The present disclosure relates to a sprayer for spraying fluids including paints and stains.
Paint sprayers are well-known in the art. For example, U.S. Pat. No. 7,360,720 discloses a spray gun for spraying paints, lacquers or similar media. This and other conventional spray guns can have a number of drawbacks. For example, conventional spray guns often lack an adequate indication to a user of the flow rate of the sprayer. Further, it is often difficult to refill the reservoir and adjust the spray pattern of conventional paint sprayers.
I would be desirable to provide a sprayer that includes an indication of the flow rate of the sprayer to the user and also simplifies the refilling of the sprayer and adjustment of the spray pattern.
This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
In some embodiments of the present disclosure, a sprayer for spraying a fluid can include a sprayer body, a fluid reservoir, a trigger assembly, a flow adjustment mechanism and an air horn assembly. The sprayer body can include a handle portion and a nozzle portion. The nozzle portion can include a nozzle assembly that defines a fluid outlet and that includes a fluid conduit and a needle arranged within the fluid conduit and extending in an axial direction. The needle can be movable to a plurality of positions between a closed position and a fully opened position, the needle closing the fluid outlet in the closed position and fully opening the fluid outlet in the fully opened position. The fluid reservoir can be coupled to the sprayer body and be in communication with the fluid outlet and fluid conduit. The trigger assembly can be coupled to the nozzle assembly and be configured to move the needle as the trigger assembly is depressed. The flow adjustment mechanism can be coupled to the trigger assembly and be configured to adjust a flow rate of the sprayer by limiting movement of the trigger assembly and the needle. The air horn assembly can include a collar removably coupled to the nozzle portion and a rotatable air horn arranged between the collar and nozzle portion. The air horn assembly can be configured to permit rotation of the air horn to a plurality of positions. The air horn can include at least one air horn projection that limits rotation of the air horn between a first position corresponding to a vertical spray pattern and a second position corresponding to a horizontal spray pattern.
In other embodiments, a sprayer for spraying a fluid can include a sprayer body, a fluid reservoir, a trigger assembly, a flow adjustment mechanism and an air horn assembly. The sprayer body can include a handle portion and a nozzle portion. The nozzle portion can include a nozzle assembly that defines a fluid outlet and that includes a fluid conduit and a needle arranged within the fluid conduit and extending in an axial direction. The needle can be movable to a plurality of positions between a closed position and a fully opened position, the needle closing the fluid outlet in the closed position and fully opening the fluid outlet in the fully opened position. The fluid reservoir can be coupled to the sprayer body and be in communication with the fluid outlet and fluid conduit. The trigger assembly can be coupled to the nozzle assembly and be configured to move the needle as the trigger assembly is depressed. The flow adjustment mechanism can be coupled to the trigger assembly and be configured to adjust a flow rate of the sprayer by limiting movement of the trigger assembly and the needle. The air horn assembly can include a collar removably coupled to the nozzle portion and a rotatable air horn arranged between the collar and nozzle portion. The air horn assembly can be configured to permit rotation of the air horn to a plurality of positions. The nozzle portion can include a ridge member that acts as a mechanical stop for the collar. The ridge member and collar can be configured to permit rotation of the air horn without loosening the collar from a fully tightened position in which the collar is in contact with the ridge member.
In various other embodiments, a sprayer for spraying a fluid can include a sprayer body, a fluid reservoir, a trigger assembly, a flow adjustment mechanism and an air horn assembly. The sprayer body can include a handle portion and a nozzle portion. The nozzle portion can include a nozzle assembly that defines a fluid outlet and that includes a fluid conduit and a needle arranged within the fluid conduit and extending in an axial direction. The needle can be movable to a plurality of positions between a closed position and a fully opened position, the needle closing the fluid outlet in the closed position and fully opening the fluid outlet in the fully opened position. The fluid reservoir can be coupled to the sprayer body and be in communication with the fluid outlet and fluid conduit. The trigger assembly can be coupled to the nozzle assembly and be configured to move the needle as the trigger assembly is depressed. The flow adjustment mechanism can be coupled to the trigger assembly and be configured to adjust a flow rate of the sprayer. The air horn assembly can include a collar removably coupled to the nozzle portion, an air diffuser coupled to the nozzle portion and a rotatable air horn arranged between the collar and air diffuser. The air horn assembly can be configured to permit rotation of the air horn to a plurality of positions. The nozzle portion can include a ridge member that acts as a mechanical stop for the collar. The ridge member and collar can be configured to permit rotation of the air horn without loosening the collar from a fully tightened position in which the collar is in contact with the ridge member. The air horn can include at least one air horn projection and the air diffuser can include at least one stop surface that interacts with the at least one air horn projection to limit rotation of the air horn between a first position corresponding to a vertical spray pattern and a second position corresponding to a horizontal spray pattern.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
Example embodiments will now be described more fully with reference to the accompanying drawings.
With reference to
With reference to
The handle portion 20 can also define an air supply chamber 23. Air supply chamber 23 can provide pressurized air to the nozzle portion 30 in order to operate sprayer 10, as described more fully below. Air supply chamber 23 can be arranged between a housing cap 46 and a handle air outlet 25. As shown in the example illustrated in
Nozzle portion 30 can be sealingly engaged with the handle portion 20 such that pressurized air exiting the handle air outlet 25 can be received within a pressurized air passageway 32 defined by the nozzle portion 30. Pressurized air passageway 32 can be a cylindrical aperture extending from a first end 30a coupled to the handle portion 20 and a second end 30b. An air horn assembly 90 can be coupled to the second end 30b of pressurized air passageway 32. During operation of the sprayer 10, pressurized air can travel from air supply chamber 23, through handle air outlet 25 and into pressurized air passageway 32, and then exit pressurized air passageway 32 through one or more air horn apertures 91 defined by the air horn assembly 90. The configuration of the one or more air horn apertures 91 can determine the spray pattern of sprayer 10.
In some embodiments, nozzle portion 30 can be removably coupled to handle portion 20. For example, the first end 30a of nozzle portion 30 can be received within an aperture 26 defined by handle portion 20. Aperture 26 can be sized to complement first end 30a such that handle portion 20 and nozzle portion 30 are frictionally engaged. In some embodiments, handle portion 20 and nozzle portion 30 can be threadably coupled by including complementary threads on each of handle portion 20 and nozzle portion 30. Handle portion 20 and nozzle portion 30 can also be coupled with a quick-disconnect mechanism 27, as shown in
A nozzle assembly 33 can be arranged within the nozzle portion 30 and include a nozzle 34, a fluid conduit 35 and a needle 36 arranged within the fluid conduit 35. The nozzle 34 can define a fluid outlet 37 in communication with the fluid conduit 35. The needle 36 can be movable to a plurality of positions between a closed position (shown in
The nozzle portion 30 can further include a reservoir coupler 60 that is configured to sealingly engage the reservoir 14. In some embodiments, the reservoir 14 can include a threaded neck 15 that threadably couples to reservoir coupler 60, for example, by a threaded collar 64. One or more seals 65 can be provided to seal the interface between reservoir coupler 60 and reservoir 14.
Reservoir coupler 60 can include an inlet conduit 61 and a pressurization conduit 62. A removable supply tube 63 can be received within the reservoir 14 and reservoir coupler 60. A first end 63a of the removable supply tube 63 can be arranged at the bottom of the reservoir 14 and a second end 63b can be arranged to sealingly mate with the inlet conduit 61. A fluid filter (not shown) can also be coupled to supply tube 63 to remove foreign objects from the fluid that could damage sprayer 10. The supply tube 63 and inlet conduit 61 can provide a communication path between fluid conduit 35 and the reservoir 14 such that fluid within reservoir 14 can be provided to fluid conduit 35. Pressurization conduit 62 can be arranged to provide pressurized air to reservoir 14 during operation of the sprayer 10 by communicatively coupling reservoir 14 with pressurized air passageway 32. A check valve 66 can be arranged within pressurization conduit 62 to allow pressurized air to enter reservoir 14 while inhibiting fluid within reservoir 14 to enter pressurized air passageway 32.
A trigger assembly 70 can be coupled to the nozzle assembly 33. A user can actuate trigger assembly 70 to begin operation of sprayer 10, as described more fully below. Trigger assembly 70 can include a trigger 71 that is coupled to a trigger collar 72. The trigger collar 72 can be coupled to the needle 36 such that, when the trigger assembly 70 is depressed, the needle 36 will move in an axial direction and open the fluid outlet 37.
A flow adjustment mechanism 73 can be coupled to the trigger assembly 70 to adjust the flow rate of fluid that exits the sprayer 10 during operation. Flow adjustment mechanism 73 can limit movement of the trigger assembly 70 and needle 36 and thereby control the size of the nozzle aperture 37a and flow rate of the sprayer 10. For example, flow adjustment mechanism 73 can act as a mechanical stop for the trigger assembly 70 by contacting he handle portion 20 when the trigger assembly 70 is depressed. As shown in
A trigger plunger 80 can be coupled to handle portion 20. Trigger plunger 80 can be coupled with switch 54 and be configured to actuate switch 54 when the trigger assembly 70 is depressed. Trigger plunger 80 can be received within an aperture 81 formed in handle portion 20. A spring 82 or other biasing member can be used to bias the trigger plunger 80 to an extended state whereby switch 54 is turned OFF. Upon depression of the trigger assembly, trigger plunger 80 can contact trigger assembly 70 and be moved to a compressed state whereby switch 54 is turned ON. For example only, switch 54 can be a mechanical switch that includes a lever arm 54a that interacts with trigger plunger 80 (such as switch arm 80d described below).
In various embodiments, sprayer 10 can include a flow rate indicator 280 to provide an indication to the user of the flow rate of sprayer 10. Referring now to
Sprayer 10 can operate as follows. Reservoir 14 can be filled by first uncoupling the reservoir 14 from the nozzle portion 30 and then pouring a desired fluid through the neck 15 into the reservoir 14. The reservoir 14 can then be sealingly coupled with the nozzle portion 30, e.g., with reservoir coupler 60, such that the first end 63a of supply tube 63 is immersed in the fluid. Power cord 52 can be plugged into a standard household outlet or other source of AC power to provide operating power to the sprayer 10.
A user can them turn ON the sprayer 10, e.g., by depressing trigger assembly 70, which then compresses trigger plunger 80 and actuates switch 54. Actuation of switch 54 can turn ON motor and fan assembly 40 to provide pressurized air to air supply chamber 23. Pressurized air can exit air supply chamber 23 through handle air outlet 25, travel through pressurized air passageway 32 and exit sprayer 10 through the one or more air horn apertures 91. Pressurized air can also be provided to reservoir 14 through pressurization conduit 62 to pressurize the reservoir 14, which can assist with drawing fluid through supply tube 63 into fluid conduit 35 and out of nozzle 33 during operation. For example only, the pressure inside of reservoir 14 during operation of sprayer 10 can be between 1.5 and 5 pounds per square inch (“psi”) or, more specifically, between 2 and 3 psi.
As the trigger assembly 70 is depressed, trigger collar 72 axially moves needle 36 to open fluid outlet 37. In the illustrated example, flow adjustment mechanism 73 acts as a mechanical stop for the trigger assembly 70 and thus limits travel of the needle 36. As described above, the size of the nozzle aperture 37a and the flow rate of the sprayer 10 can vary based on the position of the needle 36 when the trigger assembly 70 is depressed. Fluid will exit the fluid outlet 37 of nozzle 33 and enter the pressurized air stream that is flowing out of air horn aperture(s) 91 to form a fluid spray.
With reference to
Referring now to
Sprayer body 12′ can include a handle portion 20′ coupled to a nozzle portion 30′. Hose 101 can be coupled to the sprayer body 12′, e.g., by coupler 120. Similar to coupler 103, coupler 120 can be a threaded coupler, quick-release coupler or other coupling device. Hose 101 can provide pressurized air from floor unit 100 to pressurized air passageway 32 and out through air horn assembly 90, as described above. Further, pressurized air can travel from pressurized air passageway 32 through pressurization conduit 62 and into reservoir 14.
With particular reference to
A flow adjustment mechanism 73′ can be coupled to the trigger assembly 70′ to adjust the flow rate of fluid that exits the sprayer 10′ during operation. Flow adjustment mechanism 73′ can limit movement of the trigger assembly 70′ and needle 36 and thereby control the size of the nozzle aperture 37a and flow rate of the sprayer 10′. For example, flow adjustment mechanism 73′ can act as a mechanical stop for the trigger assembly 70′ by contacting the trigger lever 72′ when the trigger assembly 70′ is depressed.
Flow adjustment mechanism 73′ can include a rotatable collar 731 that interacts with a coupler 732. For example, coupler 732 can be threadably coupled to rotatable collar 731 as shown in the Figures. Collar 731 can include a ridge 733 that interacts with sprayer body 12′, such as groove 122, to maintain the collar 731 and sprayer body 12′ in a specific arrangement and inhibit movement of the collar 731 in the axial direction. Coupler 732 can include a first leg 734 that extends axially from the main body of the coupler 732. First leg 734 can be configured to contact the trigger assembly 70′ (such as trigger lever 72′) when the trigger assembly 70′ is depressed and therefore act as a mechanical stop. Coupler 732 can be slidingly coupled to nozzle portion 30′ such that, as the collar 731 is rotated, coupler 732 can travel axially, i.e., in the direction of the longitudinal axis of needle 36. In this manner, the position of coupler 732 and first leg 734 can be adjusted to limit movement of the trigger assembly 70′ and needle 36, thus controlling the flow rate of sprayer 10′.
Coupler 732 can further include a second leg 735 that includes a flow indicator 736. Second leg 735 can travel axially with the coupler 732 as the collar is rotated. Referring now to
With reference to
Reservoir 300 can be filled by first uncoupling the reservoir 300 from the sprayer body 12, 12′ and then pouring a desired liquid through the first threaded neck 315 into the reservoir 300. As will also be appreciated from this disclosure, fluid on reservoir coupler 60, supply tube 63, etc. can drip or spill onto the floor or another object when the reservoir 300 is separated from the reservoir coupler 60 during the filling of the reservoir 300. Such drips and spills can be avoided through use of a second neck 320 on the reservoir 300.
With reference to
Second neck 320 can be configured such that cap 350 can be decoupled from reservoir 300 (second neck 320) while the reservoir 300 is coupled to the sprayer body 12, 12′. For example, first threaded neck 315 can be arranged on a first side 300a of reservoir 300 and second neck 320 can be arranged on a second side 300b. As illustrated in
The reservoir 300 can be manufactured in various ways, including blow molding or a combination of injection molding and blow molding.
It will be appreciated that the reservoir 300 can be constructed somewhat differently from that which is depicted in
When filling the reservoir 300 through second neck 320 by turning the sprayer 10, 10′ upside down or on its side, it is possible that fluid could enter pressurization conduit 62 and/or pressurized air passageway 32. As described above, a check valve 66 can be arranged within pressurization conduit 62 to inhibit such fluid flow. Check valve 66 can comprise a ball check valve, as is illustrated in
Referring now to
Air horn 92 can include one or more air horn projections 95. Air horn projections 95 can be configured to interact with corresponding stop surfaces 96 formed on air diffuser 93. Stop surfaces 96 can act as a mechanical stop to limit rotation of air horn 92. The position of the stop surfaces 96 and air horn projections 95 can correspond to specific positions of air horn assembly 90, such as a vertical spray pattern position or a horizontal spray pattern position. Additionally or alternatively, air horn projections 95 can include one or more protrusions 98 that interact with a corresponding number of notches 97 formed in air diffuser 93. The position of the protrusions 98 and notches 97 can act as a detent mechanism to correspond to specific positions of air horn assembly 90, such as an angled spray pattern position (such as, at an angle of 45 degrees). One skilled in the art will appreciate that the mechanical stop and/or detent mechanism can be constructed differently from that described above. For example, a notch can be formed in the air horn 92 that interacts with a protrusion on the air diffuser. Furthermore, instead of stop surfaces 96, air horn 92 and air diffuser 93 can include a plurality of detent mechanisms (such as notches 97 and protrusions 98) that correspond to specific positions of air horn assembly 90.
The construction of air horn assembly 90 and nozzle portion 30, 30′ can allow for a simple adjustment of the position of the air horn assembly 90. For example, nozzle portion 30, 30′ can include ridge member 304 that acts as a mechanical stop for collar 94. A user can arrange the air horn 92 and air diffuser 93 in the desired position and rotate collar 94 until it contacts ridge member 304. Ridge member 304 can be positioned such that the frictional force exerted on air horn 92 when the collar 94 is in contact with ridge member 304 is an amount that inhibits undesired rotation of air horn 92 (such as that caused by vibration during operation of sprayer 10, 10′) while allowing a user to rotate the air horn 92 if desired. In this manner, the ridge member 304 and collar 94 can be configured to permit rotation of the air horn 92 without loosening the collar 94 from a fully tightened position (shown in
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the invention, and all such modifications are intended to be included within the scope of the invention.
This application claims the benefit of U.S. Provisional Application No. 61/261,953, filed on Nov. 17, 2009. The entire disclosure of the above application is incorporated herein by reference.
Number | Date | Country | |
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61261953 | Nov 2009 | US |