Abstract:
Disclosed are manifold assemblies for use in automated sprayers. The manifold assemblies provide passageways for cleaning fluid, venting air if venting is needed, and drainage fluid. They also provide a mount for a motor and a pump chamber. There are also check valves retained in the manifold assemblies to ensure that the flows are in the proper direction.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     Not applicable. 
     STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     BACKGROUND OF THE INVENTION 
     This invention relates to an apparatus for automatically spraying an area such as a bath or shower enclosure. More particularly, it relates to manifold structures for use therewith. 
     There are a number of devices that have been developed for spraying an area. For example, U.S. Pat. No. 7,021,494 describes a device for spraying the walls and doors of bath and shower enclosures with a cleaning solution in an automated fashion. This device incorporates a pump for extracting liquid from a storage reservoir and ejecting it through a nozzle housed in a rotating turret. 
     Various tubing and connections are required to mount and link the pump to its source and outlet, permit appropriate air venting, avoid unwanted backflow, accommodate the motor and pump, and link to a nozzle rotating system. All of this must be achieved while avoiding leakage of water into the device from the surrounding shower environment and other fluid leaks at the various internal connections. Requiring numerous parts that must be separately formed and assembled can increase the costs associated with the device, especially from the standpoint of increasing manufacturing costs of the components, labor costs relating to assembling the device, and quality control costs (e.g., checking for leakage at the joints between the parts). 
     In U.S. Pat. No. 5,577,638 there was disclosed a bottom pouring pot reservoir whose outflow and venting were controlled by a housing that accommodated some of the valving. While this approach addressed some of the above issues, it still was somewhat complicated (and thus costly) to manufacture, and further did not accommodate a motor or pumping apparatus (as distinguished from just using gravity flow). 
     U.S. Pat. No. 3,386,472 showed the use of one type of clamshell construction for accommodating various inlets and valving for use in a gas chromatography context. However, again, there was no teaching of how to accommodate a motor or pumping apparatus. 
     Accordingly, there still exists a need in the art for an improved assembly structure for internal portions of an automated sprayer that incorporates a motor or pumping apparatus. 
     SUMMARY OF THE INVENTION 
     The invention provides a manifold assembly suitable for use in an automated sprayer. This type of sprayer delivers fluid (e.g. a cleaning fluid) from a reservoir to a spray nozzle. 
     The manifold assembly has a housing having a fluid inlet passage, a fluid outlet passage, and a motor supported by the housing and being suitable to be operatively linked to a pump. In the most preferred form, the housing also has an air inlet and an air outlet. 
     In other embodiments the housing can have a stand for supporting the motor, there can be a pump mounted in the manifold assembly linked to both the fluid inlet passage and fluid outlet passage, the pump can be operatively linked to the motor, and there can be a check valve positioned in the manifold assembly. 
     Hence, a single manifold assembly can provide a centralized unitary structure for linking the key operational components of such a sprayer. Further, in some sprayers it is desirable to provide an additional drainage passage for fluid that may accumulate near the reservoir. If so, the unitary structure can also accommodate that. A drainage passageway can be provided for carrying drainage fluid through the manifold assembly without passing through the fluid inlet passage or fluid outlet passage. 
     In other forms, the housing can have a first housing part and a second housing part that have been coupled together. Also, there can be a gasket sandwiched between the first housing part and the second housing part, and a pump chamber integrally formed in at least one of the first housing part and the second housing part. 
     Various means may be used to link the housing parts. For example, they could be welded together by induction welding and/or ultrasonic welding. Alternatively, they could be screwed or bolted together, or clipped together. 
     Various embodiments of the invention provide varied important advantages. For example, they reduce the number of parts required to achieve the functions of an automated sprayer, they reduce assembly costs and complexity, they reduce the risk of leaks, and they provide the opportunity to use more compact designs. 
     These and other advantages of various embodiments of the present invention will be apparent from the discussion below and the drawings. Of course, the following are merely the preferred embodiments. The claims should be looked to in order to more fully appreciate the scope of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front, right perspective view of an automated sprayer incorporating the present invention; 
         FIG. 2  is a top view thereof; 
         FIG. 3  is a partially exploded view thereof; 
         FIG. 4  is a further exploded view of a portion thereof; 
         FIG. 5  is a rear upper perspective view of a manifold portion thereof; 
         FIG. 6  is a frontal upper perspective view, in exploded form, of the manifold shown in  FIG. 5 ; 
         FIG. 7  is a bottom exploded view of the manifold assembly shown in  FIG. 5 ; 
         FIG. 8  is a sectional view taken along line  8 - 8  of  FIG. 1 ; 
         FIG. 9  is an exploded view of an alternative manifold; and 
         FIG. 10  is an exploded view of another alternative manifold. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Turning first to  FIGS. 1-3 , there is shown an automated sprayer  10  having a manifold  12 . The manifold facilitates the delivery of a cleaning fluid from a reservoir to a nozzle sprayer. 
     Apart from the manifold feature, much of the preferred automated sprayer  10  is similar to a sprayer of U.S. Pat. No. 7,021,494, which is hereby incorporated by reference as if fully set forth herein. 
     The automated sprayer  10  includes a body  14  coupled to a hanger  16 . While the hanger  16  could take many forms, here it is shown as having a support  18  secured to a bracket  20  extending from the sprayer body  14 . There is also a curved hook  22  formed at the upper end of the hanger  16  to allow the automated sprayer  10 . In any event, the purpose of the hanger is to secure the sprayer on a shower pipe or the like (not shown). In one form there can be a sprayer leg  24  protruding backward from the sprayer body  14  to rest against the shower enclosure and to thereby provide the automated sprayer  10  additional stability during operation. 
     The sprayer body  14  includes an upper sprayer body  44  and a lower sprayer body  46  that combine to form the overall sprayer body  14 . The upper sprayer body  44  includes an upper flange  26  that defines a well  28 . A fluid reservoir  30 , for example a bottle, (shown in dashed lines in  FIG. 1 ) is inverted and placed into the well  28 . As seen in  FIGS. 1 ,  2  and  8 , a piercing post  32  extends up from a reservoir interface assembly  33 , enters the fluid reservoir  30 , and ultimately directs a cleaning fluid  34  to the bottom nozzle  36 . The nozzle  36  is housed in a rotating turret  38  that extends from the base of the sprayer body  14 . The nozzle assembly may be as shown, or may have other single-piece or multi-piece structures. 
     The automated sprayer  10  is activated and adjusted via buttons  40  protruding from the front of the sprayer body  14 . For example, the automated sprayer  10  can provide a warning chime and then, after a time delay, expel fluid  34  from the nozzle  36  as the turret  38  rotates for a pre-determined, or user selected, amount of time. 
     Turning now to  FIGS. 3 ,  4  and  8 , the lower sprayer body  46  includes a compartment  48  sized to house a power supply  50  (e.g., batteries) for powering a motor  52 . A cover  54  releasably secures the power supply  50  in the compartment  48  and prevents water or other fluid from entering the compartment  48 . The motor  52  is preferably a direct current electric motor capable of operating on standard AA or AAA batteries. 
     A gear train is housed within the sprayer body  14  to both rotate the turret  38  and to drive a pump  56  (best shown in  FIGS. 4 and 8 ). The motor  52  includes a drive shaft  58  coupled to a drive gear  60 . A pump gear  62  is adjacent the drive gear  60  and includes drive gear teeth  64  that engage the drive gear  60 . The pump gear  62  further defines a pump gear axis  66  about which the pump gear  62  rotates on a pin  67 . 
     The pump gear  62  includes intermediate gear teeth  68  that engage and drive an intermediate gear  69  that in turn drives a turret gear  70 . The intermediate gear  69  includes pump gear teeth  71  that engage the intermediate gear teeth  68  of the pump gear  62 , and turret gear teeth  73  that engage and drive the turret gear  70 . The intermediate gear  69  rotates about a second pin  75  defining an intermediate gear axis  77 . 
     The turret gear  70  engages the turret post  72  and coupled nozzle  36  to rotate the turret  38  during operation. The turret post  72  has a pair of arms  79  that engage mating arms  81  formed in the turret  38 . The turret post  72  also includes a central opening  83  for receiving the nozzle  36  at a nozzle port  85 . The turret post  72  is in fluid communication with the manifold  12 . The turret post  72  extends partially into the lower sprayer body  46  through an opening  87 . A lower valve seal  89  is sandwiched between the lower sprayer body  46  and the turret gear  70 . The turret post  72  continues to extend through an opening  91  in a seal holder  93  and engages an upper valve seal  95  adjacent the manifold  12 . 
     Returning to the pump gear  62 , the pump gear  62  includes a lobed portion  74  (shown in  FIG. 8  in cross-section) generally offset from the gear axis  66 . As the pump gear  62  rotates about the gear axis  66 , the lobed portion  74  communicates with a pump  56 . 
     Specifically, the pump  56  includes a pump chamber  78  in which a piston  80  rides. The pump chamber  78  is preferably integrally molded into a second housing part  94 , but may be formed integral to a first housing part  92 , or a combination of the first housing part  92  and the second housing part  94  (described below). 
     A seal  82  prevents fluid  34  from leaking around the piston  80  during operation. A connecting rod  84  is pivotally coupled to the piston  80  at one end and includes a bearing  86  at the opposite end. The lobed portion  74  of the pump gear  62  rides along an interior surface  88  of the bearing  86  to alter the rotational movement of the pump gear  62  about the gear axis  66  to essentially linear movement of the piston  80  within the pump chamber  78 . The movement of the piston  80  draws in and expels fluid  34  from the pump chamber  78  (described below). The pump  56 , drive gear  60 , pump gear  62 , intermediate gear  69 , turret gear  70 , and other drive/pump components are preferably made of plastic, such as nylon. 
     With continued reference to  FIGS. 4 and 8 , and additional reference to  FIGS. 5-7 , the manifold  12  includes a housing  90  having a first housing part  92  and a second housing part  94 . In the preferred example embodiment, the housing  90  is made from two portions that are coupled to form an essentially leak-free seal there between. However, the housing  90  may be a contiguous body having the appropriate passageways formed therein during manufacturing. 
     For example, depending upon the complexity of the housing  90 , the housing  90  may be made by investment casting in which the internal passageways are generally formed during manufacturing. The housing  90  is preferably made of two or more parts to minimize the complexity and manufacturing costs. Additionally, as will be described, several components are secured within the housing  90 , thus access to the internal components is beneficial during manufacturing and for replacement/repair purposes. 
     The second housing part  94  includes an integrally molded pump chamber  78  and motor support  96 . The motor support  96  preferably includes a collar  98  sized to receive and stabilize the motor  52 . A drive shaft opening  100  is formed in the motor support  96  to allow the drive shaft  58  to extend through and drive the gear train. The motor support  96  may be made in a variety of configurations as required by the motor  52  it is intended to restrain and the required orientation. For example, the motor  52  may be mounted such that the drive shaft  58  is essentially parallel with the pump chamber  78 . 
     The motor support  96  may be configured to support a motor  52  in any number of orientations and configurations that are within the scope of the present invention. Additionally, the motor support  96 , while shown as being a portion of the second housing part  94 , may be formed as part of the first housing part  92 , or may be formed by some combination of the first housing part  92  and the second housing part  94 . 
     A turret collar  102  extends from the second housing part  94  to engage the seal holder  93  that is coupled to the second housing part  94 , for example, with fasteners (not shown) that extend partially through the standoffs  104  and into the receiving holes  106 . The second housing part  94  further includes a unshaped support  108  that receives a controller  110  that monitors the buttons  40  and activates the automated sprayer  10 . 
     The housing  90  includes several passageways that direct fluid  34  between various portions of the automated sprayer  10 . A first passageway  112  directs fluid  34  from the fluid reservoir  30 , through the housing  90 , and ultimately to the nozzle  36  where it is expelled into the ambient environment before reaching the surrounding enclosure surfaces (not shown). As the fluid  34  is removed from the fluid reservoir  30 , the second passageway  114  allows ambient air to travel from the ambient environment, through the housing  90 , and into the fluid reservoir  30 , thus preventing a vacuum from forming in the fluid reservoir  30 . The third passageway  116  provides fluid communication between the well  28  and a drain outlet  118  to allow excess fluid  34  accumulated in the well  28  during a fluid reservoir  30  change to be expelled from the well  28  to the ambient environment. 
     With respect to the first passageway  112 , seating the fluid reservoir  30  (e.g., bottle) into the well  28  depresses a spring-loaded check valve  120  in the reservoir interface assembly  33  that allows the fluid  34  to flow through the piercing post  32  at a fluid inlet  122 . The reservoir interface assembly  33  is preferably coupled to the upper sprayer body  44  via receiving holes  35  formed in the upper sprayer body  44  and screws (not shown), best shown in  FIG. 8 . 
     The fluid  34  flows past the check valve  120  and though a fluid chamber  124  formed in the upper sprayer body  44 . The fluid  34  continues to the fluid inlet port  126  of the first passageway  112  that is formed in the first housing part  92 . A first pump check valve  129  includes a first pump valve needle  128  and a first pump valve case  130  that allows the fluid  34  to only flow downstream of the fluid reservoir  30 . 
     The fluid  34  is drawn into the first passageway  112  as the piston  80  is partially withdrawn from the pump chamber  78 . As the motor  52  continues to rotate the drive shaft  58 , the piston  80  then reduces the available volume in the pump chamber  78  causing the fluid  34  to be expelled downstream through the first passageway  112  due to the first pump valve needle  128  preventing the fluid  34  from flowing upstream back into the fluid reservoir  30 . 
     The fluid  34  is directed through the first passageway  112  formed in the second housing part  94  past a second pump check valve  133  having a second pump valve needle  132  and a second pump valve case  134 . The fluid  34  is then directed by the pressure differential created by the pump  56  through the first passageway  112  to a filter assembly  135  and then to a fluid outlet port  136 . The fluid outlet port  136  is coupled to the turret post  72 . The fluid  34  is directed through the central opening  83  and then is expelled from the nozzle  36 . 
     The first passageway  112  includes a first channel  138  formed in the first housing part  92  and a mating second channel  140  formed in the second housing part  94 . Optionally, the first passageway  112  may be all in one housing part. Coupling the first housing part  92  and the second housing part  94  essentially aligns the first channel  138  and the second channel  140 , thereby defining a portion of the first passageway  112 . The first passageway  112  is preferably sized to allow a sufficient amount of fluid  34  to flow from the fluid reservoir  30  through the passageway  112  and out the nozzle  36 . 
     With respect to the second passageway  114 , as fluid  34  is withdrawn from the fluid reservoir  30 , ambient air is drawn through the second passageway  114  and into the fluid reservoir  30 . A vent valve assembly  142  (best shown in  FIG. 4 ) includes a vent valve  144 , a diaphragm  146 , a lower o-ring  148 , and an upper o-ring  150 . The vent valve assembly  142  allows ambient air to enter an air inlet port  141  formed in the second housing part  94  and travel through the second passageway  114  into the fluid reservoir  30 . 
     Specifically, the first housing part  92  includes a third channel  152  formed therein and the second housing part  94  includes a fourth channel  154  integrally formed therein. Again, coupling the first housing part  92  and the second housing part  94  aligns the third channel  152  and the fourth channel  154  to define a portion of the second passageway  114 . Ambient air is drawn in the air inlet port  141  and directed through the second passageway  114  to an air outlet port  155  protruding from the first housing part  92 . The ambient air is then directed through an air chamber  156  formed in the upper sprayer body  44  where it can be expelled into the fluid reservoir  30  via air outlet  158  formed in the piercing post  32 . Thus, the appropriate amount of ambient air is directed into the fluid reservoir  30  as fluid  34  is expelled from the automated sprayer  10 . 
     With respect to the third passageway  116 , when replacing a nearly empty fluid reservoir  30 , a small amount of fluid  34  may initially pool in the well  28 ; however, the third passageway  116  provides a fluid  34  passage between the well  28  and the ambient environment to allow this excess fluid  34  to drain. A drain chamber  160  is formed in the upper sprayer body  44  and leads to a drain inlet  162  that protrudes from the first housing part  92 . The drain inlet  162  leads to the third passageway  116  that is integrally formed in the first housing part  92  and the second housing part  94  by a fifth channel  164  formed in the first housing part  92  and a mating sixth channel  166  formed in the second housing part  94 . 
     As with the first passageway  112  and the second passageway  114 , coupling the first housing part  92  and the second housing part  94  essentially aligns the fifth channel  164  and the sixth channel  166 , thereby defining a portion of the third passageway  116 . The excess fluid  34  is directed through the third passageway  116  downstream to the drain outlet  118  that protrudes from the second housing part  94  where it is expelled from the automated sprayer  10  through a drain hole (not shown) formed in the lower sprayer body  46  to the ambient environment. 
     The ancillary components of the manifold  12  may be formed integrally with the first housing part  92  and/or the second housing part  94 . For example, the first housing part  92  may be directly coupled to the reservoir interface assembly  33 , or alternatively, the reservoir interface assembly  33  may be formed integrally with the first housing part  92 . 
     A gasket  170  is seated between the first housing part  92  and the second housing part  94  to prevent fluid  34  from leaking when the first housing part  92  and the second housing part  94  are coupled. The gasket  170  includes a plurality of beads  172  that seat in mating grooves  174  formed in the first housing part  92  and the second housing part  94  about the perimeter of the first passageway  112 , second passageway  114 , and third passageway  116 . 
     With specific reference to  FIG. 8 , the gasket  170  is shown compressed between the first housing part  92  and the second housing part  94 . The beads  172  of the gasket  170  are shown seated in the grooves  174 , thus providing a seal between the various passageways  112 ,  114 ,  116 . Additionally, a seal is formed in the gasket  170  proximate the fluid inlet port  126  of the first passageway  112 , again to prevent leakage as the fluid  34  flows through the automated sprayer  10 . The gasket  170  is preferably made of an elastomeric material or other resilient material, such as, rubber and plastic, which are chemically resistant to the fluid  34  cleanser used in the automated sprayer  10 . 
     The first housing part  92  and the second housing part  94  are preferably coupled by a series of resilient clips  176  and tabs  178  (shown most clearly in  FIG. 5 ). In the preferred embodiment, the clips  176  are integrally formed with the first housing part  92  and the tabs are integrally formed with the second housing part  94 . As the first housing part  92  and the second housing part  94  are mated, the resilient clips  176  deflect as they ride up the tabs  178  and spring back to releasably engage the tabs  178 . 
     It is contemplated that the clips  176  and tabs  178  may be on either of the first housing part  92  and the second housing part  94 , or both. Additionally, a series of self-tapping screws (not shown) are preferably used to clamp the first housing part  92  and second housing part  94 . The screws extend through a plurality of mounting holes  180  formed through the first housing part  92  and self-thread into a plurality of receiving holes  182  formed in the second housing part  94 . Again, the number, location, and orientation of the screws, mounting holes  180 , and receiving holes  182  may be altered to various locations and configurations that remain within the scope of the present invention. 
     Turning to  FIGS. 9 and 10 , two alternative constructions for sealing and coupling the manifold  12  are shown. With reference to  FIG. 9 , a first alternative housing  290  is shown having a first housing part  292  and a second housing part  294 . The housing  290  includes a first passageway  112 , a second passageway  114 , and a third passageway  116 , similar to the previous embodiment. However, the first housing part  292  and the second housing part  294  include recesses  295  that receive a gasket  270 . 
     The gasket  270  comprises a series of metal welding parts  271  that seat in the recesses  295 . To form the housing  290 , the first housing part  292  and the second housing part  294  are coupled by mating the first housing part  292  and second housing part  294 . Next, the housing  290  is subjected to induction welding during which the metal welding parts  271  are heated causing the first housing part  292  and second housing part  294  to meld together forming a seal between the various passageways  112 ,  114 ,  116 . The metal welding parts  271  are preferably made of. 
     The first housing part  292  and the second housing part  294  are preferably made of a thermoplastic that can be heated to its flow temperature to create a bond between the first housing part  292  and the second housing part  294 . The housing  290  is preferably made of. Alternatively, the metal welding parts  271  may be excluded and the first housing part  292  and the second housing part  294  can be ultrasonically welded along the desired seals to join the first housing part  292  and the second housing part  294 . 
     With reference to  FIG. 10 , a second alternative housing  390  is shown having a first housing part  392  and a second housing part  394 . The housing  390  includes a first passageway  112 , a second passageway  114 , and a third passageway  116 , similar to the two previous embodiments. However, the second housing part  394  includes ridges  393  that extend essentially perpendicular from the interface surface  395  of the second housing part  394  about the perimeter of the first passageway  112 , second passageway  114 , and third passageway  116 . A gasket  370 , having a thickness greater than the height of the ridges  393 , is compressed between the first housing part  392  and the second housing part  394 . 
     Again, a series of mounting holes  380  and receiving holes  382  are formed in the first housing part  392  and the second housing part  394 . Alternatively, the first housing part  392  and second housing part  394  may be coupled by a combination of resilient clips and tabs (not shown), or some combination thereof. The first housing part  392  and the second housing part  394  are preferably made of plastic that is resistant to the chemicals used in the automated sprayer  10 , such as. 
     Preferred embodiments of the invention have been described in considerable detail. Many modifications and variations to the preferred embodiments will be apparent to those skilled in the art, which will be within the spirit and scope of the invention. 
     For example, rather than the gasket being in four parts as shown in  FIG. 9 , or one part as shown in  FIG. 7 , it could be in two parts. Further, the cross sectional shape of the gasket area on the right hand side of the  FIG. 7  assembly could be o-ring shaped, and the cross sectional shape of the gasket area on the left side of the gasket of  FIG. 7  could be elliptical shaped. This can reduce the compressive forces needed to achieve a good seal. 
     In another alternative the container used with such a device could be of the collapsible type which does not need to be vented. In such a case air vent passageways through the manifold would not be needed. 
     Therefore, the invention should not be limited to the described embodiments. To ascertain the full scope of the invention, reference should be made to the claims. 
     INDUSTRIAL APPLICABILITY 
     The invention provides a manifold for accommodating various functions of an automated sprayer.