Abstract:
A sprayer apparatus uses a larger canister to contain diluent (e.g. water) and a smaller canister to contain chemical concentrate (e.g. insecticide, fertilizer, soap, etc.). The larger canister has a bladder or diaphragm that separates its interior into two sections; a liquid chamber and a pressured gas chamber. A valved manifold enables diluent to be added to the apparatus via the manifold so that it mixes with the desired chemical concentrate. Mixed solution can then be dispensed via a hose, spray wand, etc. using the pressurized air to drive it out of the larger canister.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     Not applicable 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable 
     REFERENCE TO A “MICROFICHE APPENDIX” 
     Not applicable 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to pressurized liquid sprayers and more particularly to a sprayer that has a canister with a chamber interior for holding both air and a liquid, the liquid compressing the air as the canister is filled and wherein a specially configured mixing chamber receives liquid from the canister and mixes it with a desired chemical product (eg. chemical concentrate, insecticide, soap, fertilizer, etc.) before transmitting the mixed solution to a valved spray wand or spray head. 
     2. General Background of the Invention 
     Common pump-type sprayers often provide a container that holds several gallons of liquid. Most of these prior art type pump sprayers require pre-mixing of an amount of diluent such as water that is combined with a given, typically smaller volume of chemical concentrate such as a fertilizer, insecticide, soap, or the like. 
     These prior art type pump sprayers require a constant recharge of air pressure via a hand pump arrangement. Pump arrangements on commercially available and known sprayers include reciprocating pumps or lever action pumps. As the user dispenses mixed liquid through a spray head, the pump pressure gradually decreases and the user must again manually pump the unit. Such pump sprayers are usually designed to carry relatively small volumes, eg. 1-3 gallons. 
     More expensive sprayer arrangements are known that utilize an electric motor in combination with a tank. Such sprayers are typically available in 10, 15 and 25 gallon capacities. An example of such an electrically powered sprayer is sold by John Deere® wherein a user activates the electric pump when the spray head is valved to an open position, and wherein the electric motor is deactivated when the spray head valve is closed. 
     Some sprayer constructions that use tanks and bladders with pressurized air are disclosed in U.S. patents. Devices that have a bladder or diaphragm require an external source that is constantly communicating with a supply pressure for dispensing contents. 
     U.S. Pat. Nos. 2,847,249; 1,384,296; 4,962,888; and 5,398,852 all relate to sprayers that hold a fluid that is rejected by pressurized air contained within a canister. The &#39;249 patent utilizes a garden hose that adds water to a pressurized canister wherein a bladder of rubber or like material compresses the air as the water is added under pressure. 
     The Lacy patent 5,398,852 features a tank cap that connects to a standard garden hose and uses household water pressure to pressurize a tank interior and its contents. 
     U.S. Pat. No. 4,159,081 and British Patent No. 7347723 disclose sprayers for hand held, manual operation. 
     U.S. Pat. No. 3,018,970 discloses a garden hose used to pressurized a chamber of a sprayer. 
     U.S. Pat. Nos. 2,199,110 and 3,184,113 disclose portable sprayers with bladders inside that segregate the fluid to be dispensed from pressurized air on the opposing side of the bladder that propels the spray. 
     Most of these prior art patents do not provide an effective method of mixing a chemical to be dispensed in precise concentration without messy pre-mixing. 
     Most prior art sprayers either require tiring manual operation for pumping or involve the extraordinary expense of electrical motors and related power source problems. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention provides an improved sprayer apparatus that utilizes two separate chambers or canisters. The apparatus features a pre-charged or pre-pressurized bladder tank that is a larger tank or canister. The larger canister has an interior and an outlet, with an interior having a pressurized gas chamber contained that holds gas (eg. air) under pressure during use. The larger canister also includes a liquid chamber for holding a liquid solution, namely the combination of a bulk liquid (usually water) and chemical concentrate solution. 
     The second canister is a smaller, chemical concentrate containing housing. This chemical housing has a chamber that holds a desired concentrate. Both canisters are mounted on a frame that can be wheeled. 
     The chemical concentrate housing chamber holds a selected chemical concentrate to be mixed with a bulk or diluent liquid. A chemical concentrate is added to the solution housing; the final solution is formed by the addition of water to the solution housing via the manifold which mixes the water and concentrate together as they are transferred into the liquid side of the bladder tank. 
     The smaller chemical concentrate housing and valving defines a valved manifold arrangement connected to the canister at the outlet with a flowline. The manifold is configured to valve the flow of fluids as selected by a user into either the liquid chamber or into the chemical solution chamber via the concentrate chamber, or to cease any such flow. 
     The apparatus includes a spray hose and valve arrangement that enables the user to dispense a mixed solution of water and chemical or a selected liquid and chemical, the spray valve and hose being connected to the manifold. When the system is attached to a garden hose and filled under typical water pressure from the hose, the pre-pressurized air increases in pressure until reaching equilibrium with the pressure from the hose. The hose is then disconnected and the contents are discharged by the pressure developed in the filling stage. The air pressure decreases as the liquid is discharged until all the liquid is emptied, however, the pre-charged level of air pressure is maintained. The pre-charged or pre-pressurized setting is fully adjustable. Since it is set at the lowest working pressure, all the contents will be discharged without any need for a pump of any kind. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein: 
     FIG. 1 is an elevational view of the preferred embodiment of the apparatus of the present invention; 
     FIG. 2 is a partial elevational view of the preferred embodiment of the apparatus of the present invention; 
     FIG. 3 is a partial exploded view of the preferred embodiment of the apparatus of the present invention showing some of the components and removed from the frame for clarity; and 
     FIGS. 4 and 5 are alternate constructions for the tank portion of the preferred embodiment of the apparatus of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     FIGS. 1-3 show generally the preferred embodiment of the apparatus of the present invention designated generally by the numeral  10  in FIG.  1 . Spray apparatus  10  includes a frame or housing  11  that carries a first larger vessel in the form of housing or canister  12 . Frame  11  has a handle  13  that enables a user to wheel the frame  11  about. The frame  11  preferably provides a lower end portion with a pair of spaced apart wheels  14 . Canister  12  is mounted on frame  11 . A second canister or housing in the form of chemical concentrate housing  17  is also mounted to frame  11 . 
     Canister  12  has an upper end portion with opening  15 . Opening  15  carries an outlet fitting  16  that receives flow via hose  37 , valve  32  and hose  36  from chemical vessel  17 . Chemical vessel  17  has an upper end portion  18  and a lower end portion  19 . Upper end portion  18  provides a fill opening  20  with a closure cap  21 . The lower end  19  portion of chemical vessel  17  provides tee fitting  22 . The tee fitting  22  has a drain fitting  23  with closure cap  24 . This configuration enables a user to drain vessel  17  completely, such as in situations wherein the user wants to replenish vessel  17  or to completely evacuate the contents of vessel  17  and add a different chemical to it. 
     After chemical is added to chamber  17  via fill opening  20 , closure cap  21  is replaced and water is added to the vessel  17  for mixing therewith. Prior to mixing, upper valve  30  and lower valve  32  are closed. A source of liquid, such as water supplied with city or well water via water hose  27  can be added to vessel  17  at water inlet manifold  25 . 
     Inlet manifold  25  includes a connection for hose  27 , quick release fitting  26  that can be a commercially available, valving type quick release fitting  26  and a tee at gauge  28 . Such a fitting  26  shuts off the supply of water from hose  27  when the quick release fitting  26  is disconnected. Pressure gauge  28  is supplied to inlet manifold  25  for monitoring the pressure of any fluid supplied under pressure via water supply hose  27 . The gauge  18  can be provided with indicia to indicate the line pressure and the number of gallons the system will hold at a particular line pressure. In this fashion, the correct ratio of chemical can be added to the chemical housing. The pressure indicated by pressure gauge  28  is also used to monitor the pressure within canister  12  during spraying and when valves  30  and  32  are opened. In this fashion, a user knows how much of the liquid contents of canister  12  have been evacuated by watching the pressure drop at pressure gauge  28 . 
     Flow line  31  extends from inlet manifold  25  to upper valve  30 . This enables water to flow from inlet manifold  25  into flow line  31  and into hose  33 . Hose  33  communicates with inlet fitting  34  to supply water to the interior of chemical vessel  17  at its upper end  18 . Water that enters at inlet fitting  34  travels downwardly, substantially the full length of chemical vessel  17 . At the lower end  19  of chemical vessel  17 , water that has been mixed with the chemical contained within vessel  17  is discharged at outlet fitting  35  into tee  22  and into hose  36 . Hose  36  communicates with a fitting at the top of valve  32 . Fluid exiting valve  32  enters hose  37 . Hose  37  then enters canister  12  at inlet fitting  15  as indicated by arrow  43  in FIG.  1 . Hose  37  also carries tee fitting  38 . 
     During use, the user shuts the valve  30  and connects hose  27  to inlet manifold  25  at quick release fitting  26 . Valve  32  is opened. The hose  27  is then supplied with water flowing in the direction of arrow  44  in FIG. 1 under pressure from a faucet and a city water or well water supply, for example. Once the hose  27  is pressurized, pressure gauge  28  indicates the pressure of the city water supply, well water supply or the like. With the valve  30  closed, the user fills chemical vessel  17  through fill opening  20  and closes the closure cap  21 . Vessel  17  now contains a desired amount of chemical concentrate, such as a pesticide, fertilizer, soap or the like. In order to fill the canister  12  with a combination of the chemical concentrate in vessel  17  and water supplied via hose  27 , the user opens valve  30 . 
     Fluid flows from hose  27  to manifold  25  to flow line  31  to valve  30  to hose  33  to inlet fitting  34  and into vessel  17 . A mixture of chemical concentrate and water then exits the lower end of vessel  17  at fitting  35  and then flows into hose  36 , valve  32 , hose  37 , inlet fitting  15  and into chemical concentrate housing  17 . Canister  12  has a hollow interior  45  that is divided with a diaphragm or bladder  42  into an interior of bladder liquid containing portion  46  and bladder pre-pressurized air containing portion  47 . Alternatively, the canister  12 A or  12 B (see FIGS. 4-5) can be provided with a bladder  50  that receives liquid via fitting  16  on inlet  15 . As liquid enters canister  12  via inlet fitting  15  (see arrows  48  in FIG.  2 ), air outside bladder  42  is further compressed. This compressed air provides pressure to dispense fluid from canister  12  to hose  40  and its spray wand. Air valve  41  can be used to add a volume of air to canister interior  45  at air containing portion  47 . 
     Spray hose  40  connects to hose  36  at tee fitting  38 . In order to dispense the contents of canister  12  through spray hose  40  and to a valved sprayer head or wand connected to hose  40  at  39 , valves  30  and  32  are opened. This allows solution to flow via outlet fitting  15  through hose  37  through valve  32  into hose  36 , and into tee fitting  38  and then to hose  40  for dispensing. Valve  30  remains open so that gauge  28  can monitor pressure/volume as contents are dispensed. 
     In order to fill the apparatus  10  and to recharge the contents of the vessels, this process is repeated by closing both of the valves  30 ,  32  and again filling the chambers  17  and  12 . Air valve (e.g. Schraeder type)  41  can be used to increase the pressure of air in canister  12  outside bladder  42  if a higher operating pressure is desired when water supply hose  27  has a corresponding higher pressure. For example, a user might have been using well water at a pressure of 30 psi. If the user then finds a city water source with a pressure of 60 psi, air can be added to interior  45  at  47  to increase pressure since the 60 psi water pressure can compress a greater volume of air to a given pressure valve. 
     The only time valve  30  is closed, is to isolate gauge  28  to read line pressure of hose  27 , thereby indicating what volume the system will hold so the correct ratio of concentrate can be added to vessel  17  prior to filling. 
     The only time valve  32  is closed is when tank  12  needs to be isolated with a remaining volume of solution so that the system can be refilled before tank  12  is completely emptied or to isolate tank  12  with contents under pressure, so that the rest of the system can be depressurized during a long period of non-use. 
     Lines  13  through  22 : The primary purpose of air valve  41  is to give the user flexibility in setting the pre-pressurized level of air in tank  12 . Some applications will require a higher or lower minimum discharge pressure which is the pre-pressurized setting. This setting can be adjusted any time tank  12  is empty of all liquid contents. 
     The volume capacity is in direct relation to the inlet pressure at hose  27  and the pre-pressurized setting: Higher Inlet pressure at hose  27  and lower pre-pressure setting=greater volume capacity. 
     Operating Instructions 
     1. Attach the female end of the quick connector ( 26 FIGS. 1-3) to the male end of a garden hose ( 27  FIG.  1 ). Turn hose on—fully open. [Both ends of the quick connector automatically close when the two are disconnected.] 
     2. Close the inlet/fill valve ( 30 FIG. 1) on the sprayer, tank valve ( 32 ) stays open at this step if system is empty. 
     3. Attach the Quick Connector on the hose to the male end of the sprayer, the gauge ( 28 FIG. 1) will immediately display line pressure and how much volume the system will hold at that pressure. 
     4. If a chemical solution is going to be used, add the correct ratio to the solution housing ( 17  FIG.  1 ). If plain water is used go to step 5. [Make sure the solution fill cap ( 21 ) is closed and the solution drain cap ( 24 FIG. 3) is closed; both hand tight before going to step 5] 
     5. Open the inlet/fill valve ( 30 ). The system is full when the gauge ( 28 ) reads the same level as in step 3. 
     6. Disconnect the quick connector from the sprayer. [Both ends of the quick connector automatically close when the two are disconnected.] System is now ready for use. [The system will discharge all the contents under normal working pressure until empty.] 
     To Refill Before Empty 
     A. Make a note as to the remaining volume. 
     B. Close tank valve ( 32 ), then open trigger on hand held sprayer ( 49  FIG.  1 ), this releases pressure from the solution housing ( 17 ). 
     C. Open solution fill cap ( 21 ), then solution drain cap ( 24 FIG. 3) to drain solution tank. 
     D. Repeat steps 1-6 
     1. Subtract remaining volume from step A from the volume read in step 3, so that the correct ratio is added. 
     2. Open tank valve ( 32 ) before opening inlet/fill valve ( 30 ) in step 5. 
     Notes 
     Both inlet/fill ( 30 ) and tank ( 32 ) valves remain open in operation 
     If a system under pressure is left unattended for an extended period of time, close tank valve ( 32 ) and open trigger on sprayer to release pressure in solution housing. 
     To store a system for a period of non-use; Drain any contents completely. Fill system with fresh water and drain, repeat. 
     
       
         
               
               
             
           
               
                   
               
               
                 PART NO. 
                 DESCRIPTION 
               
               
                   
               
             
             
               
                 10 
                 sprayer apparatus 
               
               
                 11 
                 frame 
               
               
                 12 
                 canister 
               
               
                 13 
                 handle 
               
               
                 14 
                 wheel 
               
               
                 15 
                 canister opening 
               
               
                 16 
                 fitting 
               
               
                 17 
                 chemical vessel 
               
               
                 18 
                 upper end 
               
               
                 19 
                 lower end 
               
               
                 20 
                 fill opening 
               
               
                 21 
                 closure cap 
               
               
                 22 
                 Tee fitting 
               
               
                 23 
                 drain fitting 
               
               
                 24 
                 closure cap 
               
               
                 25 
                 water inlet manifold 
               
               
                 26 
                 quick release fitting 
               
               
                 27 
                 water supply hose 
               
               
                 28 
                 pressure gauge 
               
               
                 30 
                 upper valve 
               
               
                 31 
                 flow line 
               
               
                 32 
                 lower valve 
               
               
                 33 
                 hose 
               
               
                 34 
                 inlet fitting 
               
               
                 35 
                 outlet fitting 
               
               
                 36 
                 hose 
               
               
                 37 
                 hose 
               
               
                 38 
                 tee fitting 
               
               
                 39 
                 spray wand connection 
               
               
                 40 
                 sprayer hose 
               
               
                 41 
                 air valve 
               
               
                 42 
                 diaphragm 
               
               
                 43 
                 arrow 
               
               
                 44 
                 arrow 
               
               
                 45 
                 canister interior 
               
               
                 46 
                 water containing portion 
               
               
                 47 
                 air containing portion 
               
               
                 48 
                 arrow 
               
               
                 49 
                 spray wand 
               
               
                 50 
                 bladder 
               
               
                   
               
             
          
         
       
     
     The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.