This invention relates to the field of tank sprayers, and more particularly to a tank sprayer assembly including a tank component and a sprayer package subassembly.
Tank sprayer assemblies are often utilized to dispense low viscosity fluids. The assemblies typically include a tank component that is configured to hold a quantity of fluid to be sprayed. A hand pump is coupled to the tank component and is configured to introduce air into the tank component so as to pressurize the fluid therein. A hand sprayer is also coupled to the tank component and is utilized to disperse the pressurized fluid from the tank component.
It is common to manufacture and package for sale a tank sprayer at a site in one country, such as China, and then ship the packaged tank sprayer to another site in a remote country, such as the United States, for sale in the remote country. One disadvantage with the above process exists due to the high cost of shipping the packaged tank sprayer from the site of tank sprayer manufacturing and packaging to the site of tank sprayer sales. The high shipping cost is due in large part to the bulky nature of the packaged tank sprayer.
It would be desirable to provide a tank sprayer assembly and associated method that would facilitate manufacturing and packaging of a much smaller tank sprayer subassembly at a first site, which would then be shipped to a remote second site for assembly with a relatively large tank sprayer component at the remote site, the relatively large tank sprayer component being manufactured at or near the remote site. According to this tank sprayer assembly and associated method, the shipping cost would be significantly reduced while still benefiting from the ability to manufacture and package a substantial part of the tank sprayer assembly at the first site.
In accordance with one embodiment, a tank sprayer assembly comprises a tank component defining a chamber configured to receive fluid. The tank component includes a neck that defines a first access opening configured to allow access to the chamber. The neck has an externally threaded portion. The tank sprayer assembly also includes a subassembly comprising a packaging container and a sprayer component. The packaging container has a plurality of walls that define a cavity. The plurality of walls include a lower wall that defines a second access opening configured to allow access to the cavity. The sprayer component includes (i) a cap that defines a cap space and has a skirt that includes an internally threaded portion facing the cap space, and (ii) a pump attached to the cap that includes a cylinder and a piston movably positioned within the cylinder. The tank sprayer is positionable in an assembled configuration and disassembled configuration. When the tank sprayer is positioned in the assembled configuration, (i) the internally threaded portion of the cap is aligned with the second access opening of the lower wall, (ii) the neck extends through the second access opening of the lower wall so as to be at least partially positioned within the cavity, and (iii) the externally threaded portion of the neck is meshingly engaged with the internally threaded portion of the skirt of the cap so as to secure said sprayer component to the tank component. When the tank sprayer is positioned in the disassembled configuration, the neck is spaced apart from the cavity of the packaging container.
In another embodiment, a method of assembling a tank sprayer assembly comprises locating a sprayer component having a cap within a cavity of a packaging container so that (i) an internally threaded portion of the cap is aligned with a first access opening defined in a lower wall of the packaging component, and (ii) a subassembly is formed with the sprayer component and the packaging container. A neck of a tank component is then advanced through the first access opening and into the cavity of the packaging container. The tank component is then rotated in relation to the subassembly while the neck is located in the cavity so as to meshingly engage an externally threaded portion of the neck with the internally threaded portion of the cap so as to couple the subassembly to the tank component.
In yet another embodiment, a subassembly of a tank sprayer assembly comprises a packaging container having a plurality of walls that define a cavity. The plurality of walls includes a first wall that defines an access opening configured to allow access to the cavity. A sprayer component includes (i) a cap defining a cap space and has a skirt that includes an internally threaded portion facing the cap space, and (ii) a pump attached to the cap that includes a cylinder and a piston movably secured to the cylinder. Both the cylinder and the piston extend through the cap space. The internally threaded portion is aligned with the access opening, and both the cylinder and the piston extend from the cavity of the packaging container through the access opening.
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification. It is understood that no limitation to the scope of the invention is thereby intended. It is further understood that the present invention includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the invention as would normally occur to one of ordinary skill in the art to which this invention pertains.
With reference to
The tank component 14 of the tank sprayer assembly 10 includes a main body 26 that defines a chamber 16 (see, e.g.,
The main body 26 includes a generally flat base 27 with protuberances 29 that extend outwardly from the base 27. This configuration enables the tank component 14 to stand upright on a generally flat surface, such as the ground. A neck 20 extends from a top portion of the main body 26. The neck 20 is generally cylindrical in shape and is narrower than the main body 26 so that the main body defines a shoulder portion 24 that depends from the neck 20. As best seen in
Referring now to
As shown in
The hand sprayer 50 is configured to selectively enable fluid from the chamber 16 to be dispersed to a location outside of the chamber 16. In one embodiment, the hand sprayer 50 comprises a grip portion 52 and a wand portion 54 that extends from the grip portion 52, as best seen in
The pump 60 includes a pump cylinder 64, a piston 68, and a handle portion 70 configured to introduce air into the chamber 16 to pressurize the chamber to cause fluid flow through the uptake tube 44 and delivery tube 48 to the hand sprayer 50. As depicted in
The piston 68 of the pump 60 is positioned in the pump cylinder 64 and is configured for axial movement with respect to the pump cylinder 64. The piston 68 and the pump cylinder 64 cooperate to define a compression chamber 71. The pump 60 includes check valves 66, 67 for controlling air flow into and out of the compression chamber 71 during movement of the piston 68 with respect to the compression chamber 71. The handle portion 70 is attached to an end of the piston 68 that extends from the cylinder 64 on the upper side of the cap 32. The handle portion 70 may be used in a known manner by an operator of the tank sprayer to axially move the piston 68 so as to introduce a positive pressure into the chamber 16 of the tank component 14. For example, the handle portion 70 of the piston 68 is configured to move between a retracted position (see, e.g.,
To facilitate alignment of the cap 32 with the access opening 78, the lower wall 76 includes a rim structure 80 that surrounds the access opening 78. The rim structure 80 includes a recess or depression that defines a substantially horizontal surface 81, also referred to as seating surface 81, and a substantially vertical surface 83, also referred to as boundary surface 83. The seating surface 81 of the rim structure serves as a surface against which the skirt portion 38 of the cap 32 is placed when the cap 32 secured within the cavity 74. The vertical surface 83 extends from the seating surface 81 to form a receptacle structure in which the lower end portion of the skirt portion 38 is received. The upper wall 84 forms a barrier on an opposite side of the cavity 74 from the lower wall 76. The upper and lower walls 76, 84 trap the cap 32 therebetween. In particular, when the lower end portion of the skirt portion 38 is located within the receptacle defined by the surfaces 81, 83, the cap 32 is prevented from travelling upwardly by contact between a top portion of the cap 32 and a bottom side of the upper wall 84.
The upper wall 84 is configured to be movable in relation to the other walls to enable the sprayer component 30 to be advanced into the cavity 74 and the skirt portion 38 of the cap 32 to be placed in engagement with the seating surface 81 of the rim structure 80. Once the sprayer component 30 is positioned in the cavity 74, the upper wall 84 is moved back to its position shown in
The upper wall 84 also includes a retaining structure 110 that extends into the cavity 74 for interlocking with the handle 70 of the pump 60 to prevent lateral and/or rotational movement of the handle 70 with respect to the cavity 74. The retaining structure 110 defines a retaining space 112 that is configured to receive and interlock with the handle 70 when the sprayer component is secured in the cavity 74. The retaining structure 110 comprises a pair of posts that receive the handle 70 therebetween, as depicted in
The sprayer package subassembly 18 that results from securing the sprayer component 30 to the package container 72 as described above provides a unitary configuration that facilitates the handling, shipping, and storing of the sprayer package assembly 18 as a separate unit from the tank component 14. The sprayer package subassembly also enables the sprayer component 30 to be easily assembled to the tank component 14 for subsequent distribution to retail centers and end users without requiring removal of the spray component 30 from the package container. For example, to secure the sprayer package subassembly 18 to the tank component 14 as depicted in
The package container 72 is configured to engage the tank component 14 when the sprayer package subassembly 18 is coupled to the tank component to facilitate a stable and secure attachment to the tank component 14 and to resist unintentional rotation of the subassembly 18 with respect to the tank component 14. More specifically, the lower wall 76 of the package container, and in particular, the rim structure 80 may be positioned to be pinched or squeezed between the skirt portion 38 of the cap 32 and a portion of the tank component 14, such as the shoulder 24, as best seen in
The package container 72 also includes projections that extend below the lower wall of the container 72 toward the tank component 14. The projections are configured to be urged against the tank component 14 when the subassembly 18 is assembled to the tank component 14. For example, referring to
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same should be considered as illustrative and not restrictive in character. It is understood that only the preferred embodiments have been presented and that all changes, modifications and further applications that come within the spirit of the invention are desired to be protected.