Abstract:
A sprayer system having a sprayer assembly adaptable to a variety of sizes and shapes of containers. The sprayer assembly includes a dual venturi in the flow conduit to provide even pressure and consistent flow in the spray volume. A metering device is coupled to the flow conduit for accurate and reliable regulation of mixture ratios. A dip tube, coupled to the fluid conduit, is adaptable to a variety of container orifices. In addition to acting as a conduit for passage of concentrate into the sprayer assembly, the dip tube may also be used as a cutting device to open the container into which it will be inserted. By adapting to a variety of container orifices, the dip tube allows the sprayer assembly to fit to a variety of containers.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    The present application is a continuation of and claims priority to Applicant&#39;s U.S. Co-Pending patent application, Ser. No. 12/206,973, filed Sep. 9, 2008, now allowed. 
     
    
     BACKGROUND 
       [0002]    The present invention relates generally to spraying devices, and more particularly to spraying devices adaptable to a variety of containers. 
         [0003]    Typical lawn and garden tank sprayers that apply fertilizers, pesticides or other chemicals require a fixed dilution ratio by the addition of water thereto to provide a liquid spray mixture. There are considerable energy requirements necessary to provide adequate pressure to atomize and propel the liquid mixture into a spray. This entails manual pumping of air into a pressure chamber and building up of the pressure to a magnitude that creates an adequate spray pattern for the application, which can be manually demanding for the user. The user will also periodically pump the pressure back up to its operating pressure to re-establish the proper spray pattern, disrupting the spray process, prolonging the time it takes to complete a spray application. 
         [0004]    Currently available garden hose-end sprayers that incorporate aspirating units, utilize a series of orifices to meter the concentrate side of the system to achieve a preset mixing ratio. For example, the popular Dial N Spray™ unit available from Scotts Miracle-Gro Company uses various orifices in a rotational disk that are calibrated and labeled so that the user only needs to set the dial to the correct setting to achieve the desired mixing ratio. Downstream pressure fluctuations, sometimes present with adjustable nozzles, can affect the metering accuracy of these aspirating units. Additionally, when back pressure is created in the spray nozzle, the venturi will not operate below atmospheric pressure, resulting in a change or actual stop in the flow. The mixture ratio is also affected. These changes in the mixture ratio will in turn affect the efficacy of the spraying application. 
         [0005]    Furthermore, many of the sprayers on the market require premixing of the chemicals and water, exposing the user to chemicals and the potential for spilling of the chemicals during mixing. Initial opening of the concentrate bottle cap and typical foil seal can be difficult to break. The user usually uses a sharp tool to break the seal. There is a high probability that the tool will get concentrate on it when it punctures the foil. The tool and the process of opening the foil seal expose the user to accidental spillage of the concentrate. Sometimes a transfer container is used to measure the amount of concentrate, which is then transferred to the sprayer. There are exposure risks in this process associated with cleaning and storage of the transfer container. The user is required to manually measure out the recommended quantity of concentrate with a spoon, cap or other measuring device. The concentrate is then added and diluted with a known volume of water in the sprayer tank for use in the application. It is possible that the premixing and transfer process can deposit concentrate on undesirable surfaces of the sprayer resulting in yet more exposure to chemicals. 
         [0006]    It is a primary object of an embodiment of the invention to provide a sprayer system that eliminates or reduces the user&#39;s exposure to concentrate and diluted chemicals. It is another object of an embodiment of the invention to provide a sprayer system that does not require premixing of concentrate and water. It is a further object of an embodiment of the invention to provide a sprayer system that reduces or eliminates the environmental and other problems associated with spraying of chemicals, storage of chemicals, proper disposal of chemicals and clean-up of chemicals. It is yet another object of an embodiment of the invention to provide a sprayer system that is adaptable to any type of container. It is a further object an embodiment of the invention to provide a sprayer system having an accurate and reliable metering component. It is a further object of an embodiment of the invention to provide a sprayer system that is easy to clean. It is a further object of an embodiment of the invention to provide a transparent and visual indication of the fluid movement, mixing and filtering process. It is still another object of an embodiment of the invention to provide a sprayer system that is ergonomically designed and requires little or no effort to operate. It is a further object of an embodiment of the invention to allow only clean water in the pressurized sprayer tank. 
       SUMMARY OF THE INVENTION 
       [0007]    These and other objects and advantages are accomplished by a sprayer system having a sprayer assembly adaptable to a variety of sizes and shapes of containers. In one aspect of an embodiment of the present invention, the sprayer assembly includes a dual venturi in the flow conduit to provide even pressure and consistent flow in the spray volume. In another aspect of an embodiment of the invention, the sprayer assembly includes a metering plate for accurate and reliable regulation of mixture ratios. In yet another aspect of an embodiment of the invention, the sprayer assembly includes a dip tube that is adaptable to a variety of container orifices. In addition to acting as a conduit for passage of concentrate into the sprayer assembly, the dip tube may also be used as a cutting device to open the container into which it will be inserted. By adapting to a variety of container orifices, the dip tube allows the sprayer assembly to fit to a variety of container orifices. The sprayer assembly easily couples to the dip tube for adaptability to different types of containers. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    Embodiments of the present invention will be more fully understood and appreciated by reading the following Detailed Description in conjunction with the accompanying drawings, in which: 
           [0009]      FIG. 1  is a perspective view of an embodiment of the sprayer system of the present invention; 
           [0010]      FIG. 2  is a perspective view of an embodiment of the sprayer assembly of the present invention; 
           [0011]      FIG. 3  is a partial cross-sectional view of an embodiment of the sprayer assembly of the present invention; 
           [0012]      FIG. 4  is a partial cross-sectional view of an embodiment of the sprayer assembly of the present invention; 
           [0013]      FIG. 5   a  is a perspective view of an embodiment of the dip tube of the sprayer system of the present invention; 
           [0014]      FIG. 5   b  is a perspective view of an embodiment of the dip tube and container of the sprayer system of the present invention; 
           [0015]      FIG. 6  is an embodiment of a metering circuit diagram of the fluid flow pattern through the sprayer system of the present invention; 
           [0016]      FIG. 7  is a fragmented view of an embodiment of the spray assembly of the present invention showing the venturi; 
           [0017]      FIG. 8  is a fragmented view of an embodiment of the spray assembly of the present invention showing the venturi; 
           [0018]      FIG. 9  is a partial perspective view of an embodiment of the sprayer assembly of the present invention; 
           [0019]      FIG. 10  is a partial perspective view of an embodiment of the sprayer assembly of the present invention; 
           [0020]      FIG. 11  is a partial perspective view of an embodiment of the sprayer assembly of the present invention; and 
           [0021]      FIG. 12  is a partial perspective view of an embodiment of the sprayer assembly of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0022]    As will be appreciated, an embodiment of the present invention provides a spray system  10  as shown in  FIG. 1 , having a spray assembly  12  for convenient adaptation to a container  14  for withdrawal, mixing and dispensing of the ingredients from container  14 . Container  14  typically holds additives such as chemical or fertilizer ingredients that must be mixed with another fluid, such as water. Spray assembly  12  includes a flexible hose  16  for attachment to a fluid source, such as a water tank  18 . It is understood that the fluid source may be any of a variety of structures including back pack tanks, hand portable tanks or even tractor transported tanks. 
         [0023]    Spray assembly  12  is able to cooperate with container  14  via a dip tube  20 , shown in  FIGS. 5   a  and  5   b . Dip tube  20  is inserted in container  14  to draw the ingredients therethrough to spray assembly  12 . Dip tube  20  includes a head portion or cap  22 , a shaft  24 , and a cutting component  21 . Cap  22  is adjustable and can fit onto a variety of container orifice sizes to connect thereto. As shown in  FIG. 4 , head portion  22  of dip tube  20  is coupled to orifice  26  of container  14 . A multiple number of different-sized caps  22  may be provided with dip tube  20  to provide a precise fit to container  14  or any container that needs to attach to spray assembly  12 . Accordingly, dip tube  20  and cap  22  are easily switched from one container to another, allowing for the use of different chemicals for different applications, using the same spray assembly. 
         [0024]    In a further aspect of the invention, spray assembly  12  includes a metering device  28  to provide variations in the ratio of components being mixed together. Metering device  28  is coupled to fluid conduit  29  and is located on housing  30 , which housing further encases the components of spray assembly  12 . The ratio of ingredients in container  14  to fluid, such as water, in tank  18 , can vary from use to use, depending upon the application. Also, since the system may be used with different containers and therefore different ingredients, the different ingredients may require different mixing ratios with water. Metering device  28  addresses all of these needs by providing options for a variety of ratios including ratios of chemical concentrate to water in the range of 500:1 to 4:1. Examples of ratios that may be provided by device  28  include, but are not limited to, 0.25 concentrate:0.75 water, 0.50 concentrate:0.50 water, or 0.75 concentrate:0.25 water. Device  28  is set at the preferred ratio by turning the dial to match the preferred ratio at arrow  32  positioned above device  28 . 
         [0025]    Reference is made to  FIGS. 3 ,  4  and  12  which show the internal components in housing  30  of sprayer assembly  12 . The internal components include a fluid conduit  29 , which includes all the passages in sprayer assembly  12  for the flow of fluid and concentrate therethrough. A longitudinally extending passageway  34  is coupled to flexible hose  16  (shown in  FIG. 1 ) at the inlet side  36  of passageway  34  and continues to outlet  38 . A shut-off valve  80  is linked to passageway  34  and flexible hose  16  and connected to trigger  82 . As trigger  82  is pressed, water is allowed to flow through passageway  34 . By releasing trigger  82 , shut-off valve  80  blocks water from flowing through to passageway  34 . This protects hose  16  and container  18 . A filter  84  may be positioned proximate the fluid entrance end in housing  30  and may be easily cleaned as needed. 
         [0026]    Outlet  38  can be connected to a long shaft  40 , which is further connected to a spray nozzle tip  42 , as shown in  FIG. 1 . Passageway  34  is also connected to passageway  44 , which is positioned perpendicular to passageway  34 . Passageway  44  is further connected to passageway  46 , which runs perpendicular to passageway  44  and parallel to passageway  34 . Passageway  46  connects to passageway  48 , which is connected to passageway  34 , to complete the loop. Passageway  46  also connects to passageway  34  via passageway  50 . A check valve  35  is positioned above passageway  50  to protect container  14  from any backflow of fluid. One venturi  52  is positioned within passageway  34  and another venturi  54  is positioned within passageway  46 . The venturi effect created by the dual venturi pulls concentrate from container  14  to mix with water in the fluid conduit  29 . The dual venturi arrangement provides a high pressure spray resulting in an even and continuous spray volume. 
         [0027]    It should be mentioned that in the discussion that follows,  FIGS. 6 through 8  are mirror images of  FIGS. 1 through 4  with respect to the conduit circuit and the fluid flow. The fluid flow in  FIGS. 1 through 4  is from right to left and the fluid flow in  FIGS. 6 through 8  is from left to right. 
         [0028]    Reference is made to  FIG. 6 , which shows dual venturi circuit  60  of the present invention and clearly illustrates the flow pattern of the mix (concentrate and water) through spray system  10 . A main venturi  54  is located in passageway  46  and a secondary venturi  52  is located in passageway  34 . Concentrate from container  14  is pulled upward through dip tube  20  to passageway  56 . A shutoff valve  58  is located in passageway  50 . If shutoff valve  58  is open, concentrate can flow through two pathways. That is, it can flow through both passageway  46  to spray nozzle  42  and passageway  50  to passageway  34  to spray nozzle  42 . 
         [0029]    Water enters through flexible hose  16  at inlet  36  and is directed into two separate pathways at point  37 . It flows down passageway  44  as shown by arrow  62 . From passageway  44  it moves into and through passageway  54  and through main venturi  54 , mixing with concentrate at venturi  54 , which mixture continues up passageway  48  through passageway  34  to spray nozzle  42 . The second pathway the water stream follows is in passageway  34 . If shut off valve  58  is open, concentrate moves up passageway  50  and mixes with water in passageway  34  at the second venturi  52 . This water/concentrate stream meets the first water/concentrate mixture at point  62  and the mixtures flow together out through nozzle  42 . If shut off valve  58  is closed, only water flows through passageway  34 , adding to the water/concentrate mixture at point  62 , and flowing out through spray nozzle  42 . Accordingly, depending upon the volume of water necessary in the mixture, if more water is needed, the shut-off valve is closed and if less water is needed, the shut-off valve is left open. Shut-off valve  58  is controlled by metering device  28 . 
         [0030]    Reference is made to  FIGS. 7 and 8 , which show venturi  52  in passageway  34 . Concentrate moves up passageway  50  and enters the venturi throat, at which point it mixes with water in passageway  34 . This venturi design has an optimal throat diameter for the range of flow rates and mixture ratios used in this spray assembly  12 . This venturi allows for more energy efficiency mixing of the water and the concentrate because both are flowing in the same direction. 
         [0031]    The tuning of the size and flow characteristics of the spray nozzle and the venturi are very critical for achieving the proper atomization and spray patterns for lawn and garden applications. The spray nozzles used in garden sprayers are designed to work within their typical operating pressures. In the venturi design, there is a pressure loss downstream of the venturi throat due to the friction losses from geometry changes in the flow path and the mixing of different velocity streams in the throat. The spray nozzle is designed to have a flow coefficient in the range of from about 0.2 to about 0.4 gallons per minute and to provide a droplet size in the range from about 200 to 600 microns with adequate pattern shape and distribution. The spray nozzle design also has different spraying modes that have the same flow coefficient. This nozzle design provides the correct fluid pressure distribution and flow rates to allow the correct mixture ratios over the operating pressure range and different nozzle settings. 
         [0032]    In another aspect of the invention, reference is made to  FIG. 9 , which illustrates details of housing  30 . Housing  30  may be fabricated of any suitable material that is resistant to and compatible with the chemical fluid to be sprayed. Examples include, but are not limited to, different types of polymeric materials such as polyethylene and polypropylene, and metal, such as stainless steel. In the preferred embodiment, the housing  30  and other fluid components are fabricated of clarified polypropylene to allow the user to view chemical fluid as it passes through the system to determine when fluids are mixing. Sections  66  on housing  30  are transparent or translucent to allow the user to view the fluid passing through the system. Housing  30  may be entirely clear throughout or in only specific sections, as shown in  FIG. 9 . A flow indicator  68  also may be included on housing  30  to indicate whether the system is functioning as required. 
         [0033]    In a further aspect of the invention, sprayer assembly  12  may include a self cleaning cycle as a spray option on metering device  28 . As illustrated in  FIG. 10 , a CLEAN cycle  70  is included on metering device  28 . This self cleaning option flushes water through sprayer assembly  12  removing all traces of chemicals in the fluid conduit  29 , shaft  40  and spray nozzle  42 . This prevents aggregation and clogging of particles in nozzle  42  and fluid conduit  29  and allows the user to clean sprayer assembly  12  without having to remove spray assembly before cleaning has occurred. This further eliminates or reduces the user&#39;s exposure to chemicals. 
         [0034]    As an another option, spray assembly  12  may be easily disassembled for cleaning.  FIG. 11  shows sprayer  11  and metering device  28  as separate components, which easily disconnect, if further cleaning is necessary. 
         [0035]    While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended embodiments.