Systems and methods for dispensing texture material using dual flow adjustment

An aerosol dispenser for dispensing stored material in a spray comprises a container, a conduit, and first and second adjustment systems. The container defines a chamber containing the stored material and pressurized material. The conduit defines a conduit passageway having a conduit inlet and a conduit outlet. The conduit inlet is arranged within the chamber and the conduit outlet is arranged outside of the chamber. The first adjustment system is arranged to vary a flow of stored material along the conduit passageway and is arranged between the conduit inlet and the conduit outlet. The second adjustment system arranged to vary a flow of stored material along the conduit passageway and is arranged between the first adjustment system and the conduit outlet.

TECHNICAL FIELD

This application relates to the dispensing of texture material and, more particularly, to systems and methods for dispensing small amounts of texture material to an un-textured portion of a target surface such that an applied texture pattern of the texture material substantially matches a preexisting texture pattern on a textured portion of the target surface.

BACKGROUND

The present invention generally relates to systems and methods for applying texture material to an interior surface such as a wall or ceiling. In particular, buildings are typically constructed with a wood or metal framework. To form interior wall and ceiling surfaces, drywall material is attached to the framework. Typically, at least one primer layer and at least one paint layer is applied to the surface of the drywall material to form a finished wall surface.

For aesthetic and other reasons, a bumpy or irregular texture layer is often formed on the drywall material after the drywall material has been primed and before it has been painted. The appearance of the texture layer can take a number of patterns. As its name suggests, an “orange peel” texture pattern generally has the appearance of the surface of an orange and is formed by a spray of relatively small droplets of texture material applied in a dense, overlapping pattern. A “splatter” texture pattern is formed by larger, more spaced out droplets of texture material. A “knockdown” texture patter is formed by spraying texture material in larger droplets (like a “splatter” texture pattern) and then lightly working the surfaces of the applied droplets with a knife or scraper so that the highest points of the applied droplets are flattened. In some situations, a visible aggregate material such as polystyrene chips is added to the texture material to form what is commonly referred to as an “acoustic” or “popcorn” texture pattern. The principles of the present invention are of primary significance when applied to a texture material without visible aggregate material.

For larger applications, such as a whole room or structure, the texture layer is typically initially formed using a commercial texture sprayer. Commercial texture sprayers typically comprise a spray gun, a hopper or other source of texture material, and a source of pressurized air. The texture material is mixed with a stream of pressurized air within the texture gun, and the stream of pressurized air carries the texture material in droplets onto the target surface to be textured. Commercial texture sprayers contain numerous points of adjustment (e.g., amount of texture material, pressure of pressurized air, size of outlet opening, etc.) and thus allow precise control of the texture pattern and facilitate the quick application of texture material to large surface areas. However, commercial texture sprayers are expensive and can be difficult to set up, operate, and clean up, especially for small jobs where overspray may be a problem.

For smaller jobs and repairs, especially those performed by non-professionals, a number of “do-it-yourself” (DIY) products for applying texture material are currently available in the market. Perhaps the most common type of DIY texturing products includes aerosol systems that contain texture material and a propellant. Aerosol systems typically include a container, a valve, and an actuator. The container contains the texture material and propellant under pressure. The valve is mounted to the container selectively to allow the pressurized propellant to force the texture material out of the container. The actuator defines an outlet opening, and, when the actuator is depressed to place the valve in an open configuration, the pressurized propellant forces the texture material out of the outlet opening in a spray. The spray typically approximates only one texture pattern, so it was difficult to match a variety of perhaps unknown preexisting texture patterns with original aerosol texturing products.

A relatively crude work around for using an aerosol texturing system to apply more than one texture pattern is to reduce the pressure of the propellant material within the container prior to operating the valve. In particular, when maintained under pressure within the container, typical propellant materials exist in both a gas phase and in a liquid phase. The propellant material in the liquid phase is mixed with the texture material, and the texture material in the gas state pressurizes the mixture of texture material and liquid propellant material. When the container is held upright, the liquid contents of the container are at the bottom of the container chamber, while the gas contents of the container collect at the top of the container chamber. A dip tube extends from the valve to the bottom of the container chamber to allow the propellant in the gas phase to force the texture material up from the bottom of the container chamber and out of the outlet opening when the valve is opened. To increase the size of the droplets sprayed out of the aerosol system, the container can be inverted, the valve opened, and the gas phase propellant material allowed to flow out of the aerosol system, reducing pressure within the container chamber. The container is then returned upright and the valve operated again before the pressure of the propellant recovers such that the liquid contents are forced out in a coarser texture pattern. This technique of adjusting the applied texture pattern result in only a limited number of texture patterns that are not highly repeatable and can drain the can of propellant before the texture material is fully dispensed.

A more refined method of varying the applied texture pattern created by aerosol texturing patterns involved adjusting the size of the outlet opening formed by the actuator structure. Initially, it was discovered that the applied texture pattern could be varied by attaching one of a plurality of straws or tubes to the actuator member, where each tube defined an internal bore of a different diameter. The straws or tubes were sized and dimensioned to obtain fine, medium, and coarse texture patterns appropriate for matching a relatively wide range of pre-existing texture patterns. Additional structures such as caps and plates defining a plurality of openings each having a different cross-sectional area could be rotatably attached relative to the actuator member to change the size of the outlet opening. More recently, a class of products has been developed using a resilient member that is deformed to alter the size of the outlet opening and thus the applied texture pattern.

Existing aerosol texturing products are acceptable for many situations, especially by DIY users who do not expect perfect or professional results. Professional users and more demanding DIY users, however, will sometimes forego aerosol texturing products in favor of commercial texture sprayers because of the control provided by commercial texture sprayers.

The need thus exists for improved aerosol texturing systems and methods that can more closely approximate the results obtained by commercial texture sprayers.

SUMMARY

An aerosol dispenser for dispensing stored material in a spray comprises a container, a conduit, and first and second adjustment systems. The container defines a chamber containing the stored material and pressurized material. The conduit defines a conduit passageway having a conduit inlet and a conduit outlet. The conduit inlet is arranged within the chamber and the conduit outlet is arranged outside of the chamber. The first adjustment system is arranged to vary a flow of stored material along the conduit passageway and is arranged between the conduit inlet and the conduit outlet. The second adjustment system arranged to vary a flow of stored material along the conduit passageway and is arranged between the first adjustment system and the conduit outlet.

The present invention may also be embodied as a method of dispensing stored material in a spray comprising the following steps. The stored material and pressurized material are arranged in a chamber. A conduit is arranged such that a conduit inlet is arranged within the chamber and a conduit outlet is arranged outside of the chamber. A flow of stored material is varied at a first location along the conduit passageway. The first location is arranged between a conduit inlet defined by the conduit passageway and a conduit outlet defined by the conduit passageway. The flow of stored material is varied at a second location along the conduit passageway. The third location is arranged between the first location and the conduit outlet.

The present invention may also be embodied as an aerosol dispensing system for dispensing stored material in a spray comprising a container, a conduit, a valve assembly, and first and second adjustment members. The container defines a chamber containing the stored material and pressurized material. The conduit defines a conduit passageway having a conduit inlet and a conduit outlet. The conduit inlet is arranged within the chamber, and the conduit outlet is arranged outside of the chamber. The valve assembly is arranged selectively to allow and prevent flow of stored material along the conduit passageway. The first adjustment member arranged to vary a flow of stored material along the conduit passageway and is arranged between the conduit inlet and the conduit outlet. The second adjustment member arranged to vary a flow of stored material along the conduit passageway and is arranged between the first adjustment member and the conduit outlet.

DETAILED DESCRIPTION

The present invention may be embodied in many forms, and several examples of aerosol dispensing systems of the present invention will be discussed below. In particular, the Applicant will initially describe a first example class of aerosol systems and a number of example aerosol dispensing systems within the first class. The Applicant will then describe a second example class of aerosol systems and a number of example aerosol dispensing systems within that second class.

I. First Example Class of Aerosol Dispensing Systems

Referring initially toFIG. 1of the drawing, depicted at20atherein is a first example aerosol dispensing system constructed in accordance with, and embodying, the principles of the present invention. The first example dispensing system is adapted to spray droplets of dispensed material22aonto a target surface24a. The example target surface24ahas a textured portion26aand an un-textured portion28a. Accordingly, in the example use of the dispensing system20adepicted inFIG. 1, the dispensed material22ais or contains texture material, and the dispensing system20ais being used to form a coating on the un-textured portion28ahaving a desired texture pattern that substantially matches a pre-existing texture pattern of the textured portion26a.

FIG. 1further illustrates that the example dispensing system20acomprises a container30adefining a chamber32ain which stored material34aand pressurized material36aare contained. The stored material34ais a mixture of texture material and propellant material in liquid phase, while the pressurized material is propellant material in gas phase.

A typical texture material forming a part of the dispensed material22aand/or stored material34awill comprise a base or carrier, a binder, a filler, and, optionally, one or more additives such as surfactants, biocides and thickeners. Examples of the base or carrier include water, solvent (oil-based texture material) such as xylene, toluene, acetone, methyl ethyl ketone, and combinations of water and water soluble solvents. Examples of binders include starch, polyvinyl alcohol and latex resins (water-based systems) and a wide variety of polymers such as ethylene vinyl acetate, thermoplastic acrylics, styrenated alkyds, etc. (solvent-based systems). Examples of fillers include calcium carbonate, titanium dioxide, attapulgite clay, talc, magnesium aluminum silicate, etc.

The stored material34awill also comprise a liquid phase propellant material, and the pressurized material will typically comprise a gas phase propellant material. The following propellant materials are appropriate for use as the propellant material forming the stored material34aand the pressurized material36a: dimethyl ether, propane, butane, isobutene, difluoroethane, and tetrafluoroethane.

The following Tables A-1, A-2, and A-3 and Tables A-4 and A-5 attached hereto as Exhibit A contain example formulations of the texture material that may be used to form the dispensed material22aand stored material34aof the first example aerosol dispensing20a.

To the example texture material described in Table A-1 is added propellant material in the form of a propane/butane/isobutane blend. A first range of approximately 10-20% by weight of the propellant material is added to the example texture material of Table A-1, but the propellant material should in any event be within a second range of approximately 5-25% by weight of the propellant material.

To the example texture material described in Table A-2 is added propellant material in the form of DME. A first range of approximately 7-15% by weight of the propellant material is added to the example texture material of Table A-2, but the propellant material should in any event be within a second range of approximately 5-25% by weight of the propellant material.

To the example texture material described in Table A-3 is added propellant material in the form of DME. A first range of approximately 10-15% by weight of the propellant material is added to the example texture material of Table A-3, but the propellant material should in any event be within a second range of approximately 5-25% by weight of the propellant material.

With reference to Tables A-4 and A-5 in Exhibit A, that table contains examples of a texture material composition adapted to be combined with an aerosol and dispensed using an aerosol dispensing system in accordance with the principles of the present invention. Each value or range of values in Tables A-4 and A-5 represents the percentage of the overall weight of the example texture material composition formed by each material of the texture material composition for a specific example, a first example range, and a second example range. The composition described in Table A-5 is similar to that of Table A-4, but Table A-5 contains a number of additional materials that may optionally be added to the example texture material composition of Table A-4.

One example of a method of combining the materials set forth in Table A-4 is as follows. Materials A, B, C, and D are combined to form a first sub-composition. The first sub-composition is mixed until material D is dissolved (e.g., 30-40 minutes). Materials E and F are then added to the first sub-composition to form a second sub-composition. The second sub-composition is mixed until materials E and F are well-dispersed (e.g., at high speed for 15-20 minutes). Material G is then added to the second sub-composition to form a third sub-composition. The third sub-composition is mixed well (e.g., 10 minutes). Typically, the speed at which the third sub-composition is mixed is reduced relative to the speed at which the second sub-composition is mixed. Next, materials H, I, and J are added to the third sub-composition to form the example texture material composition of the present invention. The example texture material composition is agitated. Material K may be added as necessary to adjust (e.g., reduce) the viscosity of the example texture material composition.

The example texture material composition of the present invention may be combined with an aerosol propellant in any of the aerosol dispensing systems described herein to facilitate application of the example texture material composition to a surface to be textured.

FIG. 1further illustrates that the first example aerosol dispensing system20acomprises a conduit40adefining a conduit passageway42a. The conduit40ais supported by the container30asuch that the conduit passageway42adefines a conduit inlet44aarranged within the chamber32aand a conduit outlet46aarranged outside of the chamber32a. The conduit outlet46amay alternatively be referred to herein as an outlet opening46a. The example conduit40ais formed by an inlet tube50a, a valve housing52a, and an actuator structure54a. The conduit passageway42aextends through the inlet tube50a, the valve housing52a, and the actuator structure Ma such that the valve housing52ais arranged between the conduit inlet44aand the actuator structure54aand the actuator structure54ais arranged between the valve housing52aand the conduit outlet46a.

Arranged within the valve housing52ais a valve system60a. A first flow adjustment system70ahaving a first adjustment member72ais arranged to interface with the valve system60a. A second flow adjustment system80ahaving a second adjustment member82ais arranged in the conduit passageway42ato form at least a portion of the conduit outlet46a.

The valve system60aoperates in a closed configuration, a fully open configuration, and at least one of a continuum or plurality of partially open intermediate configurations. In the closed configuration, the valve system60asubstantially prevents flow of fluid along the conduit passageway42a. In the open configuration and the at least one intermediate configuration, the valve system60aallows flow of fluid along the conduit passageway42a. The valve system60ais normally in the closed configuration. The valve system60aengages the actuator member structure54aand is placed into the open configuration by applying deliberate manual force on the actuator structure54atowards the container30a.

The first flow adjustment system70ais supported by the container30ato engage the actuator structure such that manual operation of the first adjustment member72aaffects operation of the valve system60ato control the flow of fluid material along the conduit passageway42a. In particular, the first adjustment system70aand the valve system60afunction as a flow restrictor, where operation of the first adjustment member72aresults in a variation in the size of the conduit passageway42awithin the valve system60asuch that a pressure of the fluid material upstream of the first flow adjustment system70ais relatively higher than the pressure of the fluid material downstream of the first flow adjustment system70a.

In general, a primary purpose of the first flow adjustment system70ais to alter a distance of travel of the dispensed material22a. The first flow adjustment system70amay also have a secondary affect on the pattern in which the dispensed material22ais sprayed.

The second adjustment system80ais supported by the actuator structure54adownstream of the first adjustment system70a. Manual operation of the second adjustment member82aaffects the flow of fluid material flowing out of the conduit passageway42athrough the conduit outlet46a. In particular, the second adjustment system80afunctions as a variable orifice, where operation of the second adjustment member82avariably reduces the size of the conduit outlet46arelative to the size of the conduit passageway42aupstream of the second adjustment system80a.

A primary purpose of the second flow adjustment system80ais to alter a pattern in which the dispensed material22ais sprayed. The first flow adjustment system70amay also have a secondary affect on the distance of travel of the dispensed material22a.

To operate the first example aerosol dispensing system20, the container30ais grasped such that the finger can depress the actuator structure54a. The conduit outlet or outlet opening46ais initially aimed at a test surface and the actuator structure54ais depressed to place the valve system60ain the open configuration such that the pressurized material36aforces some of the stored material34aout of the container30aand onto the test surface to form a test texture pattern. The test texture pattern is compared to the pre-existing texture pattern defined by the textured portion26aof the target surface24a. If the test texture pattern does not match the pre-existing texture pattern, one or both of the first and second adjustment systems70aand80aare adjusted to alter the spray pattern of the droplets of dispensed material22a.

The process of spraying a test pattern and comparing it to the pre-existing pattern and adjusting the first and second adjustment members72aand82ais repeated until the dispensed material forms a desired texture pattern that substantially matches the pre-existing texture pattern.

Leaving the first and second adjustment systems70aand80aas they were when the test texture pattern matched the pre-existing texture pattern, the aerosol dispensing system20ais then arranged such that the conduit outlet or outlet opening46ais aimed at the un-textured portion28aof the target surface24a. The actuator structure54ais again depressed to operate the valve system60asuch that the pressurized material36aforces the stored material34aout of the container30aand onto the un-textured portion28aof the target surface to form the desired texture pattern.

A. Second Example Aerosol Dispensing System

Referring now toFIGS. 2-5of the drawing, depicted at120therein is a second example aerosol dispensing system constructed in accordance with, and embodying, the principles of the present invention. Like the first example aerosol dispensing system20, the second example dispensing system120is adapted to spray droplets of dispensed material122onto a target surface (not shown). In the example use of the dispensing system120depicted inFIGS. 2-5, the dispensed material122is or contains texture material, and the dispensing system120is being used to form a coating on an un-textured portion of the target surface having a desired texture pattern that substantially matches a pre-existing texture pattern of a textured portion of the target surface.

FIG. 2further illustrates that the example dispensing system120comprises a container130defining a chamber132in which stored material134and pressurized material136are contained. Like the stored material34described above, the stored material134is a mixture of texture material and propellant material in liquid phase, while the pressurized material is propellant material in gas phase. An actuator assembly138is mounted on the container assembly130to facilitate the dispensing of the dispensed material122as will be described in further detail below.

FIG. 3illustrates that the second example aerosol dispensing system120comprises a conduit140defining a conduit passageway142. The conduit140is supported by the container130such that the conduit passageway142defines a conduit inlet144arranged within the chamber132and a conduit outlet or outlet opening146arranged outside of the chamber132. The example conduit140is formed by an inlet tube150, a valve housing152, and an actuator member154. The conduit passageway142extends through the inlet tube150, the valve housing152, the actuator member154, and the outlet member156. The valve housing152is arranged between the conduit inlet144and the actuator member154, and the actuator member154is arranged between the valve housing152and the conduit outlet146. The outlet member156is supported by the actuator member154to define the conduit outlet146. A grip assembly158is supported by the container assembly130, and the grip assembly158in turn supports the actuator member154for movement relative to the container assembly130.

Arranged within the valve housing152is a valve assembly160. The example valve assembly160comprises a valve member162, a valve seat164, and a valve spring166. The valve assembly160operates in a closed configuration and an open configuration. In the closed configuration, the valve spring166forces the valve member162against the valve seat164such that the valve assembly160substantially prevents flow of fluid along the conduit passageway142. In the open configuration, the valve member162is displaced away from the valve seat164against the force of the valve spring166such that the valve assembly160allows flow of fluid along the conduit passageway142between the valve member162and the valve seat164. Because the valve spring166biases the valve member162towards the valve seat164, the example valve assembly160is normally closed. The valve assembly160engages the actuator member structure154such that the application of deliberate manual force on the actuator member154towards the container130moves the valve member162away from the valve seat164and thus places the valve system160in the open configuration.

A first flow adjustment system170comprising a first adjustment member172is arranged selectively to limit movement of the actuator member154relative to the container assembly130. In particular, the first adjustment member defines an adjustment axis AAand a stop surface174. The stop surface174extends along a varying or substantially helical path relative to the adjustment axis AA.

Rotation of the first adjustment member172relative to the grip assembly158thus alters a position of the stop surface174relative to the actuator member154. With the first adjustment member172in a first angular position as shown inFIGS. 3 and 4, the actuator member154travels a first distance relative to the valve assembly160. With the first adjustment member172in a second angular position as shown inFIG. 5, the actuator member154travels a second distance relative to the valve assembly160. The first distance is longer than the first distance as can be seen by a close inspection ofFIGS. 4 and 5, so the valve system160, in cooperation with the first adjustment system170, thus forms a bigger restriction in the conduit passageway142when the first adjustment member172is in the second angular position than when the first adjustment member172is in the first angular position.

Further, the first adjustment member172is configurable in any one of a plurality or continuum of angular positions between the first and second positions shown. The first adjustment system170thus allows the user to obtain a range of restrictions in the conduit passageway as necessary for a particular desired texture pattern.

A second flow adjustment system180having a second adjustment member182is arranged in the conduit passageway142to form at least a portion of the conduit outlet or outlet opening146. In particular, the second adjustment member182defines a plurality of adjustment openings184a,184b, and184c(FIG. 3A). The second adjustment member182is further rotatably supported by the actuator member154such that an axis of rotation ARof the second adjustment member182is offset from an outlet axis AOdefined by the conduit outlet146. Accordingly, rotating the second adjustment member182relative to the actuator member154allows any selected one of the outlet openings184a,184b, and184cto be arranged to define a cross-sectional area of the outlet opening defined by the conduit outlet146.

Manual operation of the first adjustment member172affects the flow of fluid material along the conduit passageway142upstream of the second adjustment system180. In particular, the first adjustment system170functions as a flow restrictor, where operation of the first adjustment member172variably reduces the size of the conduit passageway142such that a pressure of the fluid material upstream of the first flow adjustment system170is relatively higher than the pressure of the fluid material downstream of the first flow adjustment system170(towards the second adjustment system180).

The second adjustment system180is supported by the actuator member154downstream of the first adjustment system170. The selected one of the adjustment openings184a,184b, and184cthereby affects the flow of fluid material flowing out of the conduit passageway142. The second adjustment system180thus functions as a variable orifice system. Operation of the second adjustment member172variably reduces the size of the conduit outlet or outlet opening146relative to the size of the conduit passageway142upstream of the second adjustment system180.

The first adjustment member172and second adjustment member182are supported as described above to define a control system190.FIG. 3further shows that the grip assembly158comprises a grip housing192and that the actuator member154defines a trigger portion194. Additionally, the grip assembly158is combined with the control system190to form the actuator assembly138, and the actuator assembly138is supported by the container assembly130as generally described above. In the example actuator assembly138, the actuator assembly138is pivotably connected to the grip housing192. Accordingly, to operate the second example aerosol dispensing system120, the container130and grip housing192are grasped such that the user's fingers can squeeze the trigger portion194, thereby allowing the actuator member154to be depressed.

In use, the conduit outlet or outlet opening146is initially aimed at a test surface and the actuator member154is depressed to place the valve assembly160in the open configuration such that the pressurized material136forces some of the stored material134out of the container130and onto the test surface to form a test texture pattern. The test texture pattern is compared to the pre-existing texture pattern defined by the textured portion of the target surface. If the test texture pattern does not match the pre-existing texture pattern, one or both of the first and second adjustment members is/are adjusted to alter the spray pattern of the droplets of dispensed material122.

The process of spraying a test pattern and adjusting the first and second adjustment members172and182is repeated until the test pattern formed by the dispensed material122corresponds to a desired texture pattern that substantially matches the pre-existing texture pattern.

Leaving the first and second adjustment members172and182as they were when the test texture pattern corresponded to the desired texture pattern, the aerosol dispensing system120is then arranged such that the conduit outlet or outlet opening146is aimed at the un-textured portion of the target surface. The trigger member194is again squeezed to place the valve assembly160in the open configuration such that the pressurized material136forces the stored material134out of the container130and onto the un-textured portion of the target surface to form the desired texture pattern on the un-textured portion of the target surface, perhaps overlapping slightly with the textured portion of the target surface. Since the desired texture pattern substantially matches the pre-existing texture pattern, the dispensed material forms a coating on the previously un-textured portion of the target surface in a desired texture pattern that substantially matches a physical appearance of the textured portion. One or more layers of primer and/or paint may next be applied over the cured layer of dispensed material on the target surface.

The following Table B represents example ranges and dimensions for constructing a physical embodiment of a flow adjustment system that may be used as the example first flow adjustment system170:

Referring now toFIGS. 6-17of the drawing, depicted at220therein is a third example aerosol dispensing system constructed in accordance with, and embodying, the principles of the present invention. Like the first example aerosol dispensing system20, the third example dispensing system220is adapted to spray droplets of dispensed material222onto a target surface (not shown). In the example use of the dispensing system220depicted inFIGS. 6-17, the dispensed material222is or contains texture material, and the dispensing system220is being used to form a coating on an un-textured portion of the target surface having a desired texture pattern that substantially matches a pre-existing texture pattern of a textured portion of the target surface.

FIG. 6further illustrates that the example dispensing system220comprises a container230defining a chamber232in which stored material234and pressurized material236are contained. Like the stored material34described above, the stored material234is a mixture of texture material and propellant material in liquid phase, while the pressurized material is propellant material in gas phase. An actuator assembly238is mounted on the container assembly230to facilitate the dispensing of the dispensed material222as will be described in further detail below.

FIG. 7illustrates that the second example aerosol dispensing system220comprises a conduit240defining a conduit passageway242. The conduit240is supported by the container230such that the conduit passageway242defines a conduit inlet244arranged within the chamber232and a conduit outlet or outlet opening246arranged outside of the chamber232. The example conduit240is formed by an inlet tube250, a valve housing252, and an actuator member254. The conduit passageway242extends through the inlet tube250, the valve housing252, the actuator member254, and the outlet member256. The valve housing252is arranged between the conduit inlet244and the actuator member254, and the actuator member254is arranged between the valve housing252and the conduit outlet246. The outlet member256is supported by the actuator member254to define the conduit outlet246. A grip assembly258is supported by the container assembly230, and the grip assembly258in turn supports the actuator member254for movement relative to the container assembly230.

Arranged within the valve housing252is a valve assembly260. The example valve assembly260comprises a valve member262, a valve seat264, and a valve spring266. The valve assembly260operates in a closed configuration and an open configuration. In the closed configuration, the valve spring266forces the valve member262against the valve seat264such that the valve assembly260substantially prevents flow of fluid along the conduit passageway242. In the open configuration, the valve member262is displaced away from the valve seat264against the force of the valve spring266such that the valve assembly260allows flow of fluid along the conduit passageway242between the valve member262and the valve seat264. Because the valve spring266biases the valve member262towards the valve seat264, the example valve assembly260is normally closed. The valve assembly260engages the actuator member structure254such that the application of deliberate manual force on the actuator member254towards the container230moves the valve member262away from the valve seat264and thus places the valve system260in the open configuration.

A first flow adjustment system270comprising a first adjustment member272is arranged selectively to limit movement of the actuator member254relative to the container assembly230. In particular, the first adjustment member272is a plate or disc defining an upper surface274and a plate axis Ap, and, optionally, comprises at least one stop surface276. The at least one example stop surface276is arranged in an arcuate segment on the upper surface274and define a stop radius RSrelative to the plate axis A. In the example first adjustment member272, two pairs of stop surfaces276aand276bare formed in opposing locations relative to the plate axis A.

The example flow adjustment system270further comprises at least one engaging surface278formed on the actuator member254. The example actuator member254defines an actuator axis AA, and the at least one engaging surface278is arranged in an arcuate segment on the lower edge of the actuator member254and defines an actuator radius RArelative to the actuator axis AA. The actuator radius RAand the stop radius RSare substantially the same in the example flow adjustment system270.

In general, the actuator member254is arranged relative to the first adjustment member272such that rotation of the first adjustment member272relative to the grip assembly258alters an angular position of the at least one stop surface276relative to the at least one engaging surface278of actuator member254. The angular relationship of the at least one stop surface274relative to the at least one engaging surface278determines an amount of travel of the actuator member254relative to the container assembly230and the valve system260supported thereby.

In particular, with the first adjustment member272in a first angular position relative to the actuator member254as shown inFIGS. 15A and 15B, the actuator member254travels a first distance relative to the valve assembly260. With the first adjustment member272in a second angular position as shown inFIGS. 16A and 16B, the actuator member254travels a second distance relative to the valve assembly260. With the first adjustment member272in a third angular position as shown inFIGS. 17A and 17B, the actuator member254travels a second distance relative to the valve assembly260. The third distance is longer than the second distance and the second distance is longer than the first distance, as can be seen by a close inspection ofFIGS. 15B,16B, and17B. Travel of the actuator member254determines the size of the opening defined by the valve system260. The example valve system260, in cooperation with the first adjustment system270, thus allows the size of the restriction in the conduit passageway242formed by the valve system to be varied depending upon the angular position of the first adjustment member272.

Further, the first adjustment member272may configurable in any one of a plurality or continuum of angular positions by using slanted stop and engaging surfaces rather than the arrangement of stop surfaces276and engaging surfaces278of the example first adjustment system260. The first adjustment system270thus allows the user to obtain a range of restrictions in the conduit passageway as necessary for a particular desired texture pattern.

A second flow adjustment system280having a second adjustment member282is arranged in the conduit passageway242to form at least a portion of the conduit outlet or outlet opening246. In particular, the second adjustment member282of the example second flow adjustment system280takes the form of at least one adjustment straw or tube (FIG. 7). Each second adjustment member282defines an outlet orifice284. The example second flow adjustment system280comprises three second adjustment members282a,282b, and282cdefining outlet orifices284a,284b, and284c, respectively. Each of the outlet orifices284a,284b, and284cdefines a different cross-sectional area.

A selected one of the second adjustment members282a,282b, and284cis detachably attached to the actuator member254such that the outlet orifice284a,284b, or284cassociated with the selected second adjustment member282a,282b, or282cis aligned with the conduit outlet246. Accordingly, any selected one of the outlet orifices284a,284b, and284cmay be selected and arranged to define a cross-sectional area of the outlet opening defined by the conduit outlet246.

Manual operation of the first adjustment member272affects the flow of fluid material along the conduit passageway242upstream of the second adjustment system280. In particular, the first adjustment system270functions as a flow restrictor, where operation of the first adjustment member272variably reduces the size of the conduit passageway242such that a pressure of the fluid material upstream of the first flow adjustment system270is relatively higher than the pressure of the fluid material downstream of the first flow adjustment system270(towards the second adjustment system280).

The second adjustment system280is supported by the actuator member254downstream of the first adjustment system270. The selected one of the outlet orifices284a,284b, and284cthereby affects the flow of fluid material flowing out of the conduit passageway242. The second adjustment system280thus functions as a variable orifice system. Operation of the second adjustment member272variably reduces the size of the conduit outlet or outlet opening246relative to the size of the conduit passageway242upstream of the second adjustment system280.

The actuator member254, the first adjustment member272, and the selected one of the second adjustment members282supported to define a control system290.FIG. 7further shows that the grip assembly258comprises a grip housing292. Additionally, the grip assembly258is combined with the control system290to form the actuator assembly238, and the actuator assembly238is supported by the container assembly230as generally described above.

In the example actuator assembly238, grip housing292defines a cylindrical interior surface292aand the actuator member254defines a cylindrical outer surface254a. The outer surface254ais sized and dimensioned to allow the actuator member254to fit within a grip chamber defined by the interior surface292asuch that the grip housing292supports the actuator member254for substantially linear movement along a container axis ACdefined by the container assembly230.

Accordingly, to operate the second example aerosol dispensing system220, the container230and grip housing292are grasped such that the user's fingers can depress an upper surface of the actuator member254, thereby allowing the actuator member254to be depressed.

Further,FIGS. 11-14illustrate a locator system294that may be used to locate the first adjustment member272in the plurality of angular positions represented byFIGS. 15A and 15B,16A and16B, and17A and17B. In particular, the example lock system294comprises at least one locator recess296formed on the first adjustment member172and at least one locator projection298formed on the grip housing292. In particular, the grip housing292defines a housing slot292bthrough which a grip portion272aof the first adjustment member272extends. By pushing on the grip portion272a, the first adjustment member272may be rotated through the plurality of angular positions. The locator recess(es)296receives a locator projection298to positively hold the first adjustment member272in one of the plurality of angular positions. The shapes, locations, and relative positions of the locator recess(es)296and the locator projection(s)298may be altered. One locator recess296and three locator projections298a,298b, and298care employed by the example locator system294.

In use, the conduit outlet or outlet opening246is initially aimed at a test surface and the actuator member254is depressed to place the valve assembly260in the open configuration to allow the pressurized material236to force some of the stored material234out of the container230and onto the test surface to form a test texture pattern. The test texture pattern is compared to the pre-existing texture pattern defined by the textured portion of the target surface. If the test texture pattern does not match the pre-existing texture pattern, one or both of the first and second adjustment members is/are adjusted to alter the spray pattern of the droplets of dispensed material222.

The process of spraying a test pattern and adjusting the first and second adjustment members272and282is repeated until the test pattern formed by the dispensed material222corresponds to a desired texture pattern that substantially matches the pre-existing texture pattern.

Leaving the first and second adjustment members272and282as they were when the test texture pattern corresponded to the desired texture pattern, the aerosol dispensing system220is then arranged such that the conduit outlet or outlet opening246is aimed at the un-textured portion of the target surface. The actuator member254is again depressed to place the valve assembly260in the open configuration such that the pressurized material236forces the stored material234out of the container230and onto the un-textured portion of the target surface to form the desired texture pattern on the un-textured portion of the target surface, perhaps overlapping slightly with the textured portion of the target surface. Since the desired texture pattern substantially matches the pre-existing texture pattern, the dispensed material forms a coating on the previously un-textured portion of the target surface in a desired texture pattern that substantially matches a physical appearance of the textured portion. One or more layers of primer and/or paint may next be applied over the cured layer of dispensed material on the target surface.

The following Table C represents example ranges and dimensions for constructing a physical embodiment of a flow adjustment system that may be used as the example first flow adjustment system270:

Referring now toFIGS. 18-22of the drawing, depicted at320therein is a fourth example aerosol dispensing system constructed in accordance with, and embodying, the principles of the present invention. Like the first example aerosol dispensing system20, the fourth example dispensing system320is adapted to spray droplets of dispensed material322onto a target surface (not shown). In the example use of the dispensing system320depicted inFIGS. 18-22, the dispensed material322is or contains texture material, and the dispensing system320is being used to form a coating on an un-textured portion of the target surface having a desired texture pattern that substantially matches a pre-existing texture pattern of a textured portion of the target surface.

FIG. 18illustrates that the example dispensing system320comprises a container330defining a chamber332in which stored material334and pressurized material336are contained. Like the stored material34described above, the stored material334is a mixture of texture material and propellant material in liquid phase, while the pressurized material is propellant material in gas phase. An actuator assembly338is mounted on the container assembly330to facilitate the dispensing of the dispensed material322as will be described in further detail below.

FIG. 19illustrates that the second example aerosol dispensing system320comprises a conduit340defining a conduit passageway342. The conduit340is supported by the container330such that the conduit passageway342defines a conduit inlet344arranged within the chamber332and a conduit outlet or outlet opening346arranged outside of the chamber332. The example conduit340is formed by an inlet tube350, a valve housing352, an actuator member354, and an outlet member356. The conduit passageway342extends through the inlet tube350, the valve housing352, the actuator member354, and the outlet member356. The valve housing352is arranged between the conduit inlet344and the actuator member354, and the actuator member354is arranged between the valve housing352and the conduit outlet346. The outlet member356is supported by the actuator member354to define the conduit outlet346. A grip assembly358is supported by the container assembly330, and the grip assembly358in turn supports the actuator member354for movement relative to the container assembly330.

Arranged within the valve housing352is a valve assembly360. The example valve assembly360comprises a valve member362, a valve seat364, and a valve spring366. The valve assembly360operates in a closed configuration and an open configuration. In the closed configuration, the valve spring366forces the valve member362against the valve seat364such that the valve assembly360substantially prevents flow of fluid along the conduit passageway342. In the open configuration, the valve member362is displaced away from the valve seat364against the force of the valve spring366such that the valve assembly360allows flow of fluid along the conduit passageway342between the valve member362and the valve seat364. Because the valve spring366biases the valve member362towards the valve seat364, the example valve assembly360is normally closed. The valve assembly360engages the actuator member structure354such that the application of deliberate manual force on the actuator member354towards the container330moves the valve member362away from the valve seat364and thus places the valve system360in the open configuration.

A first flow adjustment system370comprising a first adjustment member372is arranged selectively to limit movement of the actuator member354relative to the container assembly330. In particular, the first adjustment member defines an adjustment axis AAand a stop surface374.

Rotation of the first adjustment member372about the adjustment axis AArelative to the grip assembly358thus alters a position of the stop surface374relative to the actuator member354. In particular, the first adjustment member372defines an externally threaded surface376adapted to engage a similar internally threaded surface defined by the grip assembly358. Rotating the first adjustment member372displaces the first adjustment member372towards and away from the actuator member354between a fully open position and a terminal position. In a first position as shown inFIGS. 19 and 20, the actuator member354travels a first distance relative to the valve assembly360. With the first adjustment member372in a second position as shown inFIGS. 21 and 22, the actuator member354travels a second distance relative to the valve assembly360. The first distance is longer than the second distance as can be seen by a close inspection ofFIGS. 20 and 22, so the valve system360, in cooperation with the first adjustment system370, thus forms a smaller restriction in the conduit passageway342when the first adjustment member372is in the first position than when the first adjustment member372is in the second position.

Further, the first adjustment member372is configurable in any one of a plurality or continuum of positions between the first and second positions shown. The first adjustment system370thus allows the user to obtain a range of restrictions in the conduit passageway as necessary for a particular desired texture pattern.

A second flow adjustment system380having a second adjustment member382is arranged in the conduit passageway342to form at least a portion of the conduit outlet or outlet opening346. In particular, the second adjustment system380comprises, in addition, a plurality of fingers384extending from the actuator member354and an externally threaded surface386formed on the actuator member354. The second adjustment member382defines an internally threaded surface382athat is adapted to engage the externally threaded surface386such that rotation of the second adjustment member382about an axis of rotation ARdisplaces the adjustment member in both directions along the axis of rotation AR. As the second adjustment member382is displaced along the axis of rotation AR, the second adjustment member382engages the fingers284to deform the outlet member356. Deformation of the outlet member356alters a cross-sectional area of the conduit outlet or outlet opening346. Accordingly, rotation of the second adjustment member382relative to the actuator member354allows any the cross-sectional area of the outlet opening defined by the conduit outlet346to be made larger and/or smaller within a predetermined range of cross-sectional areas.

Manual operation of the first adjustment member372affects the flow of fluid material along the conduit passageway342upstream of the second adjustment system380. In particular, the first adjustment system370functions as a flow restrictor, where operation of the first adjustment member372variably reduces the size of the conduit passageway342such that a pressure of the fluid material upstream of the first flow adjustment system370is relatively higher than the pressure of the fluid material downstream of the first flow adjustment system370(towards the second adjustment system380).

The second adjustment system380is supported by the actuator member354downstream of the first adjustment system370. Adjustment of the first adjustment system370(e.g., selecting one of the adjustment openings384a,384b, and384c) thereby affects the flow of fluid material flowing out of the conduit passageway342. The second adjustment system380thus functions as a variable orifice system. Operation of the second adjustment member372variably reduces the size of the conduit outlet or outlet opening346relative to the size of the conduit passageway342upstream of the second adjustment system380.

The first adjustment member372and second adjustment member382are supported as described above to define a control system390.FIG. 19further shows that the grip assembly358comprises a grip housing392and that the actuator member354defines a trigger portion394. Additionally, the grip assembly358is combined with the control system390to form the actuator assembly338, and the actuator assembly338is supported by the container assembly330as generally described above. In the example actuator assembly338, the actuator assembly338is pivotably connected to the grip housing392. Accordingly, to operate the second example aerosol dispensing system320, the container330and grip housing392are grasped such that the user's fingers can squeeze the trigger portion394, thereby allowing the actuator member354to be depressed.

In use, the conduit outlet or outlet opening346is initially aimed at a test surface and the actuator member354is depressed to place the valve assembly360in the open configuration such that the pressurized material336forces some of the stored material334out of the container330and onto the test surface to form a test texture pattern. The test texture pattern is compared to the pre-existing texture pattern defined by the textured portion of the target surface. If the test texture pattern does not match the pre-existing texture pattern, one or both of the first and second adjustment members is/are adjusted to alter the spray pattern of the droplets of dispensed material322.

The process of spraying a test pattern and adjusting the first and second adjustment members372and382is repeated until the test pattern formed by the dispensed material322corresponds to a desired texture pattern that substantially matches the pre-existing texture pattern.

Leaving the first and second adjustment members372and382as they were when the test texture pattern corresponded to the desired texture pattern, the aerosol dispensing system320is then arranged such that the conduit outlet or outlet opening346is aimed at the un-textured portion of the target surface. The trigger member394is again squeezed to place the valve assembly360in the open configuration such that the pressurized material336forces the stored material334out of the container330and onto the un-textured portion of the target surface to form the desired texture pattern on the un-textured portion of the target surface, perhaps overlapping slightly with the textured portion of the target surface. Since the desired texture pattern substantially matches the pre-existing texture pattern, the dispensed material forms a coating on the previously un-textured portion of the target surface in a desired texture pattern that substantially matches a physical appearance of the textured portion. One or more layers of primer and/or paint may next be applied over the cured layer of dispensed material on the target surface.

The following Table D represents example ranges and dimensions for constructing a physical embodiment of a flow adjustment system that may be used as the example first flow adjustment system370:

II. Second Example Class of Aerosol Dispensing Systems

Referring now toFIG. 23of the drawing, depicted at20btherein is a fifth example aerosol dispensing system constructed in accordance with, and embodying, the principles of the present invention. The fifth example dispensing system is adapted to spray droplets of dispensed material22bonto a target surface24b. The example target surface24bhas a textured portion26band an un-textured portion28b. Accordingly, in the example use of the dispensing system20bdepicted inFIG. 23, the dispensed material22bis or contains texture material, and the dispensing system20bis being used to form a coating on the un-textured portion28bhaving a desired texture pattern that substantially matches a pre-existing texture pattern of the textured portion26b.

FIG. 23further illustrates that the example dispensing system20bcomprises a container30bdefining a chamber32bin which stored material34band pressurized material36bare contained. The stored material34bis a mixture of texture material and propellant material in liquid phase, while the pressurized material is propellant material in gas phase.

A typical texture material forming a part of the dispensed material22band/or stored material34bwill comprise a base or carrier, a binder, a filler, and, optionally, one or more additives such as surfactants, biocides and thickeners. Examples of the base or carrier include water, solvent (oil-based texture material) such as xylene, toluene, acetone, methyl ethyl ketone, and combinations of water and water soluble solvents. Examples of binders include starch, polyvinyl alcohol and latex resins (water-based systems) and a wide variety of polymers such as ethylene vinyl acetate, thermoplastic acrylics, styrenated alkyds, etc. (solvent-based systems). Examples of fillers include calcium carbonate, titanium dioxide, attapulgite clay, talc, magnesium aluminum silicate, etc.

The stored material34bwill also comprise a liquid phase propellant material, and the pressurized material will typically comprise a gas phase propellant material. The following propellant materials are appropriate for use as the propellant material forming the stored material34band the pressurized material36b: dimethyl ether, propane, butane, isobutene, difluoroethane, and tetrafluoroethane.

The following Tables E-1, E-2, and E-3 contain example formulations of the texture material that may be used to form the dispensed material22band stored material34bof the second example aerosol dispensing20b:

To the example texture material described in Table E-1 is added 10-20% by weight of propellant material in the form of a propane/butane/isobutane blend.

To the example texture material described in Table E-2 is added 7-15% by weight of propellant material in the form of DME.

To the example texture material described in Table E-3 is added 10-15% by weight of propellant material in the form of DME.

FIG. 23further illustrates that the first example aerosol dispensing system20bcomprises a conduit40bdefining a conduit passageway42b. The conduit40bis supported by the container30bsuch that the conduit passageway42bdefines a conduit inlet44barranged within the chamber32band a conduit outlet46barranged outside of the chamber32b. The conduit outlet46bmay alternatively be referred to herein as an outlet opening46b. The example conduit40bis formed by an inlet tube50b, a valve housing52b, and an actuator structure54b. The conduit passageway42bextends through the inlet tube50b, the valve housing52b, and the actuator structure54bsuch that the valve housing52bis arranged between the conduit inlet44band the actuator structure54band the actuator structure54bis arranged between the valve housing52band the conduit outlet46b.

Arranged within the valve housing52bis a valve system60b. A first flow adjustment system70bhaving a first adjustment member72bis arranged to interface with the valve system60b. A second flow adjustment system80bhaving a second adjustment member82bis arranged in the conduit passageway42bto form at least a portion of the conduit outlet46b.

The valve system60boperates in a closed configuration, a fully open configuration, and at least one of a continuum or plurality of partially open intermediate configurations. In the closed configuration, the valve system60bsubstantially prevents flow of fluid along the conduit passageway42b. In the open configuration and the at least one intermediate configuration, the valve system60ballows flow of fluid along the conduit passageway42b. The valve system60bis normally in the closed configuration. The valve system60bengages the actuator member structure54band is placed into the open configuration by applying deliberate manual force on the actuator structure54btowards the container30b.

The first flow adjustment system70bis supported by the container30bto engage the actuator structure such that manual operation of the first adjustment member72bcontrols the flow of fluid material along the conduit passageway42b. In particular, the first adjustment system70bfunctions as a flow restrictor, where operation of the first adjustment member72bresults in a variation in the size of a portion of the conduit passageway42bsuch that a pressure of the fluid material upstream of the first flow adjustment system70bis relatively higher than the pressure of the fluid material downstream of the first flow adjustment system70b.

In general, a primary purpose of the first flow adjustment system70bis to alter a distance of travel of the dispensed material22b. The first flow adjustment system70bmay also have a secondary affect on the pattern in which the dispensed material22bis sprayed.

The second adjustment system80bis supported by the actuator structure54bdownstream of the first adjustment system70b. Manual operation of the second adjustment member82baffects the flow of fluid material flowing out of the conduit passageway42bthrough the conduit outlet46b. In particular, the second adjustment system80bfunctions as a variable orifice, where operation of the second adjustment member72bvariably reduces the size of the conduit outlet46brelative to the size of the conduit passageway42bupstream of the second adjustment system80b.

A primary purpose of the second flow adjustment system80bis to alter a pattern in which the dispensed material22bis sprayed. The first flow adjustment system70bmay also have a secondary affect on the distance of travel of the dispensed material22b.

To operate the fifth example aerosol dispensing system20b(of the second example class of dispensing systems), the container30bis grasped such that the finger can depress the actuator structure54b. The conduit outlet or outlet opening46bis initially aimed at a test surface and the actuator structure54bis depressed to place the valve system60bin the open configuration such that the pressurized material36bforces some of the stored material34bout of the container30band onto the test surface to form a test texture pattern. The test texture pattern is compared to the pre-existing texture pattern defined by the textured portion26bof the target surface24b. If the test texture pattern does not match the pre-existing texture pattern, one or both of the first and second adjustment systems70band80bare adjusted to alter the spray pattern of the droplets of dispensed material22b.

The process of spraying a test pattern and comparing it to the pre-existing pattern and adjusting the first and second adjustment members72band82bis repeated until the dispensed material forms a desired texture pattern that substantially matches the pre-existing texture pattern.

Leaving the first and second adjustment systems70band80bas they were when the test texture pattern matched the pre-existing texture pattern, the aerosol dispensing system20bis then arranged such that the conduit outlet or outlet opening46bis aimed at the un-textured portion28bof the target surface24b. The actuator structure54bis again depressed to operate the valve system60bsuch that the pressurized material36bforces the stored material34bout of the container30band onto the un-textured portion28bof the target surface to form the desired texture pattern.

A. Sixth Example Aerosol Dispensing System

Referring now toFIGS. 24-27of the drawing, depicted at420therein is a sixth example aerosol dispensing system constructed in accordance with, and embodying, the principles of the present invention. Like the fifth example aerosol dispensing system20b, the sixth example dispensing system is adapted to spray droplets of dispensed material422onto a target surface (not shown). In the example use of the dispensing system420depicted inFIG. 24, the dispensed material422is or contains texture material, and the dispensing system420is being used to form a coating on an un-textured portion of the target surface having a desired texture pattern that substantially matches a pre-existing texture pattern of a textured portion of the target surface.

FIG. 24further illustrates that the example dispensing system420comprises a container430defining a chamber432in which stored material434and pressurized material436are contained. Like the stored materials (e.g., stored materials34aand34b) described above, the stored material434is a mixture of texture material and propellant material in liquid phase, while the pressurized material is propellant material in gas phase. An actuator assembly438is mounted on the container assembly430to facilitate the dispensing of the dispensed material422as will be described in further detail below.

FIG. 25illustrates that the sixth example aerosol dispensing system420comprises a conduit440defining a conduit passageway442. The conduit440is supported by the container430such that the conduit passageway442defines a conduit inlet444arranged within the chamber432and a conduit outlet or outlet opening446arranged outside of the chamber432. The example conduit440is formed by an inlet tube450, a valve housing452, an actuator member454, and an outlet member456. The conduit passageway442extends through the inlet tube450, the valve housing452, the actuator member454, and the outlet member456. The valve housing452is arranged between the conduit inlet444and the actuator member454, and the actuator member454is arranged between the valve housing452and the conduit outlet446. The outlet member456is supported by the actuator member454to define the conduit outlet446.

FIG. 25further shows that a valve assembly460is formed within the valve housing452. The example valve assembly460comprises a valve member462, a valve seat464, and a valve spring466. The valve assembly460operates in a closed configuration and an open configuration. In the closed configuration, the valve spring466forces the valve member462against the valve seat464such that the valve assembly460substantially prevents flow of fluid along the conduit passageway442. In the open configuration, the valve member462is displaced away from the valve seat464against the force of the valve spring466such that the valve assembly460allows flow of fluid along the conduit passageway442between the valve member462and the valve seat464. Because the valve spring466biases the valve member462towards the valve seat464, the example valve assembly460is normally closed. As will be described in further detail below, the valve assembly460engages the actuator member structure454such that the application of deliberate manual force on the actuator member454towards the container430moves the valve member462away from the valve seat464and thus places the valve system460in the open configuration.

A first flow adjustment system470having a first adjustment member472having a valve surface474and an externally threaded surface476is arranged to intersect the conduit passageway442at an intermediate location442abetween the valve assembly460and the conduit outlet446. The conduit passageway has a first portion442band a second portion442c. The first passageway portion442bdefines an actuator axis AAaligned with a container axis ACdefined by the container assembly430, and the second actuator passageway portion is aligned with an outlet axis AOdefined by the outlet member456. The example intermediate location442ais located in the second passageway portion442c.

An internally threaded surface478is formed in the actuator member454. The threaded surfaces476and478are adapted to engage each other such that rotation of the first adjustment member472relative to the actuator member454causes the valve surface474to enter the conduit passageway and thus alter a cross-sectional area of the conduit passageway442between the valve system460and the second flow adjustment system480.

A second flow adjustment system480comprises a second adjustment member482and a plurality of fingers484extending from the actuator member454. The second flow adjustment system480is arranged relative to the conduit passageway442to form at least a portion of the conduit outlet (or outlet opening)446. The second adjustment member482defines an internal threaded surface486that engages an external threaded surface488of the actuator member454such that rotation of the second adjustment member482relative to the actuator member454deforms the fingers and thus the outlet member456, thereby altering a cross-sectional area of the conduit outlet or outlet opening446.

The first flow adjustment system470is supported by the actuator member454between the valve assembly460and the second adjustment system480such that manual operation of the first adjustment member472affects the flow of fluid material along the conduit passageway442. In particular, the second adjustment system480functions as a flow restrictor, where operation of the first adjustment member472variably reduces the size of the conduit passageway442such that a pressure of the fluid material upstream of the first flow adjustment system470is relatively higher than the pressure of the fluid material downstream of the first flow adjustment system470. The example first adjustment member472is movable between a fully open configuration (smallest amount of restriction) and a terminal configuration (largest amount of restriction).

The second adjustment system480is supported by the actuator member454downstream of the first adjustment system470. The outlet member456is a resiliently deformable tube, and manual operation of the second adjustment member482deforms the walls of the outlet member456and thereby affects the flow of fluid material flowing out of the conduit passageway442through the conduit outlet or outlet opening446. The second adjustment system480thus functions as a variable orifice. Operation of the second adjustment member482variably reduces the size of the conduit outlet or outlet opening446relative to the size of the conduit passageway442upstream of the second adjustment system480.

The outlet member456, first adjustment member472, and second adjustment member482are supported by the actuator member454to define a control assembly490.FIG. 25further shows that the grip assembly458comprises a grip housing492and that the actuator member454defines a trigger portion494. To form the actuator assembly438, the grip assembly458is combined with the control assembly490by pivotably attaching the actuator member454to the grip housing492. The actuator assembly438is supported by the container assembly430as generally described above. An elongated slot496is formed in the grip housing492to allow the second adjustment member482to extend through the grip housing492without interfering with operation of the actuator member454as described herein.

To operate the sixth example aerosol dispensing system420, the container430and grip housing492are grasped such that the user's fingers can squeeze the trigger portion494, thereby depressing the actuator member454. The conduit outlet or outlet opening446is initially aimed at a test surface and the actuator member454is depressed to place the valve assembly460in the open configuration such that the pressurized material436forces some of the stored material434out of the container430and onto the test surface to form a test texture pattern. The test texture pattern is compared to the pre-existing texture pattern defined by the textured portion of the target surface. If the test texture pattern does not match the pre-existing texture pattern, one or both of the first and second adjustment members is/are adjusted to alter the spray pattern of the droplets of dispensed material422.

The process of spraying a test pattern and adjusting the first and second adjustment members472and482is repeated until the test pattern formed by the dispensed material422corresponds to a desired texture pattern that substantially matches the pre-existing texture pattern.

Leaving the first and second adjustment members472and482as they were when the test texture pattern corresponded to the desired texture pattern, the aerosol dispensing system420is then arranged such that the conduit outlet or outlet opening446is aimed at the un-textured portion of the target surface. The trigger member494is again squeezed to place the valve assembly460in the open configuration such that the pressurized material436forces the stored material434out of the container430and onto the un-textured portion of the target surface to form the desired texture pattern on the un-textured portion of the target surface, perhaps overlapping slightly with the textured portion of the target surface. Since the desired texture pattern substantially matches the pre-existing texture pattern, the dispensed material forms a coating on the previously un-textured portion of the target surface in a desired texture pattern that substantially matches a physical appearance of the textured portion. One or more layers of primer and/or paint may next be applied over the cured layer of dispensed material.

The following Table F represents example ranges and dimensions for constructing a physical embodiment of a flow adjustment system that may be used as the example first flow adjustment system470:

Referring now toFIGS. 28-31of the drawing, depicted at520therein is a seventh example aerosol dispensing system constructed in accordance with, and embodying, the principles of the present invention. Like the fifth example aerosol dispensing system20b, the seventh example dispensing system is adapted to spray droplets of dispensed material522onto a target surface (not shown). In the example use of the dispensing system520depicted inFIG. 28, the dispensed material522is or contains texture material, and the dispensing system520is being used to form a coating on an un-textured portion of the target surface having a desired texture pattern that substantially matches a pre-existing texture pattern of a textured portion of the target surface.

FIG. 28further illustrates that the example dispensing system520comprises a container530defining a chamber532in which stored material534and pressurized material536are contained. Like the stored materials (e.g.34aand34b) described above, the stored material534is a mixture of texture material and propellant material in liquid phase, while the pressurized material is propellant material in gas phase. An actuator assembly538is mounted on the container assembly530to facilitate the dispensing of the dispensed material522as will be described in further detail below.

FIG. 29illustrates that the seventh example aerosol dispensing system520comprises a conduit540defining a conduit passageway542. The conduit540is supported by the container530such that the conduit passageway542defines a conduit inlet544arranged within the chamber532and a conduit outlet or outlet opening546arranged outside of the chamber532. The example conduit540is formed by an inlet tube550, a valve housing552, an actuator member554, and an outlet member556. The conduit passageway542extends through the inlet tube550, the valve housing552, the actuator member554, and the outlet member556. The valve housing552is arranged between the conduit inlet544and the actuator member554, and the actuator member554is arranged between the valve housing552and the conduit outlet546. The outlet member556is supported by the actuator member554to define the conduit outlet546.

FIG. 29further shows that a valve assembly560is formed within the valve housing552. The example valve assembly560comprises a valve member562, a valve seat564, and a valve spring566. The valve assembly560operates in a closed configuration and an open configuration. In the closed configuration, the valve spring566forces the valve member562against the valve seat564such that the valve assembly560substantially prevents flow of fluid along the conduit passageway542. In the open configuration, the valve member562is displaced away from the valve seat564against the force of the valve spring566such that the valve assembly560allows flow of fluid along the conduit passageway542between the valve member562and the valve seat564. Because the valve spring566biases the valve member562towards the valve seat564, the example valve assembly560is normally closed. As will be described in further detail below, the valve assembly560engages the actuator member structure554such that the application of deliberate manual force on the actuator member554towards the container530moves the valve member562away from the valve seat564and thus places the valve system560in the open configuration.

A first flow adjustment system570having a first adjustment member572having a valve surface574and an externally threaded surface576is arranged to intersect the conduit passageway542at an intermediate location542abetween the valve assembly560and the conduit outlet546. The conduit passageway has a first portion542band a second portion542c. The first passageway portion542bdefines an actuator axis AAaligned with a container axis ACdefined by the container assembly530, and the second actuator passageway portion542cis aligned with an outlet axis AOdefined by the outlet member556. The example intermediate location542ais located in the first passageway portion542b.

An internally threaded surface578is formed in the actuator member554. The threaded surfaces576and578are adapted to engage each other such that rotation of the first adjustment member572relative to the actuator member554causes the valve surface574to enter the conduit passageway542and thus alter a cross-sectional area of the conduit passageway542between the valve system560and the second flow adjustment system580.

A second flow adjustment system580comprises a second adjustment member582and a plurality of fingers584extending from the actuator member554. The second flow adjustment system580is arranged relative to the conduit passageway542to form at least a portion of the conduit outlet (or outlet opening)546. The second adjustment member582defines an internal threaded surface586that engages an external threaded surface588of the actuator member554such that rotation of the second adjustment member582relative to the actuator member554deforms the fingers and thus the outlet member556, thereby altering a cross-sectional area of the conduit outlet or outlet opening546.

The first flow adjustment system570is supported by the actuator member554between the valve assembly560and the second adjustment system580such that manual operation of the first adjustment member572affects the flow of fluid material along the conduit passageway542as generally described above. In particular, the second adjustment system580functions as a flow restrictor, where operation of the first adjustment member572variably reduces the size of the conduit passageway542such that a pressure of the fluid material upstream of the first flow adjustment system570is relatively higher than the pressure of the fluid material downstream of the first flow adjustment system570. The least amount of restriction created by the first flow adjustment system570is associated with a fully open configuration, while the least amount of restriction created by the first flow adjustment system570is associated with a terminal configuration.

The second adjustment system580is supported by the actuator member554downstream of the first adjustment system570. The outlet member556is a resiliently deformable tube, and manual operation of the second adjustment member582deforms the walls of the outlet member556and thereby affects the flow of fluid material flowing out of the conduit passageway542through the conduit outlet or outlet opening546. The second adjustment system580thus functions as a variable orifice. Operation of the second adjustment member582variably reduces the size of the conduit outlet or outlet opening546relative to the size of the conduit passageway542upstream of the second adjustment system580.

The outlet member556, first adjustment member572, and second adjustment member582are supported by the actuator member554to define a control assembly590.FIG. 27further shows that the grip assembly558comprises a grip housing592and that the actuator member554defines a trigger portion594. To form the actuator assembly538, the grip assembly558is combined with the control assembly590by pivotably attaching the actuator member554to the grip housing592. The actuator assembly538is supported by the container assembly530as generally described above. An elongated slot596is formed in the grip housing592to allow the second adjustment member582to extend through the grip housing592without interfering with operation of the actuator member554as described herein.

To operate the seventh example aerosol dispensing system520, the container530and grip housing592are grasped such that the user's fingers can squeeze the trigger portion594, thereby depressing the actuator member554. The conduit outlet or outlet opening546is initially aimed at a test surface and the actuator member554is depressed to place the valve assembly560in the open configuration such that the pressurized material536forces some of the stored material534out of the container530and onto the test surface to form a test texture pattern. The test texture pattern is compared to the pre-existing texture pattern defined by the textured portion of the target surface. If the test texture pattern does not match the pre-existing texture pattern, one or both of the first and second adjustment members is/are adjusted to alter the spray pattern of the droplets of dispensed material522.

The process of spraying a test pattern and adjusting the first and second adjustment members572and582is repeated until the test pattern formed by the dispensed material522corresponds to a desired texture pattern that substantially matches the pre-existing texture pattern.

Leaving the first and second adjustment members572and582as they were when the test texture pattern corresponded to the desired texture pattern, the aerosol dispensing system520is then arranged such that the conduit outlet or outlet opening546is aimed at the un-textured portion of the target surface. The trigger member594is again squeezed to place the valve assembly560in the open configuration such that the pressurized material536forces the stored material534out of the container530and onto the un-textured portion of the target surface to form the desired texture pattern on the un-textured portion of the target surface, perhaps overlapping slightly with the textured portion of the target surface. Since the desired texture pattern substantially matches the pre-existing texture pattern, the dispensed material forms a coating on the previously un-textured portion of the target surface in a desired texture pattern that substantially matches a physical appearance of the textured portion. One or more layers of primer and/or paint may next be applied over the cured layer of dispensed material.

The following Table G represents example ranges and dimensions for constructing a physical embodiment of a flow adjustment system that may be used as the example first flow adjustment system570:

Referring now toFIGS. 32-34of the drawing, depicted at620therein is a eighth example aerosol dispensing system constructed in accordance with, and embodying, the principles of the present invention. Like the fifth example aerosol dispensing system20b, the eighth example dispensing system is adapted to spray droplets of dispensed material622onto a target surface (not shown). In the example use of the dispensing system620depicted inFIG. 32, the dispensed material622is or contains texture material, and the dispensing system620is being used to form a coating on an un-textured portion of the target surface having a desired texture pattern that substantially matches a pre-existing texture pattern of a textured portion of the target surface.

FIG. 32further illustrates that the example dispensing system620comprises a container630defining a chamber632in which stored material634and pressurized material636are contained. Like the stored materials (e.g.,34aand34b) described above, the stored material634is a mixture of texture material and propellant material in liquid phase, while the pressurized material is propellant material in gas phase. An actuator assembly638is mounted on the container assembly630to facilitate the dispensing of the dispensed material622as will be described in further detail below.

FIG. 33illustrates that the eighth example aerosol dispensing system620comprises a conduit640defining a conduit passageway642. The conduit640is supported by the container630such that the conduit passageway642defines a conduit inlet644arranged within the chamber632and a conduit outlet or outlet opening646arranged outside of the chamber632. The example conduit640is formed by an inlet tube650, a valve housing652, an actuator member654, and an outlet member656. The conduit passageway642extends through the inlet tube650, the valve housing652, the actuator member654, and the outlet member656. The valve housing652is arranged between the conduit inlet644and the actuator member654, and the actuator member654is arranged between the valve housing652and the conduit outlet646. The outlet member656is supported by the actuator member654to define the conduit outlet646.

FIG. 33further shows that a valve assembly660is formed within the valve housing652. The example valve assembly660comprises a valve member662, a valve seat664, and a valve spring666. The valve assembly660operates in a closed configuration and an open configuration. In the closed configuration, the valve spring666forces the valve member662against the valve seat664such that the valve assembly660substantially prevents flow of fluid along the conduit passageway642. In the open configuration, the valve member662is displaced away from the valve seat664against the force of the valve spring666such that the valve assembly660allows flow of fluid along the conduit passageway642between the valve member662and the valve seat664. Because the valve spring666biases the valve member662towards the valve seat664, the example valve assembly660is normally closed. As will be described in further detail below, the valve assembly660engages the actuator member structure654such that the application of deliberate manual force on the actuator member654towards the container630moves the valve member662away from the valve seat664and thus places the valve system660in the open configuration.

A first flow adjustment system670having a first adjustment member672having a valve surface674and an externally threaded surface676is arranged to intersect the conduit passageway642at an intermediate location642abetween the valve assembly660and the conduit outlet646. The conduit passageway has a first portion642band a second portion642c. The first passageway portion642bdefines an actuator axis AAaligned with a container axis ACdefined by the container assembly630, and the second actuator passageway portion642cis aligned with an outlet axis AOdefined by the outlet member656. The example intermediate location642ais located in the second passageway portion642c.

An internally threaded surface678is formed in the actuator member654. The threaded surfaces676and678are adapted to engage each other such that, as shown inFIG. 34, rotation of the first adjustment member672relative to the actuator member654causes the valve surface674to engage and deform the outlet member656and thus alter a cross-sectional area of the conduit passageway642between the valve system660and the second flow adjustment system680.

A second flow adjustment system680comprises a second adjustment member682and a plurality of fingers684extending from the actuator member654. The second flow adjustment system680is arranged relative to the conduit passageway642to form at least a portion of the conduit outlet (or outlet opening)646. The second adjustment member682defines an internal threaded surface686that engages an external threaded surface688of the actuator member654such that rotation of the second adjustment member682relative to the actuator member654deforms the fingers and thus the outlet member656, thereby altering a cross-sectional area of the conduit outlet or outlet opening646.

The first flow adjustment system670is supported by the actuator member654between the valve assembly660and the second adjustment system680such that manual operation of the first adjustment member672affects the flow of fluid material along the conduit passageway642as generally described above. In particular, the second adjustment system680functions as a flow restrictor, where operation of the first adjustment member672variably reduces the size of the conduit passageway642such that a pressure of the fluid material upstream of the first flow adjustment system670is relatively higher than the pressure of the fluid material downstream of the first flow adjustment system670. The first flow adjustment system670defines a fully open configuration (smallest restriction) and a terminal configuration (largest restriction).

The second adjustment system680is supported by the actuator member654downstream of the first adjustment system670. The outlet member656is a resiliently deformable tube, and manual operation of the second adjustment member682deforms the walls of the outlet member656and thereby affects the flow of fluid material flowing out of the conduit passageway642through the conduit outlet or outlet opening646. The second adjustment system680thus functions as a variable orifice. Operation of the second adjustment member682variably reduces the size of the conduit outlet or outlet opening646relative to the size of the conduit passageway642upstream of the second adjustment system680.

The outlet member656, first adjustment member672, and second adjustment member682are supported by the actuator member654to define a control assembly690.FIG. 33further shows that the grip assembly658comprises a grip housing692and that the actuator member654defines a trigger portion694. To form the actuator assembly638, the grip assembly658is combined with the control assembly690by pivotably attaching the actuator member654to the grip housing692. The actuator assembly638is supported by the container assembly630as generally described above. An elongated slot696is formed in the grip housing692to allow the first adjustment member672to extend through the grip housing692without interfering with operation of the actuator member654as described herein.

To operate the eighth example aerosol dispensing system620, the container630and grip housing692are grasped such that the user's fingers can squeeze the trigger portion694, thereby depressing the actuator member654. The conduit outlet or outlet opening646is initially aimed at a test surface and the actuator member654is depressed to place the valve assembly660in the open configuration such that the pressurized material636forces some of the stored material634out of the container630and onto the test surface to form a test texture pattern. The test texture pattern is compared to the pre-existing texture pattern defined by the textured portion of the target surface. If the test texture pattern does not match the pre-existing texture pattern, one or both of the first and second adjustment members is/are adjusted to alter the spray pattern of the droplets of dispensed material622.

The process of spraying a test pattern and adjusting the first and second adjustment members672and682is repeated until the test pattern formed by the dispensed material622corresponds to a desired texture pattern that substantially matches the pre-existing texture pattern.

Leaving the first and second adjustment members672and682as they were when the test texture pattern corresponded to the desired texture pattern, the aerosol dispensing system620is then arranged such that the conduit outlet or outlet opening646is aimed at the un-textured portion of the target surface. The trigger member694is again squeezed to place the valve assembly660in the open configuration such that the pressurized material636forces the stored material634out of the container630and onto the un-textured portion of the target surface to form the desired texture pattern on the un-textured portion of the target surface, perhaps overlapping slightly with the textured portion of the target surface. Since the desired texture pattern substantially matches the pre-existing texture pattern, the dispensed material forms a coating on the previously un-textured portion of the target surface in a desired texture pattern that substantially matches a physical appearance of the textured portion. One or more layers of primer and/or paint may next be applied over the cured layer of dispensed material.

The following Table H represents example ranges and dimensions for constructing a physical embodiment of a flow adjustment system that may be used as the example first flow adjustment system670:

Referring now toFIGS. 35-38of the drawing, depicted at720therein is a ninth example aerosol dispensing system constructed in accordance with, and embodying, the principles of the present invention. Like the fifth example aerosol dispensing system20b, the ninth example dispensing system is adapted to spray droplets of dispensed material722onto a target surface (not shown). In the example use of the dispensing system720depicted inFIG. 35, the dispensed material722is or contains texture material, and the dispensing system720is being used to form a coating on an un-textured portion of the target surface having a desired texture pattern that substantially matches a pre-existing texture pattern of a textured portion of the target surface.

FIG. 35further illustrates that the example dispensing system720comprises a container730defining a chamber732in which stored material734and pressurized material736are contained. Like the stored materials (e.g.,34aand34b) described above, the stored material734is a mixture of texture material and propellant material in liquid phase, while the pressurized material is propellant material in gas phase. An actuator assembly738is mounted on the container assembly730to facilitate the dispensing of the dispensed material722as will be described in further detail below.

FIG. 36illustrates that the ninth example aerosol dispensing system720comprises a conduit740defining a conduit passageway742. The conduit740is supported by the container730such that the conduit passageway742defines a conduit inlet744arranged within the chamber732and a conduit outlet or outlet opening746arranged outside of the chamber732. The example conduit740is formed by an inlet tube750, a valve housing752, an actuator member754, and an outlet member756. The conduit passageway742extends through the inlet tube750, the valve housing752, the actuator member754, and the outlet member756. The valve housing752is arranged between the conduit inlet744and the actuator member754, and the actuator member754is arranged between the valve housing752and the conduit outlet746. The outlet member756is supported by the actuator member754to define the conduit outlet746.

FIG. 36further shows that a valve assembly760is formed within the valve housing752. The example valve assembly760comprises a valve member762, a valve seat764, and a valve spring766. The valve assembly760operates in a closed configuration and an open configuration. In the closed configuration, the valve spring766forces the valve member762against the valve seat764such that the valve assembly760substantially prevents flow of fluid along the conduit passageway742. In the open configuration, the valve member762is displaced away from the valve seat764against the force of the valve spring766such that the valve assembly760allows flow of fluid along the conduit passageway742between the valve member762and the valve seat764. Because the valve spring766biases the valve member762towards the valve seat764, the example valve assembly760is normally closed. As will be described in further detail below, the valve assembly760engages the actuator member structure754such that the application of deliberate manual force on the actuator member754towards the container730moves the valve member762away from the valve seat764and thus places the valve system760in the open configuration.

A first flow adjustment system770having a first adjustment member772having a valve surface774and an externally threaded surface776is arranged to intersect the conduit passageway742at an intermediate location742abetween the valve assembly760and the conduit outlet746. The conduit passageway has a first portion742band a second portion742c. The first passageway portion742bdefines an actuator axis AAaligned with a container axis ACdefined by the container assembly730, and the second actuator passageway portion742cis aligned with an outlet axis AOdefined by the outlet member756. The example intermediate location742ais located at the juncture of the first and second passageway portions742band742c. A juncture surface742dhaving a profile that matches that of the valve surface774is arranged at the intermediate location742aas perhaps best shown inFIG. 37.

An internally threaded surface778is formed in the actuator member754. The threaded surfaces776and778are adapted to engage each other such that, as shown inFIG. 34, rotation of the first adjustment member772relative to the actuator member754causes the valve surface774move into the conduit passageway742and thus alter a cross-sectional area of the conduit passageway742between the valve system760and the second flow adjustment system780.

A second flow adjustment system780comprises a second adjustment member782and a plurality of fingers784extending from the actuator member754. The second flow adjustment system780is arranged relative to the conduit passageway742to form at least a portion of the conduit outlet (or outlet opening)746. The second adjustment member782defines an internal threaded surface786that engages an external threaded surface788of the actuator member754such that rotation of the second adjustment member782relative to the actuator member754deforms the fingers and thus the outlet member756, thereby altering a cross-sectional area of the conduit outlet or outlet opening746.

The first flow adjustment system770is supported by the actuator member754between the valve assembly760and the second adjustment system780such that manual operation of the first adjustment member772affects the flow of fluid material along the conduit passageway742as generally described above. In particular, the second adjustment system780functions as a flow restrictor, where operation of the first adjustment member772variably reduces the size of the conduit passageway742such that a pressure of the fluid material upstream of the first flow adjustment system770is relatively higher than the pressure of the fluid material downstream of the first flow adjustment system770. The example first flow adjustment system770operates in a fully open configuration (least amount of flow restriction) and a terminal configuration (largest amount of flow restriction).

The second adjustment system780is supported by the actuator member754downstream of the first adjustment system770. The outlet member756is a resiliently deformable tube, and manual operation of the second adjustment member782deforms the walls of the outlet member756and thereby affects the flow of fluid material flowing out of the conduit passageway742through the conduit outlet or outlet opening746. The second adjustment system780thus functions as a variable orifice. Operation of the second adjustment member782variably reduces the size of the conduit outlet or outlet opening746relative to the size of the conduit passageway742upstream of the second adjustment system780.

The outlet member756, first adjustment member772, and second adjustment member782are supported by the actuator member754to define a control assembly790.FIG. 36further shows that the grip assembly758comprises a grip housing792and that the actuator member754defines a trigger portion794. To form the actuator assembly738, the grip assembly758is combined with the control assembly790by pivotably attaching the actuator member754to the grip housing792. The actuator assembly738is supported by the container assembly730as generally described above. An elongated slot796is formed in the grip housing792to allow the first adjustment member772to extend through the grip housing792without interfering with operation of the actuator member754as described herein.

To operate the ninth example aerosol dispensing system720, the container730and grip housing792are grasped such that the user's fingers can squeeze the trigger portion794, thereby depressing the actuator member754. The conduit outlet or outlet opening746is initially aimed at a test surface and the actuator member754is depressed to place the valve assembly760in the open configuration such that the pressurized material736forces some of the stored material734out of the container730and onto the test surface to form a test texture pattern. The test texture pattern is compared to the pre-existing texture pattern defined by the textured portion of the target surface. If the test texture pattern does not match the pre-existing texture pattern, one or both of the first and second adjustment members is/are adjusted to alter the spray pattern of the droplets of dispensed material722.

The process of spraying a test pattern and adjusting the first and second adjustment members772and782is repeated until the test pattern formed by the dispensed material722corresponds to a desired texture pattern that substantially matches the pre-existing texture pattern.

Leaving the first and second adjustment members772and782as they were when the test texture pattern corresponded to the desired texture pattern, the aerosol dispensing system720is then arranged such that the conduit outlet or outlet opening746is aimed at the un-textured portion of the target surface. The trigger member794is again squeezed to place the valve assembly760in the open configuration such that the pressurized material736forces the stored material734out of the container730and onto the un-textured portion of the target surface to form the desired texture pattern on the un-textured portion of the target surface, perhaps overlapping slightly with the textured portion of the target surface. Since the desired texture pattern substantially matches the pre-existing texture pattern, the dispensed material forms a coating on the previously un-textured portion of the target surface in a desired texture pattern that substantially matches a physical appearance of the textured portion. One or more layers of primer and/or paint may next be applied over the cured layer of dispensed material.

The following Table I represents example ranges and dimensions for constructing a physical embodiment of a flow adjustment system that may be used as the example first flow adjustment system770:

Referring now toFIGS. 39-42of the drawing, depicted at920therein is a tenth example aerosol dispensing system constructed in accordance with, and embodying, the principles of the present invention. Like the fifth example aerosol dispensing system20b, the tenth example dispensing system is adapted to spray droplets of dispensed material922onto a target surface (not shown). In the example use of the dispensing system920depicted inFIG. 39, the dispensed material922is or contains texture material, and the dispensing system920is being used to form a coating on an un-textured portion of the target surface having a desired texture pattern that substantially matches a pre-existing texture pattern of a textured portion of the target surface.

FIG. 39further illustrates that the example dispensing system920comprises a container930defining a chamber932in which stored material934and pressurized material936are contained. Like the stored materials (e.g.,34aand34b) described above, the stored material934is a mixture of texture material and propellant material in liquid phase, while the pressurized material is propellant material in gas phase. An actuator assembly938is mounted on the container assembly930to facilitate the dispensing of the dispensed material922as will be described in further detail below.

FIG. 40illustrates that the tenth example aerosol dispensing system920comprises a conduit940defining a conduit passageway942. The conduit940is supported by the container930such that the conduit passageway942defines a conduit inlet944arranged within the chamber932and a conduit outlet or outlet opening946arranged outside of the chamber932. The example conduit940is formed by an inlet tube950, a valve housing952, an actuator member954, and an outlet member956. The conduit passageway942extends through the inlet tube950, the valve housing952, the actuator member954, and the outlet member956. The valve housing952is arranged between the conduit inlet944and the actuator member954, and the actuator member954is arranged between the valve housing952and the conduit outlet946. The outlet member956is supported by the actuator member954to define the conduit outlet946.

FIG. 40further shows that a valve assembly960is formed within the valve housing952. The example valve assembly960comprises a valve member962, a valve seat964, and a valve spring966. The valve assembly960operates in a closed configuration and an open configuration. In the closed configuration, the valve spring966forces the valve member962against the valve seat964such that the valve assembly960substantially prevents flow of fluid along the conduit passageway942. In the open configuration, the valve member962is displaced away from the valve seat964against the force of the valve spring966such that the valve assembly960allows flow of fluid along the conduit passageway942between the valve member962and the valve seat964. Because the valve spring966biases the valve member962towards the valve seat964, the example valve assembly960is normally closed. As will be described in further detail below, the valve assembly960engages the actuator member structure954such that the application of deliberate manual force on the actuator member954towards the container930moves the valve member962away from the valve seat964and thus places the valve system960in the open configuration.

A first flow adjustment system970having a first adjustment member972having a valve surface974and a shaft portion976is arranged to intersect the conduit passageway942at an intermediate location942abetween the valve assembly960and the conduit outlet946. The conduit passageway has a first portion942band a second portion942c. The first passageway portion942bdefines an actuator axis AAaligned with a container axis ACdefined by the container assembly930, and the second actuator passageway portion is aligned with an outlet axis AOdefined by the outlet member956. The example intermediate location942ais located in the second passageway portion942c.

A support opening978is formed in the actuator member954. The shaft976extends through the opening978such that, as shown inFIGS. 45 and 47, rotation of the first adjustment member972relative to the actuator member954causes the valve surface974to engage and deform the outlet member956and thus alter a cross-sectional area of the conduit passageway942between the valve system960and the second flow adjustment system980. In particular, the valve surface974defines a valve axis AVthat is offset from a shaft axis ASdefined by the shaft portion976. Accordingly, rotation of the first adjustment member972about the shaft axis AScauses eccentric rotation of the valve surface974. Because of this eccentric rotation, a distance between the portion of the valve surface974in contact with the outlet member956, relative to the shaft axis AS, increases and decreases based on an angular position of the first adjustment member972.

A second flow adjustment system980comprises a second adjustment member982and a plurality of fingers984extending from the actuator member954. The second flow adjustment system980is arranged relative to the conduit passageway942to form at least a portion of the conduit outlet (or outlet opening)946. The second adjustment member982defines an internal threaded surface986that engages an external threaded surface988of the actuator member954such that rotation of the second adjustment member982relative to the actuator member954deforms the fingers and thus the outlet member956, thereby altering a cross-sectional area of the conduit outlet or outlet opening946.

The first flow adjustment system970is supported by the actuator member954between the valve assembly960and the second adjustment system980such that manual operation of the first adjustment member972affects the flow of fluid material along the conduit passageway942as generally described above. In particular, the second adjustment system980functions as a flow restrictor, where operation of the first adjustment member972variably reduces the size of the conduit passageway942such that a pressure of the fluid material upstream of the first flow adjustment system970is relatively higher than the pressure of the fluid material downstream of the first flow adjustment system970. The example first flow adjustment system970thus is operable in a fully open configuration (least amount of flow restriction) and a terminal configuration (greatest amount of flow restriction).

The second adjustment system980is supported by the actuator member954downstream of the first adjustment system970. The outlet member956is a resiliently deformable tube, and manual operation of the second adjustment member982deforms the walls of the outlet member956and thereby affects the flow of fluid material flowing out of the conduit passageway942through the conduit outlet or outlet opening946. The second adjustment system980thus functions as a variable orifice. Operation of the second adjustment member982variably reduces the size of the conduit outlet or outlet opening946relative to the size of the conduit passageway942upstream of the second adjustment system980.

The outlet member956, first adjustment member972, and second adjustment member982are supported by the actuator member954to define a control assembly990.FIG. 40further shows that the grip assembly958comprises a grip housing992and that the actuator member954defines a trigger portion994. To form the actuator assembly938, the grip assembly958is combined with the control assembly990by pivotably attaching the actuator member954to the grip housing992. The actuator assembly938is supported by the container assembly930as generally described above. An elongated slot996is formed in the grip housing992to allow the first adjustment member972to extend through the grip housing992without interfering with operation of the actuator member954as described herein.

To operate the tenth example aerosol dispensing system920, the container930and grip housing992are grasped such that the user's fingers can squeeze the trigger portion994, thereby depressing the actuator member954. The conduit outlet or outlet opening946is initially aimed at a test surface and the actuator member954is depressed to place the valve assembly960in the open configuration such that the pressurized material936forces some of the stored material934out of the container930and onto the test surface to form a test texture pattern. The test texture pattern is compared to the pre-existing texture pattern defined by the textured portion of the target surface. If the test texture pattern does not match the pre-existing texture pattern, one or both of the first and second adjustment members is/are adjusted to alter the spray pattern of the droplets of dispensed material922.

The process of spraying a test pattern and adjusting the first and second adjustment members972and982is repeated until the test pattern formed by the dispensed material922corresponds to a desired texture pattern that substantially matches the pre-existing texture pattern.

Leaving the first and second adjustment members972and982as they were when the test texture pattern corresponded to the desired texture pattern, the aerosol dispensing system920is then arranged such that the conduit outlet or outlet opening946is aimed at the un-textured portion of the target surface. The trigger member994is again squeezed to place the valve assembly960in the open configuration such that the pressurized material936forces the stored material934out of the container930and onto the un-textured portion of the target surface to form the desired texture pattern on the un-textured portion of the target surface, perhaps overlapping slightly with the textured portion of the target surface. Since the desired texture pattern substantially matches the pre-existing texture pattern, the dispensed material forms a coating on the previously un-textured portion of the target surface in a desired texture pattern that substantially matches a physical appearance of the textured portion. One or more layers of primer and/or paint may next be applied over the cured layer of dispensed material.

The following Table K represents example ranges and dimensions for constructing a physical embodiment of a flow adjustment system that may be used as the example first flow adjustment system970:

Each of the embodiments described above contains a unique first adjustment system and one of several example second adjustment systems. Any one of the example second adjustment systems disclosed herein may be combined with any one of the unique first adjustment systems associated with each of the embodiments discussed above. Accordingly, the specific pairings of example first and second adjustment systems as described above are for illustrative purposes only, and, in one form, the principles of the present invention may be implemented by using any pair of example first and second adjustment systems whether that particular pairing is disclosed explicitly above or disclosed implicitly by reference in this Summary section.

Accordingly, the embodiments described herein may be embodied in other specific forms without departing from their spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the claims to be appended hereto rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.