FOAM SPRAYER WITH ADAPTER AND MULTIPLE PRESSURE MODES

A foam sprayer includes a body defining a channel, a nozzle, and an adapter configured to releasably attach to a first fluid source that provides a first fluid at a first pressure. The foam sprayer includes a connector attached to the body and configured to releasably connect the body to the adapter or to a second fluid source that provides a second fluid at a second pressure that is substantially greater than the first pressure. The foam sprayer also includes a mode selection device configured to switch the foam sprayer between a low-pressure mode and a high-pressure mode. The foam sprayer is configured to generate foam from the first fluid when the foam sprayer is in the high-pressure mode. The foam sprayer is configured to generate foam from the second fluid when the foam sprayer is in the high-pressure mode.

FIELD OF THE DISCLOSURE

The present disclosure relates to a foam sprayer including an adapter configured to attach to a low-pressure fluid source and a high-pressure fluid source.

BACKGROUND OF THE DISCLOSURE

Foam sprayers are configured to generate foam that is sprayed onto objects such as vehicles for cleaning the objects. Dirt and debris on the objects may be collected by the foam which is removed using a fluid or a cloth. Some foam sprayers are attached to a pressurized fluid source, e.g., a pressure washer, or high-pressure water sprayer, and configured to spray pressurized fluid, such as water, with the foam. The pressurized fluid might provide improved cleaning of the object and facilitate removal of strongly adhered dirt and debris. Other foam sprayers are attached to fluid sources such as a standard garden hose connected to a residential water supply, that do not provide a high-pressure fluid. The low-pressure fluid sources are appropriate for applications where high-pressure fluid could cause damage to the object or where a high-pressure fluid source is not available. However, conventional foam sprayers may not be used with both a high-pressure fluid source and a low-pressure fluid source. As used herein, low pressure refers to a pressure of 120 psi or less and high-pressure refers to a pressure of 500 psi or greater. As a result, people are required to utilize two or more different foam sprayers for applications that require high-pressure and low-pressure spray. Also, conventional foam sprayers may be difficult to attach to or detach from a fluid source. Moreover, the foam sprayers may have complicated settings and be hard to operate.

Accordingly, there is a need for a foam sprayer that is configured to attach to a low-pressure fluid source and a high-pressure fluid source and operate in a high-pressure mode and a low-pressure mode. In addition, the foam sprayer should be simple to operate.

SUMMARY OF THE DISCLOSURE

In one aspect, a foam sprayer includes a body defining a channel, a nozzle attached to the body and configured to emit foam, and an adapter configured to releasably attach to a first fluid source that provides a first fluid at a first pressure. The foam sprayer includes a connector attached to the body and configured to releasably connect the body to the adapter or to a second fluid source that provides a second fluid at a second pressure that is substantially greater than the first pressure. The foam sprayer also includes a mode selection device mounted to the body and configured to switch the foam sprayer between a low-pressure mode and a high-pressure mode. The foam sprayer is configured to generate foam from the first fluid when the foam sprayer is in the low-pressure mode. The foam sprayer is configured to generate foam from the second fluid when the foam sprayer is in the high-pressure mode.

In another aspect, a spray system includes a first fluid source configured to provide a first fluid at a first pressure, and a second fluid source configured to provide a second fluid at a second pressure. The second pressure is at least five times greater than the first pressure. The spray system also includes a foam sprayer including a body defining a channel, a nozzle attached to the body and configured to emit foam, and a connector attached to the body. The connector is configured to releasably connect to the second fluid source to allow the second fluid from the second fluid source to flow into the channel of the body. The spray system also includes an adapter configured to releasably attach to the connector when the connector is not attached to the second fluid source. The adapter is configured to releasably attach to the first fluid source and direct the first fluid from the first fluid source through the connector and into the channel of the body. The foam sprayer is configured to operate in a low-pressure mode to generate foam from the first fluid, and operate in a high-pressure mode to generate foam from the second fluid.

In yet another aspect, a method of emitting foam from a sprayer includes attaching a first fluid source or a second fluid source to the sprayer. The sprayer includes a body defining a channel, a nozzle configured to emit foam, a connector attached to the body, and an adapter configured to releasably attach to the connector and to the first fluid source to allow a first fluid at a first pressure from the first fluid source to flow into the channel of the body. The connector configured to releasably connect the body to the second fluid source when the adapter is not connected to the connector. The second fluid source provides a second fluid at a second pressure that is greater than the first pressure. The method also includes selecting a low-pressure mode or a high-pressure mode of the sprayer using a mode selection device. The method further includes emitting foam from the sprayer. The sprayer is configured to emit foam from the first fluid when the foam sprayer is in the low-pressure mode. The foam sprayer is configured to emit foam from the second fluid when the foam sprayer is in the high-pressure mode.

DETAILED DESCRIPTION

The embodiments of the present disclosure described below are not intended to be exhaustive or to limit the disclosure to the precise forms disclosed in the following detailed description. Rather a purpose of the embodiments chosen and described is so that the appreciation and understanding by others skilled in the art of the principles and practices of the present disclosure may be facilitated.

Turning now to the Figures,FIG.1is a perspective view of one suitable embodiment of a spray system, indicated generally at100. For example, the spray system100may be configured for spraying an object such as a vehicle with a fluid or a foam for cleaning the object. In embodiments, the vehicle may be an automobile, an aerial vehicle, a watercraft, or any other vehicle. In addition, the foam sprayer110is configured to spray other objects such as surfaces, buildings, animals, and structures.

The spray system100includes a first fluid source102configured to provide a first fluid104at a first pressure, a second fluid source106configured to provide a second fluid108at a second pressure, and a foam sprayer110. For example, the first fluid source102comprises a hose or other conduit for the first fluid104to flow through. The first fluid104comprises a liquid such as water. The first fluid source102is configured to provide the first fluid104at a pressure provided by, for example, a municipal water reservoir or other water supply. For example, the first pressure is less than 120 pounds per square inch (psi), such as 120 psi, 110 psi, 100 psi, 90 psi, 80 psi 70 psi, 60 psi or 50 psi.

In the illustrated embodiment, the second fluid source106includes a pressurized fluid gun112(e.g., a pressure washer), a conduit114, and a pressure apparatus116. The pressure apparatus116is configured to increase and regulate the pressure of the second fluid108. The pressure apparatus116provides the second fluid108at a second pressure that is higher than the first pressure of the first fluid104. For example, the second pressure is at least 1,000 psi. Accordingly, the second pressure is at least five times greater than the first pressure. The pressure apparatus116includes a pump118and a tank120. The tank120contains the second fluid108. The pump118is configured to pressurize the second fluid108in the tank120and provide the second fluid108to the pressurized fluid gun112at the second pressure. The pump118may be any suitable pump. In some embodiments, the pump118is motorized. In other embodiments, the pump118is manually operated (e.g., a hand pump).

Referring toFIGS.1-6, the foam sprayer110includes a body122, a nozzle124attached to the body122, a connector126attached to the body122, and an adapter128. The foam sprayer110has multiple pressure modes (e.g., a high-pressure mode and a low-pressure mode) and is configured to attach to the first fluid source102or the second fluid source106. The adapter128is connectable to the connector126and is configured to releasably connect to the first fluid source102to allow the first fluid104from the first fluid source102to flow into the foam sprayer110through the adapter128, as shown inFIG.17. The foam sprayer110is able to operate in a low-pressure mode when the adapter128and the first fluid source102are attached to the foam sprayer110.

The connector126is configured to releasably connect to the second fluid source106when the adapter128is not attached to the connector126, as shown inFIG.17. The connector126is configured to connect to the pressurized fluid gun112to allow the second fluid108from the second fluid source106to flow into the foam sprayer110. For example, the connector126includes a male engagement piece130that is inserted into and engages a tip of the pressurized fluid gun112. The male engagement piece130defines at least one groove132that is engaged by the tip of the pressurized fluid gun112. The foam sprayer110is able to operate in a high-pressure mode when the second fluid source106is attached to the foam sprayer110.

The foam sprayer110may have a discrete and compact shape and size. For example, an overall length134of the foam sprayer110may be in a range from 200 millimeters (mm) to 400 mm. In the illustrated embodiment, the overall length134of the foam sprayer110is 315 mm. The body122and the nozzle124have a cumulative length136in a range of 150 mm to 250 mm. The adapter128has a length138in a range of 50 mm to 150 mm.

In some embodiments, the nozzle124includes one or more nozzle spray tips that are attached to the end of the coupler to control the spray pattern of the first fluid104or second fluid108that is dispensed from the nozzle124. The nozzle124may include an adjustment device that provides one or more spray settings, for example a wide spray pattern or a narrow spray pattern.

With reference toFIGS.3and4, the foam sprayer110includes a mode selection device140mounted to the body122. The mode selection device140is configured to switch the foam sprayer110between a low-pressure mode and a high-pressure mode. For example, the mode selection device140includes a knob142and an actuator144that are rotatable to switch the foam sprayer110between the low-pressure mode and the high-pressure mode. As described in detail herein, the foam sprayer110includes a valve164(shown inFIGS.11and12) that regulates liquid flow based on the position of the mode selection device140such that the foam sprayer110is configured to generate foam from the first fluid104when the foam sprayer110is in the low-pressure mode and generate foam from the second fluid108when the foam sprayer110is in the high-pressure mode.

Referring toFIGS.6-9, the foam sprayer110includes a reservoir146attached to the body122. The reservoir146is configured to dispense a cleaning agent (e.g. soap) to be mixed with the first fluid104or the second fluid108within the body122to generate foam. In the illustrated embodiment, the reservoir146comprises a bottle that is screwed into a collar148on a lower portion of the body122. The reservoir146may be removed from the body122for filling or replacement of the reservoir146by unscrewing the reservoir146from the collar148. The reservoir146may be any suitable shape or size. In the illustrated embodiment, the reservoir146is constructed of plastic and is configured to contain at least 40 ounces (oz) of cleaning agent. In other embodiments, the reservoir146may be sized to contain more or less than 40 oz.

As shown inFIGS.4and10-12, the foam sprayer110includes an air intake150. The air intake150is configured to allow air into the body122to mix with the cleaning agent and the first fluid or the second fluid. The foam sprayer110also includes an intake adjustment device152mounted to the body122. The intake adjustment device152is configured to regulate the amount of air that is allowed into the body122through the air intake150. For example, the intake adjustment device152includes a knob154that is rotated to selectively close or open the air intake150.

As illustrated inFIGS.10-12, the body122defines a mixing chamber156and a channel158. The mixing chamber156is in fluid communication with the reservoir146and the air intake150. Also, the mixing chamber156includes an inlet160located at the connector126. The inlet160is arranged for the fluid from the fluid source that is connected to the connector126to flow into the mixing chamber156. The mixing chamber156is configured to facilitate mixing of the cleaning agent and the fluid. The channel158extends from the mixing chamber156to the nozzle124at a distal end of the body122. During operation, the cleaning agent and the air are mixed with the first fluid104or the second fluid108and directed along the channel158to generate foam that is emitted from the body122through the nozzle124. The nozzle124receives the mixture of the cleaning agent, air, and the first or second fluid104,108and channels the mixture to an outlet at the tip of the nozzle124where the foam is emitted. In the example, foam is generated from the mixture at least partly within the nozzle124. For example, the nozzle124includes a foam generating chamber159that extends from the channel158to the outlet tip of the nozzle124. In the illustrated embodiment, the foam generating chamber159includes an inner diameter that widens out along the extension of the nozzle124. Therefore, the mixture decreases in pressure within the foam generating chamber159and the foam generating chamber159facilitates the generation of foam.

The intake adjustment device152is positioned at least partly in or on the air intake150and allows adjustment of the airflow into the mixing chamber156for mixing with the cleaning agent and the first fluid104or the second fluid108. The consistency and concentration of the cleaning agent in the foam are at least partially regulated by the intake adjustment device152because airflow into the mixing chamber156facilitates the cleaning agent being drawn into the mixing chamber156and the cleaning agent forming foam with the fluid. In the example, the body122includes a stem162that extends into the reservoir146for drawing cleaning agent from the reservoir146into the mixing chamber156.

Referring toFIGS.11and12, the mode selection device140is connected to a valve164located downstream of the connector126and upstream of each of the air intake150, the stem162that provides the cleaning agent, the mixing chamber156, and the channel158. The valve164regulates liquid flow into the mixing chamber156through the inlet160. For example, the valve164is rotatable between a first position166(shown inFIG.11) and a second position168(shown inFIG.12). In one embodiment, the valve164is rotated approximately 90° to switch between the first position166and the second position168. In other embodiments, the rotation of the valve164may be less than or greater than 90 degrees for such operation. The valve164is in the first position166when the low-pressure mode is selected using the mode selection device140. The valve164is in the second position168when the high-pressure mode is selected using the mode selection device140.

The valve164has a body170defining a first channel172and a second channel174. The first channel172and the second channel174are perpendicular to each other. The first channel172is in fluid communication with the inlet160when the valve164is in the first position166, as shown inFIG.11. The second channel174is in fluid communication with the inlet160when the valve164is in the second position168, as shown inFIG.12. The first channel172has a larger cross-sectional area than the second channel174. For example, in one embodiment, the second channel174has a diameter that is no more than 1.5 millimeter (mm) and the first channel172has a diameter that is greater than 1.5 mm. In an example, the diameter of the second channel174is 1.0 mm and the diameter of the first channel172is 3 mm. Accordingly, the first channel172is sized for a lower pressure source (e.g., the first fluid source102) and the second channel174is sized for a higher pressure source (e.g., the second fluid source106).

As a result, the foam sprayer110has multiple pressure modes and is able to utilize different fluid sources having different pressures. Moreover, the foam sprayer110is simple to operate and the mode selection device140and the intake adjustment device152provide easy adjustment of the foam sprayer110. In addition, the valve164and the mode selection device140provide a simple and reliable adjustment mechanism.

With reference toFIGS.13-16, the adapter128includes a coupler176, a barrel178, a handle180extending from the barrel178, and a threaded bore182. The coupler176is disposed on an end of the barrel178and is configured to engage the connector126(shown inFIG.8). For example, the coupler176includes a collar184, a sleeve186sized to receive the connector126, and engagement members188. The collar184extends around the sleeve186and is positionable between a locked position and an unlocked position. For example, the collar184slides axially along the sleeve186between the locked position and the unlocked position. The collar184may be biased toward the locked position. The engagement members188are positioned on the interior of the sleeve186and are arranged to engage the connector126when the connector126is positioned within the sleeve186and the collar184is in the locked position. For example, the engagement members188comprise retractable protrusions that extend into the groove132(shown inFIG.8) in the connector126. In other embodiments, the adapter128may include other couplers176without departing from some aspects of the disclosure.

The handle180extends at an oblique angle relative to the barrel178and is sized for the user to grasp the foam sprayer110. The threaded bore182is disposed at the distal end of the handle180opposite the barrel178and is configured to threadingly connect to a fluid source (e.g., the first fluid source102shown inFIG.1). The handle180includes a trigger190for an operator to control fluid flow through the adapter128when the fluid source is attached to the threaded bore182.

Referring toFIGS.1-12, the foam sprayer110may be assembled in any suitable manner. For example, one suitable method of assembling the foam sprayer110includes providing the body122that defines the channel158. The nozzle124is attached to the body122and configured to emit foam. In the illustrated embodiment, the body122and the nozzle124are constructed as separate pieces and are attached together to assemble the foam sprayer110. For example, the nozzle124is constructed of plastic and the body122is constructed of metal. In other embodiments, the body122and the nozzle124are constructed of the same materials and may be integrally formed as a single piece.

The method also includes attaching the connector126to the body122. For example, in the illustrated embodiment, the connector126is metal and is integrally formed with the body122. In other embodiments, the connector126is formed as a separate piece and attached to the body122using welds, fasteners, adhesives, or any other suitable attachment. The adapter128is releasably attached to the connector126to facilitate the first fluid source102attaching to the foam sprayer110. In some embodiments, the adapter128is packaged or provided with the foam sprayer110but is not attached to the body122until use.

In addition, the method includes attaching the mode selection device140to the body122. The mode selection device140is rotatably mounted to the body122and configured to cause the valve164to move between the first position166and the second position168when the mode selection device140is switched between the low-pressure mode and the high-pressure mode. For example, the mode selection device140includes the knob142that causes the valve164to move. The knob142is attached to the valve164by the actuator144extending through an opening in the body122.

In some embodiments, the method includes attaching the reservoir146to the body122. For example, the reservoir146is screwed into the collar148of the body122. The reservoir146dispenses a cleaning agent to the body122.

In further embodiments, the method includes attaching the intake adjustment device152to the body122. For example, the intake adjustment device152is rotatably mounted to the body122. In the illustrated embodiment, rotation of the intake adjustment device152selectively opens or closes the air intake150and adjusts the concentration of the foam dispersed by the foam sprayer110.

Referring toFIGS.17and18, the foam sprayer110is operable in a low-pressure mode (FIG.17) or a high-pressure mode (FIG.18). The foam sprayer110may include graphics, alpha-numeric characters, lights, or other indicators to facilitate the operator selecting the proper mode. In the illustrated embodiment, the foam sprayer110includes illustrations192of the fluid sources that correspond to the respective pressure modes.

To operate the foam sprayer110in the low-pressure mode, the mode selection device140is positioned to select the low-pressure mode as shown inFIG.17, and the adapter128is connected to the body122of the foam sprayer110. The first fluid source102is connected to the adapter128. The trigger190of the adapter128is actuated to allow the first fluid104from the first fluid source102to flow into the body122of the foam sprayer110through the adapter128. The first fluid source102provides the first fluid104at the first pressure. The first fluid104is mixed with air and the cleaning agent within the body122The mixture of the first fluid104, the air, and the cleaning agent flows through the channel158and the nozzle124and generates foam. The intake adjustment device152is adjusted to regulate the air that flows into the body122and, thus, the concentration of the foam. The foam is dispersed from the foam sprayer110through the nozzle124.

To operate the foam sprayer110in the high-pressure mode, the adapter128is removed from the body122of the foam sprayer110and the pressurized fluid gun112of the second fluid source106is connected directly to the body122. The mode selection device140is positioned to select the high-pressure mode as shown inFIG.18. The trigger198of the pressurized fluid gun112is actuated to allow the second fluid108from the second fluid source106to flow into the body122of the foam sprayer110through the pressurized fluid gun112. The second fluid source106provides the second fluid108at the second pressure. The second fluid108is mixed with air and the cleaning agent within the body122. The mixture of the first fluid108, the air, and the cleaning agent flows through the channel158and the nozzle124and generates foam. The intake adjustment device152is adjusted to regulate the air that flows into the body122and, thus, the concentration of the foam. The foam is dispersed from the foam sprayer110through the nozzle124.

The pressurized fluid gun112of the second fluid source106includes a body194, a coupler196, and a trigger198. The coupler196is configured to engage the connector126of the foam sprayer110. For example, the coupler196may be similar to the coupler176of the adapter128. The coupler196receives and engages the connector126. Suitably, the pressurized fluid gun112is a standard apparatus without modifications and the foam sprayer110is compatible with existing types of the pressurized fluid gun112. In some embodiments, the coupler196is a separate piece from the pressurized fluid gun112that is provided to facilitate connection of the foam sprayer110to the pressurized fluid gun112.

Referring toFIG.19, the adapter128can be used to spray fluid when the adapter128is not attached to the body122of the foam sprayer110(shown inFIG.1). For example, the adapter128is configured to connect to the first fluid source102and dispense the first fluid104provided by the first fluid source102without being attached to the foam sprayer110. The first fluid source102is attached to the bottom of the handle180. The adapter128dispenses the first fluid104through the coupler176when the trigger190is pressed. As a result, the adapter128serves multiple purposes and facilitates dispensing the first fluid104without generating foam. In other embodiments, the adapter128is configured to work with other fluid sources such as the second fluid source106(shown inFIG.1) with or without the foam sprayer110attached to the adapter128. In some embodiments, the adapter128includes one or more nozzle spray tips that are attached to the end of the coupler to control the spray pattern of the first fluid104that is dispensed from the adapter128. The adapter128may include an adjustment device that provides one or more spray settings.

Compared to conventional spray systems, the spray system of embodiments of the present disclosure has several advantages. For example, embodiments of the spray system include a foam sprayer that is usable with a high-pressure fluid source or a low-pressure fluid source. The foam sprayer has a high-pressure mode and a low-pressure mode. In addition, the foam sprayer includes a connector that is quickly and easily connected to a high-pressure fluid source. Also, the spray system includes an adapter that facilitates connection of a low pressure source and that is configured to dispense low-pressure fluid without the foam sprayer. Moreover, the foam sprayer has a compact shape and size that may provide an improved aesthetic appearance and be easier to handle than other spray systems.

Numerous characteristics and advantages of the embodiments described by this document have been set forth in the foregoing description. As various changes, including modifications to shape, and arrangement of parts, and the like, could be made in the above constructions and methods without departing from the scope of the disclosure, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Various modifications, can be made without departing from the spirit and scope of the disclosure.