Patent Application
20130026253
This application relates to the dispensing of texture material and, more particularly, to systems and methods for dispensing small amounts of texture material to an un-textured portion of a target surface such that an applied texture pattern of the texture material substantially matches a preexisting texture pattern on a textured portion of the target surface.
The present invention generally relates to systems and methods for applying texture material to an interior surface such as a wall or ceiling. In particular, buildings are typically constructed with a wood or metal framework. To form interior wall and ceiling surfaces, drywall material is attached to the framework. Typically, at least one primer layer and at least one paint layer is applied to the surface of the drywall material to form a finished wall surface.
For aesthetic and other reasons, a bumpy or irregular texture layer is often formed on the drywall material after the drywall material has been primed and before it has been painted. The appearance of the texture layer can take a number of patterns. As its name suggests, an “orange peel” texture pattern generally has the appearance of the surface of an orange and is formed by a spray of relatively small droplets of texture material applied in a dense, overlapping pattern. A “splatter” texture pattern is formed by larger, more spaced out droplets of texture material. A “knockdown” texture patter is formed by spraying texture material in larger droplets (like a “splatter” texture pattern) and then lightly working the surfaces of the applied droplets with a knife or scraper so that the highest points of the applied droplets are flattened. In some situations, a visible aggregate material such as polystyrene chips is added to the texture material to form what is commonly referred to as an “acoustic” or “popcorn” texture pattern. The principles of the present invention are of primary significance when applied to a texture material without visible aggregate material.
For larger applications, such as a whole room or structure, the texture layer is typically initially formed using a commercial texture sprayer. Commercial texture sprayers typically comprise a spray gun, a hopper or other source of texture material, and a source of pressurized air. The texture material is mixed with a stream of pressurized air within the texture gun, and the stream of pressurized air carries the texture material in droplets onto the target surface to be textured. Commercial texture sprayers contain numerous points of adjustment (e.g., amount of texture material, pressure of pressurized air, size of outlet opening, etc.) and thus allow precise control of the texture pattern and facilitate the quick application of texture material to large surface areas. However, commercial texture sprayers are expensive and can be difficult to set up, operate, and clean up, especially for small jobs where overspray may be a problem.
For smaller jobs and repairs, especially those performed by non-professionals, a number of “do-it-yourself” (DIY) products for applying texture material are currently available in the market. Perhaps the most common type of DIY texturing products includes aerosol systems that contain texture material and a propellant. Aerosol systems typically include a container, a valve, and an actuator. The container contains the texture material and propellant under pressure. The valve is mounted to the container selectively to allow the pressurized propellant to force the texture material out of the container. The actuator defines an outlet opening, and, when the actuator is depressed to place the valve in an open configuration, the pressurized propellant forces the texture material out of the outlet opening in a spray. The spray typically approximates only one texture pattern, so it was difficult to match a variety of perhaps unknown preexisting texture patterns with original aerosol texturing products.
A relatively crude work around for using an aerosol texturing system to apply more than one texture pattern is to reduce the pressure of the propellant material within the container prior to operating the valve. In particular, when maintained under pressure within the container, typical propellant materials exist in both a gas phase and in a liquid phase. The propellant material in the liquid phase is mixed with the texture material, and the texture material in the gas state pressurizes the mixture of texture material and liquid propellant material. When the container is held upright, the liquid contents of the container are at the bottom of the container chamber, while the gas contents of the container collect at the top of the container chamber. A dip tube extends from the valve to the bottom of the container chamber to allow the propellant in the gas phase to force the texture material up from the bottom of the container chamber and out of the outlet opening when the valve is opened. To increase the size of the droplets sprayed out of the aerosol system, the container can be inverted, the valve opened, and the gas phase propellant material allowed to flow out of the aerosol system, reducing pressure within the container chamber. The container is then returned upright and the valve operated again before the pressure of the propellant recovers such that the liquid contents are forced out in a coarser texture pattern. This technique of adjusting the applied texture pattern result in only a limited number of texture patterns that are not highly repeatable and can drain the can of propellant before the texture material is fully dispensed.
A more refined method of varying the applied texture pattern created by aerosol texturing patterns involved adjusting the size of the outlet opening formed by the actuator structure. Initially, it was discovered that the applied texture pattern could be varied by attaching one of a plurality of straws or tubes to the actuator member, where each tube defined an internal bore of a different diameter. The straws or tubes were sized and dimensioned to obtain fine, medium, and coarse texture patterns appropriate for matching a relatively wide range of pre-existing texture patterns. Additional structures such as caps and plates defining a plurality of openings each having a different cross-sectional area could be rotatably attached relative to the actuator member to change the size of the outlet opening. More recently, a class of products has been developed using a resilient member that is deformed to alter the size of the outlet opening and thus the applied texture pattern.
Existing aerosol texturing products are acceptable for many situations, especially by DIY users who do not expect perfect or professional results. Professional users and more demanding DIY users, however, will sometimes forego aerosol texturing products in favor of commercial texture sprayers because of the control provided by commercial texture sprayers.
The need thus exists for improved aerosol texturing systems and methods that can more closely approximate the results obtained by commercial texture sprayers.
An aerosol dispenser for dispensing stored material in a spray comprises a container, a conduit, and first and second adjustment systems. The container defines a chamber containing the stored material and pressurized material. The conduit defines a conduit passageway having a conduit inlet and a conduit outlet. The conduit inlet is arranged within the chamber and the conduit outlet is arranged outside of the chamber. The first adjustment system is arranged to vary a flow of stored material along the conduit passageway and is arranged between the conduit inlet and the conduit outlet. The second adjustment system arranged to vary a flow of stored material along the conduit passageway and is arranged between the first adjustment system and the conduit outlet.
The present invention may also be embodied as a method of dispensing stored material in a spray comprising the following steps. The stored material and pressurized material are arranged in a chamber. A conduit is arranged such that a conduit inlet is arranged within the chamber and a conduit outlet is arranged outside of the chamber. A flow of stored material is varied at a first location along the conduit passageway. The first location is arranged between a conduit inlet defined by the conduit passageway and a conduit outlet defined by the conduit passageway. The flow of stored material is varied at a second location along the conduit passageway. The third location is arranged between the first location and the conduit outlet.
The present invention may also be embodied as an aerosol dispensing system for dispensing stored material in a spray comprising a container, a conduit, a valve assembly, and first and second adjustment members. The container defines a chamber containing the stored material and pressurized material. The conduit defines a conduit passageway having a conduit inlet and a conduit outlet. The conduit inlet is arranged within the chamber, and the conduit outlet is arranged outside of the chamber. The valve assembly is arranged selectively to allow and prevent flow of stored material along the conduit passageway. The first adjustment member arranged to vary a flow of stored material along the conduit passageway and is arranged between the conduit inlet and the conduit outlet. The second adjustment member arranged to vary a flow of stored material along the conduit passageway and is arranged between the first adjustment member and the conduit outlet.
The present invention may be embodied in many forms, and several examples of aerosol dispensing systems of the present invention will be discussed below. In particular, the Applicant will initially describe a first example class of aerosol systems and a number of example aerosol dispensing systems within the first class. The Applicant will then describe a second example class of aerosol systems and a number of example aerosol dispensing systems within that second class.
Referring initially to
A typical texture material forming a part of the dispensed material 22a and/or stored material 34a will comprise a base or carrier, a binder, a filler, and, optionally, one or more additives such as surfactants, biocides and thickeners. Examples of the base or carrier include water, solvent (oil-based texture material) such as xylene, toluene, acetone, methyl ethyl ketone, and combinations of water and water soluble solvents. Examples of binders include starch, polyvinyl alcohol and latex resins (water-based systems) and a wide variety of polymers such as ethylene vinyl acetate, thermoplastic acrylics, styrenated alkyds, etc. (solvent-based systems.). Examples of fillers include calcium carbonate, titanium dioxide, attapulgite clay, talc, magnesium aluminum silicate, etc.
The stored material 34a will also comprise a liquid phase propellant material, and the pressurized material will typically comprise a gas phase propellant material. The following propellant materials are appropriate for use as the propellant material forming the stored material 34a and the pressurized material 36a: dimethyl ether, propane, butane, isobutene, difluoroethane, and tetrafluoroethane.
The following Tables A-1, A-2, and A-3 and Tables A-4 and A-5 attached hereto as Exhibit A contain example formulations of the texture material that may be used to form the dispensed material 22a and stored material 34a of the first example aerosol dispensing 20a.
To the example texture material described in Table A-1 is added propellant material in the form of a propane/butane/isobutane blend. A first range of approximately 10-20% by weight of the propellant material is added to the example texture material of Table A-1, but the propellant material should in any event be within a second range of approximately 5-25% by weight of the propellant material.
To the example texture material described in Table A-2 is added propellant material in the form of DME. A first range of approximately 7-15% by weight of the propellant material is added to the example texture material of Table A-2, but the propellant material should in any event be within a second range of approximately 5-25% by weight of the propellant material.
To the example texture material described in Table A-3 is added propellant material in the form of DME. A first range of approximately 10-15% by weight of the propellant material is added to the example texture material of Table A-3, but the propellant material should in any event be within a second range of approximately 5-25% by weight of the propellant material.
With reference to Tables A-4 and A-5 in Exhibit A, that table contains examples of a texture material composition adapted to be combined with an aerosol and dispensed using an aerosol dispensing system in accordance with the principles of the present invention. Each value or range of values in Tables A-4 and A-5 represents the percentage of the overall weight of the example texture material composition formed by each material of the texture material composition for a specific example, a first example range, and a second example range. The composition described in Table A-5 is similar to that of Table A-4, but Table A-5 contains a number of additional materials that may optionally be added to the example texture material composition of Table A-4.
One example of a method of combining the materials set forth in Table A-4 is as follows. Materials A, B, C, and D are combined to form a first sub-composition. The first sub-composition is mixed until material D is dissolved (e.g., 30-40 minutes). Materials E and F are then added to the first sub-composition to form a second sub-composition. The second sub-composition is mixed until materials E and F are well-dispersed (e.g., at high speed for 15-20 minutes). Material G is then added to the second sub-composition to form a third sub-composition. The third sub-composition is mixed well (e.g., 10 minutes). Typically, the speed at which the third sub-composition is mixed is reduced relative to the speed at which the second sub-composition is mixed. Next, materials H, I, and J are added to the third sub-composition to form the example texture material composition of the present invention. The example texture material composition is agitated. Material K may be added as necessary to adjust (e.g., reduce) the viscosity of the example texture material composition.
The example texture material composition of the present invention may be combined with an aerosol propellant in any of the aerosol dispensing systems described herein to facilitate application of the example texture material composition to a surface to be textured.
Arranged within the valve housing 52a is a valve system 60a. A first flow adjustment system 70a having a first adjustment member 72a is arranged to interface with the valve system 60a. A second flow adjustment system 80a having a second adjustment member 82a is arranged in the conduit passageway 42a to form at least a portion of the conduit outlet 46a.
The valve system 60a operates in a closed configuration, a fully open configuration, and at least one of a continuum or plurality of partially open intermediate configurations. In the closed configuration, the valve system 60a substantially prevents flow of fluid along the conduit passageway 42a. In the open configuration and the at least one intermediate configuration, the valve system 60a allows flow of fluid along the conduit passageway 42a. The valve system 60a is normally in the closed configuration. The valve system 60a engages the actuator member structure 54a and is placed into the open configuration by applying deliberate manual force on the actuator structure 54a towards the container 30a.
The first flow adjustment system 70a is supported by the container 30a to engage the actuator structure such that manual operation of the first adjustment member 72a affects operation of the valve system 60a to control the flow of fluid material along the conduit passageway 42a. In particular, the first adjustment system 70a and the valve system 60a function as a flow restrictor, where operation of the first adjustment member 72a results in a variation in the size of the conduit passageway 42a within the valve system 60a such that a pressure of the fluid material upstream of the first flow adjustment system 70a is relatively higher than the pressure of the fluid material downstream of the first flow adjustment system 70a.
In general, a primary purpose of the first flow adjustment system 70a is to alter a distance of travel of the dispensed material 22a. The first flow adjustment system 70a may also have a secondary affect on the pattern in which the dispensed material 22a is sprayed.
The second adjustment system 80a is supported by the actuator structure 54a downstream of the first adjustment system 70a. Manual operation of the second adjustment member 82a affects the flow of fluid material flowing out of the conduit passageway 42a through the conduit outlet 46a. In particular, the second adjustment system 80a functions as a variable orifice, where operation of the second adjustment member 82a variably reduces the size of the conduit outlet 46a relative to the size of the conduit passageway 42a upstream of the second adjustment system 80a.
A primary purpose of the second flow adjustment system 80a is to alter a pattern in which the dispensed material 22a is sprayed. The first flow adjustment system 70a may also have a secondary affect on the distance of travel of the dispensed material 22a.
To operate the first example aerosol dispensing system 20, the container 30a is grasped such that the finger can depress the actuator structure 54a. The conduit outlet or outlet opening 46a is initially aimed at a test surface and the actuator structure 54a is depressed to place the valve system 60a in the open configuration such that the pressurized material 36a forces some of the stored material 34a out of the container 30a and onto the test surface to form a test texture pattern. The test texture pattern is compared to the pre-existing texture pattern defined by the textured portion 26a of the target surface 24a. If the test texture pattern does not match the pre-existing texture pattern, one or both of the first and second adjustment systems 70a and 80a are adjusted to alter the spray pattern of the droplets of dispensed material 22a.
The process of spraying a test pattern and comparing it to the pre-existing pattern and adjusting the first and second adjustment members 72a and 82a is repeated until the dispensed material forms a desired texture pattern that substantially matches the pre-existing texture pattern.
Leaving the first and second adjustment systems 70a and 80a as they were when the test texture pattern matched the pre-existing texture pattern, the aerosol dispensing system 20a is then arranged such that the conduit outlet or outlet opening 46a is aimed at the un-textured portion 28a of the target surface 24a. The actuator structure 54a is again depressed to operate the valve system 60a such that the pressurized material 36a forces the stored material 34a out of the container 30a and onto the un-textured portion 28a of the target surface to form the desired texture pattern.
Referring now to
Arranged within the valve housing 152 is a valve assembly 160. The example valve assembly 160 comprises a valve member 162, a valve seat 164, and a valve spring 166. The valve assembly 160 operates in a closed configuration and an open configuration. In the closed configuration, the valve spring 166 forces the valve member 162 against the valve seat 164 such that the valve assembly 160 substantially prevents flow of fluid along the conduit passageway 142. In the open configuration, the valve member 162 is displaced away from the valve seat 164 against the force of the valve spring 166 such that the valve assembly 160 allows flow of fluid along the conduit passageway 142 between the valve member 162 and the valve seat 164. Because the valve spring 166 biases the valve member 162 towards the valve seat 164, the example valve assembly 160 is normally closed. The valve assembly 160 engages the actuator member structure 154 such that the application of deliberate manual force on the actuator member 154 towards the container 130 moves the valve member 162 away from the valve seat 164 and thus places the valve system 160 in the open configuration.
A first flow adjustment system 170 comprising a first adjustment member 172 is arranged selectively to limit movement of the actuator member 154 relative to the container assembly 130. In particular, the first adjustment member defines an adjustment axis AA and a stop surface 174. The stop surface 174 extends along a varying or substantially helical path relative to the adjustment axis AA.
Rotation of the first adjustment member 172 relative to the grip assembly 158 thus alters a position of the stop surface 174 relative to the actuator member 154. With the first adjustment member 172 in a first angular position as shown in
Further, the first adjustment member 172 is configurable in any one of a plurality or continuum of angular positions between the first and second positions shown. The first adjustment system 170 thus allows the user to obtain a range of restrictions in the conduit passageway as necessary for a particular desired texture pattern.
A second flow adjustment system 180 having a second adjustment member 182 is arranged in the conduit passageway 142 to form at least a portion of the conduit outlet or outlet opening 146. In particular, the second adjustment member 182 defines a plurality of adjustment openings 184a, 184b, and 184c (
Manual operation of the first adjustment member 172 affects the flow of fluid material along the conduit passageway 142 upstream of the second adjustment system 180. In particular, the first adjustment system 170 functions as a flow restrictor, where operation of the first adjustment member 172 variably reduces the size of the conduit passageway 142 such that a pressure of the fluid material upstream of the first flow adjustment system 170 is relatively higher than the pressure of the fluid material downstream of the first flow adjustment system 170 (towards the second adjustment system 180).
The second adjustment system 180 is supported by the actuator member 154 downstream of the first adjustment system 170. The selected one of the adjustment openings 184a, 184b, and 184c thereby affects the flow of fluid material flowing out of the conduit passageway 142. The second adjustment system 180 thus functions as a variable orifice system. Operation of the second adjustment member 172 variably reduces the size of the conduit outlet or outlet opening 146 relative to the size of the conduit passageway 142 upstream of the second adjustment system 180.
The first adjustment member 172 and second adjustment member 182 are supported as described above to define a control system 190.
In use, the conduit outlet or outlet opening 146 is initially aimed at a test surface and the actuator member 154 is depressed to place the valve assembly 160 in the open configuration such that the pressurized material 136 forces some of the stored material 134 out of the container 130 and onto the test surface to form a test texture pattern. The test texture pattern is compared to the pre-existing texture pattern defined by the textured portion of the target surface. If the test texture pattern does not match the pre-existing texture pattern, one or both of the first and second adjustment members is/are adjusted to alter the spray pattern of the droplets of dispensed material 122.
The process of spraying a test pattern and adjusting the first and second adjustment members 172 and 182 is repeated until the test pattern formed by the dispensed material 122 corresponds to a desired texture pattern that substantially matches the pre-existing texture pattern.
Leaving the first and second adjustment members 172 and 182 as they were when the test texture pattern corresponded to the desired texture pattern, the aerosol dispensing system 120 is then arranged such that the conduit outlet or outlet opening 146 is aimed at the un-textured portion of the target surface. The trigger member 194 is again squeezed to place the valve assembly 160 in the open configuration such that the pressurized material 136 forces the stored material 134 out of the container 130 and onto the un-textured portion of the target surface to form the desired texture pattern on the un-textured portion of the target surface, perhaps overlapping slightly with the textured portion of the target surface. Since the desired texture pattern substantially matches the pre-existing texture pattern, the dispensed material forms a coating on the previously un-textured portion of the target surface in a desired texture pattern that substantially matches a physical appearance of the textured portion. One or more layers of primer and/or paint may next be applied over the cured layer of dispensed material on the target surface.
The following Table B represents example ranges and dimensions for constructing a physical embodiment of a flow adjustment system that may be used as the example first flow adjustment system 170:
Referring now to
Arranged within the valve housing 252 is a valve assembly 260. The example valve assembly 260 comprises a valve member 262, a valve seat 264, and a valve spring 266. The valve assembly 260 operates in a closed configuration and an open configuration. In the closed configuration, the valve spring 266 forces the valve member 262 against the valve seat 264 such that the valve assembly 260 substantially prevents flow of fluid along the conduit passageway 242. In the open configuration, the valve member 262 is displaced away from the valve seat 264 against the force of the valve spring 266 such that the valve assembly 260 allows flow of fluid along the conduit passageway 242 between the valve member 262 and the valve seat 264. Because the valve spring 266 biases the valve member 262 towards the valve seat 264, the example valve assembly 260 is normally closed. The valve assembly 260 engages the actuator member structure 254 such that the application of deliberate manual force on the actuator member 254 towards the container 230 moves the valve member 262 away from the valve seat 264 and thus places the valve system 260 in the open configuration.
A first flow adjustment system 270 comprising a first adjustment member 272 is arranged selectively to limit movement of the actuator member 254 relative to the container assembly 230. In particular, the first adjustment member 272 is a plate or disc defining an upper surface 274 and a plate axis Ap, and, optionally, comprises at least one stop surface 276. The at least one example stop surface 276 is arranged in an arcuate segment on the upper surface 274 and define a stop radius RS relative to the plate axis A. In the example first adjustment member 272, two pairs of stop surfaces 276a and 276b are formed in opposing locations relative to the plate axis A.
The example flow adjustment system 270 further comprises at least one engaging surface 278 formed on the actuator member 254. The example actuator member 254 defines an actuator axis AA, and the at least one engaging surface 278 is arranged in an arcuate segment on the lower edge of the actuator member 254 and defines an actuator radius RA relative to the actuator axis AA. The actuator radius RA and the stop radius RS are substantially the same in the example flow adjustment system 270.
In general, the actuator member 254 is arranged relative to the first adjustment member 272 such that rotation of the first adjustment member 272 relative to the grip assembly 258 alters an angular position of the at least one stop surface 276 relative to the at least one engaging surface 278 of actuator member 254. The angular relationship of the at least one stop surface 274 relative to the at least one engaging surface 278 determines an amount of travel of the actuator member 254 relative to the container assembly 230 and the valve system 260 supported thereby.
In particular, with the first adjustment member 272 in a first angular position relative to the actuator member 254 as shown in
Further, the first adjustment member 272 may configurable in any one of a plurality or continuum of angular positions by using slanted stop and engaging surfaces rather than the arrangement of stop surfaces 276 and engaging surfaces 278 of the example first adjustment system 260. The first adjustment system 270 thus allows the user to obtain a range of restrictions in the conduit passageway as necessary for a particular desired texture pattern.
A second flow adjustment system 280 having a second adjustment member 282 is arranged in the conduit passageway 242 to form at least a portion of the conduit outlet or outlet opening 246. In particular, the second adjustment member 282 of the example second flow adjustment system 280 takes the form of at least one adjustment straw or tube (
A selected one of the second adjustment members 282a, 282b, and 284c is detachably attached to the actuator member 254 such that the outlet orifice 284a, 284b, or 284c associated with the selected second adjustment member 282a, 282b, or 282c is aligned with the conduit outlet 246. Accordingly, any selected one of the outlet orifices 284a, 284b, and 284c may be selected and arranged to define a cross-sectional area of the outlet opening defined by the conduit outlet 246.
Manual operation of the first adjustment member 272 affects the flow of fluid material along the conduit passageway 242 upstream of the second adjustment system 280. In particular, the first adjustment system 270 functions as a flow restrictor, where operation of the first adjustment member 272 variably reduces the size of the conduit passageway 242 such that a pressure of the fluid material upstream of the first flow adjustment system 270 is relatively higher than the pressure of the fluid material downstream of the first flow adjustment system 270 (towards the second adjustment system 280).
The second adjustment system 280 is supported by the actuator member 254 downstream of the first adjustment system 270. The selected one of the outlet orifices 284a, 284b, and 284c thereby affects the flow of fluid material flowing out of the conduit passageway 242. The second adjustment system 280 thus functions as a variable orifice system. Operation of the second adjustment member 272 variably reduces the size of the conduit outlet or outlet opening 246 relative to the size of the conduit passageway 242 upstream of the second adjustment system 280.
The actuator member 254, the first adjustment member 272, and the selected one of the second adjustment members 282 supported to define a control system 290.
In the example actuator assembly 238, grip housing 292 defines a cylindrical interior surface 292a and the actuator member 254 defines a cylindrical outer surface 254a. The outer surface 254a is sized and dimensioned to allow the actuator member 254 to fit within a grip chamber defined by the interior surface 292a such that the grip housing 292 supports the actuator member 254 for substantially linear movement along a container axis AC defined by the container assembly 230.
Accordingly, to operate the second example aerosol dispensing system 220, the container 230 and grip housing 292 are grasped such that the user's fingers can depress an upper surface of the actuator member 254, thereby allowing the actuator member 254 to be depressed.
Further,
In use, the conduit outlet or outlet opening 246 is initially aimed at a test surface and the actuator member 254 is depressed to place the valve assembly 260 in the open configuration to allow the pressurized material 236 to force some of the stored material 234 out of the container 230 and onto the test surface to form a test texture pattern. The test texture pattern is compared to the pre-existing texture pattern defined by the textured portion of the target surface. If the test texture pattern does not match the pre-existing texture pattern, one or both of the first and second adjustment members is/are adjusted to alter the spray pattern of the droplets of dispensed material 222.
The process of spraying a test pattern and adjusting the first and second adjustment members 272 and 282 is repeated until the test pattern formed by the dispensed material 222 corresponds to a desired texture pattern that substantially matches the pre-existing texture pattern.
Leaving the first and second adjustment members 272 and 282 as they were when the test texture pattern corresponded to the desired texture pattern, the aerosol dispensing system 220 is then arranged such that the conduit outlet or outlet opening 246 is aimed at the un-textured portion of the target surface. The actuator member 254 is again depressed to place the valve assembly 260 in the open configuration such that the pressurized material 236 forces the stored material 234 out of the container 230 and onto the un-textured portion of the target surface to form the desired texture pattern on the un-textured portion of the target surface, perhaps overlapping slightly with the textured portion of the target surface. Since the desired texture pattern substantially matches the pre-existing texture pattern, the dispensed material forms a coating on the previously un-textured portion of the target surface in a desired texture pattern that substantially matches a physical appearance of the textured portion. One or more layers of primer and/or paint may next be applied over the cured layer of dispensed material on the target surface.
The following Table C represents example ranges and dimensions for constructing a physical embodiment of a flow adjustment system that may be used as the example first flow adjustment system 270:
Referring now to
Arranged within the valve housing 352 is a valve assembly 360. The example valve assembly 360 comprises a valve member 362, a valve seat 364, and a valve spring 366. The valve assembly 360 operates in a closed configuration and an open configuration. In the closed configuration, the valve spring 366 forces the valve member 362 against the valve seat 364 such that the valve assembly 360 substantially prevents flow of fluid along the conduit passageway 342. In the open configuration, the valve member 362 is displaced away from the valve seat 364 against the force of the valve spring 366 such that the valve assembly 360 allows flow of fluid along the conduit passageway 342 between the valve member 362 and the valve seat 364. Because the valve spring 366 biases the valve member 362 towards the valve seat 364, the example valve assembly 360 is normally closed. The valve assembly 360 engages the actuator member structure 354 such that the application of deliberate manual force on the actuator member 354 towards the container 330 moves the valve member 362 away from the valve seat 364 and thus places the valve system 360 in the open configuration.
A first flow adjustment system 370 comprising a first adjustment member 372 is arranged selectively to limit movement of the actuator member 354 relative to the container assembly 330. In particular, the first adjustment member defines an adjustment axis AA and a stop surface 374.
Rotation of the first adjustment member 372 about the adjustment axis AA relative to the grip assembly 358 thus alters a position of the stop surface 374 relative to the actuator member 354. In particular, the first adjustment member 372 defines an externally threaded surface 376 adapted to engage a similar internally threaded surface defined by the grip assembly 358. Rotating the first adjustment member 372 displaces the first adjustment member 372 towards and away from the actuator member 354 between a fully open position and a terminal position. In a first position as shown in
Further, the first adjustment member 372 is configurable in any one of a plurality or continuum of positions between the first and second positions shown. The first adjustment system 370 thus allows the user to obtain a range of restrictions in the conduit passageway as necessary for a particular desired texture pattern.
A second flow adjustment system 380 having a second adjustment member 382 is arranged in the conduit passageway 342 to form at least a portion of the conduit outlet or outlet opening 346. In particular, the second adjustment system 380 comprises, in addition, a plurality of fingers 384 extending from the actuator member 354 and an externally threaded surface 386 formed on the actuator member 354. The second adjustment member 382 defines an internally threaded surface 382a that is adapted to engage the externally threaded surface 386 such that rotation of the second adjustment member 382 about an axis of rotation AR displaces the adjustment member in both directions along the axis of rotation AR. As the second adjustment member 382 is displaced along the axis of rotation AR, the second adjustment member 382 engages the fingers 284 to deform the outlet member 356. Deformation of the outlet member 356 alters a cross-sectional area of the conduit outlet or outlet opening 346. Accordingly, rotation of the second adjustment member 382 relative to the actuator member 354 allows any the cross-sectional area of the outlet opening defined by the conduit outlet 346 to be made larger and/or smaller within a predetermined range of cross-sectional areas.
Manual operation of the first adjustment member 372 affects the flow of fluid material along the conduit passageway 342 upstream of the second adjustment system 380. In particular, the first adjustment system 370 functions as a flow restrictor, where operation of the first adjustment member 372 variably reduces the size of the conduit passageway 342 such that a pressure of the fluid material upstream of the first flow adjustment system 370 is relatively higher than the pressure of the fluid material downstream of the first flow adjustment system 370 (towards the second adjustment system 380).
The second adjustment system 380 is supported by the actuator member 354 downstream of the first adjustment system 370. Adjustment of the first adjustment system 370 (e.g., selecting one of the adjustment openings 384a, 384b, and 384c) thereby affects the flow of fluid material flowing out of the conduit passageway 342. The second adjustment system 380 thus functions as a variable orifice system. Operation of the second adjustment member 372 variably reduces the size of the conduit outlet or outlet opening 346 relative to the size of the conduit passageway 342 upstream of the second adjustment system 380.
The first adjustment member 372 and second adjustment member 382 are supported as described above to define a control system 390.
In use, the conduit outlet or outlet opening 346 is initially aimed at a test surface and the actuator member 354 is depressed to place the valve assembly 360 in the open configuration such that the pressurized material 336 forces some of the stored material 334 out of the container 330 and onto the test surface to form a test texture pattern. The test texture pattern is compared to the pre-existing texture pattern defined by the textured portion of the target surface. If the test texture pattern does not match the pre-existing texture pattern, one or both of the first and second adjustment members is/are adjusted to alter the spray pattern of the droplets of dispensed material 322.
The process of spraying a test pattern and adjusting the first and second adjustment members 372 and 382 is repeated until the test pattern formed by the dispensed material 322 corresponds to a desired texture pattern that substantially matches the pre-existing texture pattern.
Leaving the first and second adjustment members 372 and 382 as they were when the test texture pattern corresponded to the desired texture pattern, the aerosol dispensing system 320 is then arranged such that the conduit outlet or outlet opening 346 is aimed at the un-textured portion of the target surface. The trigger member 394 is again squeezed to place the valve assembly 360 in the open configuration such that the pressurized material 336 forces the stored material 334 out of the container 330 and onto the un-textured portion of the target surface to form the desired texture pattern on the un-textured portion of the target surface, perhaps overlapping slightly with the textured portion of the target surface. Since the desired texture pattern substantially matches the pre-existing texture pattern, the dispensed material forms a coating on the previously un-textured portion of the target surface in a desired texture pattern that substantially matches a physical appearance of the textured portion. One or more layers of primer and/or paint may next be applied over the cured layer of dispensed material on the target surface.
The following Table D represents example ranges and dimensions for constructing a physical embodiment of a flow adjustment system that may be used as the example first flow adjustment system 370:
Referring now to
A typical texture material forming a part of the dispensed material 22b and/or stored material 34b will comprise a base or carrier, a binder, a filler, and, optionally, one or more additives such as surfactants, biocides and thickeners. Examples of the base or carrier include water, solvent (oil-based texture material) such as xylene, toluene, acetone, methyl ethyl ketone, and combinations of water and water soluble solvents. Examples of binders include starch, polyvinyl alcohol and latex resins (water-based systems) and a wide variety of polymers such as ethylene vinyl acetate, thermoplastic acrylics, styrenated alkyds, etc. (solvent-based systems.). Examples of fillers include calcium carbonate, titanium dioxide, attapulgite clay, talc, magnesium aluminum silicate, etc.
The stored material 34b will also comprise a liquid phase propellant material, and the pressurized material will typically comprise a gas phase propellant material. The following propellant materials are appropriate for use as the propellant material forming the stored material 34b and the pressurized material 36b: dimethyl ether, propane, butane, isobutene, difluoroethane, and tetrafluoroethane.
The following Tables E-1, E-2, and E-3 contain example formulations of the texture material that may be used to form the dispensed material 22b and stored material 34b of the second example aerosol dispensing 20b:
To the example texture material described in Table E-1 is added 10-20% by weight of propellant material in the form of a propane/butane/isobutane blend.
To the example texture material described in Table E-2 is added 7-15% by weight of propellant material in the form of DME.
To the example texture material described in Table E-3 is added 10-15% by weight of propellant material in the form of DME.
Arranged within the valve housing 52b is a valve system 60b. A first flow adjustment system 70b having a first adjustment member 72b is arranged to interface with the valve system 60b. A second flow adjustment system 80b having a second adjustment member 82b is arranged in the conduit passageway 42b to form at least a portion of the conduit outlet 46b.
The valve system 60b operates in a closed configuration, a fully open configuration, and at least one of a continuum or plurality of partially open intermediate configurations. In the closed configuration, the valve system 60b substantially prevents flow of fluid along the conduit passageway 42b. In the open configuration and the at least one intermediate configuration, the valve system 60b allows flow of fluid along the conduit passageway 42b. The valve system 60b is normally in the closed configuration. The valve system 60b engages the actuator member structure 54b and is placed into the open configuration by applying deliberate manual force on the actuator structure 54b towards the container 30b.
The first flow adjustment system 70b is supported by the container 30b to engage the actuator structure such that manual operation of the first adjustment member 72b controls the flow of fluid material along the conduit passageway 42b. In particular, the first adjustment system 70b functions as a flow restrictor, where operation of the first adjustment member 72b results in a variation in the size of a portion of the conduit passageway 42b such that a pressure of the fluid material upstream of the first flow adjustment system 70b is relatively higher than the pressure of the fluid material downstream of the first flow adjustment system 70b.
In general, a primary purpose of the first flow adjustment system 70b is to alter a distance of travel of the dispensed material 22b. The first flow adjustment system 70b may also have a secondary affect on the pattern in which the dispensed material 22b is sprayed.
The second adjustment system 80b is supported by the actuator structure 54b downstream of the first adjustment system 70b. Manual operation of the second adjustment member 82b affects the flow of fluid material flowing out of the conduit passageway 42b through the conduit outlet 46b. In particular, the second adjustment system 80b functions as a variable orifice, where operation of the second adjustment member 72b variably reduces the size of the conduit outlet 46b relative to the size of the conduit passageway 42b upstream of the second adjustment system 80b.
A primary purpose of the second flow adjustment system 80b is to alter a pattern in which the dispensed material 22b is sprayed. The first flow adjustment system 70b may also have a secondary affect on the distance of travel of the dispensed material 22b.
To operate the fifth example aerosol dispensing system 20b (of the second example class of dispensing systems), the container 30b is grasped such that the finger can depress the actuator structure 54b. The conduit outlet or outlet opening 46b is initially aimed at a test surface and the actuator structure 54b is depressed to place the valve system 60b in the open configuration such that the pressurized material 36b forces some of the stored material 34b out of the container 30b and onto the test surface to form a test texture pattern. The test texture pattern is compared to the pre-existing texture pattern defined by the textured portion 26b of the target surface 24b. If the test texture pattern does not match the pre-existing texture pattern, one or both of the first and second adjustment systems 70b and 80b are adjusted to alter the spray pattern of the droplets of dispensed material 22b.
The process of spraying a test pattern and comparing it to the pre-existing pattern and adjusting the first and second adjustment members 72b and 82b is repeated until the dispensed material forms a desired texture pattern that substantially matches the pre-existing texture pattern.
Leaving the first and second adjustment systems 70b and 80b as they were when the test texture pattern matched the pre-existing texture pattern, the aerosol dispensing system 20b is then arranged such that the conduit outlet or outlet opening 46b is aimed at the un-textured portion 28b of the target surface 24b. The actuator structure 54b is again depressed to operate the valve system 60b such that the pressurized material 36b forces the stored material 34b out of the container 30b and onto the un-textured portion 28b of the target surface to form the desired texture pattern.
Referring now to
A first flow adjustment system 470 having a first adjustment member 472 having a valve surface 474 and an externally threaded surface 476 is arranged to intersect the conduit passageway 442 at an intermediate location 442a between the valve assembly 460 and the conduit outlet 446. The conduit passageway has a first portion 442b and a second portion 442c. The first passageway portion 442b defines an actuator axis AA aligned with a container axis AC defined by the container assembly 430, and the second actuator passageway portion is aligned with an outlet axis AO defined by the outlet member 456. The example intermediate location 442a is located in the second passageway portion 442c.
An internally threaded surface 478 is formed in the actuator member 454. The threaded surfaces 476 and 478 are adapted to engage each other such that rotation of the first adjustment member 472 relative to the actuator member 454 causes the valve surface 474 to enter the conduit passageway and thus alter a cross-sectional area of the conduit passageway 442 between the valve system 460 and the second flow adjustment system 480.
A second flow adjustment system 480 comprises a second adjustment member 482 and a plurality of fingers 484 extending from the actuator member 454. The second flow adjustment system 480 is arranged relative to the conduit passageway 442 to form at least a portion of the conduit outlet (or outlet opening) 446. The second adjustment member 482 defines an internal threaded surface 486 that engages an external threaded surface 488 of the actuator member 454 such that rotation of the second adjustment member 482 relative to the actuator member 454 deforms the fingers and thus the outlet member 456, thereby altering a cross-sectional area of the conduit outlet or outlet opening 446.
The first flow adjustment system 470 is supported by the actuator member 454 between the valve assembly 460 and the second adjustment system 480 such that manual operation of the first adjustment member 472 affects the flow of fluid material along the conduit passageway 442. In particular, the second adjustment system 480 functions as a flow restrictor, where operation of the first adjustment member 472 variably reduces the size of the conduit passageway 442 such that a pressure of the fluid material upstream of the first flow adjustment system 470 is relatively higher than the pressure of the fluid material downstream of the first flow adjustment system 470. The example first adjustment member 472 is movable between a fully open configuration (smallest amount of restriction) and a terminal configuration (largest amount of restriction).
The second adjustment system 480 is supported by the actuator member 454 downstream of the first adjustment system 470. The outlet member 456 is a resiliently deformable tube, and manual operation of the second adjustment member 482 deforms the walls of the outlet member 456 and thereby affects the flow of fluid material flowing out of the conduit passageway 442 through the conduit outlet or outlet opening 446. The second adjustment system 480 thus functions as a variable orifice. Operation of the second adjustment member 482 variably reduces the size of the conduit outlet or outlet opening 446 relative to the size of the conduit passageway 442 upstream of the second adjustment system 480.
The outlet member 456, first adjustment member 472, and second adjustment member 482 are supported by the actuator member 454 to define a control assembly 490.
To operate the sixth example aerosol dispensing system 420, the container 430 and grip housing 492 are grasped such that the user's fingers can squeeze the trigger portion 494, thereby depressing the actuator member 454. The conduit outlet or outlet opening 446 is initially aimed at a test surface and the actuator member 454 is depressed to place the valve assembly 460 in the open configuration such that the pressurized material 436 forces some of the stored material 434 out of the container 430 and onto the test surface to form a test texture pattern. The test texture pattern is compared to the pre-existing texture pattern defined by the textured portion of the target surface. If the test texture pattern does not match the pre-existing texture pattern, one or both of the first and second adjustment members is/are adjusted to alter the spray pattern of the droplets of dispensed material 422.
The process of spraying a test pattern and adjusting the first and second adjustment members 472 and 482 is repeated until the test pattern formed by the dispensed material 422 corresponds to a desired texture pattern that substantially matches the pre-existing texture pattern.
Leaving the first and second adjustment members 472 and 482 as they were when the test texture pattern corresponded to the desired texture pattern, the aerosol dispensing system 420 is then arranged such that the conduit outlet or outlet opening 446 is aimed at the un-textured portion of the target surface. The trigger member 494 is again squeezed to place the valve assembly 460 in the open configuration such that the pressurized material 436 forces the stored material 434 out of the container 430 and onto the un-textured portion of the target surface to form the desired texture pattern on the un-textured portion of the target surface, perhaps overlapping slightly with the textured portion of the target surface. Since the desired texture pattern substantially matches the pre-existing texture pattern, the dispensed material forms a coating on the previously un-textured portion of the target surface in a desired texture pattern that substantially matches a physical appearance of the textured portion. One or more layers of primer and/or paint may next be applied over the cured layer of dispensed material.
The following Table F represents example ranges and dimensions for constructing a physical embodiment of a flow adjustment system that may be used as the example first flow adjustment system 470:
Referring now to
A first flow adjustment system 570 having a first adjustment member 572 having a valve surface 574 and an externally threaded surface 576 is arranged to intersect the conduit passageway 542 at an intermediate location 542a between the valve assembly 560 and the conduit outlet 546. The conduit passageway has a first portion 542b and a second portion 542c. The first passageway portion 542b defines an actuator axis AA aligned with a container axis AC defined by the container assembly 530, and the second actuator passageway portion 542c is aligned with an outlet axis AO defined by the outlet member 556. The example intermediate location 542a is located in the first passageway portion 542b.
An internally threaded surface 578 is formed in the actuator member 554. The threaded surfaces 576 and 578 are adapted to engage each other such that rotation of the first adjustment member 572 relative to the actuator member 554 causes the valve surface 574 to enter the conduit passageway 542 and thus alter a cross-sectional area of the conduit passageway 542 between the valve system 560 and the second flow adjustment system 580.
A second flow adjustment system 580 comprises a second adjustment member 582 and a plurality of fingers 584 extending from the actuator member 554. The second flow adjustment system 580 is arranged relative to the conduit passageway 542 to form at least a portion of the conduit outlet (or outlet opening) 546. The second adjustment member 582 defines an internal threaded surface 586 that engages an external threaded surface 588 of the actuator member 554 such that rotation of the second adjustment member 582 relative to the actuator member 554 deforms the fingers and thus the outlet member 556, thereby altering a cross-sectional area of the conduit outlet or outlet opening 546.
The first flow adjustment system 570 is supported by the actuator member 554 between the valve assembly 560 and the second adjustment system 580 such that manual operation of the first adjustment member 572 affects the flow of fluid material along the conduit passageway 542 as generally described above. In particular, the second adjustment system 580 functions as a flow restrictor, where operation of the first adjustment member 572 variably reduces the size of the conduit passageway 542 such that a pressure of the fluid material upstream of the first flow adjustment system 570 is relatively higher than the pressure of the fluid material downstream of the first flow adjustment system 570. The least amount of restriction created by the first flow adjustment system 570 is associated with a fully open configuration, while the least amount of restriction created by the first flow adjustment system 570 is associated with a terminal configuration.
The second adjustment system 580 is supported by the actuator member 554 downstream of the first adjustment system 570. The outlet member 556 is a resiliently deformable tube, and manual operation of the second adjustment member 582 deforms the walls of the outlet member 556 and thereby affects the flow of fluid material flowing out of the conduit passageway 542 through the conduit outlet or outlet opening 546. The second adjustment system 580 thus functions as a variable orifice. Operation of the second adjustment member 582 variably reduces the size of the conduit outlet or outlet opening 546 relative to the size of the conduit passageway 542 upstream of the second adjustment system 580.
The outlet member 556, first adjustment member 572, and second adjustment member 582 are supported by the actuator member 554 to define a control assembly 590.
To operate the seventh example aerosol dispensing system 520, the container 530 and grip housing 592 are grasped such that the user's fingers can squeeze the trigger portion 594, thereby depressing the actuator member 554. The conduit outlet or outlet opening 546 is initially aimed at a test surface and the actuator member 554 is depressed to place the valve assembly 560 in the open configuration such that the pressurized material 536 forces some of the stored material 534 out of the container 530 and onto the test surface to form a test texture pattern. The test texture pattern is compared to the pre-existing texture pattern defined by the textured portion of the target surface. If the test texture pattern does not match the pre-existing texture pattern, one or both of the first and second adjustment members is/are adjusted to alter the spray pattern of the droplets of dispensed material 522.
The process of spraying a test pattern and adjusting the first and second adjustment members 572 and 582 is repeated until the test pattern formed by the dispensed material 522 corresponds to a desired texture pattern that substantially matches the pre-existing texture pattern.
Leaving the first and second adjustment members 572 and 582 as they were when the test texture pattern corresponded to the desired texture pattern, the aerosol dispensing system 520 is then arranged such that the conduit outlet or outlet opening 546 is aimed at the un-textured portion of the target surface. The trigger member 594 is again squeezed to place the valve assembly 560 in the open configuration such that the pressurized material 536 forces the stored material 534 out of the container 530 and onto the un-textured portion of the target surface to form the desired texture pattern on the un-textured portion of the target surface, perhaps overlapping slightly with the textured portion of the target surface. Since the desired texture pattern substantially matches the pre-existing texture pattern, the dispensed material forms a coating on the previously un-textured portion of the target surface in a desired texture pattern that substantially matches a physical appearance of the textured portion. One or more layers of primer and/or paint may next be applied over the cured layer of dispensed material.
The following Table G represents example ranges and dimensions for constructing a physical embodiment of a flow adjustment system that may be used as the example first flow adjustment system 570:
Referring now to
A first flow adjustment system 670 having a first adjustment member 672 having a valve surface 674 and an externally threaded surface 676 is arranged to intersect the conduit passageway 642 at an intermediate location 642a between the valve assembly 660 and the conduit outlet 646. The conduit passageway has a first portion 642b and a second portion 642c. The first passageway portion 642b defines an actuator axis AA aligned with a container axis AC defined by the container assembly 630, and the second actuator passageway portion 642c is aligned with an outlet axis AO defined by the outlet member 656. The example intermediate location 642a is located in the second passageway portion 642c.
An internally threaded surface 678 is formed in the actuator member 654. The threaded surfaces 676 and 678 are adapted to engage each other such that, as shown in
A second flow adjustment system 680 comprises a second adjustment member 682 and a plurality of fingers 684 extending from the actuator member 654. The second flow adjustment system 680 is arranged relative to the conduit passageway 642 to form at least a portion of the conduit outlet (or outlet opening) 646. The second adjustment member 682 defines an internal threaded surface 686 that engages an external threaded surface 688 of the actuator member 654 such that rotation of the second adjustment member 682 relative to the actuator member 654 deforms the fingers and thus the outlet member 656, thereby altering a cross-sectional area of the conduit outlet or outlet opening 646.
The first flow adjustment system 670 is supported by the actuator member 654 between the valve assembly 660 and the second adjustment system 680 such that manual operation of the first adjustment member 672 affects the flow of fluid material along the conduit passageway 642 as generally described above. In particular, the second adjustment system 680 functions as a flow restrictor, where operation of the first adjustment member 672 variably reduces the size of the conduit passageway 642 such that a pressure of the fluid material upstream of the first flow adjustment system 670 is relatively higher than the pressure of the fluid material downstream of the first flow adjustment system 670. The first flow adjustment system 670 defines a fully open configuration (smallest restriction) and a terminal configuration (largest restriction).
The second adjustment system 680 is supported by the actuator member 654 downstream of the first adjustment system 670. The outlet member 656 is a resiliently deformable tube, and manual operation of the second adjustment member 682 deforms the walls of the outlet member 656 and thereby affects the flow of fluid material flowing out of the conduit passageway 642 through the conduit outlet or outlet opening 646. The second adjustment system 680 thus functions as a variable orifice. Operation of the second adjustment member 682 variably reduces the size of the conduit outlet or outlet opening 646 relative to the size of the conduit passageway 642 upstream of the second adjustment system 680.
The outlet member 656, first adjustment member 672, and second adjustment member 682 are supported by the actuator member 654 to define a control assembly 690.
To operate the eighth example aerosol dispensing system 620, the container 630 and grip housing 692 are grasped such that the user's fingers can squeeze the trigger portion 694, thereby depressing the actuator member 654. The conduit outlet or outlet opening 646 is initially aimed at a test surface and the actuator member 654 is depressed to place the valve assembly 660 in the open configuration such that the pressurized material 636 forces some of the stored material 634 out of the container 630 and onto the test surface to form a test texture pattern. The test texture pattern is compared to the pre-existing texture pattern defined by the textured portion of the target surface. If the test texture pattern does not match the pre-existing texture pattern, one or both of the first and second adjustment members is/are adjusted to alter the spray pattern of the droplets of dispensed material 622.
The process of spraying a test pattern and adjusting the first and second adjustment members 672 and 682 is repeated until the test pattern formed by the dispensed material 622 corresponds to a desired texture pattern that substantially matches the pre-existing texture pattern.
Leaving the first and second adjustment members 672 and 682 as they were when the test texture pattern corresponded to the desired texture pattern, the aerosol dispensing system 620 is then arranged such that the conduit outlet or outlet opening 646 is aimed at the un-textured portion of the target surface. The trigger member 694 is again squeezed to place the valve assembly 660 in the open configuration such that the pressurized material 636 forces the stored material 634 out of the container 630 and onto the un-textured portion of the target surface to form the desired texture pattern on the un-textured portion of the target surface, perhaps overlapping slightly with the textured portion of the target surface. Since the desired texture pattern substantially matches the pre-existing texture pattern, the dispensed material forms a coating on the previously un-textured portion of the target surface in a desired texture pattern that substantially matches a physical appearance of the textured portion. One or more layers of primer and/or paint may next be applied over the cured layer of dispensed material.
The following Table H represents example ranges and dimensions for constructing a physical embodiment of a flow adjustment system that may be used as the example first flow adjustment system 670:
Referring now to
A first flow adjustment system 770 having a first adjustment member 772 having a valve surface 774 and an externally threaded surface 776 is arranged to intersect the conduit passageway 742 at an intermediate location 742a between the valve assembly 760 and the conduit outlet 746. The conduit passageway has a first portion 742b and a second portion 742c. The first passageway portion 742b defines an actuator axis AA aligned with a container axis AC defined by the container assembly 730, and the second actuator passageway portion 742c is aligned with an outlet axis AO defined by the outlet member 756. The example intermediate location 742a is located at the juncture of the first and second passageway portions 742b and 742c. A juncture surface 742d having a profile that matches that of the valve surface 774 is arranged at the intermediate location 742a as perhaps best shown in
An internally threaded surface 778 is formed in the actuator member 754. The threaded surfaces 776 and 778 are adapted to engage each other such that, as shown in
A second flow adjustment system 780 comprises a second adjustment member 782 and a plurality of fingers 784 extending from the actuator member 754. The second flow adjustment system 780 is arranged relative to the conduit passageway 742 to form at least a portion of the conduit outlet (or outlet opening) 746. The second adjustment member 782 defines an internal threaded surface 786 that engages an external threaded surface 788 of the actuator member 754 such that rotation of the second adjustment member 782 relative to the actuator member 754 deforms the fingers and thus the outlet member 756, thereby altering a cross-sectional area of the conduit outlet or outlet opening 746.
The first flow adjustment system 770 is supported by the actuator member 754 between the valve assembly 760 and the second adjustment system 780 such that manual operation of the first adjustment member 772 affects the flow of fluid material along the conduit passageway 742 as generally described above. In particular, the second adjustment system 780 functions as a flow restrictor, where operation of the first adjustment member 772 variably reduces the size of the conduit passageway 742 such that a pressure of the fluid material upstream of the first flow adjustment system 770 is relatively higher than the pressure of the fluid material downstream of the first flow adjustment system 770. The example first flow adjustment system 770 operates in a fully open configuration (least amount of flow restriction) and a terminal configuration (largest amount of flow restriction).
The second adjustment system 780 is supported by the actuator member 754 downstream of the first adjustment system 770. The outlet member 756 is a resiliently deformable tube, and manual operation of the second adjustment member 782 deforms the walls of the outlet member 756 and thereby affects the flow of fluid material flowing out of the conduit passageway 742 through the conduit outlet or outlet opening 746. The second adjustment system 780 thus functions as a variable orifice. Operation of the second adjustment member 782 variably reduces the size of the conduit outlet or outlet opening 746 relative to the size of the conduit passageway 742 upstream of the second adjustment system 780.
The outlet member 756, first adjustment member 772, and second adjustment member 782 are supported by the actuator member 754 to define a control assembly 790.
To operate the ninth example aerosol dispensing system 720, the container 730 and grip housing 792 are grasped such that the user's fingers can squeeze the trigger portion 794, thereby depressing the actuator member 754. The conduit outlet or outlet opening 746 is initially aimed at a test surface and the actuator member 754 is depressed to place the valve assembly 760 in the open configuration such that the pressurized material 736 forces some of the stored material 734 out of the container 730 and onto the test surface to form a test texture pattern. The test texture pattern is compared to the pre-existing texture pattern defined by the textured portion of the target surface. If the test texture pattern does not match the pre-existing texture pattern, one or both of the first and second adjustment members is/are adjusted to alter the spray pattern of the droplets of dispensed material 722.
The process of spraying a test pattern and adjusting the first and second adjustment members 772 and 782 is repeated until the test pattern formed by the dispensed material 722 corresponds to a desired texture pattern that substantially matches the pre-existing texture pattern.
Leaving the first and second adjustment members 772 and 782 as they were when the test texture pattern corresponded to the desired texture pattern, the aerosol dispensing system 720 is then arranged such that the conduit outlet or outlet opening 746 is aimed at the un-textured portion of the target surface. The trigger member 794 is again squeezed to place the valve assembly 760 in the open configuration such that the pressurized material 736 forces the stored material 734 out of the container 730 and onto the un-textured portion of the target surface to form the desired texture pattern on the un-textured portion of the target surface, perhaps overlapping slightly with the textured portion of the target surface. Since the desired texture pattern substantially matches the pre-existing texture pattern, the dispensed material forms a coating on the previously un-textured portion of the target surface in a desired texture pattern that substantially matches a physical appearance of the textured portion. One or more layers of primer and/or paint may next be applied over the cured layer of dispensed material.
The following Table I represents example ranges and dimensions for constructing a physical embodiment of a flow adjustment system that may be used as the example first flow adjustment system 770:
Referring now to
A first flow adjustment system 970 having a first adjustment member 972 having a valve surface 974 and a shaft portion 976 is arranged to intersect the conduit passageway 942 at an intermediate location 942a between the valve assembly 960 and the conduit outlet 946. The conduit passageway has a first portion 942b and a second portion 942c. The first passageway portion 942b defines an actuator axis AA aligned with a container axis AC defined by the container assembly 930, and the second actuator passageway portion is aligned with an outlet axis AO defined by the outlet member 956. The example intermediate location 942a is located in the second passageway portion 942c.
A support opening 978 is formed in the actuator member 954. The shaft 976 extends through the opening 978 such that, as shown in
A second flow adjustment system 980 comprises a second adjustment member 982 and a plurality of fingers 984 extending from the actuator member 954. The second flow adjustment system 980 is arranged relative to the conduit passageway 942 to form at least a portion of the conduit outlet (or outlet opening) 946. The second adjustment member 982 defines an internal threaded surface 986 that engages an external threaded surface 988 of the actuator member 954 such that rotation of the second adjustment member 982 relative to the actuator member 954 deforms the fingers and thus the outlet member 956, thereby altering a cross-sectional area of the conduit outlet or outlet opening 946.
The first flow adjustment system 970 is supported by the actuator member 954 between the valve assembly 960 and the second adjustment system 980 such that manual operation of the first adjustment member 972 affects the flow of fluid material along the conduit passageway 942 as generally described above. In particular, the second adjustment system 980 functions as a flow restrictor, where operation of the first adjustment member 972 variably reduces the size of the conduit passageway 942 such that a pressure of the fluid material upstream of the first flow adjustment system 970 is relatively higher than the pressure of the fluid material downstream of the first flow adjustment system 970. The example first flow adjustment system 970 thus is operable in a fully open configuration (least amount of flow restriction) and a terminal configuration (greatest amount of flow restriction).
The second adjustment system 980 is supported by the actuator member 954 downstream of the first adjustment system 970. The outlet member 956 is a resiliently deformable tube, and manual operation of the second adjustment member 982 deforms the walls of the outlet member 956 and thereby affects the flow of fluid material flowing out of the conduit passageway 942 through the conduit outlet or outlet opening 946. The second adjustment system 980 thus functions as a variable orifice. Operation of the second adjustment member 982 variably reduces the size of the conduit outlet or outlet opening 946 relative to the size of the conduit passageway 942 upstream of the second adjustment system 980.
The outlet member 956, first adjustment member 972, and second adjustment member 982 are supported by the actuator member 954 to define a control assembly 990.
To operate the tenth example aerosol dispensing system 920, the container 930 and grip housing 992 are grasped such that the user's fingers can squeeze the trigger portion 994, thereby depressing the actuator member 954. The conduit outlet or outlet opening 946 is initially aimed at a test surface and the actuator member 954 is depressed to place the valve assembly 960 in the open configuration such that the pressurized material 936 forces some of the stored material 934 out of the container 930 and onto the test surface to form a test texture pattern. The test texture pattern is compared to the pre-existing texture pattern defined by the textured portion of the target surface. If the test texture pattern does not match the pre-existing texture pattern, one or both of the first and second adjustment members is/are adjusted to alter the spray pattern of the droplets of dispensed material 922.
The process of spraying a test pattern and adjusting the first and second adjustment members 972 and 982 is repeated until the test pattern formed by the dispensed material 922 corresponds to a desired texture pattern that substantially matches the pre-existing texture pattern.
Leaving the first and second adjustment members 972 and 982 as they were when the test texture pattern corresponded to the desired texture pattern, the aerosol dispensing system 920 is then arranged such that the conduit outlet or outlet opening 946 is aimed at the un-textured portion of the target surface. The trigger member 994 is again squeezed to place the valve assembly 960 in the open configuration such that the pressurized material 936 forces the stored material 934 out of the container 930 and onto the un-textured portion of the target surface to form the desired texture pattern on the un-textured portion of the target surface, perhaps overlapping slightly with the textured portion of the target surface. Since the desired texture pattern substantially matches the pre-existing texture pattern, the dispensed material forms a coating on the previously un-textured portion of the target surface in a desired texture pattern that substantially matches a physical appearance of the textured portion. One or more layers of primer and/or paint may next be applied over the cured layer of dispensed material.
The following Table K represents example ranges and dimensions for constructing a physical embodiment of a flow adjustment system that may be used as the example first flow adjustment system 970:
Each of the embodiments described above contains a unique first adjustment system and one of several example second adjustment systems. Any one of the example second adjustment systems disclosed herein may be combined with any one of the unique first adjustment systems associated with each of the embodiments discussed above. Accordingly, the specific pairings of example first and second adjustment systems as described above are for illustrative purposes only, and, in one form, the principles of the present invention may be implemented by using any pair of example first and second adjustment systems whether that particular pairing is disclosed explicitly above or disclosed implicitly by reference in this Summary section.
Accordingly, the embodiments described herein may be embodied in other specific forms without departing from their spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the claims to be appended hereto rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
This application (Attorney's Ref. No. P217003) claims benefit of U.S. Provisional Application Ser. Nos. 61/513,401 filed Jul. 29, 2011, and 61/664,678 filed Jun. 26, 2012, the contents of which are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61513401 | Jul 2011 | US | |
| 61664678 | Jun 2012 | US |
