Single valve ready to use sprayer

A sprayer head assembly for dispensing a chemical stored within a container comprises a body having a bore and a valve moveably positioned at least partially within the bore. The sprayer head assembly includes passages for the carrier fluid and the chemical. A vent passage is also provided. The valve selectively closes and opens the carrier fluid, chemical and vent passages. The valve is configured to move in a side to side motion which is generally transverse to a longitudinal axis of the assembly.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to chemical dispensing sprayers and, in particular, to aspiration-type sprayers that use a relatively large amount of carrier fluid for dispensing a relatively small amount of a chemical solution.

2. Description of the Related Art

Every year consumers apply thousands of gallons of chemicals such as fertilizers or pesticides to plants, lawns, flowers, vegetable gardens and other organic type vegetation. Typically, such chemicals are sold in plastic containers in a concentrated form. While in this concentrated form, the chemical is extremely hazardous to the consumer end user and the environment in general. Accordingly, the container typically includes an aspiration-type sprayer head assembly. An aspiration-type sprayer uses a relatively large amount of carrier fluid, such as water, to withdraw, dilute and dispense a relatively small amount of chemical from the container. To further prevent harm to the consumer, the container and the sprayer head assembly are preferably disposed of after the container's contents are exhausted. It is therefore desirable to provide a sprayer head assembly that is sufficiently low cost so as to allow the entire unit to be discarded and yet reliable and safe.

SUMMARY OF THE INVENTION

It is therefore an object of one embodiment to provide a safe and reliable aspiration type chemical sprayer that utilizes a minimum number of components and that is relatively easy to manufacture and assemble.

Accordingly, one embodiment of the present invention comprises a chemical sprayer for dispensing a chemical from a container. The sprayer includes a body and a valve. The body comprises a bore, a chemical passage and a carrier fluid passage. The chemical passage is in communication with a cavity in the container. The carrier fluid passage is in communication with a carrier fluid source. The bore is in communication with the chemical passage and the carrier fluid passage. The carrier fluid passage extends generally in a first direction. A valve is moveably positioned at least partially within the bore. The valve at least partially defines a first passage and a second passage. The first passage and the second passage merge at the valve. The first passage is configured so as to be in communication with the chemical passage when the valve is in an open position. The second passage is configured so as to be in communication with the carrier fluid passage when the valve is in the open position. The first passage and the second passage are configured so as to not be in communication with the chemical and carrier fluid passages when the valve is in a closed position. The valve is configured such that as the valve moves between the open and closed positions, the valve moves along a second direction. The second direction extends generally traverse to the first direction. The valve further comprises one or more sealing portions positioned so as to block both the chemical passage and the carrier fluid passages when the valve is in the closed position.

All of these embodiments are intended to be within the scope of the invention herein disclosed. These and other embodiments of the present invention will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiments having reference to the attached FIGS., the invention not being limited to any particular preferred embodiment(s) disclosed.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIGS. 1-14illustrate an embodiment of a sprayer head assembly10.FIGS. 1-4illustrate the assembly in a closed position.FIGS. 5-9show the assembly in an open position.FIG. 10shows a sprayer head14of the assembly10without a valve20andFIGS. 11 and 12show the valve20removed from the assembly10.

With reference toFIG. 1, the sprayer head assembly10includes a sprayer head14, a container connection portion16, a supply fluid connection portion18, and a control valve20. As will be explained below, the container connection portion16may be used to connect the assembly to a container that contains a chemical. The supply fluid connection portion18may be used to connect the assembly to a carrier fluid source, such as, for example, a garden hose. The sprayer head assembly10may be made of any suitable material that is resistant to and compatible with the chemical fluid to be sprayed. However, a flexible plastic material, such as polypropylene, is preferred because it is resilient yet durable.

With reference toFIGS. 1,3and5, the valve20is moveably positioned in a bore22that is formed in the sprayer head14of the sprayer head assembly10. In the illustrated embodiment, the bore22is generally cylindrical and the valve20is moveable in a side to side motion (see arrows A and B inFIGS. 1 and 5) which is generally transverse to a longitudinal axis of the assembly10. In the illustrated embodiment, the valve20also moves in a direction that is generally horizontal with respect to the user that is holding the assembly10.

With referenceFIGS. 1,3and4, the connection between the sprayer head assembly10and the container can be achieved by providing the container connection portion16with a conventional rotatable coupler26and a washer28. The rotatable coupler26includes internal threads30that cooperate with corresponding threads (not shown) formed on the neck of the container.

The sprayer head assembly10can also be permanently attached to the container. In such an arrangement, adhesive17can be applied to the inner surface of the connection portion16before it is fitted over the neck of the container. Alternatively, the connection portion16can include an inwardly projecting ratchet that opposes a cooperating ratchet formed on the container.

When the sprayer head assembly10is installed onto a container, the interior of the container is in communication with a chemical passage32that is also in communication with the interior of the cylindrical bore22. In the illustrated arrangement, the chemical passage32is defined in part by a downwardly depending chemical flow tube or dip tube34. The dip tube34extends into the container and preferably terminates near a bottom surface of the container. The chemical passage32is also defined in part by an internal passage38, which is formed in the sprayer head14. The internal passage38communicates with the interior of the cylindrical bore22and the dip tube34. The dip tube34is secured in fluid communication with the internal passage38by a cylindrical boss36(seeFIG. 3). Although, in the illustrated arrangement the chemical passage32is defined by two components (the dip tube34and the internal passage38), it should be appreciated that the chemical passage32can be defined by a single component or more than two components. For example, the dip tube34may be integrally formed with the body of the sprayer head14. The illustrated arrangement, however, is preferred because it is easy to manufacture and yet uses a small number of components.

Preferably, the sprayer head assembly10includes a vent passage52, which is shown inFIG. 10. In the illustrated arrangement, the vent passage52is defined by a small hole formed in the head14of the assembly. As with the chemical passage32, the vent passage52communicates with the interior of the container when the assembly10is mounted onto the container. The vent passage52extends up through head14and communicates with the interior of the cylindrical bore22. In the illustrated embodiment, the vent passage52lies generally parallel to and spaced along the axis of the valve from the interior passage32. Although, in the illustrated arrangement the vent passage52is formed on the assembly10, it should be appreciated that the vent passage52can be located on the container. However, the illustrated arrangement is preferred because, as will be explained below, it allows the vent passage52to be opened and closed with the chemical passage32.

As mentioned above, the sprayer head assembly10also includes the supply fluid connection portion18(seeFIG. 3). The supply fluid connection portion18connects the assembly to a pressurized supply fluid source. In the illustrated arrangement, the connection is formed by a conventional rotatable coupler40and a washer42. The coupler40includes threads44that cooperate with corresponding threads (not shown) formed on the supply fluid source. One of ordinary skill in the art will appreciate that other configurations can be used to connect the assembly10to the supply fluid source.

With reference toFIGS. 3 and 4, the sprayer head assembly10defines a supply passage46. The supply passage46is in communication with the supply fluid source and the interior of the bore22. In the illustrated arrangement, the supply passage46is defined in part by a side wall48of the sprayer head14. The side wall48extends from the coupler40towards the cylindrical bore22.

As seen inFIGS. 11 and 12, the illustrated valve20comprises a wall54that defines a cylindrical periphery53for sliding engagement with the bore22. Preferably, the outer wall54includes a rib or key51that is configured to fit within a corresponding longitudinal groove55(seeFIG. 10) formed in the bore22. The interaction between the rib51and the groove55guides the side to side movement of the valve20and limits rotation of the valve20in the bore22. In one embodiment, the groove55is generally parallel to the axis of movement C (seeFIG. 5) of the valve20. The valve20preferably includes a pair of enlarged portions21aat the opposing ends of the valve20. The function of the enlarged portions will be described below.

As will be explained below, the valve20controls the flow of chemical through the assembly10. The valve20also preferably controls the flow of supply fluid through the assembly10. More preferably, the valve20also controls the communication of the vent passage52with atmospheric pressure.

Accordingly, as best seen inFIGS. 7 and 8, the valve20defines at least in part a first passage56. The first passage56is configured and positioned within the valve20such that when the valve20is an open position (i.e., the position shown inFIG. 7) the first passage56is in communication with the chemical passage32. In the illustrated embodiment, the first passage56is placed in communication with the chemical passage by aligning its inlet with the outlet of the chemical passage32.

The first passage56preferably includes a cylindrical metering orifice (not shown) that preferably terminates within a graduated suction generating recess76, which is formed on a valve surface57. Preferably, the valve20defines the metering orifice, the suction generating recess76and the valve surface57. However, it should be appreciated that several advantages of the embodiment can be achieved in an arrangement where the metering orifice, the suction generating recess76and/or the valve surface57are not defined by the valve20. The illustrated arrangement is preferred because, as will be explained in more detail below, the metering orifice can be more accurately manufactured. For example, in one embodiment the metering orifice can be formed in the sprayer head14.

The diameter of the metering orifice represents the narrowest cross-sectional area encountered by the chemical moving through the assembly. As such, the metering orifice determines, for the most part, the dilution ratio of the sprayer head assembly10. The method for determining the diameter of the metering orifice to achieve a desired dilution ratio is well known to those of ordinary skill in the art; therefore, a detailed description of such a method is not necessary.

As seen inFIGS. 7 and 8, the valve surface57defines a generally inclined surface within the valve20. The recess76is formed in the surface57. The recess76has a generally triangular shape that is formed by two side walls and a rounded end wall. Preferably, a mouth of the metering orifice (not shown) lies on a lower face of the recess76near the rounded end wall. The recess76is deepest at the apex where the mouth75of the metering orifice is located. The graduated suction generating recess76is sized and configured, as is well known in the art, so that when carrier fluid flows over the76recess a suction force is created. The suction force draws the chemical from the container through the chemical passage32. Of course, one of ordinary skill in the art will recognize that the desired suction force can be created with graduated suction generating recesses of other shapes and sizes and in some embodiments without a suction generating recess.

As seen inFIGS. 7 and 8, the valve20also defines, at least partially, a second passage58that is in communication with the supply passage46when the valve20is in the open position. The second passage58is preferably defined at least in part by an opening99formed in the wall22of the valve20, the valve surface57and the inner surface of the cylindrical bore22. It should also be appreciated that the second passage58can be defined entirely by the valve20. That is, interior surface of the cylindrical bore22can be replaced, wholly or in part, by an additional wall of the valve20. However, the illustrated arrangement is preferred for several reasons. For example, this arrangement reduces the amount of material needed to form the valve20and increases ease of manufacturing.

In the illustrated embodiment, the second passage58is placed in communication with the supply passage46by aligning the inlet of the second passage58(i.e., the opening99) with the outlet3(seeFIG. 10) of the supply passage46. In this position, the outlet of the second passage58is also in communication with a discharge opening90formed in the sprayer head14. The fluid traveling through the second passage58in the bore22flows through the discharge opening90and is discharged from the assembly10.

With continued reference toFIGS. 7 and 8, the valve20forms a sealing portion63that forms at least in part an annular seal with the bore22around the interface between the chemical passage32and the first passage56. Accordingly, the connection between the chemical passage32and the first passage56is sealed and chemical is prevented from leaking into the gaps between the valve20and the cylindrical bore22.

The sealing portion63may be formed in several different manners. In the illustrated embodiment, the sealing portion63is formed from a separate sealing pad63athat is positioned within a recess11(seeFIG. 11) formed on the valve20. As such, the sealing pad63amoves with the valve20as it is moved from the open to closed positions. With reference toFIG. 13, the sealing member63aincludes an opening63b, which is aligned with the first passage56and with the chemical passage32when the valve20is in the open position. The sealing pad63ain such an embodiment is preferably made of a soft plastic elastomer material or other suitable synthetic rubber material. Such material provides an effective seal with the bore22, which as mentioned above is preferably made of a harder plastic material. In another embodiment, a sealing pad or O-ring (not shown) may be positioned within a recess formed in the bottom wall23(seeFIG. 10) of the sprayer head14. In other embodiments, the valve20and/or the bore22may be may be coated with an elastomer, rubber or rubber like material. In another embodiment, the wall54of the valve20forms the sealing portion41. In such embodiments, a seal may be formed with a sealing member on the bore22and/or by forming or coating the bore22and/or valve20with seal promoting material.

In the open position, the vent passage52is in communication with a vent opening or channel55a(seeFIG. 10) in the valve20. In the open position, the vent channel55aextends beyond the bore22to place the vent passage52in communication with an atmospheric pressure source.

As shown, inFIGS. 3 and 4, in a closed position, the first passage56and the vent channel55aare not in communication with the respective vent and internal passages52,38. In the illustrated embodiment, the vent channel and first passage55a,56are placed out of communication with the vent and internal passages52,38by sliding the valve such that portions of the valve20cover or block the outlets of these passages52,38. In the illustrated embodiment, the portion of the valve20that blocks these passages55a,56is the sealing portion63described above. That is, as the valve20is moved to the closed position, the sealing portion63slides over the outlet of the vent and chemical passages55a,56. In modified embodiments, the valve20may be arranged to block only one of the passages38,52. As discussed above, those of skill in the art will also recognize that the valve20or the inner bore22may be provided with various combinations of sealing members, coatings and/or integrally formed pieces preferably made from a elastic material (e.g., elastomer, rubber or rubber like material) to provide modified sealing arrangements in the closed and open positions. In such embodiments, the outer surfaces of the valve20may block the vent and/or chemical passages52,32.

With reference back toFIGS. 7 and 8, when the valve20is in the open position, a stream of pressurized carrier fluid is discharged into the second passage58. As the carrier fluid flows over the valve surface57, a suction force is created that draws chemical through the dip tube34, internal passage38, and first passage56and into the stream of carrier fluid. Venting is provided through the vent passage52.

Preferably, the chemical and carrier fluid is directly discharged from the assembly10through the second passage58and the opening90. A hood80may be provided to prevent spraying on the user. The upwardly inclined orientation of the valve surface57of the valve20also helps to direct the chemical and carrier fluid stream away from the user. It should also be appreciated that an additional outlet nozzle could be added to the assembly10to further direct the water and chemical flow. Such a nozzle can extend from the second passage58and would offer additional control of the carrier fluid and chemical stream.

When the valve is moved to the closed position (see e.g.,FIGS. 3 and 4), the carrier passage46is closed by the valve20. In this position, the valve20covers or blocks the carrier fluid passage46. As discussed above, the inner bore22and/or the valve20may be configured in a variety of ways to provide a tight seal between the valve20and the carrier fluid passages. In the illustrated embodiment, the valve20forms a sealing portion41. In the illustrated embodiment, the sealing portion41is formed by a sealing member or pad41a(see alsoFIG. 14) that is positioned within a recess43formed in the valve20(seeFIG. 13). In this manner, the sealing portion41moves with the valve20and in the closed positioned is positioned over the outlet of the carrier fluid passage46. In other embodiments, the valve and/or inner bore22may include additional or replacement sealing members (e.g., O-rings), coatings and/or integral formed materials that are configured to prevent leakage past the valve20when the valve20is in the closed position. In another embodiment, the wall54of the valve20forms the sealing portion41. In such embodiments, a seal may be formed with a sealing member on the bore22and/or by forming or coating the bore22and/or valve20with seal promoting material.

As mentioned above, in the open position (seeFIGS. 7 and 8), the opening99that is formed in the wall54of the valve20(FIG. 11) is aligned with the outlet3of the carrier fluid passage46to place the second passage56in communication with the carrier fluid passage46. In the embodiment, to provide a seal between these passages, the sealing pad41aincludes an opening41b(seeFIG. 14) that is aligned with the carrier passage46in the open position. In this manner, the sealing member41aforms an annular seal between the interface of the opening99and carrier fluid passage46preventing leakage into the bore22in the open position. In modified embodiments, the leakage may be prevented or limited by providing the valve and/or bore with any of a variety of combinations of sealing arrangements including coatings on the valve20and/or bore22and/or sealing member(s) (e.g., O-rings) positioned on the bore22.

It should be appreciated that the valve20advantageously can be operated with one hand while the assembly10, container, and hose can be controlled with the other hand thereby providing a safe spray operation. The valve20is moved between the open and closed position by pushing on the enlarged portions21a,21b. Specifically, with reference toFIG. 1, the valve20may be moved from the closed position by pushing on the enlarged portion21ain the direction of arrow A. This causes to valve20to slide in the bore22to the open position ofFIG. 5. From the open position, the valve20may be moved to the closed position by pushing on the enlarged portion21bin the direction of arrow B inFIG. 5. In modified embodiments, the valve20may be pulled from the closed and/or open position. In such embodiments, the valve20may be provided with a grasping member (e.g., a handle) for grasping and pulling the valve20.

With reference toFIG. 11, the valve20may be formed in two portions. The first portion includes one enlarged portion21aand the portions of the valve20configured to fit within the bore22. The second portion includes the other enlarged portion21b, which may be coupled to the first portion after the valve20is assembled into the sprayer head14.

The illustrated assembly10described above is particularly adapted to be manufactured by injection molding. Because the assembly10will typically be discarded after the chemical in the container is exhausted, the costs of manufacturing the assembly10must be low. Injection molding is a particularly low cost method of making parts out of plastic-type materials. Those of ordinary skill in the art will recognize that the sprayer head14, the container connection portion16, the supply fluid connection portion18, the sealing member and the control valve20can all be formed using injection molding.

FIGS. 15-22illustrate a modified embodiment of a sprayer head assembly100. In these figures, like numbers have been used to designate components that are similar to the components described above with reference to the embodiment ofFIGS. 1-14. In addition, in the following description reference will be made only to components that are needed in order to understand certain modifications or changes as compared to the previous embodiment. For components not specifically mentioned, reference may be made to the description above.

With initial reference toFIGS. 15-19, the sprayer head assembly100generally includes a sprayer head14, a container connection portion16, a supply fluid connection portion18, and a control valve20, which can be configured substantially as described above. The valve20is moveably positioned in a bore22that is formed in the sprayer head14of the sprayer head assembly100. As with the embodiment ofFIGS. 1-16, the bore22is generally cylindrical and the valve20is moveable in a side to side motion which is generally traverse to a longitudinal axis of the assembly100. In the illustrated embodiment, the valve20also moves in a direction that is generally horizontal with respect to the user that is holding the assembly100.

In this embodiment, the assembly100includes a child safety feature102, which requires a level of strength and dexterity that is typically not possessed by children in order to operate the valve20. The child safety feature102may comprise any of a variety of interlocking structures. In the illustrated embodiment, the child safety feature comprises a flange104positioned on the valve20, which interacts with a corresponding opening106positioned on the sprayer head14. With reference to theFIGS. 16A and 20, the flange104in the illustrated arrangement is positioned on the periphery of the valve20, has a generally rectangular shape and extends in a direction generally perpendicular to the longitudinal axis of the valve20. With reference toFIGS. 16A and 19, the opening106includes a first, shallow portion108and a second extended portion110. In the closed position (FIG. 16A), the distal end of the flange104is positioned in the shallow portion108of the opening106. In this position, the valve20cannot be pushed towards the open position in the bore22. The valve20may be provided with a gripping portion (e.g., a knurled area)112, such that the valve20can be rotated within the bore22. In this manner, the distal end of the flange104becomes aligned with the second extended portion110of the opening106. The valve20may then be pushed into the open position.

As mentioned above with reference toFIGS. 1-14, the valve20may comprise a first portion and a second portion.FIGS. 21-22illustrate the second portion120of the valve20. This portion120of the valve20maybe coupled to the first portion122(seeFIG. 20) after the valve20has been positioned within the bore22of the sprayer head14. In the illustrated embodiment, the second portion122includes an annular flange124that may be press-fitted into a corresponding recess (not shown) in the valve20.

With reference toFIG. 18, in this embodiment, the inner bore includes a recess128(see alsoFIG. 19) in which a sealing member130(e.g., an O-ring) is positioned generally about the outlet3of the carrier fluid passage46. In addition the sealing portion41is formed by the outer surface of the valve20. Of course, as described above, a variety of other sealing arrangement may be used in modified embodiments.

FIGS. 23 and 24illustrate another modified embodiment of a sprayer head assembly200. In these figures, like numbers have been used to designate components that are similar to the components described above with reference to the embodiment ofFIGS. 1-14. In addition, in the following description reference will be made only to components that are needed in order to understand certain modifications or changes as compared to the previous embodiment. For components not specifically mentioned, reference may be made to the description above.

In this embodiment, the supply fluid connection portion18further comprises a downwardly extending portion202. In the illustrated embodiment, this portion202extends at a downwardly directed with respect to the longitudinal axis of the sprayer head14. In one embodiment, the portion202extends along an angle that is between about 30 to about 60 degrees with respect to the longitudinal axis of the sprayer head14. In another embodiment, the portion202extends along an angle that is about 45 degrees with respect to the longitudinal axis of the sprayer head14. This arrangement may provide a more ergonomically correct positioning of the user's hand with respect to the container that is attached to the sprayer head. This embodiment200may also be provided with a child safety feature as described above.