Abstract:
A valve having a membrane for controlling flow through the valve, the membrane having open and closed positions. An element urges the membrane to the closed position, and a vacuum pressure at one end of the valve may overcome the urging of the element, thereby moving the membrane to the open position. An actuator is provided for easing or initiating the movement of the membrane. In some embodiments, the valve may take the form of a valve assembly for use in a variety of applications, for example, a valve assembly for relieving a vacuum pressure wherein the assembly includes intake and exhaust ends, a membrane for controlling flow through the assembly, a spring providing a closing bias to the membrane that the vacuum pressure may overcome to move the membrane, and an actuator for initiating the movement of the membrane.

Description:
BACKGROUND 
       [0001]    The present disclosure relates to flow controls, valves, and devices for controlling, starting, and stopping a flow, and to methods of making and using such controls, valves, and devices. More particularly, the present disclosure relates to controls, valves, and devices that control, start, and/or stop a flow in one direction and, more particularly, to one-way valves having an actuator assist. 
         [0002]    Valves, including one-way valves, are used in many situations and arts to influence, control, or regulate flows of substances. Examples include the refining or chemical processing industries, coating systems or mechanisms, and dispensing systems or mechanisms, such as handheld sprayers, water guns, robotic sprayers, and the like. 
         [0003]    No matter what flow, spray system, or flow path a valve may be associated with or used in, the flowing substance to be controlled may include aggressive formulas that leak and/or leave a sticky residue in the interior of a nozzle, dispensing system or sprayer head, and on valve components or surfaces, e.g., the seat, stem, peripheral edge, etc. Valves provided inside a sprayer head, for example, may be used to regulate the flow of air and fluid in the sprayer and prevent leaks. However, such valves may become sticky due to the residues left by the fluids. Thus, the valves may tend to stick open and leak, and/or stick closed and prevent the air or fluid from passing through. The sticky residue may be caused by direct contact between the valves and fluid from a reservoir of the sprayer or by contact with vapors from the fluid in the reservoir. 
         [0004]    There is a need in the flow control art for a valve, and in some embodiments a one-way valve, that compensates for and/or reduces the likelihood of leakage, substandard performance, or malfunction. There is a need in the art for a valve having an actuator assist for initiating and/or facilitating the opening of the valve. There is a further need in the art for a dispensing or spray system, sprayer, power sprayer, or the like that maintains a properly pressurized fluid reservoir and a valve that maintains proper operation under use with aggressive formulas. 
       SUMMARY 
       [0005]    In one embodiment, the present disclosure relates to a valve having first and second ends or sides (e.g., an inlet and an outlet side) and a membrane for controlling a flow through the valve between the first and second ends or sides, the membrane having open and closed positions. An element urges the membrane to a closed position, and a vacuum pressure at either the first or second end overcomes the urging of the element, thereby moving the membrane to the open position. An actuator is provided for easing or initiating the movement of the membrane. 
         [0006]    The present disclosure, in another embodiment, relates to a one-way valve having an actuator assist for initiating the opening of the one-way valve. The present disclosure, in yet another embodiment, relates to a valve assembly operably coupled to a reservoir, the valve assembly having a generally closed position when the air pressure in the reservoir is substantially ambient air pressure, and the valve assembly has a generally open position when the air pressure in the reservoir is generally lower than ambient pressure allowing air flow into the container. 
         [0007]    The present disclosure further relates to a valve assembly for relieving a vacuum pressure. The valve assembly comprises an intake end, an exhaust end, a valve membrane for controlling flow through the valve assembly between the intake end and the exhaust end, a spring member providing a closed bias to the valve membrane that the vacuum pressure may overcome in order to open the valve membrane, and an actuator for initiating the opening of the valve membrane. The valve assembly of the present disclosure is not limited to use with power sprayers and may be used in a variety of applications including, but not limited to, handheld sprayers, water guns or other toys, paint sprayers, or any other environment where relief of a vacuum pressure is desired, including the return of air into a container having a fluid, where dispensing the fluid creates a vacuum. 
         [0008]    The present disclosure, in another embodiment, relates to a novel and advantageous powered dispenser that includes means for returning air to the reservoir of the dispenser. A powered dispenser may include a return air valve that may be actuated by the vacuum created in the reservoir. The return air valve may include a lever or tab, etc. that may be used to initiate the opening of the valve, after which the vacuum created in the reservoir may then open the valve and maintain the valve in an open position until the vacuum is minimized or eliminated. 
         [0009]    In one embodiment, the dispenser of the present disclosure comprises a motorized liquid spray pump which may be used interchangeably on typical containers or bottles for a variety of substances. A spray pump of the present disclosure may be used for a variety of purposes. For example, in the home, cleaning solutions such as window cleaners may be sprayed or dispensed with it. In the garage, for automotive uses, various cleaning materials may be dispensed or applied using the sprayer of the present disclosure. In the garden, the spray pump may be used for spraying or dispensing insecticides and herbicides or for misting plants. It may be used in a wide variety of applications or uses at home or on the job, anywhere, for example, that hand-pumped sprayers are currently in use. In one embodiment, a spray pump of the present disclosure is designed to fit any standard cleaner bottle, but it may also comprise an empty bottle that the user can fill and use to dispense substances. 
         [0010]    While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the invention is capable of modifications in various aspects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  includes a top, side, front, and back view as well as a side cross-sectional view of a valve assembly in accordance with the present disclosure. 
           [0012]      FIG. 2  is a partial side cross-sectional view of an embodiment of a handheld power sprayer having an air flow valve assembly in accordance with the present disclosure. 
           [0013]      FIG. 3  is a partial side cross-sectional view of another embodiment of a handheld power sprayer having an air flow valve assembly in accordance with the present disclosure. 
           [0014]      FIG. 4  is an elevation view of a power sprayer in accordance with the present disclosure mounted on a reservoir adapted to contain a fluid. 
           [0015]      FIG. 5  is an elevation view of a power sprayer in accordance with the present disclosure and a reservoir adapted to contain a fluid, wherein the sprayer is not mounted on the reservoir. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    The present disclosure relates to novel and advantageous flow controls, valves, and devices for controlling, starting, and stopping a flow, and to methods of making and using such controls, valves, and devices. More particularly, the present disclosure relates to controls, valves, and devices that control, start, and/or stop a flow in one direction and, more particularly, to one-way valves having an actuator assist. The present disclosure further relates to novel and advantageous dispensing or spray systems, sprayers, power sprayers, handheld sprayers, water guns or other toys, paint sprayers, or the like that include means for returning fluid or air to a reservoir of the device. Particularly, a dispensing device, for example, may include a return air valve that may be actuated by the vacuum created in the reservoir. In a further embodiment, the return air valve may include an actuator, such as a lever, tab, etc., that may be used to initiate the opening of the valve, after which the vacuum created in the reservoir may then open the valve and maintain the valve in an open position until the vacuum is minimized or eliminated. A dispensing device of the present disclosure may further include means for returning air to a reservoir during the removal of fluid from the reservoir or shortly after removal of fluid from the reservoir, such that the air pressure inside the reservoir returns to substantially the ambient air pressure. 
         [0017]    In one embodiment, as illustrated in  FIG. 1 , a valve  10 , or similar device for controlling, starting, and stopping a flow may be or comprise an umbrella-type valve or butterfly-type valve. In some embodiments, the valve  10  may be a unidirectional, or one-way valve, thereby allowing fluid or air flow in a single direction. In further embodiments, the valve  10  may be adapted to be coupled, operably coupled, or otherwise connected to a system having an air or fluid reservoir. The valve  10  may comprise an umbrella membrane or disc  12 , a spring or spring-like structure  14 , an intake end  16 , and an exhaust end  18 . The umbrella disc  12  may be generally thin, flat and circular in shape. However, it is recognized that other suitable shapes and thicknesses may be used, such as but not limited to, elliptical. The material from which the umbrella disc  12  may be manufactured can vary depending on the use of the valve  10 , dispensing device or system in which the valve  10  is used, and/or fluid that is provided in a reservoir of the dispensing device or system. The umbrella disc  12  may be manufactured from any suitable material, including but not limited to, rubber, plastic or other suitable polymer, etc. The umbrella disc  12  may have a normally closed position, wherein the umbrella disc  12  substantially forms a seal against disc seat  20 , thereby preventing air to flow from the intake end  16  to the exhaust end  18 . 
         [0018]    The spring  14  may provide a bias to the umbrella disc  12  towards a closed position. The valve  10  may further include a support structure  22  between the spring  14  and the umbrella disc  12 . The support structure  22  may prevent direct contact between the spring  14  and the umbrella disc  12 , thereby preventing damage to the umbrella disc  12  that may be caused by direct contact with the spring  14 . 
         [0019]    In some embodiments, the valve  10  may be used as an air return valve. The intake end  16  may comprise one or more slots or openings  24  for allowing air to enter the valve  10 . The exhaust end  18  may be directly or operably coupled to a reservoir or other source of vacuum pressure. 
         [0020]    When the vacuum pressure at the exhaust end  18 , or pressure in the reservoir, drops below the ambient pressure by, for example, actuation of the dispensing device or system and removal of air or fluid from the reservoir, the vacuum created at the exhaust end  18  may cause the valve  10  to open. That is, a vacuum created at the exhaust end  18  may cause the umbrella disc  12  to overcome the bias of the spring  14  and support structure  22  and become unseated from the disc seat  20 . Thus, the umbrella disc  12  may open, allowing air flow from the intake end  16  to the exhaust end  18 , and, in some embodiments, into a reservoir. In one embodiment, the umbrella disc  12  and valve  10  may be configured such that minimal vacuum pressure at the exhaust end  18  can open the umbrella disc  12  or unseat the umbrella disc  12  from the disc seat  20 . However, the umbrella disc  12  may also be configured to be strong enough so that, in the closed or seated position, leaks of fluid from the reservoir are not allowed through the valve  10 . Once the vacuum pressure at the exhaust end  18 , or pressure in the reservoir, reaches substantially ambient pressure, the bias of the spring  14  and support structure  22  may overcome the vacuum created at the exhaust end  18  and the umbrella disc  12  may become reseated on the disc seat  20 , thereby preventing air flow from the intake end  16  to the exhaust end  18 . 
         [0021]    In some cases, fluid in the reservoir may include air fresheners, insecticides, soap scum remover, tile grout cleaner, window cleaner, all purpose cleaner, etc. Therefore, in some cases, the fluid may comprise an aggressive formula that may leave a sticky residue on the umbrella disc  12 , thereby causing valve failure or inconsistency in valve operation, etc. and preventing correct air flow into the reservoir. For example, the sticky residue may cause the umbrella disc  12  to stick in an open position and allow leaks and/or stick in a closed position such that fluid or air is prevented from passing through. The sticky residue may be caused, for example, by direct contact between the umbrella disc  12  and fluid from the reservoir that has seeped up into the valve  10  or by contact with vapors from the fluid in the reservoir. 
         [0022]    Therefore, in one embodiment, the valve  10  may further include a mechanical actuator, such as a mechanical tab, rod, or lever, etc., that may open or initiate the opening of the valve  10 . Once the opening of the valve  10  has been initiated using the mechanical actuator, the vacuum created by the reservoir may maintain the valve  10  in an open position, or continue opening the valve  10 , such that air may flow from the intake end  16  to the exhaust end  18 . The mechanical actuator, in one embodiment, may be a push rod  26  generally near the intake end  16 . The push rod  26  may have a normal position with one end protruding from the intake end  16  of the valve  10 . In one embodiment, the push rod  26  may be activated by a trigger of the dispensing device or system. Upon actuation of the trigger, the trigger may abut the protruding end of the push rod  26  and cause the opposite end of the push rod to contact the umbrella disc  12 . Contact between the push rod  26  and the umbrella disc  12  may unseat, or initiate the unseating of, the umbrella disc  12  from the disc seat  20 . As the trigger may also actuate flow of air or fluid from a reservoir, the resulting vacuum created in the reservoir may cause the umbrella disc  12  to remain unseated or continue to become unseated from the disc seat  20 , thereby opening the valve  10 . In other embodiments, the vacuum at the exhaust end  18  may be created independently from the mechanism used to actuate the push rod  26 . In alternative embodiments, the push rod  26  may be activated by a component other than a trigger, such as but not limited to, a switch, a gear box assembly, etc. In further embodiments, the push rod  26  may be activated by any suitable mechanism in the dispensing device or system, such as any cam or lever assembly from a pump, gear box, motor assembly, etc. of the dispensing device or system. 
         [0023]    In one embodiment, the mechanical actuator does not open the valve  10  enough to sufficiently allow air or fluid to flow from the intake end  16  to the exhaust end  18 . Rather, the mechanical actuator initiates the opening while the vacuum created in the reservoir may provide the force to sufficiently open the umbrella disc  12 . Once the pressure in the reservoir reaches substantially ambient pressure, the bias of the spring  14  and support structure  22  may overcome the vacuum created by the reservoir and the umbrella disc  12  may become reseated on the disc seat  20 , thereby preventing flow from the intake end  16  to the exhaust end  18 . In alternative embodiments, the mechanical actuator opens the valve  10  enough to sufficiently allow air or fluid to flow from the intake end  16  to the exhaust end  18 , and the vacuum created in the reservoir may provide the force to maintain the valve  10  in an open position. Furthermore, the mechanical actuator may be used to unseat the umbrella disc  12  to any suitable extent, such that the vacuum created in the reservoir can maintain the umbrella disc  12  in an open position or continue to open the umbrella disc  12  to a fully opened position. In other embodiments, mechanical actuators other than a push rod may be used, such as a tab or mechanical slider, etc. 
         [0024]    As illustrated in  FIGS. 2 and 3 , in some embodiments, an air return valve  30  may be used to allow air to return to a reservoir  32  of a dispensing device or system  28 , such as, but not limited to, a sprayer. The air return valve  30  may be a one-way valve that allows air flow in one direction while preventing air flow or fluid flow in the opposite direction. For example, the air return valve  30  may only allow air flow towards and into the reservoir  32 , but may not allow air flow out of the reservoir  32 . The air return valve  30  may be directly or operably coupled to the reservoir  32 . As such, air may flow through the air return valve  30  and into the reservoir  32 . 
         [0025]    In one embodiment, the air return valve  30  may allow air to flow into the reservoir  32  when the seal of the air return valve is released or open. The seal in the air return valve  30  may be released or opened by the vacuum pressure created in the reservoir  32  when fluid is pulled from, and out of, the reservoir  32 . Thus, in one embodiment, the air return valve  30  may open and allow air to flow into the reservoir  32  during the removal of fluid from the reservoir  32  or shortly after removal of fluid from the reservoir  32 . Particularly, the air return valve  30  may allow air to flow into the reservoir  32 , upon, during, and/or shortly after actuation of the dispensing device  28  by, for example, a trigger  34 . 
         [0026]    In further embodiments, as discussed above, the push rod  26  of the air return valve  30  may be activated by the trigger  34 . The trigger  34 , as illustrated in  FIG. 3 , may have a tab, lever, contact point, or the like  36  that may abut and/or push on push rod  26  when the trigger  34  is activated. In alternative embodiments, the trigger  34  need not include tab  36 , but may be shaped or configured in any other suitable manner such that the trigger  34  activates push rod  26 . In yet further embodiments, the trigger may include another tab, lever, contact point, or the like  38  that, upon activation of the trigger  34 , may abut and/or contact an isolated battery compartment, further discussed below, to complete an electrical circuit and activate a dispensing device  28 . In alternative embodiments, the trigger  34  need not include tab  38 , but may be shaped or configured in any other suitable manner such that the trigger  34  completes an electrical circuit to activate the dispensing device  28 . In one embodiment, the tabs  36  and  38  are configured so that upon activation of the trigger  34 , the tab  36  and tab  38  generally simultaneously, and respectively, activate the push rod  26  and the dispensing device  28 . 
         [0027]    A dispensing device of the present disclosure may include some or all of the components, features, and advantages of a power sprayer as disclosed in U.S. patent application Ser. No. 11/693,426, filed Mar. 29, 2007, entitled Power Sprayer, and published on Oct. 4, 2007 under U.S. Publication No. 2007/0228186, the entirety of which is hereby incorporated by reference herein. With reference to  FIGS. 4 and 5 , a dispensing device  40  may include a spray head  42 , a cap  44 , and a flexible intake tube  46 . When the dispensing device  40  is mounted on a reservoir  48 , the spray head  42  and cap  44  may be located outside the reservoir  48 , while the flexible intake tube  46  may be located inside the reservoir  48 . As further shown in  FIGS. 4 and 5 , the spray head  42  may include a housing  50 , a nozzle cap  52 , a trigger  54 , and a safety lock  56 . The cap  44  may connect the spray head  42  to the reservoir  48  via female threads adapted to mate with the male threads of the neck  58 . The cap  44  may be adapted to be compatible with most reservoirs  48  used to hold common household, garage, and garden liquids. The trigger  54  is used to actuate the sprayer dispensing device  40 . As indicated in  FIGS. 4 and 5 , in one embodiment, the dispensing device  40  may be actuated by partially displacing the trigger  54  into the housing  50 . When the spray head  42  is mounted on a reservoir  48 , a battery tube  60  may extend from the cap  44  down into the reservoir  48 . In an alternate embodiment, as shown in  FIG. 5 , an isolated or separate battery compartment  62  may be contained within the sprayer housing  50 , to the rear of the housing, and spaced away from and generally downwardly from the pump and motor. Those skilled in the art will readily understand that the dispensing device may include a reciprocating piston-type pump, dual reciprocating pump, a gear pump, a peristaltic pump, or other suitable pumping assembly without departing from the spirit and scope of the invention. 
         [0028]    In a further embodiment, the spray head  42  may be operably coupled to, but remote from, separate, or not directly connected to the reservoir  48  of material to be dispensed. Similarly, it should be appreciated that any embodiment of the spray head  42  in accordance with the present invention could be disposable. 
         [0029]    Although the present invention has been described with reference to preferred embodiments, persons skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. For example, although described in some embodiments with respect to a power sprayer, the air valve of the present disclosure is not limited to use with power sprayers and may be used in a variety of applications including, but not limited to, refining or chemical processing industries, coating systems or mechanisms, handheld sprayers, water guns or other toys, paint sprayers, or any other environment where relief of a vacuum pressure is desired, including the return of air into a container having a fluid, where dispensing the fluid creates a vacuum. Although illustrated as having a generally horizontal position, the air return valve may be oriented generally vertically, diagonally, or at any other suitable angle without departing from the spirit and scope of the present disclosure.