Abstract:
The present disclosure relates to a system and method for spraying one or more target objects. A primary blower system is adapted to create a relatively isolated field of circulating air by creating a primary air stream around the field of circulating air. A secondary blower system is adapted to circulate air within the isolated field by flowing a secondary air stream in directions contrary to the primary air stream. A chemical spray comprising liquid, aerosol droplets, particulate matter, or the like may be emitted into the circulating air within the field and thereby deposited on target objects within the field. Embodiments of the present disclosure may be used for agricultural, automotive, aerospace, and other applications to emit, contain, and/or recapture a spray.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority under 35 USC §119 to U.S. Provisional Patent Application Ser. No. 61/630,469, filed on Dec. 13, 2011, and titled “Non-Mechanical Method for Orchard Spray Recapture,” the entire contents of which are hereby incorporated by reference. 
     
    
     TECHNICAL FIELD 
       [0002]    The present disclosure relates generally to a spray recapture system and method. More particularly, the disclosure relates to a system and method for spraying, containing, recirculating, and recapturing a spray discharge. 
       BACKGROUND 
       [0003]    Spray recapture systems have been used in the past to prevent overspray of paint, agricultural chemicals including fertilizers, fungicides, herbicides, and pesticides, and other types of spray discharge intended for one or more target objects. Such sprays may be harmful to environs surrounding the target objects. Thus, it may be desirable to mitigate dispersal of such chemicals. In some cases, spray containment shells are used to contain overspray. However, very large target objects, such as a fully mature tree or an airplane, may be too large to fit within a practically-sized spray containment shell. 
         [0004]    What is needed, therefore, is a method and system for mitigating overspray while enhancing spray coverage on a target object and increasing spray recapture. 
       SUMMARY 
       [0005]    In one embodiment, a method of spraying a target object is disclosed. The method includes creating a first stream of air around a target space, creating a second stream of air within the target space, wherein the second stream of air flows counter to the first stream of air, locating a target object within the target space, and emitting a spray within the target space. 
         [0006]    In another embodiment, an apparatus for spraying a target object is disclosed. The apparatus includes a primary blower adapted to direct a first flow of air through multiple radially-distributed air vents, a secondary blower, and a spray nozzle. The radially-distributed air vents are adapted to direct the first flow of air in a first direction. The secondary blower is adapted to direct a second flow of air in a second direction. The second direction is approximately opposed to the first direction. The spray nozzle is adapted to emit a spray into the second flow of air. 
         [0007]    The present disclosure will now be described more fully with reference to the accompanying drawings, which are intended to be read in conjunction with both this summary, the detailed description, and any preferred or particular embodiments specifically discussed or otherwise disclosed. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided by way of illustration only so that this disclosure will be thorough, and fully convey the full scope of the disclosure to those skilled in the art. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    This disclosure may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements, and in which: 
           [0009]      FIG. 1  is a perspective view of a recapture sprayer according to an embodiment of the present disclosure; 
           [0010]      FIG. 2  is a side view of a recapture sprayer according to an embodiment; 
           [0011]      FIG. 3  is a front view of a recapture sprayer according to an embodiment; 
           [0012]      FIG. 4  is an isometric top view of a recapture sprayer according to an embodiment; and 
           [0013]      FIG. 5  is a perspective view of a recapture sprayer in use. 
       
    
    
     DETAILED DESCRIPTION 
       [0014]    In the following description, reference is made to the accompanying drawings that form a part thereof, and in which is shown by way of illustration specific exemplary embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the concepts disclosed, and it is to be understood that modifications to the various disclosed embodiments may be made, and other embodiments may be utilized, without departing from the spirit and scope of the present disclosure. The following detailed description is, therefore, not to be taken in a limiting sense. 
         [0015]    An objective of embodiments of the present disclosure is to apply a spray to a target object within a field of circulating air and recapture some of the spray while minimizing overspray, spill, and loss. Embodiments of the present disclosure comprise a powered or unpowered vehicle having spray nozzles, air pressure nozzles, and air inlet ports. 
         [0016]    With reference to  FIG. 1 , an embodiment of the present disclosure comprises vehicle  100 . In an embodiment, vehicle  100  comprises a non-self-propelled vehicle adapted for towing behind a tractor or similar self-propelled vehicle. In alternative embodiments, vehicle  100  comprises a self-propelled vehicle. Vehicle  100  may be adapted for use in orchards, fields, on-road, or other various environments. 
         [0017]    Embodiments of the present disclosure comprise nose member  110 . Nose member  110  comprises multiple radially-distributed air vents  115 . Generally, vents  115  comprise pass-through holes in nose member  110  in communication with an inner volume of nose member  110 , which comprises a plenum. Nose vents  115  are targeted at multiple radially-distributed directions roughly perpendicular to a direction of travel of vehicle  100 . In alternative embodiments, nose vents  115  are directed at points behind nose member  110 , such that an emitted air stream may be directed at various outward and rearward angles relative to vehicle  100 . The embodiment depicted in  FIG. 1  comprises approximately forty vents  115  distributed roughly evenly around nose member  110 . Alternative embodiments may comprise other numbers of vents  115  while still falling under the scope of the present disclosure. Plenum of nose member  110  is in fluid communication with an output port of primary blower assembly  125  via primary blower outlet duct  130 . Primary blower inlet duct  135  is attached at an inlet port of primary blower  125  and comprises primary air intake vent  140  located at the rear of vehicle  100 . Primary air intake vent  140  comprises vent filter  145 . In embodiments of the present disclosure, a dust recapture system (not depicted) may be located within primary air intake vent  140  or inlet duct  135 . 
         [0018]    The embodiment depicted in  FIG. 1  further comprises side support beams  150 . Side support beams  150  comprise trestle members  155 . Near the rear of vehicle  100 , stanchions  160  support side support beams  150  and anchor side support beams  150  to vehicle  100 . Side support beams  150  support secondary air pipes  165 , which extend laterally beyond each side of vehicle  100 . In alternative embodiments, side support beams  150  are integrated with secondary air pipes  165 . For example, in an embodiment, side support beams  150  comprise a steel tube through which a stream of air may be carried. Secondary air pipes  165  comprise downturn pipes  170  at their lateral extremities, upon which secondary side vents  175  are attached. In the embodiment depicted in  FIG. 1 , spray nozzles  180  are also attached on downturn pipe  170  and are connected to spray hose  185 , which provides fluid communication to a storage tank (not depicted). In an embodiment, the storage tank comprises an atomizer or other apparatus to convert liquid within the tank to an aerosol prior to transmitting the aerosol in a fluid stream through spray hose  185 . The storage tank may be installed on vehicle  100  or on a tow vehicle. 
         [0019]    Secondary air pipes  165  are in fluid communication with an output port of secondary blower assembly  190  via secondary blower outlet duct  195 . Secondary central vent  200  is also in communication with secondary blower outlet duct  195 . Secondary central vent  200  comprises a large nozzle having internal vanes adapted to create cyclonic air movement on an air stream passing therethrough. Secondary blower inlet duct  205  is attached at an inlet port of secondary blower  190  and comprises fluid communication to secondary air intake vent  210  located behind nose member  110  near the front of vehicle  100 . In embodiments of the present disclosure, a filtration system (not depicted) may be located within secondary air intake vent  210  or secondary inlet duct  205 . 
         [0020]    Alternative embodiments comprise additional spray nozzles  180  located at or near secondary air intake vent  205  and/or secondary central vent  200 . In alternative embodiments, functions served by primary blower assembly  125  and/or secondary blower assembly  190  may be fulfilled instead by one or more air compressors and/or air generators. 
         [0021]    As depicted in  FIGS. 1 ,  2 , and  3 , vehicle  100  comprises two wheels  215  on an axle. In alternative embodiments, vehicle  100  additionally comprises one or two steerable or non-steerable front wheels. Vehicle  100  may be motivated by towing via tow hitch  220 . Alternatively, vehicle  100  comprises driven wheels and may thus be self-powered. 
         [0022]    In operation, vehicle is moved next to target objects  310  or one or two rows of target objects  310  where a spray application is intended. Referring now to  FIG. 4 , Primary blower  125  may be activated to create a primary air system  300 . As a result, an air stream is ejected from nose vents  115  and surrounds the vehicle  100 , forming a field that may be shielded from ambient air. The primary air system  300  may prevent ingress of bulk ambient air as vehicle  100  moves forward or ambient winds blow around or at vehicle  100 . Likewise, a substantially isolated field of circulating air may be maintained within the primary air system  300 , so as to minimize or reduce the potential for air that is circulating within the target space  110  to drift out of the field. The air stream of the primary air system  300  passes around the outside of the vehicle  100  and is drawn into primary air intake vent  140 , before the air stream passes through primary blower  125  and is recirculated through nose vents  115 . Primary air system  300  may comprise laminar air flow around the field of recirculating air. 
         [0023]    Secondary blower  190  may be activated to create a secondary air system  305 . The secondary air system  305  comprises air circulating in the field encompassed within the primary air system  300 . A chemical spray, an aerosol, particular matter, and/or other like substance may be entrained within the secondary air system  305 . An air stream is ejected from secondary side vents  175  and secondary central vent  200  and circulated within the vicinity of vehicle  100  in the field surrounded by primary air system  300 . Air ejected from secondary central vent  200  may experience cyclonic mixing and circulation as caused by vanes within secondary central vent  200 . Air in the secondary air system  305  may be pulled into secondary intake vent  210  and pass through secondary inlet duct  205  to secondary blower  190  and be recirculated through secondary side vents  175  and secondary central vent  200 . Secondary air system  305  may comprise turbulent air flow within the field and around target objects  310 . 
         [0024]    Spray nozzles  180  may emit a spray in liquid form, in aerosol form, as particulates entrained in an air stream, or the like. Spray nozzles  180  may be adapted to emit an electrostatic spray. A pump may be activated to transmit the spray from a storage tank to spray nozzles  180  through spray hose  185 . In one embodiment, liquid stored in tank is converted to aerosol by an atomizer installed at or near the tank or at nozzles  180 . An aerosol may selectively be applied as spray if doing so might result in increased coverage on target objects  310  in comparison to liquid spray. 
         [0025]    Spray may enter the secondary air system  305  and remain entrained therein as the air recirculates through the system. Alternate embodiments may not include nozzles  180  located at the secondary side vents  175 , but rather emit spray elsewhere into the secondary air system. To apply a spray to a larger target object, volumetric air flows and air pressures may be increased to thereby increase the size of the field of recirculating air. Additionally, the size, direction, and number of nose vents  115  may be altered to change the shape of the field of recirculating air. 
         [0026]    Referring now to  FIG. 5 , vehicle  100  may pass between rows of target objects  310  as the blower assemblies  125 ,  190  create the primary air system  300  and secondary air system  305  (depicted in  FIG. 4 ) and to thereby encompass the target objects  310  within the field of secondary air system  305 . Sprays may include pesticides, nutrients, fungicides, herbicides, defoliants, and the like, as desired. Due to the recirculation of the secondary air system  305  and the turbulent nature thereof, the spray entrained therein may contact target objects  310  at multiple angles and therefore may cover multiple surfaces, so that, for example, coverage may occur on both the top and the bottom of leaves. The speed of the vehicle  100 , whether towed by a tractor, other tow vehicle, or under self-power, may be typical of existing spray methods, which may typically be four to five miles per hour. 
         [0027]    Alternative embodiments of the present disclosure may be utilized for spraying paint in automotive, aerospace, or like applications. Embodiments may be used for spraying de-icing spray in aerospace or like applications, spraying paint on road surfaces, or other applications wherein a spray may be applied to a target object. 
         [0028]    In alternative embodiments of the present embodiment, vehicle  100  comprises curved skin surfaces at front and/or rear sections to improve laminar flow of primary air system  300  and to keep the primary air system  300  and secondary air system  305  from mixing with each other. 
         [0029]    Systems and methods of the present disclosure may present numerous advantages over traditional spray technology and methods. Spray may be applied more precisely on target objects  310 , so that fewer nozzles may be used. Spray may be ejected at lower pressure, using lower volumetric airflow, and with less chemicals emitted than traditional methods. The recaptured and recycled spray in the secondary air system  305  may result in less wasted chemicals, thereby resulting in less chemical released into the atmosphere and less overall cost. 
         [0030]    Another advantage is that systems of the present disclosure may be employed in fields even with overhead obstacles such as power lines since there is no large spray recapture shell. Another advantage is that embodiments of the present disclosure may be used in environments experiencing relatively strong side winds because the primary air system  300  may isolate the field enclosed therein. 
         [0031]    Although the present disclosure uses terms of certain embodiments, other embodiments will be apparent to those of ordinary skill in the art having the benefit of this disclosure, including embodiments that do not provide all of the benefits and features set forth herein, which are also within the scope of this disclosure. It is to be understood that other embodiments may be utilized, without departing from the spirit and scope of the present disclosure.