Quick release mechanism for paint sprayer

A sprayer generally includes a tool housing have a wet housing portion that disconnects from a dry housing portion. A solenoid motor is contained in the dry housing portion. An arm member is connected to the dry housing portion. The solenoid motor is operable to move the arm member relative to the dry housing portion. A spray nozzle is connected to a chamber member in the wet housing portion. A piston member extends from the wet housing portion and terminates with a tip portion operable to engage the arm member. A catch member is movably connected to the dry housing portion having an extended condition and a retracted condition. The catch member in the retracted condition is operable to release the wet housing portion from the dry housing portion and disconnect the piston member from the solenoid motor. The catch member in the extended condition is operable to lock the wet housing portion to the dry housing portion and keep the piston member engaged with the arm member.

FIELD

The present disclosure relates to a sprayer for spraying fluids including paints and stains, and specifically relates to a sprayer having a housing where a wet side can be disconnected from a dry side with a quick release mechanism.

BACKGROUND

Typically, when changing paint in a paint sprayer, a reservoir of paint is emptied and cleaned before different paint is introduced. Cleaning the reservoir can expose the sprayer body and pump to the cleaning process. In certain examples where portions of the housing detach with the reservoir, the process to separate the housings can be relatively complex and require two hands to perform.

SUMMARY

The present teachings generally include a sprayer that includes a tool housing have a wet housing portion that disconnects from a dry housing portion. A solenoid motor is contained in the dry housing portion. An arm member is connected to the dry housing portion. The solenoid motor is operable to move the arm member relative to the dry housing portion. A spray nozzle is connected to a chamber member in the wet housing portion. A piston member extends from the wet housing portion and terminates with a tip portion operable to engage the arm member. A catch member is movably connected to the dry housing portion having an extended condition and a retracted condition. The catch member in the retracted condition is operable to release the wet housing portion from the dry housing portion and disconnect the piston member from the solenoid motor. The catch member in the extended condition is operable to lock the wet housing portion to the dry housing portion and keep the piston member engaged with the arm member.

DETAILED DESCRIPTION

Example aspects of the present teachings will now be described more fully with reference to the accompanying drawings.

With reference toFIG. 1of the drawings, a sprayer constructed in accordance with the present teachings is generally indicated by reference numeral10. The sprayer10can have a tool housing12including a dry housing portion14and a wet housing portion16. The wet housing portion16can be disconnected from the dry housing portion14. A reservoir body18can connect to and disconnect from the wet housing portion16.

With reference toFIGS. 1,2, and3, the dry housing portion14can include a catch member20that is configured to permit the wet and dry housing portions14,16to be locked to and uncoupled from one another. The dry housing portion can be formed of a pair of clam shell housing halves, and can define a housing body22and a handle24. The wet housing portion16can also be formed of a pair of clam shell housing halves.

With reference toFIGS. 2,3,4, and5, a solenoid motor30can be contained in the dry housing portion14. In this example, the solenoid motor30can include an armature that can reciprocate to drive an arm member32. The arm member32can pivot about a pin member34. The arm member32can have an engagement portion36. The engagement portion36on the arm member32can be disposed at an aperture38in a channel member40that can be connected to the dry housing portion14. The channel member40can extend toward the wet housing portion16and can facilitate connection of the wet housing portion16with the dry housing portion14. The channel member40can be disposed in the dry housing portion14and can be adjacent to the solenoid motor30. The channel member40can have a receiving aperture42opposite the aperture38(FIG. 3) that can accept a piston member50that extends from the wet housing portion16.

With reference toFIGS. 3,4,5, and6, the wet housing portion16can include the piston member50that can extend toward the dry housing portion14. The piston member50can include a tip portion52. The tip portion52can extend through the channel member40on the dry housing portion14and can connect with the engagement portion36on the arm member32. In doing so, the solenoid motor30can be engaged with the piston member50and when the solenoid motor30is initiated it can cause the reciprocation of the piston member50.

With reference toFIG. 12, a center of mass of the solenoid motor30is indicated by reference numeral30aat an intersection of axes A and B and a center balance point of the handle24is indicated by reference numeral24aat an intersection of axes A and C. The center of mass30aof the solenoid motor30can be configured to be in line with the center balance point24aof the handle24, i.e., arranged on axis A. In this manner, the balance of the sprayer10can be improved, which can be shown to increase comfort of a user during operation of the sprayer10. Furthermore, a support casting isolator56can be coupled to the channel member40and the solenoid motor30and can be shown to reduce vibration of the sprayer10during operation. Arrangement of the support casting isolator56along the axis A can also be shown to reduce vibration of the solenoid motor30during operation of the sprayer10.

In certain examples, the positioning of the center of mass30aof the solenoid motor30to be in line with the center balance point24aof the handle24can result in an increased length of the piston member50. The piston member50can reciprocate with the channel member40as the sprayer10operates. As the length of the piston member50increases, however, the bending stress exerted on the piston member50can also increase. With reference toFIGS. 13 and 14, a supporting boss58can be arranged within the channel member40in order to reduce the propensity of the piston member50bending while reciprocating in the channel member40. The supporting boss58can define a supporting boss aperture60in which the piston member50is received. The supporting boss58can provide support to, and can be shown to inhibit bending of, the piston member50during operation of the sprayer10.

During operation of the sprayer10, heat can be generated due to the friction between the piston member50and the supporting boss58as the piston member50reciprocates within the supporting boss aperture60of the supporting boss58. In order to among other things reduce the heat generated, the supporting boss58can be formed of a material having a low coefficient of friction such as Teflon™ manufactured by E.I. Du Pont de Nemours & Company.

Additionally or alternatively, a supporting boss sleeve62having a low coefficient of friction can be arranged within the supporting boss aperture60, as shown inFIG. 14. In another example, the piston member50can include a band member64that can be positioned on the piston member50to slidingly engage the supporting boss sleeve62on the supporting boss58. The band member64can be an annular unitary structure or made from a multi-piece construction. The band member64can be recessed in the piston member50so as to be flush (or almost flush) with an outer periphery of the piston member50. The supporting boss sleeve62or the band member64or both can be formed of a material having a low coefficient of friction such as Teflon™.

With reference toFIGS. 2,3,4, and5, the piston member50can extend from and can connect to a chamber member66in the wet housing portion16. An elastic member70can be disposed between a surface72formed on the chamber member66and a surface74formed on the piston member50. The elastic member70can urge the tip portion52of the piston member50away from the chamber member66and into an extended condition. In this regard, the piston member50can reciprocate against the elastic member70and relative to the chamber member66between a retracted condition (FIG. 9) and the extended condition (FIG. 11). When the piston member50reciprocates, paint can be pumped out of the reservoir body18and into the chamber member66. From the chamber member66, the piston member50can pump the paint out of a spray nozzle76. In doing so, the piston member50can actuate a pump78in the chamber member66. In one example, the pump78can operate in a positive displacement fashion to pump paint from the reservoir body18to the spray nozzle76.

When the wet housing portion16is locked to the dry housing portion14and the tip portion52of the piston member50is engaged with the engagement portion36on the arm member32, the elastic member70can be in the retracted condition and further compressed between the chamber member66and the piston member50. When the wet housing portion16is released from the dry housing portion14, the elastic member70can urge the surfaces72,74further apart to increase the spacing between the chamber member66and the tip portion52of the piston member50.

The wet housing portion16can have a guard member80that can hold the spray nozzle76, which can be fluidly connected to the chamber member66on a side opposite of the piston member50. The spray nozzle76can include an orifice portion from which the paint can be directed out of the chamber member66and on to a workpiece. The spray nozzle76and the orifice portion can be fluidly connected to the chamber member66and can deliver a spray of paint in a pattern. The orifice portion can be a separate component from the spray nozzle76, so that the spray nozzle76can rotate relative to the orifice portion. The orifice portion can atomize the paint and the spray nozzle76can impart the pattern. In other examples, a single component can atomize the paint and can impart the pattern on the spray of paint.

The guard member80can be disposed around the spray nozzle76and can have a multitude of finger depressions90. The multitude of finger depressions90can be used to rotate the guard member80that is fixed for rotation with the spray nozzle76. By rotating the guard member80, the rotation of the spray nozzle76can provide different orientations of the pattern of the spray that is emitted from the spray nozzle76. In one example, the spray nozzle76can produce a flat, planar spray pattern. By rotating the guard member80, the plane of the spray pattern can be rotated. In doing so, it can be shown that the paint can be more easily directed in more specific and relatively harder to reach locations.

With reference toFIGS. 4 and 5, a protrusion100and a protrusion102can be connected to the chamber member66. The protrusions100,102can be on opposite sides of the chamber member66. The protrusion100can have a leading edge104, a trailing edge106and a tip108. As such, the protrusion100can include a wing member110that can form at least a partial rectangular shape. The tip108of the protrusion100can include a post member112. In this arrangement, the leading edge104can be longer than the trailing edge106and can terminate at the post member112.

The protrusion102can have a similar structure and can have a leading edge120, a trailing edge122and a tip124. As such, the protrusion102can include a wing member126that can form at least a partial rectangular shape. The tip124of the protrusion102can include a post member128. Similarly, the leading edge120can be longer than the trailing edge122and can terminate at the post member128. The wing members110,126can extend longitudinally in the same direction as the piston member50. In this regard, the protrusions100,102can engage with the channel member40.

The channel member40can include a groove130and a groove132. The grooves130,132can be formed on opposite sides of the channel member40and can be configured to receive the protrusions100,102. The grooves130,132can be formed at the receiving aperture42of the channel member40. As the piston member50is inserted into the channel member40, the grooves130,132can receive the protrusions100,102. The leading edge104of the protrusion100can abut a stop134formed in the groove130opposite the receiving aperture42. Similarly, the leading edge120can abut a stop136formed in the groove132opposite the receiving aperture42. When the protrusions100,102are held in the grooves130,132and up against the stops134,136, the wet housing portion16can be in the proper position to be locked to the dry housing portion14. Moreover, the tip portion52of the piston member50can be positioned to be in contact with the engagement portion36of the arm member32.

The groove130can define a pair of walls140and the groove132can define a pair of walls142that can extend between the receiving aperture42and the stops134,136, respectively. The pair of walls140can hold the wing member110and the pair of walls142can hold the wing member126. When the protrusions100,102are secured in the grooves130,132, the complementary partial rectangular shapes can be configured to be shown to limit movement of the piston member50in the channel member40but for its reciprocating movement. By limiting the movement as described above, the tip portion52can be aligned with and engaged to the receiving portion of the arm member32. The limiting of the movement can also be shown to reduce the motion of the wet housing portion16relative to the dry housing portion14. Put another way, to properly align the tip portion52with the engagement portion36, the user need only insert the piston member50into the channel member40so that the protrusions100,102are accepted by the grooves130,132. It can also be shown that the vibration experienced by the wet housing portion16that can affect the pattern of the spray can be reduced or eliminated, when the protrusions100,102are seated in the grooves130,132, respectively.

With reference toFIGS. 2,3,4, and5, the dry housing portion14includes the catch member20. In one example, the catch member20can include a clasp member150disposed between an elastic member152and a button member154. The button member154can have a surface156that can extend out of and be accessible from an exterior158of the dry housing portion14. A surface160of the button member154opposite the surface156can connect to a top portion162of the clasp member150. The clasp member150can also include a first leg member164opposite a second leg member166. The first leg member164can be disposed far enough from the second leg member166so that the clasp member150can be disposed over the channel member40in the dry housing portion14.

With reference toFIG. 2, the first leg member164of the clasp member150can include a pocket170that is adjacent a ramp172. The second leg member166can also include a pocket174that is adjacent a ramp176. The elastic member152can be further compressed when the catch member20is pushed from the extended condition into the retracted condition. From the retracted condition, the elastic member152can extend and push the catch member20from the retracted condition into the extended condition. The catch member20can move along an axis180(FIGS. 2 and 3) between the extended and retracted conditions. With reference toFIGS. 2 and 3, the axis180can be disposed transverse to an axis182along which the piston member50can reciprocate in the longitudinal direction. In one example, the axes180,182can be perpendicular.

With reference toFIGS. 2,3,9,10, and11, the pockets170,174on the catch member20in the extended condition can hold the post members112,128on the protrusions100,102, respectively, that extend from the chamber member66. In doing so, the wet housing portion16can be locked to the dry housing portion14and the tip portion52of the piston member50can be held in contact with the engagement portion36on the arm member32in the dry housing portion14.

With reference toFIGS. 2,3, and10, the button member154can be pushed to drive the clasp member150toward the channel member40and into the retracted condition. As such, the elastic member152between the channel member40and the clasp member150can be compressed further and the legs164,166of the clasp member150can travel downward and move the ramps172,176of each leg member164,166out of obstruction with the post members112,128on each side of the chamber member66. With the obstruction removed from the post members112,128, the elastic member70between the chamber member66and the piston member50can extend and increase the space between the chamber member66and the piston member50, as shown inFIG. 11. This can result in the wet housing portion16being pushed away from the dry housing portion14to begin the process of disconnecting the wet housing portion16from the dry housing portion14. In doing so, the piston member50can be withdrawn from the channel member40and the engagement between the wet housing portion16and the dry housing portion14can be broken. In this arrangement, the wet housing portion16and the reservoir body18can be cleaned and washed without exposing the dry housing portion14to such a cleaning process.

The wet housing portion16can be unlocked from the dry housing portion14by pressing the button member154perpendicular to the direction along which the wet housing portion16separates from the dry housing portion14.

With reference toFIGS. 2,3,9,10, and11, the wet housing portion16can be connected to the dry housing portion14, when the catch member20is in the extended condition. In this regard, the piston member50can be inserted into the channel member40and the wet housing portion16can be pushed against the dry housing portion14. When the post members112,128on the chamber member66encounter the ramps172,176on the leg members164,166of the catch member20, the post members112,128can drive the ramps172,176downward, thus moving the catch member20from the extended condition to the retracted condition (or at least partially).

The wet housing portion16can be further pushed into locking engagement with the dry housing portion14and the post members112,128on the chamber member66can move over the ramps172,176and into the pockets170,174formed on the leg members164,166. Once the post members112,128on the chamber member66seat into the pockets170,174on the leg members164,166of the clasp member150, the catch member20can move from the retracted condition back to the extended condition. In this position, the tip portion52of the piston member50can be held in contact with the engagement portion36and the solenoid motor30can cause the reciprocation of the piston member50. The ramps172,176can also be square shaped (i.e., not ramped), and therefore require that the user move the catch member20to the retracted condition to permit connection and locking of the wet housing portion16to the dry housing portion14.

With reference toFIGS. 2,3, and4, it will be appreciated in light of the disclosure that the sprayer10need only be tipped on its side and a cap184can be removed to permit access to a cavity186defined by the reservoir body to fill or empty the reservoir body18as desired. The reservoir body18may be manufactured in various ways, including blow molding or a combination of injection molding and blow molding.

Additionally or alternatively, a connection bore188acan be included on the dry housing portion14and a connection bore188bcan be included on the wet housing portion16. The connection bores188a,188bcan be pinned to lock the wet housing portion16to the dry housing portion14.

With reference toFIGS. 1,2,7, and8, a spray adjuster190can be configured to control the solenoid motor30. The spray adjuster190can comprise a knob192that can be rotated into one of a multitude of positions as selected by the user of the sprayer10. Moreover, a system of indicia can be employed to communicate to the user information concerning the placement of the knob192. In a basic form, the system of indicia can include words or numbers that relate to the volume of paint that is dispensed when the sprayer10is operated and the knob192is in a particular position. For examples, a series of words (e.g.: very small, small, medium, large, extra large) or a series of numbers (e.g.: 1, 3, 7, 11, 19) could be employed.

As another example, the system of indicia can comprise a multitude of icons194that illustrate one or more tasks that could be performed satisfactorily when the knob192is placed in a specific position. The icons194can include a chair project196a, a door project196b, a picnic table project196c, a shed door project196d, and a gate project196e, where the projects can require increasing paint flow from the sprayer10, as the knob is rotated clockwise relative toFIG. 8. By way of this example, the gate project196ecan require the largest magnitude of paint flow relative to chair project196a.

With reference toFIG. 7, a stopper member198can be configured to selectively retract into or extend from the knob192, as the knob192is rotated relative to the tool housing12. The stopper member198can be disposed within the tool housing12of the dry housing portion14. The stopper member198can be in engagement with the arm member32upon which the solenoid motor30imparts a pivoting motion. In this regard, the pivoting motion of the arm member32can be limited by obstruction with the stopper member198. As the knob192is rotated to a certain position that requires less volume of paint to be emitted from the sprayer10(e.g.: the door project196b), the stopper member198can limit the pivoting motion of the arm member32relative to an application that requires relatively larger volumes of paint (e.g.: the gate project196e) to be emitted from the sprayer10. It will be appreciated in light of the disclosure that the spray adjuster190can mechanically limit (in contrast to electronically limiting) the amount of paint that the solenoid motor30causes the piston member50to pump from the reservoir body18.

With reference toFIGS. 2,3,4, and5, a control module200can be included in the dry housing portion14. A switch202can be connected to the control module200and can be accessible on the exterior158of the tool housing12. The user can use the switch202to limit the output of the solenoid motor30. In doing so, the solenoid motor30can be switched, for example, between a low mode and a high mode. In this example, the rate at which the solenoid motor30reciprocates can be reduced to provide relatively less pumping action. A trigger204can be arranged in the tool housing12of the dry housing portion14near the handle24. The trigger204can be electrically connected to the control module200and can be configured to move in an aperture206between an extended condition and a retracted condition. The trigger204in the retracted condition can actuate the solenoid motor30.

The foregoing description of the exemplary aspects of the present teachings has been provided for purposes of illustration and description. Individual elements or features of a particular aspect of the present teachings are generally not limited to that particular aspect, but, where applicable, are interchangeable and can be used in other aspects, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the present teachings, and all such modifications are intended to be included within the scope of the present teachings.