Portable texturing machine

Abstract: A portable texturing system is disclosed which includes a small spray unit (10) and a source of portable compressed air (11) which may simply be a small tank which the workman may wear on a belt or shoulder harness. The spray unit (10) includes a reservoir (12) for holding a charge of texturizing mixture and a cap assembly (13) incorporating a mixer/spray mechanism. In use, the cap (13) is positioned below the reservoir (12) such that the texturizing mixture can flow by gravity and suction to the spray mechanism. The cap assembly (13) includes a quick connect coupling (8) and a valve (15) for receiving and controlling air from the supply. A discharge nozzle is provided for directing the compressed air/texturizer mixture toward a wall area to be texturized. A mixing region within the cap assembly (13) permits the texturizing mixture to be entrained with a stream of compressed air and discharged from the nozzle whenever the valve (15) is actuated. Adjustment structure for regulating the rate at which the texturizing material is entrained is provided in the mixing region and, in some embodiments, is adjustable as by a mechanism which provides adjustment to the area available for the texturizing material to enter the discharge nozzle. In one particularly simple and reliable embodiment, the area is established by the provision of a pair of fixed size apertures in the wall of a tube which also serves as the discharge nozzle.

Description: This invention relates to the building construction arts and, more particularly, to a spray device, especially a device for applying a texturized finish to interior drywall surfaces, and an adapter for use with the device. In the method of construction in which the interior walls are fabricated from wallboard, the wallboard is frequently finished by a textured layer to provide the appearance of a plastered wall. The texturing is accomplished by spraying a special preparation upon the smooth surface of the wallboard, and this process is carried out using large, expensive equipment appropriate for texturizing an entire room or house. However, as those in the art are aware, there has been no lightweight portable texturizing apparatus for attending to patch and repair work to a texturized wall. As a result, texturized walls needing touchup or repair have often been left in their somewhat unsightly and unpleasing state since the economics of effecting such touchup and repair have been prohibitive unless there is a great deal of such work to do. Occasionally, touchup or repair of texturized walls is attempted using spackling compound or the like in which a speculative effort is made to work a matching texturized finish into the still fluid compound. Whilst sometimes achieving acceptable results, such attempts are very laborious and rarely result in touchup or repair which can stand close inspection. One spray device for plaster and similar materials is described in US-A-2887274 which describes a spray device comprising: (a) a reservoir for containing a charge of material; (b) a cap fitted on the bottom of said reservoir, the interior of said cap being in direct communication with the interior of said reservoir in order that material tends to gravity flow into said cap interior; (c) a discharge nozzle suitable for discharging a relatively viscous texturizer material, said discharge nozzle including an entry end disposed within said cap, a discharge end projecting outwardly of said cap, and a bore extending between said entry end and said discharge end; and (d) an air nozzle for discharging compressed air within said cap, said air nozzle being aligned with said entry end of said discharge nozzle. Another spray device is of somewhat different construction is described in US-A-2101922. Thus, it will be apparent to those skilled in the art that it would be highly desirable to provide a true texturizing system which is genuinely portable, lightweight and easy to use, and it is to these ends that the invention is directed. It is therefore a broad object of the invention to provide a portable texturizing device for finishing or refinishing a wall surface, eg. wallboards covered with textured material. It is another object of the invention to provide such a device which is lightweight and easy to handle and use. In one aspect, the invention provides a spray device as defined by Claim 1. Preferably such a device includes adjustment structure for regulating the rate at which viscous fluid texturizing material is delivered from a reservoir and mixed with air under pressure to obtain the desired spray characteristics. Preferably the unit further includes means for selectively varying the pattern in which the texturizing material is sprayed. It is a further object of the invention to provide such a device which is economical to fabricate and which has a long life in service. In another aspect, the invention provides an adapter as defined by Claim 4. A preferred embodiment of the invention comprises a small spray device which, together with a source of portable compressed air which may simply be a small tank which the workman may wear on a belt or shoulder harness, provides a portable texturizing system. The spray device includes a reservoir for holding a charge of texturizing mixture and a cap assembly incorporating a mixer/spray mechanism. In use, the cap is positioned down such that the texturizing mixture can flow by gravity and suction to the spray mechanism. Preferably, the reservoir has a removable cover at its other end to permit recharging the device without the necessity for removing the cap assembly. The cap assembly includes a quick connect coupling for receiving an air hose from the compressed air supply and a valve for selectively applying and interrupting the supply of compressed air to the unit. Diametrically oppositely directed from the air supply structure, there is provided a nozzle for discharging the compressed air/texturizer mixture toward a wall area to be texturized. A mixing region within the cap assembly permits the texturizing mixture to be entrained with a stream of compressed air admitted into the cap assembly and discharged from the nozzle whenever the valve is actuated. Adjustment structure for regulating the rate at which the texturizing material is entrained is provided in the mixing region and, in some embodiments, is adjustable as by a mechanism which provides corresponding adjustment to the area available for the texturizing material to enter the discharge nozzle. Further included in the device are selectively variable spray control means for discharging the texturizer mixture in a predetermined pattern. In a preferred embodiment, the spray control means includes a tip which is detachably securable to the nozzle. A discharge orifice extending through the tip has a configuration chosen to discharge a predetermined pattern. Also included is an attachment especially adapted for converting the system for spraying non-viscous material. The adapter includes an outer tube coaxially receivable within the discharge nozzle and having at least one aperture therethrough within the region of the cap. An inner tube, coaxially carried within the outer tube, has a discharge end spaced inboard of the discharge end of the outer tube and an inlet end for receiving compressed air from the air supply structure. The attachment is detachably securable to the discharge nozzle. The subject matter of the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of operation, may best be understood by reference to the following description taken in conjunction with the subjoined claims and the accompanying drawing of which: Figure 1 is an exterior perspective view of one embodiment of a spray device; Figure 2 is a cross sectional view taken along the lines 2-2 of Figure 1 and illustrates certain internal adjustment structure of the mixing region in the cap assembly of the spray device disposed in a first extreme position; Figure 3 is a view similar to the bottom portion of Figure 2 and illustrates the internal adjustment structure in a second extreme position; Figure 4 is a cross- sectional view taken along the lines 4-4 of Figure 1 and represents a top view of the adjustment structure configured in its first extreme position as in Figure 2; Figure 5 is a view similar to Figure 4 showing a top view of the adjustment structure configured in its second extreme position as in Figure 3; Figure 6 is a broken away isolated view of certain components of the adjustment structure showing their operative relationships; Figure 7 is a top view of a second embodiment of the adjustment structure; Figure 8 is an illustration generally similar to the view of Figure 7 showing attachment structure especially adapted for spraying non-viscous material; and Figure 9 is an exploded fragmentary perspective view of the embodiment of Figure 8. Referring now to Figure 1, the exterior appearance of one spray device 10 is shown. A source 11 of compressed air may take any convenient form such as a small tank which the workman may wear on a belt or shoulder harness. The source 11 of compressed air may be coupled to the spray device 10 by a hose 9 in the conventional fashion, preferably at a quick connect 8 integrated with a manually actuable valve 15. A discharge nozzle 16 extends from an entry end within the cap assembly 13 to a discharge end outside the cap and situated diametrically opposite the air inlet. A control adjusting knob 17 is employed to adjust the spray mixture as will be described more fully below. A removable cover 7 permits charging the reservoir 12 with a load of texturizing material, and one convenient securing arrangement for removably affixing the cover 7 to the reservoir 12 is by the use of bayonet slots 6 in opposing positions on the cover 7 in co-operation with appropriately positioned outwardly directed pins 5 fixed to the walls of the reservoir 12. Attention is now directed also to Figures 2,3,4 and 5 in which it can be seen that an air stream passing from air nozzle 18 in the direction of arrowed line A (Figure 2) passes through a free space before entering the inlet of discharge nozzle 16. As a result of the inverted position of the reservoir 12, texturizer material within the reservoir settles by gravity (and, during actual operation, also somewhat under the influence of the suction obtained through the Bernoulli effect) into the interior of the cap assembly 13 around the air nozzle 18 and the discharge nozzle 16. Accordingly, the texturing material is entrained into the air stream to be discharged in a spray represented by the arrowed lines B. The concentration of texturing material has access to the air stream which is, in turn, a direct result of the distance between the inlet of discharge nozzle 16 and the air nozzle 18. Figures 2 and 4 illustrate the extreme position of the adjustment structure in which the highest concentration of texturing material is entrained into the air stream whereas Figures 3 and 5 illustrate the extreme position of the adjustment structure in which the lowest concentration of texturing material is entrained. Referring also to Figure 6, the manner in which the adjustment structure may be set to these two extreme positions and all intermediate positions will now be discussed. Turning the control adjustment knob 17 causes axle 24 to turn and an arm 19 (which has its inboard end fixed to the axle) to pivot through an identical arc represented by double-ended arrow C in Figure 6. A link 20 is pivotally connected at a first end to the outboard end of arm 19 and at a second end to slide member 21 which is fixed to discharge nozzle 16 near its inlet and supports the discharge nozzle in that region. As best seen in Figures 4,5 and 6, slide member 21 is, in turn, slideably supported by elongated guides 22 positioned generally parallel to and offset from the axis formed by the air nozzle 18 and the discharge nozzle 16. Thus, by turning control adjusting knob 15 in first one direction and then the other, the discharge nozzle may be moved longitudinally between its extreme axial positions (as represented by the double-ended arrow D in Figure 6) to change the area available for the texturizer to enter the air stream and accordingly change the concentration of texturizer material in the spray delivered from the discharge nozzle. The skilled workman will appreciate that the range of texturizer concentration in the airstream which obtains the desired characteristics of the spray issued from the discharge nozzle is relatively constant and predictable given a particular texturizer, a particular air source operating at a known pressure and a given spray device. It is therefore possible to provide a somewhat simpler spray adjustment which need only be occasionally set and locked. An embodiment of the invention directed to one such arrangement is illustrated in Figure 7. In this embodiment, the cap 25 includes a thickened wall region 26 through which an internally threaded aperture extends. The discharge nozzle 27 includes an externally threaded portion 28 which may be selectively threaded into the thickened wall region 26. Consequently, the position of the inlet to the discharge nozzle 27 with respect to the air nozzle 29 may as readily be adjusted to suit the workman by turning the discharge nozzle, as by using an integral knurled knob 30, to establish the desired spray characteristics. Preferably, the discharge nozzle is then locked into this selected longitudinal position by screwing a lock nut 31 against the outer surface of the thickened wall region 26 of the cap 25, the locknut being threaded onto the portion 28 intermediate the knurled knob 30 and the cap. The texturizing material is sprayed from the discharge nozzle in a characteristic pattern. Pattern, as used herein, refers to the cross-sectional shape of the spray and the cross-sectional measurement at any given distance from the nozzle. The pattern is controlled by the cross-sectional shape and dimension of the discharge nozzle. The tubular discharge nozzles described in connection with the foregoing embodiments of the invention emit a pattern that is round and of substantial cross-sectional dimension. Contemplated by the invention are means for selectively varying the pattern. A tip having internally threaded bore and end wall can be detachably securable to tubular discharge nozzle by virtue of engagement between the threaded bore and a threaded terminal portion of the discharge nozzle; a discharge orifice can extend through the end wall. The pattern of spray corresponds to the configuration of orifice. For example, an orifice which is circular in cross-section emits a spray which is circular in cross-section. Similarly, an orifice that is ovate in cross-section will emit a pattern that is ovate in cross-section. The cross-sectional dimension of the pattern is directly proportional to the cross-sectional dimension of the orifice. A plurality of tips each having an orifice of predetermined configuration may be made available for convenient use of the workman. Structure especially adapted for converting the previously described spray devices for spraying a non-viscous material, such as paint, will now be described with reference to Figures 8 and 9. For simplicity of illustration there is seen a cap 35 a having an integrally formed discharge nozzle 50 having externally threaded terminal portion 52. Valve 15 terminating with air nozzle 18 and carried by cap 35a as previously described, is diametrically opposed to discharge nozzle 50. The attachment includes an elongate outer tube 53 coaxially receivable through nozzle 50 and including outboard end 54 and inboard end 55. Outboard end 54 functions as the discharge end. Inboard end 55, which is closed, is directed toward air nozzle 18. Tip 57 affixed to tube 53 proximate outboard end 54 includes internally threaded bore 58 which is concentric with tube 53 and removably engageable with the terminal portion 52 of nozzle 50. A pair of diametrically opposed apertures 59 extend through tube 53 to reside within cap 35. Inner tube 68, coaxially residing within the outer tube 53 extends between a discharge end 62 and inlet end 63. Discharge end 62 is spaced inboard of the outboard end 54 of outer tube 53. Inlet end 56 projects beyond the inboard end 55 of inner tube 53. Intermediate the ends, inner tube 68 passes through inboard end 55. Tube 68 is affixed to end 55 by any convenient well known means such as crimping or soldering. Inlet end 63 of inner tube 68 functions to receive pressurized air from the respective source. In the embodiment chosen for purposes of illustration, which is analogous to the embodiments seen in Figures 1-7, inlet end 63 is flared to mate with the frustoconical air nozzle. As will be appreciated by those skilled in the art, openings 59 are sized in proportion to the flow rate of the non-viscous material. Air passing through inner tube 68 draws the material into outer tube 58 through openings 59. The air and the material are mixed within outer tube 53 intermediate the end 54 thereof and the end 62 of inner tube 68 to be sprayed in a manner analogous to that provided by a conventional spray painting apparatus. Thus, while the principles of the invention have now been made clear in an illustrative embodiment, there will be immediately obvious to those skilled in the art many modifications of structure, arrangements, proportions, the elements, materials and components used in the practice of the invention which are particularly adapted for specific environments and operating requirements without departing from those principles.

Claims: A spray device comprising: (a) a reservoir 12 for containing a charge of material; (b) a cap 13; 35a fitted on the bottom of said reservoir, the interior of said cap being in direct communication with the interior of said reservoir in order that material tends to gravity flow into said cap interior; (c) a discharge nozzle 16; 27; 50 suitable for discharging a relatively viscous texturizer material, said discharge nozzle including an entry end disposed within said cap, a discharge end projecting outwardly of said cap, and a bore extending between said entry end and said discharge end; and (d) an air nozzle 18 for discharging compressed air within said cap, said air nozzle 18 being aligned with said entry end of said discharge nozzle 16; 27; 50, and (e) an adapter for removable placement in said cap 13; 35 a to convert the device from a first configuration suitable for spraying said viscous texturizing material to a second configuration suitable for spraying relatively non-viscous material, said adapter including: i) an outer tube 53 coaxially receivable within the bore of said discharge nozzle 16; 27; 50 and having a discharge end 54, an inboard end 55 directed toward said air nozzle 18, and at least one aperture 59 formed intermediate said discharge end 54 and said inboard end 55 for admitting material from said reservoir 12; ii) an inner tube (68) coaxially carried within said outer tube 53 and including a discharge end 62 disposed between said at least one aperture 59 and said discharge end 54 of said outer tube 53, and an inlet end 63 for receiving compressed air from said nozzle 18; and iii) attachment means 57 for detachably securing said outer tube 53 to said discharge nozzle 16; 27; 50. A device according to Claim 1, wherein said inboard end 55 of said outer tube 53 is closed, and said inner tube 68 extends through said closed inboard end 55. A device according to either one of Claims 1 and 2, wherein said at least one aperture 59 comprises a pair of apertures 59 formed on diametrically opposite locations on said outer tube 53. An adapter suitable for removable placement in a spray device including a reservoir 12 for containing a charge on one of said materials having a cap 13; 35 a removably fitted to the bottom thereof; a discharge nozzle 16; 27; 50 suitable for discharging a relatively viscous material, said discharge nozzle being mounted proximate the bottom end of said reservoir and including an entry end within said cap, a discharge end projecting outwardly of said cap, and a bore extending between said entry end and said discharge end; and an air nozzle 18 for discharging compressed air, within said cap, said air nozzle being aligned with said entry end of said discharge nozzle, the adapter being so constructed and arranged as to convert the device from a first configuration suitable for spraying relatively viscous material to a second configuration suitable for spraying relatively non-viscous material, said adapter comprising (a) an outer tube 53 coaxially receivable within the bore of said discharge nozzle 16; 27; 50 and having i) a discharge end 54, ii) an inboard end 55 directed toward said air nozzle 18, and iii) at least one aperture 59 formed intermediate said discharge end 54 and said inboard end 55 for admitting material from said reservoir 12; (b) an inner tube 68 coaxially carried within said outer tube 53 and including i) a discharge end 62 disposed between said at least one aperture 59 and said discharge end 54 of said outer tube 53, and ii) an inlet end 63 for receiving compressed air from said nozzle 18; and (c) attachment means 57 for detachably securing said outer tube 53 to said discharge nozzle 16; 27; 50. An adapter according to Claim 4, wherein said inboard end 55 of said outer tube 53 is closed, and said inner tube 68 extends through said closed inboard end 55. A device according to either one of Claims 4 or 5, wherein said at least one aperture 59 comprises a pair of apertures 59 formed on diametrically opposite locations on said outer tube 53.

Inventors: HOWE DAVID, HOWE, DAVID
Applicants: HOWE DAVID, HOWE, DAVID
Application year: 1990
Main classification: E04F21
IPC codes: B05B7, E04F21