Abstract:
A specialized nozzle assembly that dispenses spray patterns of varying textures, e.g., coarse or fine particles; for use in an aerosol system for applying a spray texture material to a wall or like supporting structure. The nozzle assembly includes an elongated passageway and a generally cone-shaped member attached thereon.

Description:
FIELD OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     Embodiments of the present invention relate generally to an aerosol system for applying a spray texture material to a wall or like supporting structure. More particularly, embodiments are directed to a nozzle adapted to provide variable spraying of the material so as to dispense spray patterns that may vary in texture, e.g., coarser or finer particles, may be achieved. The system further comprises an aerosol container that holds the pressurized spray texture material. The material is dispensed through a dip tube that connects to a nozzle. The spray texture material exits from the container through the nozzle.  
         [0003]     2. Description of Related Art  
         [0004]     It has been the conventional practice in the procedure of repairing drywall or other like areas to remove the damaged portion of the surface and subsequently fill any holes, depressions, or the like with a prepared patch material. The patch or replacement material is applied by means of a trowel or other flattening tool that will press the patch material into the hole or depression and that will prepare and provide a surface area to receive a finish surface coating. After the patch material has cured and adhered to the original support material, a smooth surface is provided that receives the final coating. This coating leaves a smooth surface that is unmatched to the surrounding textured or roughened surface.  
         [0005]     Drywall or other like surfaces usually present a surface texture that is not smooth but has an irregular texture or look. Such an appearance and surface texture cannot be attained through the use of smoothing tools or patch tools once the patch material has been applied to the damaged or repaired area. Therefore, difficulties and problems have been encountered that stem largely from the fact that the use and application of conventional patching materials on the repairs of such surfaces leaves a surface texture that does not match the surrounding area and is noticeable after the repair has been completed.  
         [0006]     Thus, there have been developed sprayable texture materials that can be conveniently used to repair or patch drywall or other like surfaces in a manner that provides a repair area that visually assumes the surface texture of the surrounding wall area. U.S. Pat. No. 6,386,4025, to the present Applicant, discloses a sprayable drywall texture that is sprayable from a hand-held aerosol dispenser and is hereby incorporated in its entirety.  
         [0007]     However, because the wall textures themselves may vary, e.g. coarser or finer texture, it is useful to have a single aerosol apparatus that may dispense the sprayable material in more than one spray texture. There are known apparatuses which provide variable nozzle which may spray varying textures, however, those involve nozzles having multiple outlet components or requiring various manual steps.  
         [0008]     Therefore, there is a need for an aerosol apparatus that has a nozzle that can spray varying texture patterns in a more simple and efficient manner, without involving too many components or steps.  
       BRIEF SUMMARY OF THE INVENTION  
       [0009]     In accordance with embodiments of the invention, an object of an embodiment of the present invention is to provide an apparatus with a specialized nozzle that can provide spray patterns of varying textures in a simple and efficient manner.  
         [0010]     In an embodiment, there is provided a nozzle having an elongated passageway that extends from the nozzle that serves as an extension of the nozzle. Slidably attached to this elongated passageway is a generally cone-shaped member which is adapted to slide from a first position to a second position interchangeably. For example, the generally cone-shaped member may be slidably attached by screwing threads on the inside of the cone-shaped member and on the outside of the elongated passageway that allow the cone-shaped member to swivel up and down the elongated passageway. When the cone member is in the first position, the cone member is located closer to the nozzle. When the cone member is in the second position, the cone member is located at the end of the elongated passageway, farthest away from the nozzle. In the first position, the sprayable material contained in the aerosol apparatus will be dispensed according to the sole orifice of the single elongated passageway. The spray will be smaller in scope and more concentrated with finer particles. In the second position, the cone member is located at the end of the elongated passageway and thus expands the trajectory of the spray as it exits the single orifice of the single elongated passageway. The second position thus facilitates a broader spray which is less concentrated with coarser particles. In embodiments, the slidably attached member is generally flared.  
         [0011]     The variation between dispensing a finer texture and dispensing a more coarse texture is thus provided through the cone member. The sprayable product exits from only one orifice, that of the elongated passageway, which does not vary in diameter or cross-sectional area. Whether the generally cone-shaped member is in the first or the second position, the sprayable product is dispensed through the unchanging diameter of the sole orifice of the elongated passageway. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]     A detailed description of embodiments of the invention will be made with reference to the accompanying drawings, wherein like numerals designate corresponding parts in the figures.  
         [0013]      FIG. 1  illustrates a perspective view of a variable nozzle with a generally cone-shaped member in a first position according to an embodiment of the invention.  
         [0014]      FIG. 2  illustrates perspective view of a variable nozzle with a generally cone-shaped member in a second position according to an embodiment of the present.  
         [0015]      FIG. 3  illustrates a cross-sectional perspective view of an aerosol system having a variable nozzle with a generally cone-shaped member in a first position according to an embodiment of the present. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0016]     In the following description, reference is made to the accompanying drawings which form a part hereof and which illustrate several embodiments of the present inventions. It is understood that other embodiments may be utilized and structural and operational changes may be made without departing from the scope of the present inventions.  
         [0017]     As shown in  FIG. 1 , there is provided a nozzle assembly  5  of an aerosol apparatus for spraying variable textures. The nozzle assembly  5  has a single elongated passageway  10  that extends from an actuator  15 . The actuator  15  includes an aperture  20  forming a nozzle opening  25  to which the elongated passageway  10  is connected and from which the elongated passageway  10  serves as an extension. The elongated passageway  10  has a single orifice  30  from which the spray exits. Slidably attached to this elongated passageway  10  is a generally flared or cone-shaped member  35  which is adapted to slide from a first position  40  to a second position  45  interchangeably. For example, in the embodiment shown in  FIG. 1  and  FIG. 2 , the generally cone-shaped member may be slidably attached by screwing threads  75  that allow the cone-shaped member to swivel up and down the elongated passageway. In the first position  40 , as depicted in  FIG. 1 , the cone member  35  is located closer to the actuator  15 . In the second position  45 , as depicted in  FIG. 2 , the cone member  35  is located at the end of the elongated passageway  10 , farthest away from the actuator  15 .  
         [0018]     In the first position  40 , the sprayable material contained in the aerosol apparatus will be dispensed according to the single orifice  30  of the elongated passageway  10 . The spray will be smaller in scope and more concentrated with finer particles. In the second position  45 , the cone member  35  is located at the end of the elongated passageway  10  and thus expands the trajectory of the spray as it exits the orifice  30  of the elongated passageway  10 , as can be seen in  FIG. 2 . The second position  45  thus facilitates a broader spray which is less concentrated with coarser particles.  
         [0019]     The variability of the dispensed spray is provided by the positions of the generally flared or cone-shaped member  35 , shown in  FIGS. 1 and 2 . The difference in spray texture is caused by the manner in which the cone member  35  expands the trajectory of the spray as it exits the orifice  30  of the elongated passageway  10  in the second position  45 . The sprayable product exits from only one orifice  30 , that of the single elongated passageway  10 , which remains constant in diameter. Whether the cone member  35  is in the first position  40  or the second position  45 , the sprayable product is dispensed through the unchanging diameter of the orifice  30  of the elongated passageway  10 , which provides a convenient and efficient manner of varying spray textures without involving much manipulation or multiple parts. The variation of spray textures is achieved by simply sliding the cone member  35  on the elongated passageway  10  from the first position  40  to the second position  45 . The cone member  35 , in the second position  45 , extends the trajectory of the exiting material and thus provides a broader spray with coarser, less concentrated texture. In either position, the sprayable material is dispensed from the same orifice  30 . The orifice  30  of the elongated passageway  10  and the orifice  70  of the cone member  35  each remain the same and do not vary, nor are they ever switched for a counterpart with a larger or smaller orifice.  
         [0020]     In  FIG. 3 , an aerosol system, using the nozzle assembly  5  according to an embodiment of the invention, is illustrated schematically by the reference numeral  50 . The system  50  comprises a container  55  that holds a sprayable texture material  60 , a dip tube  65  disposed inside the container in contact with the sprayable texture material  60 , and a nozzle assembly  5 . The dip tube  65  has a top opening and a bottom opening disposed and extends to a bottom of the container  55  without contacting the bottom. The nozzle assembly  5  is disposed on the container  55  and connected to the dip tube  65 . As discussed above, the nozzle assembly  5  comprises an actuator  15  with an aperture  20  forming a nozzle opening  25  capable of dispensing variable sprays of the sprayable texture material  60  when the actuator  15  is depressed. An elongated passageway  10  is connected to the nozzle opening  25  and extends therefrom. The nozzle assembly  5  maintains fluid communication with the dip tube  65  and is adapted to open the communication when the actuator  15  is depressed, allowing the sprayable texture material  60  to be dispensed out through the elongated passageway  10  as with other aerosol spray systems or apparatuses known in the art. Fluid communication is closed when the actuator  15  is released. The container may include a propellant, such as compressed air or liquid gas, to further facilitate the force of expulsion and blast velocity released.  
         [0021]     While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention.  
         [0022]     The presently disclosed embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than the foregoing description. All changes that come within the meaning of and range of equivalency of the claims are intended to be embraced therein.