72. In other non-limiting embodiments, alternative mechanical elements, other than collar 72 and head 70, can connect to piston 50 to reciprocating drive mechanism 24. For example, a metal pin that extends through aligned holes in collar 72 and piston 50 can couple collar 72 and piston 50, wherein the holes extend transverse to the long axes of collar 72 and piston 50.
Clamp 42 presses and holds annular flanges 66 and 60 against one another to seal the joint between elbow 34 and pump 28 (and/or lower section 32). Connector 48 on hose 22 allows hose 22 to be attached, and easily removed, from connection with pump 28. Piston 50 linearly moves with collar 72 as driven by reciprocating drive mechanism 24 to operate pump 28. During the upstroke of piston 50, the ball of first check valve 52 is pushed off of its seat as fluid is drawn from intake 58 past the seat and ball of first check valve 52 and further into lower section 32. Also on the upstroke of piston 50, the ball is forced onto the seat of second check valve 56 to prevent fluid that has already passed through second check valve 56 from flowing backwards through second check valve 56.
On the downstroke of piston 50, the ball of first check valve 52 seals against its seat on the downstroke of piston 50 to prevent retrograde flow of fluid back through intake 58. Meanwhile on the downstroke, the ball of second check valve 56 is pushed off of its seat as fluid, having already passed by first check valve 52 on the upstroke, is forced into an intake on the face of piston 50 and through second check valve 56. Packing ring stack 64 seals between piston 50 and cylinder 30 to force the fluid through the intake on the face of piston 50.
The use of second check valve 56 in piston 50 provides for a double displacement action of pump 28, whereby pump 28 expels fluid on the upstroke of piston 50 as well as on the downstroke of piston 50. Therefore, on both of the up-strokes and down-strokes, fluid is forced through output port 54 formed in cylinder 30, outputting the pumped fluid under pressure through hose 22 for spraying by a gun or other outlet. In the non-limiting embodiment of second check valve 56 being mounted to cylinder 30, pump 28 would be a single displacement pump, sucking fluid into pump 28 on the upstroke of piston 50 and expelling the fluid from pump 28 on the downstroke of piston 50.
Annular flanges 66 and 60 engage with each other to seal the joint between elbow 34 and pump 28. Annular protrusion 62 aligns lower section 32 of pump 28 with second end 34C of elbow 34 and allows for rotational misalignment between pump 28 and elbow 34. Packing ring stack 64 seals between the dynamic surfaces of pump 28 to force fluid through intake 58 on a face of piston 50. O-ring 68 seals the interface between annular flanges 60 and 66. Pump head 70 and first end 34A of elbow 34 are configured to make both a mechanical connection and a fluid connection with a single linear motion of pump 28. During operation, collar 72 moves piston 50 up and down. Collar 72 is reciprocated by connecting arm 74. In one non-limiting embodiment, connecting arm 74 is part of a crank that connects with an eccentric rotated by motor of reciprocating drive mechanism 24 to convert rotational motion of the eccentric into a linear reciprocating motion of collar 72. In another non-limiting embodiment, a scotch yoke can convert the rotational motion of the eccentric into a linear reciprocating motion of collar 72 in order to drive piston 50. Slot 76 is configured to receive or accept head 70 of piston 50.
Rib 78 is a ring of solid material. Shelf 80 is an annular lip or shoulder of solid material. Slot 76 receives and houses head 70 of piston 50. A shape of slot 76 matches and/or conforms to a shape of head 70 such that head 70 can be linearly translated in and out of slot 76. When inserted into slot 76, head 70 is in contact with collar 72. Rib 78 extends entirely annularly around pump 28 and radially outwards from cylinder 30. In one non-limiting embodiment, slot 76 can be formed as part of cylinder 30, or can be attached to the top end of cylinder 30. Shelf 80 is in contact with rib 78.
Each of slot 76 and pump mount frame 36 form grooves into which clamp 44 protrudes to secure pump 28 to pump mount frame 36. This interface braces pump 28 from moving while collar 72 reciprocates piston 50 within pump 28. Slot 76 also forms a receiving space configured to receive head 70 of piston 50. As head 70 inserts completely into slot 76 during installation of head 70 of pump 50 into slot 76, a dynamic mechanical connection is formed between pump 28 and reciprocating drive mechanism 24. Rib 78 mates with shelf 80 of pump mount frame 36 to brace cylinder 30 to pump mount frame 36. Clamp 44 (as shown in
As shown in
The single linear motion removal allows for quick removal of pump assembly 26 from hopper 16. If pump 28 did not remove together with elbow 34, then pump 28 would be stuck because decoupling of head 70 from collar 72 requires a linear sliding motion yet pump 28 (and lower section 32 in particular) could not be removed from elbow 34 with the same linear sliding motion. Removal of pump assembly 26 allows pump assembly 26 to be cleaned and serviced, such as disassembly of the components of pump assembly 26 and replacement of wear components, such as first and second check valves 52 and 56 and packing ring stack 64. In another non-limiting embodiment, pump assembly 26 can be removed in this single linear motion manner for replacement by a newer, cleaner, or alternatively configured pump (e.g., larger or smaller pump, as well as a pump adapted for different fluids or pressures).
In one non-limiting embodiment, pump assembly 26 is remounted on material sprayer 10 by essentially a similar, but opposite, linear motion as described with respect to
In another non-limiting embodiment, a method of installing pump assembly 26 onto material sprayer 10 includes aligning first end 34A of elbow 34 with port 18 and aligning head 70 of piston 50 with slot 76. Pump axis AP is aligned with axis ADM of reciprocating drive mechanism 24. In one non-limiting embodiment, pump axis AP can be oriented at 15 to 65 degrees relative to a direction of gravity. In another non-limiting embodiment, pump axis AP can be oriented at approximately 45 degrees relative to the vertical direction of gravity. First end 34A of elbow 34 is inserted into port 18 of hopper 16. Pump assembly 26 is translated in a linear motion relative to hopper 16 and reciprocating drive mechanism 24 such that head 70 is inserted into slot 76 of collar 72 of reciprocating drive mechanism 24. Pump 28 is engaged with reciprocating drive mechanism 24 and elbow 34 is engaged with hopper 16. A dynamic mechanical connection is formed between pump 28 and reciprocating drive mechanism 24. A fluidic connection is formed between pump 28 and port 18. Port 18 is clamped to fitting 20 with clamp 40. Head 70 is clamped into slot 76 with clamp 44.
The single linear motion reconnection allows quick remounting of pump assembly 26. If pump assembly 26 did not remount together with elbow 34, then head 70 of piston 50 could not slide into slot 76 of collar 72 because lower section 32 would intersect elbow 34 or elbow 34 could not be slid into connection with each of the second end of fitting 20 (e.g., taper end 82 being received within opening 82) and first end 28A (not shown in
The following are non-exclusive descriptions of possible embodiments of the present invention.
In a first example, a pump for use with a material sprayer includes a cylinder, a piston disposed in the cylinder, a pump head attached to the piston, first and second check valves, and an elbow connected to the cylinder. The cylinder and the piston are coaxial with a pump axis of the pump. The pump head is configured to make a mechanical connection with the reciprocating drive mechanism so as to allow the reciprocating drive mechanism to reciprocate the piston along the pump axis. The elbow includes a first end, a second end, and an inner fluid channel. The first end is configured to make a fluid connection with the hopper. The second end is configured to be fixed with respect to the cylinder. The inner fluid channel extends from the first end to the second end and bends between the first end and the second end. The pump head and the first end of the elbow are configured to make both a mechanical connection and a fluid connection with a single linear motion of the pump.
The material sprayer of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components.
In the first example, an elbow can fluidly connect the pump to the hopper, wherein the elbow can be a bent tube configured to transport a fluid therethrough, the elbow can comprise a first end fluidly connected to a port of the hopper, a second end can be attached to the pump on an end of the pump opposite from the reciprocating drive mechanism, and/or a bend portion can extend between the first and second ends of the elbow.
In the first example, the pump axis can be oriented at an angle of approximately 45 degrees relative to the vertical direction of gravity.
In the first example, a first ball check valve can be disposed within a lower section of the pump, and/or a second ball check valve can be disposed with a portion of a first end of the piston.
In the first example, the first and second ball check valves can be orientated coaxial with the pump axis.
In the first example, the pump assembly can be configured to be attached to and/or detached from the hopper and the reciprocating drive mechanism with a single linear motion of the pump assembly relative to the hopper and the reciprocating drive mechanism.
In the first example, the single linear motion can slide the pump head into the reciprocating drive mechanism and/or can slide the first end of the elbow into a receiving port of the hopper.
In the first example, a material sprayer can have the reciprocating drive mechanism and/or the hopper.
In a second example, a pump assembly for a material sprayer with a hopper and a reciprocating drive mechanism includes a pump and an elbow. The pump is configured to pressurize a fluid and is mechanically attached to the reciprocating drive mechanism and fluidly attached to the hopper. The pump includes a cylinder, a piston disposed in and slideably engaged with the cylinder, and a pump axis. The piston includes a pump head connected to the reciprocating drive mechanism. The cylinder and the piston are coaxial with the pump axis such that the piston reciprocates along the pump axis. The piston is connected to the reciprocating drive mechanism such that the piston is coaxial with and is driven by the reciprocating drive mechanism to reciprocate along the pump axis. The elbow is a bent tube configured to transport a fluid therethrough and fluidly connects the pump to the hopper. The elbow includes a first end, a second end, and a bend portion. The first end is fluidly connected to a port of the hopper. The second end of the elbow is attached to the pump on a first end of the pump opposite from the reciprocating drive mechanism. The bend portion extends between the first and second ends of the elbow. The pump assembly is configured to be attached to or detached from the hopper and the reciprocating drive mechanism with a single linear motion of the pump assembly relative to the hopper and the reciprocating drive mechanism.
The pump assembly of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components.
In the second example, the second end of the elbow can be coaxial with the pump axis, wherein the first end of the elbow can include a centerline axis, and wherein the centerline axis of the first end of the elbow can be oriented approximately 90 degrees relative to the pump axis.
In the second example, the first end of the elbow can include a taper such that the first end of the elbow can be configured to insert into the port of the hopper.
In the second example, the second end of the elbow can include a first flange, wherein the pump can include a second flange, wherein the first flange and the second flange can be in contact with each other, and further comprising a first clamp, wherein the first clamp can press and/or hold the first flange against the second flange.
In the second example, a lower section can be mounted to the cylinder at the first end of the pump, wherein the lower section can comprise an annular protrusion that extends into a portion of the elbow, and wherein the second flange of the pump can encircle a portion of the lower section of the pump.
In the second example, an annular fitting can include a first end and/or a second end, a second clamp can attach the first end of the annular fitting to the hopper, and/or a third clamp can attach the second end of the annular fitting to the first end of the elbow.
In a third example, a method of installing a pump assembly onto a material sprayer with a hopper and a reciprocating drive mechanism includes inserting a first end of an elbow of the pump assembly into a port of the hopper. The pump assembly includes a pump and an elbow. The pump includes a cylinder and a piston disposed in and slideably engaged with the cylinder. The piston includes a piston head. The cylinder and the piston are coaxial with the pump axis. The elbow includes the first end, a second end, and a bend portion. The second end of the elbow is attached to the pump on a first end of the pump opposite from the reciprocating drive mechanism. The bend portion of the elbow extends between the first and second ends of the elbow. The piston head is inserted into a slot of a collar of the reciprocating drive mechanism. A dynamic mechanical connection is formed between the pump and the reciprocating drive mechanism. A fluidic connection is formed between the pump and the port of the hopper.
The method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following steps, features, configurations and/or additional components.
In the third example, a first end of the elbow can be aligned with a port of the hopper and/or a head of the piston of the pump can be aligned with the slot of the collar of the reciprocating drive mechanism.
In the third example, the port of the hopper can be clamped to an annular fitting that can be attached to the first end of the elbow with a first clamp and/or the head of the piston can be clamped into the slot of the collar of the reciprocating drive mechanism with a second clamp.
In the third example, an axis of the pump can be aligned with an axis of the reciprocating drive mechanism such that the axis of the pump can be coaxial with the axis of the reciprocating drive mechanism.
In the third example, the piston can be engaged with the reciprocating drive mechanism such that the reciprocating drive mechanism can be configured to reciprocate the piston along the pump axis.
In the third example, the pump assembly can be translated in a linear motion relative to the hopper and/or to the reciprocating drive mechanism to engage the pump with the reciprocating drive mechanism and/or to engage the elbow with the hopper.
In the third example, the pump axis can be oriented at 15 to 65 degrees relative to a direction of gravity.
In the third example, the pump axis can be oriented at approximately 45 degrees relative to the vertical direction of gravity.
In the third example, a tapered end of the first end of the elbow can be inserted into an opening of the port of the hopper.
While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.
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