Abstract:
A system for coating a target surface employs a bottle for containing the texture material and a spray pump assembly. A resilient member is supported by a pump housing to define an outlet opening. A collar member is supported by the pump housing. The resilient member is normally in an undeformed configuration in which the outlet opening defines a first cross-sectional area. Moving the collar member relative to the pump housing causes the collar member to act on the resilient member to deform the resilient member from the undeformed configuration to a deformed configuration in which the outlet opening defines a second cross-sectional area, where the second cross-sectional area is greater than the first cross-sectional area.

Description:
RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 13/113,816 filed May 23, 2011. 
     U.S. patent application Ser. No. 13/113,816 is a continuation of U.S. patent application Ser. No. 12/080,097 filed Mar. 31, 2008, now abandoned. 
     U.S. patent application Ser. No. 12/080,097 claims benefit of U.S. Provisional Application Ser. No. 60/922,040 filed Apr. 4, 2007. 
     The contents of all applications from which the present application claims priority are incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present invention relates to systems and methods for applying texture materials to a target surface and, more specifically, to compositions of texture materials and dispensing systems and methods for dispensing texture material in small quantities. 
     BACKGROUND 
     The surfaces of drywall materials defining wall and ceiling surfaces are commonly coated with texture materials. Texture materials are coatings that are deposited in discrete drops that dry to form a bumpy, irregular texture on the destination surface. Texture materials are commonly applied using a hopper gun connected to a source of pressurized air. However, when only a small area is to be coated or an existing textured surface is repaired, texture materials are typically applied using an aerosol dispensing system. 
     An aerosol dispensing system for dispensing texture material typically comprises a container assembly, a valve assembly, and an outlet assembly. The container assembly contains the texture material and a propellant material. The propellant material pressurizes the texture material within the container assembly. The valve assembly is mounted to the container assembly in a normally closed configuration but can be placed in an open configuration to define a dispensing path along which the pressurized texture material is forced out of the container assembly by the propellant material. Displacement of the outlet assembly places the valve assembly in the open configuration. The outlet assembly defines a portion of the outlet path and is configured such that the texture material is applied to the destination surface in an applied texture pattern. 
     The need exists for alternatives to aerosol systems for dispensing of texture materials. 
     SUMMARY 
     The present invention may be embodied as a system for coating a target surface in a desired texture pattern that substantially matches a preexisting texture pattern on the target surface, comprising texture material, a bottle, a spray pump assembly, a resilient member, and a collar member. The bottle contains the texture material. The spray pump assembly comprises a pump housing operatively connected to the bottle, a dip tube extending from the pump housing to the texture material within the bottle, and an actuator member. The resilient member is supported by the pump housing to define an outlet opening. The collar member is supported by the pump housing such that the collar member is movable relative to the resilient member. The resilient member is normally in an undeformed configuration in which the outlet opening defines a first cross-sectional area. Moving the collar member relative to the pump housing causes the collar member to act on the resilient member to deform the resilient member from the undeformed configuration to a deformed configuration in which the outlet opening defines a second cross-sectional area, where the second cross-sectional area is greater than the first cross-sectional area. Displacing the actuator member forces the texture material through the dip tube, out of the bottle member, through the outlet opening, and onto the target surface such that the texture material dries to form a coating in the desired texture pattern. 
     The present invention may also be embodied as a method of coating a target surface in a desired texture pattern that substantially matches a preexisting texture pattern on the target surface comprising the following steps. The texture material is contained within a bottle. A spray pump assembly is operatively connected to the bottle. A resilient member is supported from the spray pump assembly in an undeformed configuration to define an outlet opening having a first cross-sectional area. A dip tube is arranged to extend from spray pump assembly to the texture material contained within the bottle. A collar member is supported for movement relative to the spray pump assembly such that the collar member deforms the resilient member from the undeformed configuration to a deformed configuration in which the outlet opening defines a second cross-sectional area, where the second cross-sectional area is greater than the first cross-sectional area. Selectively moving the collar member relative to the pump housing obtains a desired cross-sectional area between the first cross-sectional area and the second cross-sectional area, inclusive. The spray pump assembly is operated to force the texture material through the dip tube, out of the bottle member, through the outlet opening, and onto the target surface such that the texture material dries to form a coating in the desired texture pattern. 
     The present invention may also be embodied as a system for coating a target surface in a desired texture pattern that substantially matches a preexisting texture pattern on the target surface comprising texture material a bottle for containing the texture material, a spray pump assembly, a resilient tube, and a collar member. The spray pump assembly comprises a pump housing operatively connected to the bottle, a dip tube extending from the pump housing to the texture material within the bottle, and an actuator member. The resilient tube is supported by the pump housing to define an outlet passageway and an outlet opening. The collar member is supported by the pump housing such that the collar member is movable relative to the resilient member. The resilient member is normally in an undeformed configuration in which the outlet opening defines a first cross-sectional area. Moving the collar member relative to the pump housing causes the collar member to act on the resilient member to deform the resilient member from the undeformed configuration to a deformed configuration in which the outlet opening defines a second cross-sectional area, where the second cross-sectional area is greater than the first cross-sectional area. Displacing the actuator member forces the texture material through the dip tube, out of the bottle member, through the outlet passageway, and out of the outlet opening onto the target surface such that the texture material dries to form a coating in the desired texture pattern. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is a side elevation view depicting a first example hand-operated dispensing system of the present invention being used to apply texture material to a target surface; 
         FIG. 1B  is a side elevation view depicting the target surface with texture material applied thereto; 
         FIG. 2  is an exploded view of a first example outlet assembly that may be used by the example dispensing systems described herein; 
         FIG. 3  is a section view of the first example outlet assembly in a first configuration; 
         FIG. 4  is an end elevation view of the first example outlet assembly in the first configuration; 
         FIG. 5  is a section view of a collar member of the first example outlet assembly; 
         FIG. 6  is a section view of the first example outlet assembly in a second configuration; 
         FIG. 7  is an end elevation view of the first example outlet assembly in the second configuration; 
         FIG. 8  is a section view of a second example outlet assembly in a first configuration; 
         FIG. 9  is a section view of the second example outlet assembly in a second configuration; 
         FIG. 10  is a section view of a third example outlet assembly; 
         FIG. 11  is an end elevation view of the third example outlet assembly; 
         FIG. 12  is a side elevation view of a second example hand-operated dispensing system of the present invention; and 
         FIG. 13  is a side elevation view of a third example hand-operated dispensing system of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Referring initially to  FIGS. 1-7  of the drawings, depicted therein is a hand-operated dispensing system  20  for dispensing texture materials. As perhaps best shown in  FIGS. 1A and 1B , the dispensing system  20  is adapted to dispense texture material onto a target surface portion  22  of a wall structure  24 . A main surface portion  26  of the wall structure  24  is coated with existing coating material  28 . In the example depicted in  FIG. 1A , the target surface portion  22  has been repaired, so the existing surface coating material  28  is not present at the target surface portion  22 . 
     While the present invention is of particular significance in the context of repairing a target surface portion such as the example target surface portion  22 , the present invention can be used in other situations. For example, dispensing system  20  can be used to apply texture material to a bare wall surface, or the dispensing system  20  can be used to apply texture material of a second color on top of an existing coating material of a first color. 
     The dispensing system  20  dispenses texture material  30 . The dispensing system  20  comprises a bottle assembly  32  comprising a bottle member  34 , a spray pump assembly  36 , and an outlet assembly  38 . The example spray pump assembly  36  is or may be conventional and comprises a pump housing  40 , pump actuator  42 , pump sleeve  44 , and dip tube  46 . The pump sleeve  44  secures the pump housing  40  to the bottle member  34 , and movement of the actuator member  42  forces the liquid texture material out of the bottle assembly  32  through the dip tube  46  and the outlet assembly  38 . 
     The construction of the dispensing system  20  and formulation of the texture material  30  are such that the dry texture material  30   c  defines a bumpy, variegated surface pattern that substantially matches an existing surface pattern defined by the existing surface coating material  28 . In particular, the texture material  30  is stored within the bottle assembly in a liquid form  30   a  and is dispensed by the pump assembly  36  through the outlet assembly  38  in a spray form  30   b .  FIGS. 1A and 1B  show that the spray of texture material  30   b  is deposited onto the target surface portion  22 , where it dries to form a dry texture material  30   c.    
     The outlet assembly  38  is configured to allow a user of the dispensing system  20  generally to control the size of droplets forming the spray form  30   b  of the texture pattern. The size of these droplets in turn determines the height of the projections and depth of the valleys that determine the texture pattern defined by the dry texture material  30   c.    
     Referring now more specifically to  FIG. 2  of the drawings, the first example outlet assembly  38  will be described in further detail. The first example outlet assembly  38  comprises an outlet member  50 , a resilient member  52 , and a collar member  54 . The outlet member  50  may be secured relative to, rigidly connected to, or integrally formed with the pump housing  40 ; the example outlet member  50  is integrally formed with the pump housing  40 . 
     The outlet member  50  defines a first threaded portion  60 , a plurality (two or more) of finger portions  62  defining distal and proximal cam surfaces  62   a  and  62   b , and a dispensing passageway  64  along which the liquid texture material  30   a  is forced out of the bottle assembly  32 . The outlet member  50  defines a socket portion  66  within the dispensing passageway  64 . A finger slit  68  is formed between each adjacent pair of finger portions  62 . The outlet member  50  is made of a resilient material such that the finger portions  62  can be displaced relative to the first threaded portion  60 . 
     The example resilient member  52  is a hollow tube formed of deformable material that defines an outlet passageway  70  and an outlet opening  72 . The resilient member  52  is configured to engage the socket portion  66  such that the resilient member  52  is supported at least partly within the dispensing passageway  64  and at least partly between the finger portions  62 . 
     A dispensing axis  74  extends along the outlet passageway  70 . Texture material forced out of the bottle assembly  32  travels along the dispensing axis  74  through the dispensing passageway  64  and the outlet opening  72 . 
     The collar member  54  defines a collar passageway  80 , a second threaded portion  82 , a cam ring portion  84 , and a grip surface  86 . The collar member  54  is displaced relative to the outlet member  50  such that finger portions  62  of the outlet member  50  enter the collar passageway  80 . Continued displacement of the collar member  54  causes the first and second threaded portions  60  and  82  to touch each other. At that point, the grip surface  86  may be gripped to rotate the collar member  54  relative to the outlet member  50  to cause the threaded portions  60  and  82  to engage each other such that the collar member  54  moves along the dispensing axis  74  relative to the outlet member  50 . 
     As the collar member  54  moves along the dispensing axis  74  relative to the outlet member  50 , the cam ring portion  84  of the collar member  54  engages the distal cam surfaces  62   a  on the finger portions  62 . Continued rotation of the collar member  54  relative to the outlet member  50  causes the finger portions  62  to move radially inwardly towards the dispensing axis A. As these finger portions  62  move radially inwardly, they deform the resilient member  52  to alter a cross-sectional area of the outlet opening  72 . 
     The altering of the cross-sectional area of the outlet opening  72  is shown by a comparison of  FIGS. 3 and 4 , where the outlet opening  72  is at its maximum cross-sectional area, and  FIGS. 6 and 7 , where the outlet opening  72  is at its minimum cross-sectional area. The cross-sectional area may be at any one of a continuum of values between the maximum and minimum positions. 
     The collar member  54  is thus rotated relative to the outlet member  50  such that the cross-sectional area of the outlet opening  72  is set at a value at which the texture material is dispensed in a desired texture pattern that substantially matches an existing texture pattern of the existing surface coating  28 . 
     Turning now to  FIGS. 8 and 9  of the drawings, depicted therein is a second example outlet assembly  120  that may be used as part of a dispensing system of the present invention. The outlet assembly  120  comprises an outlet member  122 , a resilient member  124 , and a collar member  126 . The second example outlet assembly  120  may be secured relative to, rigidly connected to, or integrally formed with the pump housing  40 ; the example outlet member  122  is integrally formed with the pump housing  40 . 
     The outlet member  122  defines a first threaded portion  130 , a socket portion  132 , and a dispensing passageway  134  along which the liquid texture material  30   a  is forced out of the bottle assembly  32 . 
     The example resilient member  124  defines an outlet passageway  140  and an outlet opening  142 . The example resilient member comprises a base portion  144  and a flange portion  146 . The base portion  144  is sized and dimensioned to secure the resilient member  124  within the dispensing passageway  134 . The outlet passageway  140  defines a dispensing axis  148  along which texture material passes as the texture material is forced out of the bottle assembly  32 . 
     The collar member  126  defines a collar passageway  150 , a second threaded portion  152 , retaining portion  154 , and a grip surface  156 . The collar member  126  is displaced relative to the outlet member  122  such that resilient member  124  enters the collar passageway  150 . Continued displacement of the collar member  126  causes the first and second threaded portions  130  and  152  to touch each other. At that point, the grip surface  156  may be gripped to rotate the collar member  126  relative to the outlet member  122  to cause the threaded portions  130  and  152  to engage each other such that the collar member  126  moves along the dispensing axis  148  relative to the outlet member  122 . 
     As the collar member  126  moves along the dispensing axis  148  relative to the outlet member  122 , the retaining portion  154  of the collar member  126  engages the flange portion  146  of the resilient member  124 . Continued rotation of the collar member  126  relative to the outlet member  122  causes the retaining portion  154  to engage the flange portion  146  to deform the resilient member and thereby alter a cross-sectional area of the outlet opening  142 . 
     The altering of the cross-sectional area of the outlet opening  142  is shown by a comparison of  FIG. 9 , where the outlet opening  142  is at its maximum cross-sectional area, and  FIG. 8 , where the outlet opening  142  is at its minimum cross-sectional area. The cross-sectional area may be at any one of a continuum of values between the maximum and minimum positions. 
     The collar member  126  is thus rotated relative to the outlet member  122  such that the cross-sectional area of the outlet opening  142  is set at a value at which the texture material is dispensed in a desired texture pattern that substantially matches an existing texture pattern of the existing surface coating  28 . 
     Referring now to  FIGS. 10 and 11  of the drawings, depicted therein is a third example outlet assembly  160  that may be used as part of a dispensing system of the present invention. The outlet assembly  160  comprises an outlet member  162  and a collar member  164 . The third example outlet assembly  160  may be secured relative to, rigidly connected to, or integrally formed with the pump housing  40 ; the example outlet member  162  is integrally formed with the pump housing  40 . 
     The outlet member  162  defines a mounting groove  170  and a dispensing passageway  172 . The dispensing passageway is offset from a longitudinal axis  174  of the outlet member  162 . The collar member  164  defines a first collar opening  180 , a second collar opening  182 , a third collar opening  184 , a mounting projection  186 , and a grip surface  188 . The collar member  164  receives a portion of the outlet member  162  such that the mounting groove  170  receives the mounting projection  186 . 
     With the mounting projection  186  in the mounting groove  170 , the collar member  164  is held against inadvertent movement along the longitudinal axis  174  but can rotate about the longitudinal axis  174 . In this configuration, any one of the collar openings  180 ,  182 , and  184  can be aligned with the dispensing passageway. 
     The collar openings  180 ,  182 , and  184  each define a different cross-sectional area. Accordingly, arranging a selected one of the collar openings  180 ,  182 , or  184  such that fluid flowing along the dispensing passageway  172  last flows out of the selected collar opening  180 ,  182 , or  184 . The collar member  164  is thus rotated relative to the outlet member  162  such that the cross-sectional area of the selected collar openings  180 ,  182 , and  184  determines a desired texture pattern in which deposited on the target surface  22  such that the desired texture pattern substantially matches an existing texture pattern of the existing surface coating  28 . 
     Referring now to  FIG. 12  of the drawings, depicted therein is a second example dispensing system  220  constructed in accordance with, and embodying, the principles of the present invention. The second example dispensing system  220  comprises a pump assembly  222 , a hopper  224 , and an outlet assembly  226 . The pump assembly  222  comprises a pump housing  230  and a piston member  232 . 
     The outlet assembly  226  may be any one of the first, second, or third example outlet assemblies  38 ,  120 , or  160  described above. In any case, the outlet assembly may be secured relative to, rigidly connected to, or integrally formed with the pump housing  230 . The example outlet assembly  226  is illustrated as either the first example outlet assembly  38  or the second example outlet assembly  120 , and the outlet member  50  or  122  of either of these assemblies  38  or  120  is integrally formed with the pump housing  230 . 
     Texture material is held in liquid form  30   a  in the hopper  224 . The hopper  224  is connected to the pump housing  230  such that texture material flows into a mixing chamber (not shown) defined by the pump housing  230 . Displacing the piston member  232  relative to the pump housing  230  forces air through the mixing chamber, thereby entraining texture material within the mixing chamber such that the stream of air carries the texture material out of the pump housing  230  in a spray that is deposited onto the target surface  22 . Again, the outlet assembly  226  may be configured to define the cross-sectional area of an outlet opening defined thereby and thereby deposit texture material in a desired texture pattern that substantially matches the existing texture pattern. 
     Referring now to  FIG. 13  of the drawings, depicted therein is a third example dispensing system  250  constructed in accordance with, and embodying, the principles of the present invention. The third example dispensing system  250  comprises a spray gun assembly  252 , a hopper  254 , and an outlet assembly  256 . The spray gun assembly  252  comprises a gun housing  260 , a trigger member  262 , and an air inlet  264 . 
     The outlet assembly  256  may be any one of the first, second, or third example outlet assemblies  38 ,  120 , or  160  described above. In any case, the outlet assembly may be secured relative to, rigidly connected to, or integrally formed with the gun housing  260 . The example outlet assembly  256  is illustrated as either the first example outlet assembly  38  or the second example outlet assembly  120 , and the outlet member  50  or  122  of either of these assemblies  38  or  120  is integrally formed with the gun housing  260 . 
     Texture material is held in liquid form  30   a  in the hopper  254 . The hopper  254  is connected to the gun housing  260  such that texture material flows into a mixing chamber (not shown) defined by the gun housing  260 . Pressurized air introduce into the gun housing  260  through the air inlet  264  forces air through the mixing chamber, thereby entraining texture material within the mixing chamber such that the stream of air carries the texture material out of the gun housing  260  in a spray that is deposited onto the target surface  22 . Again, the outlet assembly  256  may be configured to define the cross-sectional area of an outlet opening defined thereby and thereby deposit texture material in a desired texture pattern that substantially matches the existing texture pattern. 
     The texture material  30  may be conventional, and one example of a texture material to be dispensed using the dispensing systems described herein is described in the following table. 
     General Example of Texture Material Concentrate 
     
       
         
               
               
               
               
             
           
               
                   
                   
               
               
                   
                   
                 FIRST 
                 SECOND 
               
               
                   
                   
                 PREFERRED 
                 PREFERRED 
               
               
                   
                 COMPONENT 
                 RANGE 
                 RANGE 
               
               
                   
                   
               
             
             
               
                   
                 solvent/carrier 
                 30-60% 
                 25-65% 
               
               
                   
                 fillers 
                 40-60% 
                 20-70% 
               
               
                   
                 resin/binder 
                 4.5-5.5% 
                 3-7% 
               
               
                   
                 additives 
                 0.250-0.750% 
                 0.000-1.000% 
               
               
                   
                   
               
             
          
         
       
     
     The example texture material  30  will most likely be water based, and the solvent/carrier component forms the base. In a water based texture material, the solvent/carrier component will be water or a combination of water and a water soluble solvent such as tetrahydrofuran, acetone, methanol, iso-propanol, ethanol, N-propanol, propylene glycol monomethylether, propylene glycol n-propyl ether, diethylene glycol monomethyl ether, diacetone alcohol, ethylene glycol monobutyl ether, N-methyl pyrrolidone, dipropylene glycol methyl ether, diethanolamine, diethylene glycol monethyl ether, diethylene glycol, methyl ethyl ketone, and methyl acetate. 
     The filler component typically comprises clay, talc, calcium carbonate, pigments, and other materials that add body, color, and the like to the dry coating  30   c . The filler component may also comprise one or more thickener materials. Ideally, the texture material  30  is formulated such that it is sufficiently thick to hold its shape when initially applied to the target surface  22  in the liquid form  30   a  but which is thin enough to be dispensed in an acceptable spray pattern in the spray form  30   b  using a spray pump assembly such as the spray pump assembly  36 . 
     One example thickener that meets these requirements is a thickener available from Rohm and Haas under the tradename Accusol 820. The filler component thus may incorporate a thickener such as the Accusol 820 product or its equivalent. One example of a texture material incorporating the Accusol 820 thickener product includes approximately 3.3% by weight of that ingredient. The exact amount of Accusol 820 will depend upon a particular formulation and purpose of the texture material but is typically within a first preferred range of substantially between 2.3% and 4.3% by weight and in any event should be within a second preferred range of substantially between 2% and 10% by weight. 
     The resin binder component is typically a latex material such as is commonly used in coating materials such as texture material or paint. The additives may be biocides, defoamers, dispersants, and the like. 
     The present invention may be embodied in forms other than those described above. The scope of the present invention should thus be determined by the scope of the claims appended hereto and not the foregoing detailed description of the invention.