Abstract:
The handheld spray receptor provides an apparatus which, when used with a supply of a liquid under pressure, dispenses a liquid material in a pattern that is controlled by an inexpensive and disposable actuator. Such actuators are employed as an industry standard part that would be found on any aerosol spray can, and feature small cylindrical actuators that may be easily interchanged, so as to provide varied spray patterns. A purging model provides for a quick and convenient method of purging liquid from the actuator, so as to prevent hardening of liquid material exposed to the atmosphere, and a subsequent clogging of the receptor. When used with a supply of liquid under pressure and access to a propellant, the handheld spray receptor significantly reduces the amount of hazardous waste, in the form of partially consumed aerosol cans, that would otherwise enter landfills or hazardous waste recycling facilities.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a divisional application from application Ser. No. 10/179,088 filed 25 Jun. 2002, now U.S. Pat. No. x,xxx,xxx, the disclosure of which is hereby incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The handheld spray receptor provides an alternative method of dispensing liquids under pressure, as might be alternatively accomplished with an aerosol container, or a traditional spray gun. Traditional aerosol cans often dispense hazardous materials, and when the actuator or vertical valve on an aerosol can becomes clogged, the entire can becomes useless, and is often discarded improperly, creating a hazard. Cleaning out the actuator and vertical valve of an aerosol can is difficult and often ineffective. A purging capability can be approximated with an aerosol can, but requires expensive equipment specially designed, in most instances. 
         [0004]    2. Description of Prior Art 
         [0005]    The most traditional method of selling and dispensing liquid materials is by way of the traditional aerosol can. The propellant utilized in traditional aerosol cans is often hostile to living beings, and as such provides a hazard to the user of the aerosol can, as well as a pollutant to the environment as a whole. Aerosol cans also provide poor economy for viscous liquids. Viscous liquids must be thinned with a material which is often detrimental to the user and the environment, such as paint thinner or methyl alcohol. It is not uncommon for a consumer to receive an aerosol product with 90% thinner, and 10% product, making the aerosol can an expensive method of delivering product. An aerosol can may purge the material in the feed tube and actuator button, by holding the can upside down and depressing the actuator button, but this can cause the propellant to become exhausted, rendering the aerosol can useless, even though there may be additional liquid still in the can. In addition, the actuator button often becomes clogged, causing the remaining liquid to be unusable. Aerosol cans create a major disposal problem, when they become empty, and are hazardous materials that must be properly handled to be safely disposed of. 
         [0006]    A variant of the traditional aerosol can is the aerosol powered foam container, as might be used to dispense shaving cream. These cans typically utilize an actuator that is crimped to the mouth of the can, accompanied by a slot or other large flow opening which releases the material rather than spraying it. U.S. Pat. No. 5,027,986 provides an example of this kind of application. Other mechanisms utilize an extension tube and a piston effect to dispense liquid in a flow, not a spray. U.S. Pat. No. 3,346,194 provides an example of this kind of dispenser. 
         [0007]    Lawn and garden sprayers have been developed which dispense liquid materials under pressure. These are often provided with a compression pump, allowing the operator to pressurize the liquid in the tank, and to release fertilizer, herbicides, or pesticides (or any other liquid that might be useful in gardening) by means of a trigger mechanism. U.S. Pat. No. 5,307,995 discloses an enhanced method of attaching a hose to such a sprayer. U.S. Pat. No. 6,278,837 discloses a sprayer with a traditional vertical action valve assembly. Inventions directed to dispensing personal care products perform similar functions. U.S. Pat. No. 3,190,502 discloses an invention that will dispense shampoo in a commercial shop, such as a beauty salon or a barber shop. A fixed electrical pump is used to create pressure on the tank of liquid to be dispensed, and the handheld receptor creates a flow of shampoo, and not a spray of material. 
         [0008]    Handheld pump sprayers are available to dispense insecticides, such as the spray pumps that come attached to ant or roach poison products sold in hardware and lawn and garden stores. The dispensed material is typically carried in one hand, and the other hand dispenses materials by squeezing the handle in a repeated fashion, so as to cause the liquid to be dispensed in a spray or a single stream. Such systems have also been developed to dispense cooking oil, or other such viscous liquids. U.S. Pat. No. 5,718,383 discloses a handheld pumping mechanism attached to a feed hose, so that vegetable oil may be sprayed on a cooking surface. The liquid is not under pressure, and the operator provides the mechanical energy required to operate the hand pump, thereby controlling the amount of material dispensed. 
         [0009]    A traditional spray-gun, as might be utilized to spray paint, utilizes an air compressor to provide pressure, and typically features a container into which the liquid to be sprayed is placed. Some spraying systems have been developed specifically for dispensing a measured amount of material from an aerosol can. U.S. Pat. No. 5,427,281 utilizes a reservoir onto which an vertical action valve assembly is attached. Both a traditional spray-gun and a device with a reservoir have the problem of cleaning out the residual material upon last use of the day. When used to dispense materials that harden when exposed to air, such as paint, both the reservoir and the actuator must be purged of material. 
         [0010]    U.S. Pat. No. 5,170,939 discloses a handheld paint sprayer which does not contain a reservoir, but which provides a special valve which directs compressed air through the spray actuator while insuring that no compressed air causes “backflow” of the liquid intake hoses. Like many other actuator assemblies, cleaning of the actuator and valve assemblies is time consuming and complicated. 
         [0011]    The cleaning of actuators, also referred to as nozzles, can be accomplished with specialized and dedicated equipment. U.S. Pat. No. 6,355,114 B1 demonstrates an apparatus for forcing solvent through one or more nozzles, and capturing the spray for reuse, or for disposal. When portability is not required, there are a number of inventions which provide purging capabilities. U.S. Pat. Nos. 5,803,109 and 6,116,261 are examples of mechanisms employed in automated paint application systems, as might be found in an automotive assembly plant. These systems employ complex automation to engage the purge cycle, and are integrated into a factory&#39;s equipment. 
         [0012]    Large industrial paint systems, which are designed to change the color of paint applied on a frequent basis, often include a purging capability. U.S. Pat. Nos. 3,981,320; 4,232,055; 5,072,881; 3,240,225; and 3,716,191 are examples of large industrial systems designed with purge capabilities. The purge capability is included to permit a single nozzle or set of nozzles to be supplied with different colors of paint, without disassembling the equipment for cleaning. 
         [0013]    Systems designed to dispense special materials, such as powder paint, also employ purging systems. U.S. Pat. Nos. 6,112,999 and 6,315,214 provide examples of systems that dispense special paints, and employ a purging capability. Specialized amine-assisted systems disclosed in U.S. Pat. No. 4,862,196 also employ purging systems to clean the nozzle of the mechanism. 
         [0014]    The prior art provides solutions for the casual consumer, such as a typical homeowner, and for the major industrial factory. The consumer on a shop floor, such as a maintenance depot, finds aerosol cans to be hazardous, ineffective, wasteful, and expensive. A simple handheld receptor, made from standard parts or easily manufactured parts, has not been available to a facility that is otherwise forced to use many aerosol cans, or expensive equipment that is not cost effective. Such a handheld receptor is the object of this invention, through a model that dispenses a liquid which is not prone to clog the nozzle on the actuator, as well as a model that provides a simple purging mechanism, for use with paints and other liquids which have a tendency to clog the actuator. 
       SUMMARY OF THE INVENTION 
       [0015]    The invention features a handheld body incorporating an actuator that would be found on any aerosol spray can. By utilizing a standard part incorporated in aerosol spray cans, maintenance costs and manufacturing costs are minimized. In one embodiment, a purge capability is provided so as to preserve the usefulness of the actuator by blasting out any material that might harden when contact is made with the atmosphere, such as when paint is dispensed. Different spray patterns are easily achieved by replacing the cylindrical actuator button component of the spray actuator. 
         [0016]    One of the main advantages of the invention is the reduction of discarded standard aerosol cans, and the hazardous material they often contain. When traditional aerosol cans clog, either due to the actuator clogging with dirt or dried liquid, such as paint, or due to the vertical valve clogging—the consumer often discards the can and whatever contents remain in the can. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]      FIG. 1  shows a perspective view of the preferred embodiment, viewed from a point above, to the side, and to the front of the invention. 
           [0018]      FIG. 2  shows a perspective of an explosion view of the parts that make up the preferred embodiment. 
           [0019]      FIG. 2   a  shows a top view of the preferred design for the insert. 
           [0020]      FIG. 2   b  shows a perspective view of the preferred design for insert. 
           [0021]      FIG. 3  shows a cross section explosion view of the invention, taking a cross section as viewed from the front of the invention. 
           [0022]      FIG. 4  shows a cross section of the assembled invention, excluding the pistol grip and the intake tubing attachment apparatus. 
           [0023]      FIG. 5  shows a cross section viewed from the front, prior to the insertion of plugs. 
           [0024]      FIG. 6   a  shows a view from the side, prior to the insertion of plugs. A view of the other side is symmetrical and identical. 
           [0025]      FIG. 6   b  shows a view from the top, prior to the insertion of plugs. 
           [0026]      FIG. 6   c  shows a view from the bottom, prior to the insertion of plugs. 
           [0027]      FIG. 7   a  shows a needle valve assembly in the closed position. 
           [0028]      FIG. 7   b  shows a needle valve assembly in the open position. 
           [0029]      FIG. 8  shows the needle valve assembly with a detente in place, to prevent the inadvertent removal of the needle valve stem from the valve. 
           [0030]      FIG. 9  shows an embodiment of the invention which has but one inlet. 
           [0031]      FIG. 10  shows a cross section of the body of the simplified embodiment with one inlet. 
           [0032]      FIG. 11  shows a perspective isometric of the simplified embodiment of the invention, to include the grip assembly. 
           [0033]      FIG. 12  shows a perspective explosion view of the preferred embodiment, to include the grip assembly and intake attachment assemblies. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0034]    The preferred embodiment of the invention is shown in  FIG. 1 . The handheld receptor  1  features a pistol handle assembly  2  which has a pistol handle trigger  3 , which, when operated with the index finger of an operator presses the actuator  12  downward, releasing a spray of material dispensed by the handheld receptor  1 . A cylindrical shaped receptor body  5  utilizes a needle valve assembly  6  on opposite sides to control the flow of propellant entering through an inlet propellant tubing  8  through a tubing connector assembly  7 , or controls the flow of dispensed liquid fed to the handheld receptor  1  through the dispensing liquid tubing  9  through a tubing connector assembly. An valve locking ring  4  holds the vertical action valve assembly to the receptor body  5 . Two flat surfaces  26  are provided to assist in securing the cylindrical receptor body  5 , by means of a wrench or vise, so as to tighten the threaded tubing connector assemblies  7  to the receptor body  5 . In the preferred embodiment the pistol handle assembly  2  is a commercially available product constructed of plastic, the vertical action valve assembly  11  is a standard part as would be employed in the manufacturing of traditional aerosol spray cans, the seals  13 ,  16  are of a material appropriate for the liquid being dispensed. For dispensing paint, a butyl material is preferred; for brake cleaner and penetrant, a buna seal is preferred; Teflon works well for many other liquids, and rubber seals are appropriate for some liquids. The tubing  8 ,  9  is a commercially rated Teflon FEP (fluorinated ethylene propylene), and the remaining parts are machined aluminum. Any material that is either machinable or moldable could be employed to construct the handheld receptor  1 , e.g. plastic, brass or stainless steel. 
         [0035]    The purging model of the handheld receptor  1  permits the operator to close the needle valve assembly  6  that provides a flow of liquid dispensed, such as paint, and by opening the opposite needle valve assembly  6 , force air or a propellant through the vertical valve assembly  11  and actuator  12  thereby clearing any material from the vertical valve assembly  11  and the actuator  12 , thereby eliminating the need to clean the vertical valve assembly  11  and the actuator  12 . When the handheld receptor  1  is used in conjunction with a tank that dispenses liquid under pressure, using gas compressed to serve as a propellant, the two feed lines to the handheld receptor  1  provide an integrated solution. 
         [0036]      FIG. 2  depicts an exploded view of the handheld receptor  1 , without the pistol handle assembly  2 . A receptor body  5  incorporates an vertical action valve assembly  11  which provides a actuator  12  for dispensing liquids. An insert  10  provides a ridge for attaching the pistol handle assembly  2 . 
         [0037]    The insert  10  and vertical action valve assembly  11  are held in place with the valve locking ring  4 . The receptor body  5  may be held stationary by means of two parallel flat surfaces  26  secured with a traditional wrench or vise, permitting the tubing connector assemblies  7  to be secured by means of a threaded end to the receptor body  5 . The valve locking ring  4  should be hand tightened. Two tubing connector assemblies  7  provide for the secure attachment of tubing that supplies propellant for purging the vertical valve assembly  11  and actuator  12 , and liquid to be dispensed through the actuator  12 . Needle valves comprise a needle valve seal  13  that prevents leakage from the receptor body  5 , a needle valve seat  14 , a detente pin  15  which prevents the needle valve stem  17  from being removed completely from the needle valve seat  14 , a needle valve stem seal  16  that prevents leakage from the needle valve seat  14 , and the needle valve stem  17 . 
         [0038]      FIG. 2   a  shows a top view of the insert  10 , showing two straight edges  10   a  which are parallel and opposing to one another, so as to provide a lip for attaching an optional pistol handle assembly  2 . When inserted, the pistol handle assembly  2  is inserted into the elongated opening defined on the sides by the two parallel edges on the insert  10 , and once inserted, the pistol handle assembly is twisted a quarter turn so that the pistol handle assembly is pointed in a direction that is perpendicular to the two parallel edges in the insert  10 . 
         [0039]      FIG. 2   b  shows a perspective view of the insert  10 . with a cross section selected from a point on the insert  10  that defines the end of the slot into which the optional pistol grip assembly  2  would be first inserted, or from which the pistol grip assembly  10  would be removed. In the preferred embodiment of this insert design, the outer diameter is 1.15 inches, the diameter of the inner circular opening is one inch, the straight edges are eight tenths of an inch apart, and the insert is 0.025 inches thick. 
         [0040]      FIG. 3  depicts a cross-section, exploded view of the handheld receptor  1 , without the pistol handle assembly  2 . A receptor body  5  incorporates an vertical action valve assembly  11  which provides a actuator  12  for dispensing liquids. An insert  10  provides a ridge for attaching the pistol handle assembly  2 . The insert  10  and vertical action valve assembly  11  are held in place with the valve locking ring  4 . Valves comprise a needle valve seal  13  that prevents leakage from the receptor body  5 , a needle valve seat  14 , a detente which prevents the needle valve stem  17  from being removed completely from the needle valve seat  14 , a needle valve stem seal  16  that prevents leakage from the needle valve seat  14 , and the needle valve stem  17 . Two threaded tubing connector receptors  18  permit the attachment of tubing connector assemblies  7 , which are shown in  FIG. 2 . 
         [0041]      FIG. 4  depicts a cross section of an assembled handheld receptor  1 . Two threaded tubing connector receptors  18  permit the attachment of tubing connector assemblies  7 , which are shown in  FIG. 2 . A receptor body  5  incorporates an vertical action valve assembly  11  which provides a actuator  12  for dispensing liquids. The vertical action valve assembly  11  is held in place with the valve locking ring  4 . Two valve assemblies  6  provide control of the liquid to be dispensed and the purging gas. 
         [0042]      FIG. 5  depicts a cross section of a receptor body  5  with a number of bores that facilitate the flow of liquid or purging gas within the receptor body  5 . These bores are created with a drill or other removal tool, or are incorporated into a mold to prevent material from filling the spaces. Two valve access bores  19  are created from the top of the receptor body  5 , stopping when they reach the feed bore  21 . The feed bore  21  traverses the receptor body  5  from one side to the other, passing through a point in the center of the cylindrical receptor body  5  when viewed from the top. Two smaller valve bores  20  create a channel for material to flow from an open needle valve assembly  6  through the feed bore  21  and into the cavity substantially filled by the vertical action valve assembly  11 . Two transfer bores  22  are created by drilling from the bottom of the receptor body, in two parallel paths, and carry material from the bottom of the receptor body  5  to the valve assemblies  6 . Two inlet traverse bores  23  are produced by drilling from the outside surface of the cylindrical receptor body, stopping when they reach the transfer bore  22 . Two connector bores  24  are made from the bottom surface of the receptor body  5 , stopping when they reach the inlet transverse bore  23 . The connector bores  24  are enlarged and machined to form a threaded tubing connector receptor  18  for the liquid to be dispensed and the purging gas. Tapered plugs are inserted into the various bores in order to form a receptor body  5  as depicted in  FIG. 4 . The tapered plugs are trimmed to a length that will not impede any right angle flows of liquid or gas within the receptor body  5 , and are pressed in place with a machine press that exerts three thousand pounds per square inch of pressure upon each plug. 
         [0043]      FIGS. 6   a ,  6   b , and  6   c  show a side, top, and bottom view of the receptor body  5 .  FIG. 6   a  shows a side view in perspective, and depicts the feed bore  21  and one of the inlet transverse bores  23 . Both the feed bore  21  and the inlet transverse bores  23  are plugged with tapered plugs, inserted under pressure.  FIG. 6   b  shows a top view, and depicts the connector bores  24  prior to plugs inserted.  FIG. 6   c  shows a bottom view of the receptor body  5 , and shows the threaded tubing connector receptors  18  that are enlarged after the connector bores  24  are created. The transfer bores  22  are machined and then plugged with tapered plugs. The two flat surfaces  26  are depicted, which permit the cylindrical receptor body  5  to be firmly held with a wrench or vise. 
         [0044]      FIGS. 7   a  and  7   b  show the needle valve assembly  6  in an open and closed position.  FIG. 7   a  depicts the needle valve assembly  6  in a closed position. The needle valve assembly  6  is placed in this position by turning the needle valve stem  17  clockwise until the needle valve stem  17  seats firmly in the needle valve seat  14 . A needle valve stem seal  16  prevents leakage of the controlled material from the needle valve assembly  6 .  FIG. 7   b  shows the needle valve assembly  6  in an open position. The needle valve assembly  6  is places in this state by turning the needle valve stem  17  in a counter-clockwise direction. 
         [0045]      FIG. 8  shows the needle valve assembly  6  in an open position, wherein the needle valve stem  17  is prevented from disengaging from the needle valve seat  14  by means of a detente pin  15  which restricts the path of the needle valve stem  17 . A valve transfer bore  25  permits the flow of material to leave the needle valve assembly  6  when the needle valve assembly  6  is in an open position. 
         [0046]      FIG. 9  depicts the simplest embodiment of the handheld receptor  1 . A receptor body  5  incorporates an vertical action valve assembly  11  held in place by an valve locking ring  4 .  FIG. 10  depicts the receptor body  5  for this minimal implementation, with a threaded tubing connector receptor  18  shown that provides a liquid to be dispensed which does not require that the actuator  12  be purged. A solvent, for example, will evaporate and not clog the actuator  12 , if left in the actuator  12  after use. 
         [0047]      FIG. 11  depicts a non-purging version of the handheld receptor  1 . An optional pistol handle assembly  2  is attached to the handheld receptor  1  by means of an insert  10 . The insert  10  and vertical action valve assembly  11 , which includes a actuator  12 , and is attached to the receptor body by means of an valve locking ring  4 . A tubing connector assembly  7  mechanically attaches a tubing supplying a liquid under pressure to the handheld receptor  1 . Two parallel flat edges provide a means of firmly gripping the receptor body  5  when the valve locking ring  4  is tightened. 
         [0048]      FIG. 12  depicts a perspective isometric view of the preferred embodiment, with the optional pistol handle assembly  2  in place. A receptor body  5  incorporates an vertical action valve assembly  11  which provides a actuator  12  for dispensing liquids. An insert  10  provides a ridge for attaching the pistol handle assembly  2 . The insert  10  and vertical action valve assembly  11  are held in place with the valve locking ring  4 . The receptor body  5  may be held stationary by means of two parallel flat surfaces  26  secured with a traditional wrench or vise. Two tubing connector assemblies  7  provide for the secure attachment of tubing that supplies propellant for purging the actuator  12 , and liquid to be dispensed through the actuator  12 . Valves comprise a needle valve seal  13  that prevents leakage from the receptor body  5 , a needle valve seat  14 , a detente which prevents the needle valve stem  17  from being removed completely from the needle valve seat  14 , a needle valve stem seal  16  that prevents leakage from the needle valve seat  14 , and the needle valve stem  17 .