Abstract:
A system for dispensing sprayable material such as paint and other liquefied products. The system includes a dispenser designed to accept a flexible, crushable container filled with sprayable material and having a valve and spray tip at one end. The container is placed into an interior portion in the dispenser with the valve on the container secured in the housing of the dispenser. In operation, a pump action lever is activated causing a piston to slide lengthwise in the housing of the dispenser and exert force on the bottom of the container crushing it as it is emptied and forcing the sprayable material out through the valve and spray tip.

Description:
RELATED U.S. APPLICATION DATA 
       [0001]    This is a continuation-in-part of U.S. application Ser. No. 12/831,263 filed Jul. 7, 2010 entitled “System for Dispensing Sprayable Material,” which claims priority benefit from provisional application No. 61/270,568 filed on Jul. 10, 2009 entitled “System for Dispensing Sprayable Material.” 
     
    
     COPYRIGHT NOTICE 
       [0002]    Portions of this disclosure contain material in which copyright is claimed by the applicant. The applicant has no objection to the copying of this material in the course of making copies of the application file or any patents that may issue on the application, but all other rights whatsoever in the copyrighted material are reserved. 
       BACKGROUND 
       [0003]    Aerosol cans for depositing paint and other sprayable materials have been in use for some time. The term “aerosol” as used herein refers to a suspension of liquid or solid particles in a gas. Most aerosol cans are made of tin-plated steel or aluminum. Once an aerosol can has been used and emptied in any of its many possible applications such as for food, beverage, paint and aerosol products, it is in demand for recycling. There are over three billion aerosol cans manufactured in the U.S. annually. Many of the products contained in these cans, such as paint products, light lubricants, starting fluids, polishes and waxes, and cleaners, contain substantial amounts of volatile organic compounds (VOCs) as solvents and include flammable propellants. As a result, partially empty aerosol cans are treated as a hazardous waste at collection centers, military bases, industries utilizing large quantities of aerosols, and treatment, storage, and disposal facilities. Typically, an aerosol package consists of a pressurized liquid product packaged inside a hermetically sealed can that is dispensed through a push button spray tip/valve combination. The pressure is created in the aerosol can via a propellant that atomizes the chemical contents and creates the force to easily dispense the product through the valve/tip in a cost effective manner. The spray delivery which is efficient and effective is commonly used across a wide array of products. The hermetic seal saves the product from contamination during storage. 
         [0004]    Some specialized products use a bag or container inside a pressurized can. The liquid product is stored inside the bag and the propellant is inside the space in the can surrounding the bag. The propellant creates pressure on the bag to force the product through the spray tip/valve system for use. This type of aerosol packaging can be expensive and redundant and is typically used in creams and lotions. Given the public&#39;s concern about solid waste disposal, the aerosol industry teamed with the steel industry to promote the collection of empty aerosol cans in recycling programs nationwide. Thousands of communities now include aerosol product recycling in both household residential and curbside buy-back and drop-off programs. However, solid waste management firms are questioning the potential safety hazards of processing even ‘empty’ aerosols. This safety question is primarily due to the highly flammable propellants still contained in many cans even when the liquid contents are discharged. 
         [0005]    There have been extensive efforts to find alternative solutions to aerosol cans, many of which have proven unsatisfactory. The use of aerosol bags without the can is an option that has not been previously addressed in the prior art. The rigid exterior of a can has been considered essential because of safety concerns for a user in the event that an aerosol bag bursts, causing injury from the propellant materials contained inside the can, or the possibility of fire fueled by these materials. An enormous amount of resources are expended to manufacture cans, collect empty cans, and recycle the empty cans. As a result, it would be highly beneficial to find a solution for deploying aerosol bags but without the can and the propellant. Such a solution would eliminate flammability concerns during dispensing, while still providing the performance results of a spray can application. 
         [0006]    The present invention is a system that utilizes a flexible, crushable container similar to the type of container used in some aerosol products, although in this case without a surrounding can and propellant. A dispenser having an elongated housing is provided for receiving the bag. The dispenser is a gun type device that uses a plunger to apply force to the bottom of the bag while the top of the bag with the valve and spray tip is held securely in a slot or valve seat in the other end of the housing. The force exerted by the plunger within the housing creates the hydrostatic pressure inside the bag needed to spray the product through the valve and spray tip. A first trigger and handle on the device are squeezed together to exert force on the plunger. This, in turn, compresses a container spring creating the hydrostatic pressure inside the bag. The user then pulls a second trigger, which activates the valve and dispenses the product. As the product is dispensed, the bag collapses and the container spring extends to its free length. At this point there is little or no pressure on the bag. In a mechanical version of the system, the user renews the cycle by squeezing the first trigger and handle to move the plunger while compressing the container spring and re-creating the hydrostatic pressure needed to dispense remaining product from the bag. The user again pulls the second trigger to dispense the product. This cycle is repeated until the bag is emptied. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    For a better understanding of the present invention, and to show more clearly how it functions, reference will now be made, by way of example, to the accompanying drawings. The drawings show preferred embodiments of the present invention in which: 
           [0008]      FIG. 1  is a side exterior view of a first embodiment of the dispenser of the system of the present invention; 
           [0009]      FIG. 2  is a side exterior view of a first embodiment of a crushable container with a valve and spray tip; 
           [0010]      FIG. 3  is a side exterior view of a second embodiment of a crushable container with a valve and spray tip; and 
           [0011]      FIG. 4  is a side exterior view of a third embodiment of a crushable container with a valve and spray tip. 
           [0012]      FIG. 5  is a cross-sectional view showing the internal components of the present invention in a second embodiment; 
           [0013]      FIG. 6  is an exploded cross-sectional view of the plunger and associated components of the present invention wherein the plunger trigger is shown in an open position in the second embodiment; 
           [0014]      FIG. 7  is an exploded cross-sectional view of the plunger and associated components of the present invention wherein the plunger trigger is shown partially depressed in the second embodiment; 
           [0015]      FIG. 8  is an exploded cross-sectional view of the plunger and associated components of the present invention wherein the plunger trigger has been released in the second embodiment; 
           [0016]      FIG. 9  is an exploded cross-sectional view of the spray trigger and associated components of the present invention where the spray trigger is in an initial state in the second embodiment; 
           [0017]      FIG. 10  is an exploded cross-sectional view of the spray trigger and associated components of the present invention where the spray trigger is has been released in the second embodiment; 
           [0018]      FIG. 11  is a side exterior view of a third embodiment of the dispenser system of the present invention using an air bladder; 
           [0019]      FIG. 12  is a perspective view of a fourth embodiment of the invention; 
           [0020]      FIG. 13  is a cut-away side perspective view of the fourth embodiment of the invention; 
           [0021]      FIG. 14  is a cut-away side perspective view of a fourth embodiment showing a piston and associated components; 
           [0022]      FIG. 15  is a side exterior view of a fourth embodiment showing a crushable container with a valve and spray tip; and 
           [0023]      FIG. 16  is a perspective view of a fourth embodiment showing a cap, valve and spray tip. 
       
    
    
     DETAILED DESCRIPTION 
       [0024]    The present invention will now be described more fully with reference to the accompanying drawings. It should be understood that the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Throughout  FIGS. 1-16 , like elements of the invention are referred to by the same reference numerals for consistency purposes. 
         [0025]      FIGS. 1-11  show various views of a dispenser system  101  with a dispenser in the general shape of a gun. Elongated cylinder shaped housing  103  is configured to receive a flexible bag or flexible container  105 . Container  105  is shown in  FIGS. 2-4  with three different valve and tip embodiments, although there are other embodiments that would work with dispenser system  101  as well. 
         [0026]    Container  105  is sealed, and is filled with a sprayable liquid material such as paint. At one end of container  105  is a cap area that has a spray tip  107  situated at the end of a valve  109 . Valve  109  is attached to container  105 . Spray tip  107  can be of different types.  FIG. 2  shows spray tip  107  with a side spray configuration. This type of spray tip is activated by pushing down and to the side and is also referred to as a triangle tilt configuration.  FIGS. 3 and 4  show other spray tip types that are both activated by depressing the tip downward in a direction towards the body of bag  105 . 
         [0027]    Referring to FIGS.  1  and  5 - 11 , container  105  is placed in housing  103  with valve  109  seated in valve seat  113  that is set in the forward end of housing  103 . In  FIG. 1 , spray tip  107  is the depress-activated type like that shown in  FIG. 4 . A hinged panel  111  matching the shape of housing  103  opens to allow housing  103  to receive container  105  and closes once container  105  has been placed inside. Valve seat  113  is shaped to keep valve  109  in an immobilized state during operation of dispenser  101  with fingers  115  extending on either side of valve  109 . 
         [0028]    Alternative embodiments for activating spray tip  107  are contemplated and will be apparent to one skilled in the art. In the embodiments shown in  FIGS. 5-11 , trigger rod  117  makes contact with the forward surface of valve seat  113  and is attached to trigger plate  119 . Trigger plate  119  is a substantially triangular flat component that provides a mounting point at each of its three corners. While trigger rod  117  is attached to one mounting point, the second mounting point is attached to trigger bracket  121 . The third mounting point of trigger plate  119  is attached to spray trigger  123 . Trigger pin  125  secures trigger rod  117  such that, when a user pulls spray trigger  123 , trigger rod  117  pulls back spray tip  107  thereby allowing the pressurized contents of container  105  to spray through valve  109  and spray tip  107 , and deliver the contents of container  105  as needed. 
         [0029]    In an alternative embodiment for activating spray tip  107  shown in  FIG. 1 , spray trigger  123  can be mounted along the bottom of dispenser housing  103 . Instead of using trigger plate  119  and trigger bracket  121 , a design using a trigger extender  116 , trigger rod  117  and trigger rod spring  118  could be used. Trigger rod  117  is mounted to the end of trigger extender  116 . A trigger bracket  121  secures trigger extender  116  to housing  103 . By pulling back on spray trigger  123 , trigger extender  116  moves with trigger  123  to pull back on trigger rod  117 . This action pushes down on spray tip  107  releasing the materials from container  105 . 
         [0030]    A combination of a plunger trigger  127  and a handle  129  is used to apply a load to the bottom of container  105 . Plunger trigger  127  and handle are in a hinged configuration that is squeezed together to cause a pumping action that applies pressure to container  105 . The pumping action drives a plunger  131  that has progressive ratchet notches  133  along its length. A plunger bracket  134  is affixed to the housing for keeping plunger  131  in place and a plunger spring biases the plunger in position relative to housing bracket  134 . Pressure on container  105  can be re-applied as plunger  131  moves along its length and is re-engaged in the progressive notches as needed when pressure inside container  105  drops below an acceptable level. By repeatedly squeezing plunger trigger  127 , a piston spring  135  that sits between housing  103  and plunger bracket  134  is compressed and pressed forward against a piston (or force platen)  137 . Piston  137  is substantially flat on both sides and being of large enough width and mass to apply pressure on container  105  while maintaining its shape. The front surface  139  of piston  137  presses against a bottom surface  141  of container  105  with piston  137  being held in place by a surrounding interior surface  143  of housing  103 . It is contemplated that during use of dispenser  101 , a user alternates between pulling spray trigger  123  to dispense the contents of container  105  as needed, and pumping plunger trigger  127  to restore pressure to container  105 . 
         [0031]    A configuration for ratcheting plunger  131  is shown in  FIG. 6 . A biasing spring  145  and a jam plate  147  having a hole  149  for receiving the plunger  131  are shown. Jam plate  147  is disposed about plunger  131  and rests against an inside surface of handle  127  and a driving pin  151  attached to plunger trigger  127 . Biasing spring  145  urges jam plate  47  away from housing  103  so that it is pressed against driving pin  151  and plunger trigger  127   
         [0032]    A description of the operation of the biased-spring  145  is as follows: handle  129  is depressed in the direction of arrow  153 , pivoting about pivot pin  155  so that driving pin  151  moves the lower edge of jam plate  147  forward, toward housing  103 . This causes the jam plate to cant so that it jams on one of the notches  133  along the length of plunger  131 . Then, as plunger trigger  127  is moved further in the direction of arrow  153 , jam plate  147  and plunger  131  move together towards housing  103 .  FIG. 7  shows plunger trigger  127  in the fully depressed state. 
         [0033]    When plunger trigger  127  is released it moves in the direction of arrow  155 , as shown in  FIG. 8 . Jam plate  147  and plunger  131  move backward, together, away from housing  103 . When plunger trigger  127  is fully released, jam plate  147  again rests against the inside surface of handle  129  and driving pin  151 , having been moved back into position by biasing spring  145 . With plunger trigger  127  fully released, as shown in  FIG. 5  there is no resistance on plunger  131  and it slides freely through handle  129 , jam plate  147 , biasing spring  145 , and housing  103 . 
         [0034]    The action of plunger  131  drives piston  137  against bottom surface  141  of container  105  crushing it from the bottom up as piston  137  moves along inside housing  103 . As noted above, piston  137  is preferably a solid disk shape with a width large enough to prevent it from bending or otherwise causing it to become misshapen as it exerts force on container  105 . Piston  137  may be made of metal, plastic or other materials that hold their shape. The operative features of piston  137  will now be described. 
         [0035]    As described above, operation of plunger trigger  127  in the direction of arrow  153  moves plunger  131  while simultaneously allowing piston spring  135  to extend to push piston  137  against bottom surface  141  of container  105 . As shown in  FIG. 6  and  FIG. 7 , moving plunger  131  in the direction of container  105  causes piston  137  to contact and exert force on container  105  crushing it as piston  137  slides along the inside of housing  103 . The crushing action on container  105  continues as piston spring  135  and piston  137  move in unison along the inside of housing  103 . In addition to having a width permitting it to maintain its shape, piston  137  is also designed in a cylindrical shape to fit snugly within the cylindrical interior portion of housing  103 . Interior surface  143  of housing  103  acts as a guide for piston  137  to keep it in place as it moves inside housing  103 . 
         [0036]    While forming housing  103  and piston  137  in a cylindrical shape has been proven to work, it is also possible that housing  103  and piston  137  could take on other shapes provided they are compatible. Interior surface  143  of housing  103  functions as a guide for piston  137  as the sidewalls of piston  137  contact interior surface  143  during operation of dispenser  101 . It should also be noted that housing  103  works best when fully enclosed. One embodiment that is shown in the figures includes hinged panel  111  that is closed once container  105  is seated within housing  103 . A hinge works well to ensure proper positioning of panel  111  and to prevent loss of panel  111  when it is open during loading of container  105 . However, panel  111  could be removable without a hinge using tabs or other components to keep it in place. Or, slots could be cut in the side of housing  103  to allow the user to have a view of container  105  during operation so that a user can determine when container  105  is empty or nearly empty. 
         [0037]    Once plunger  131  is locked in place, jam plate  147  engages one of notches  133  along plunger  131  and container  105  is under pressure from piston  137  as it exerts force against bottom surface  141  of container  105 . Container  105  is ready to release its contents through spray tip  107  as shown in  FIG. 9 . 
         [0038]    To operate spray tip  107 , a user pulls spray trigger  123  as shown in  FIG. 10  in the direction of arrow  157 . Trigger rod  117  contacts the forward surface of valve seat  113  and is attached to trigger plate  119 . Trigger plate  119  is a substantially triangular flat component that provides a mounting point at each of its three corners. While trigger rod  117  is attached to one mounting point, the second mounting point is attached to trigger bracket  121 . The third mounting point of trigger plate  119  is attached to spray trigger  123 . Trigger pin  125  secures trigger rod  117  such that, when a user pulls spray trigger  123 , trigger rod  117  pulls back spray tip  107 , thereby allowing the pressurized contents of container  105  to spray through valve  109  and spray tip  107 , and deliver the contents of container  105  as needed. There are many ways to design spray trigger  123  to cause spray tip  107  to open and release the contents of container  105  depending on the type of spray tip used. Two embodiments have been described herein, but many others would be apparent to one skilled in the art. 
         [0039]      FIG. 11  shows a pump  161  and air bladder  159  in combination to apply pressure to the piston and compress the container in place of the spring and plunger. By pumping up air bladder  159  with pump  161 , air bladder  159  expands at expansion areas  163  to apply pressure directly to container  105  with the other components of the dispenser being as described above with respect to  FIGS. 1-10 . It is also possible to use a compressed air cartridge power source as an alternative to pump and air bladder  159  as a source of pressure against the piston. 
         [0040]    A fourth embodiment will now be described with respect to  FIGS. 12-16 .  FIG. 12  shows a perspective view of a fourth embodiment of the invention. In the embodiment of  FIG. 12 , dispenser  101  includes an elongated mounting rod  1205 , on which handle  129  and trigger  123  are positioned at one end, and housing  103  is positioned at the other end. Mounting rod  1205  extends the length of dispenser system  101  and permits a user to grasp handle  129  and operate trigger  123  at a distance from spray tip  107  so that spray tip may be near a spray target while the operator of system  101  is at a comfortable distance holding handle  129 . For example, this configuration works well when system  101  is being used to spray a line down a length of road or on a grassy area to indicate the location of a gas line, water line, electrical line or other utility line. While mounting rod  1205  is useful in these types of applications, it is also possible to mount handle  129  and trigger  123  directly to housing  103  or an added upper portion  1208  of housing  103  within which other components of system  101  may be housed. 
         [0041]    According to the design of the fourth embodiment, flexible container  105 , spray tip  107 , valve  109  and valve seat  113  are all configured similarly to the other embodiments described above. A cylindrical shaped end cap  1215  shown in detail in  FIG. 16  is positioned over the end of flexible container  105  to ease the seating of valve  109  in valve seat  113 . It should be understood that end cap  1215  is an optional component and is not necessary for effective operation of the invention. If end cap  1215  is used, spray tip  107  and valve  109  are inserted through an opening in end cap  1215  and spray tip  107  and valve  109  further pass through to the outside of housing  103 . End cap  1215  may be made of plastic, aluminum or other molded, lightweight, inexpensive material. During the process of sliding within housing  103  and crushing bag  105 , as piston  1305  reaches the top of bag  105 , it engages snugly against the open end of end cap  1215  to ensure that the contents of the bag are fully exited from bag  105 . 
         [0042]    Hinged panel  111  attached to housing  103  rotates between an open position in which flexible container  105  may be inserted into housing  103 , and a closed position in which panel  111  forms a portion of housing  103  to securely maintain flexible container  105  within housing  103 . 
         [0043]    A guide wheel  1205  is shown attached to upper portion  1208  of housing  103 . Guide wheel  1205  may be used to maintain the spray tip at a particular distance from the spray target as it is rolled along the ground or a wall. Guide wheel  1205  is an optional feature of dispenser  101 . 
         [0044]    A movable piston  1305  is shown in the cutaway view of dispenser  101  in  FIG. 13  where the interior of housing  103  can be seen. Piston  1305  is biased against flexible container  105  and operates in a manner similar to piston  137  as described with respect to the embodiment of  FIG. 1 . Instead of using a trigger  127  to apply pressure to piston  137  against flexible container  105  as in the above described embodiments, in the embodiment of  FIGS. 12-16 , a coil spring  1330  is used. Coil spring  1330  is positioned inside housing  103  with an uncoiled end portion  1335  attached to piston  1305 . Coil springs of the type such as coil spring  1330  as shown are well known and are biased to draw uncoiled end portion  1335  back towards coil  1330 . In so doing, coil spring  1330  applies continuous pressure to piston  1305  to maintain piston  1305  in contact with the bottom of bag  105  pulling piston  1305  against bag  105  as bag  105  is crushed. The dimensions and tension of coil spring  1330  are design choices for the designer and depend on the size of bag  105 , housing  103  and the positioning of coil spring  1330  in housing  103  relative to piston  1305 . 
         [0045]    A hinged lever  1310  (see  FIG. 13 ) attached to a shell  1210  that matches the shape of the bottom of housing  103  is used to release piston  1305  so that a new bag may be inserted in dispenser  101  when the current bag has been emptied. When shell  1210  pivots between an open and a closed position, hinged lever  1310  mounted to the inside surface of shell  1210  moves an arm  1315 , a first end of which is attached to hinged lever  1310  and a second end of which fits in a slot  1320  in a rib  1325  extending from the backside of piston  1305 . When hinged lever  1310  is pivoted open or closed, a pin  1345  at the second end of arm  1315  moves through slot  1320  (see  FIG. 14 ) between the two ends  1340   a  and  1340   b  of slot  1320 . While a new container is inserted into housing  103 , lever  1310  is open and arm  1315  is at end  1340   a . When lever  1310  is closed, arm  1315  slides to end  1340   b  in slot  1320  and coil spring  1330  engages piston  1305  causing it to be pulled against flexible container  105 . Pressure from coil spring  1330  is applied to the bottom of container  105 , which in turn maintains pressure on the contents of container  105 . 
         [0046]    While the invention has been described with respect to the figures, it will be appreciated that many modifications and changes may be made by those skilled in the art without departing from the spirit of the invention. Any variation and derivation from the above description and drawings are included in the scope of the present invention as defined by the claims. For example, in the alternative, dispenser  101  may be implemented using an electric or battery powered plunger and piston arrangement that may be adapted for use from the description of U.S. Pat. No. 6,123,235 to Hsu which is incorporated by reference herein. A battery powered plunger and piston of the type described by Hsu would eliminate the need to manually ratchet the plunger and piston configuration of the present invention. In addition, instead of using a coil spring to apply pressure to the piston as shown in the fourth embodiment of  FIGS. 12-16 , a spring-loaded rotating spool onto which a cloth or nylon band or cord is spooled could be used to apply tension to the piston.