Abstract:
A sprayer that delivers a pattern of paint that can be obtained from a container. The sprayer generally includes a sprayer body that emits the pattern with the paint. The sprayer also includes a reservoir including a cavity that when connected thereto provides the paint to the sprayer body. The reservoir includes a cylinder and a piston assembly manually movable in the cylinder to draw the paint into the cylinder when the reservoir is connected to the container.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/261,953, filed on Nov. 17, 2009. The entire disclosure of the above application is incorporated herein by reference. 
     
    
     FIELD 
       [0002]    The present disclosure relates to a sprayer for spraying fluids including paints and stains and a reservoir body for holding such liquids. 
       BACKGROUND 
       [0003]    This section provides background information related to the present disclosure which is not necessarily prior art. 
         [0004]    Typically, when changing paint in a paint sprayer, a reservoir of paint is emptied and cleaned before different paint is introduced. Cleaning the reservoir can expose the sprayer body and pump to the cleaning process. Filling the reservoir with paint can also be a messy process. 
       SUMMARY 
       [0005]    This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. 
         [0006]    The present teachings generally include a sprayer that delivers a pattern of paint that can be obtained from a container. The sprayer generally includes a sprayer body that emits the pattern with the paint. The sprayer also includes a reservoir including a cavity that when connected thereto provides the paint to the sprayer body. The reservoir includes a cylinder and a piston assembly manually movable in the cylinder to draw the paint into the cylinder when the reservoir is connected to the container. 
         [0007]    Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
     
    
     
       DRAWINGS 
         [0008]    The drawings described herein are for illustrative purposes only of certain aspects of the present teachings and not all possible implementations, and are not intended to limit the scope of the present teachings. 
           [0009]      FIG. 1  is a side elevation view of a sprayer constructed in accordance with the present teachings. 
           [0010]      FIG. 2  is a perspective view of a reservoir body of the sprayer of  FIG. 1  constructed in accordance with the present teachings. 
           [0011]      FIG. 3  is an exploded perspective view of the reservoir body of  FIG. 2  constructed in accordance with the present teachings. 
           [0012]      FIG. 4  is a partial cross-sectional view of a portion of the sprayer of  FIG. 1  illustrating the reservoir body connected to the sprayer body and constructed in accordance with the present teachings. 
           [0013]      FIGS. 5 and 6  are perspective views of a container adapter to facilitate adding liquid to the reservoir body in accordance with the present teachings. 
           [0014]      FIG. 7  is a partial perspective view illustrating the attachment of the container adapter of  FIG. 6  to a paint container constructed in accordance with the present teachings. 
           [0015]      FIG. 8  is a perspective view illustrating the container adapter of  FIG. 6  coupled to the paint container and employed to guide a stream of liquid dispensed from the paint container adapter through a pour port that is constructed in accordance with the present teachings. 
           [0016]      FIGS. 9 and 10  are partial perspective views illustrating the use of the container adapter of  FIG. 6  with the reservoir body of  FIG. 2  in accordance with the present teachings. 
           [0017]      FIGS. 11 ,  12 ,  13 , and  14  are perspective views illustrating further examples of means for coupling a reservoir to a sprayer body constructed in accordance with the present teachings. 
           [0018]      FIGS. 15 and 16  are exploded perspective views illustrating further examples of means for coupling a reservoir to a sprayer body constructed in accordance with the present teachings. 
       
    
    
       [0019]    Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
       DETAILED DESCRIPTION 
       [0020]    Example aspects of the present teachings will now be described more fully with reference to the accompanying drawings. 
         [0021]    With reference to  FIGS. 1 and 2 , a sprayer constructed in accordance with the present teachings is generally indicated by reference numeral  100 . The sprayer  100  can include a sprayer body  102  and a reservoir  104  that can be removably coupled to the sprayer body  102 . With reference to  FIGS. 2 ,  3 , and  4 , the reservoir  104  can comprise a cylinder  110 , a valve assembly  112 , and a piston assembly  114 . 
         [0022]    The cylinder  110  can comprise a cylinder structure  120 , an upper cap member  122 , and a threaded ring  124 . The cylinder structure  120  can be unitarily formed, but in the example provided, can include a cylinder member  130  and an externally threaded ring member  132  that can be fixedly coupled to a lower end of the cylinder member  130 . The cylinder member  130  can be formed of a transparent plastic material, such as an acrylic plastic, which can permit the user of the sprayer  100  to determine the extent to which a cavity  134  of the cylinder structure  120  is filled with paint (or other suitable liquid) that is to be dispensed from the sprayer  100 . 
         [0023]    With reference to  FIGS. 3 and 4 , the upper cap member  122  can be fixedly coupled to an upper end  136  of the cylinder member  130 . The upper cap member  122  can include an end member  140 , a threaded exterior mount  142 , and a coupling neck  144 . The end member  140  can be contoured on its interior surface  148  in a desired manner to permit air within the cylinder structure  120  to collect immediately below the coupling neck  144 . In the example, the interior surface  148  can be tapered toward the coupling neck  144  (i.e., the interior surface  148  can be frusto-conically shaped with the narrower end of the frusto-conical shape extending in a direction away from the cylinder member  130 ). It will appreciated in light of the disclosure that other shapes, such as a spherical radius, can also be shown to be effective in collecting air within the cylinder structure  120  below the coupling neck  144 . 
         [0024]    The threaded exterior mount  142  can be integrally formed with the end member  140  and can extend about the outer circumferential surface of the upper cap member  122 . The threaded exterior mount  142  can comprise a plurality of threads that can be threadably engaged to a collar  150  of the sprayer body  102  to couple (and uncouple) the reservoir  104  to the sprayer body  102 . The coupling neck  144  can include a neck structure  154  and one or more seal members  156 . The neck structure  154  can define an outlet port  160  that can be employed to discharge paint contained in the reservoir  104 . The neck structure  154  can be a tubular member that can extend from the end member  140  and can be configured to engage and establish a fluid connection with an inlet  162  of a pump assembly  164  in the sprayer body  102   
         [0025]    In one example, a single seal member  170  (e.g.: an o-ring, or a lip seal) is received in a groove  172  in the neck structure  154  and can form a seal between an exterior surface of the neck structure  154  and an interior surface of the inlet  162  of the pump assembly  164 . It will be appreciated in light of the disclosure that the inlet  162  can be contoured (e.g.: tapered, or rounded) to permit the coupling neck  144  to be introduced to the inlet  162  without sealing engagement and thereafter sealing engagement can be produced when the coupling neck  144  is translated into (or further translated into) the inlet  162  by threading the collar  150  onto the threaded exterior mount  142 . 
         [0026]    The threaded ring  124  can be threadably engaged to the externally threaded ring member  132  and can include an annular abutment  174  that can be employed to restrict movement of the piston assembly  114  in a direction away from the upper cap member  122 . It will be appreciated in light of the disclosure that removal of the threaded ring  124  from the externally threaded ring member  132  can permit the piston assembly  114  to be removed from the cylinder member  130 . 
         [0027]    The valve assembly  112  can comprise a valve element  180  that can be moved between a closed position and an open position to selectively vent air from the cylinder  110 , discharge liquid from the cylinder  110 , or draw liquid into the cylinder  110  or both. In one example, the valve element  180  can be a hollow ball and the valve assembly  112  further comprises a ball cage  182  and a valve seat  184 . The ball cage  182  can be fixedly coupled to the upper cap member  122  and can be configured to confine the movement of the valve element  180  within a predetermined range. The valve seat  184  can be a separate component as is illustrated, or can be integrally formed with the upper cap member  122 . The valve seat  184  can be configured to engage the valve element  180  to close the outlet port  160 . In some instances, the valve assembly  112  can further comprise an elastic element, such as a spring  186  that can bias the valve element  180  in a direction toward the valve seat  184 , i.e., in a direction that closes the outlet port  160 . 
         [0028]    The piston assembly  114  can comprise a piston  190 , a seal system  192 , and a handle  194 . The piston  190  can be received in the cylinder member  130  for translation between the upper cap member  122  and the annular abutment  174 . The seal system  192  can comprise one or more seal members  196  that can be received between the piston  190  and an interior surface of the cylinder member  130 . In one example, the seal system  192  comprises a single seal member  196  having a pair of lip seals  198 . The handle  194  can be coupled to a side of the piston  190  opposite the upper cap member  122  and can be employed to permit the user of the sprayer  100  to manually move the piston  190  within the cylinder  110 . 
         [0029]    With reference to  FIGS. 5 and 6 , a container adapter  300  is illustrated. The container adapter  300  can comprise a lid portion  302  and a supply tube  304 . In one example, the lid portion  302  and the supply tube  304  can be discrete components that can be coupled to one another, but it will be appreciated in light of the disclosure that the lid portion  302  and the supply tube  304  can also be integrally formed. 
         [0030]    With reference to  FIGS. 5 ,  6 , and  7 , the lid portion  302  can comprise a lid flange  310 , a pour port  312 , a pour spout  314 , a fill port  316 , and a decoupling handle  318 . In one example, the lid portion  302  can be unitarily formed in a suitable process, such as injection molding, but it will appreciated in light of the disclosure that the lid portion  302  can also be formed of two or more components. 
         [0031]    The lid flange  310  can comprise a generally planar lid member  320  and a circumferentially extending sealing rim  322 . The lid member  320  can be configured to cover all or a portion of an opening  330  in a container  332  that holds paint (or other suitable liquid) that is to be dispensed by the sprayer  100 . The sealing rim  322  of the container adapter  300  can be configured to engage the container  332  (e.g.: a paint can) when the lid portion  302  is secured to the container  332 . In this regard, leakage can be avoided between the lid flange  310  and the top of the container  332  when liquid is poured from the container  332 . In the various examples, the container  332  can be a conventionally-shaped and constructed one-gallon pail (e.g.: a pail that holds a gallon of paint) having an annular top rim  336  that can define the opening  330 . In this arrangement, the sealing rim  322  can be configured to engage the inside diameter of the annular top rim  336 . 
         [0032]    The lid flange  310  can include one example of means for securing the lid member  320  to the container  332 . The means for securing the lid member  320  to the container  332  include a plurality of resilient tabs  340  that are formed into the sealing rim  322 . The resilient tabs  340  can be configured to deflect radially inwardly in response to contact with the annular top rim  336  when the lid flange  310  is seated against the top of the container  332  and thereafter disengage and release (or snap back) against the underside of the annular top rim  336 . The resilient tabs  340  can form pivoting hooks that can be employed to releasably secure the lid flange  310  to the top of the container  332 . It will be appreciated in light of the disclosure that the means for securing the lid flange  310  to the sealing rim  322  can be tailored to the particular type of container that is employed and as such, the particular examples provided are not to be interpreted as limiting the scope of the present teachings. 
         [0033]    The pour port  312  can comprise an aperture that can be formed through the lid member  320  proximate a radially outward edge of the lid flange  310 . The pour spout  314  can be an arcuate or angular structure (e.g.: V-shaped) that can be coupled to the lid member  320  proximate the pour port  312 . With reference to  FIG. 8 , the pour spout  314  can extend outwardly and upwardly from the lid member  320  and can be configured to cooperate with the pour port  312  to aid in controlling a stream of paint (or other suitable liquid) dispensed from the container  332  through the pour port  312 . Preferably, the pour spout  314  can extend radially outwardly from the lid member  320  to an extent where liquid dispensed from the container  332  through the pour port  312  does not contact the container  332 , e.g.: the annular top rim  336 . 
         [0034]    With reference to  FIGS. 5-10 , the fill port  316  can be a hollow structure that can include an annular side wall  350  that can define an interior surface  352  that can be configured to engage the coupling neck  144  of the reservoir  104 . The fill port  316  can include a valve opening feature that can be configured to contact the valve element  180  and urge the valve element  180  away from the valve seat  184 . The fill port  316  and the coupling neck  144  can be configured such that the valve element  180  can contact the valve opening feature each time the coupling neck  144  is inserted into the fill port  316 . In another instance, contact between the valve element  180  and the valve opening feature can occur only when the coupling neck  144  is oriented in a predetermined position relative to the fill port  316 . In these arrangements, the valve assembly  112  can be opened automatically upon engagement of the reservoir  104  to the lid portion  302 . 
         [0035]    The decoupling handle  318  can be coupled to the lid flange  310  at an appropriate location and can be employed to remove (or pry) the lid member  320  away from the container  332  so as to remove the lid portion  302  from the container  332 . 
         [0036]    The supply tube  304  can be a generally tubular structure that can be engaged to the fill port  316  (e.g.: with a friction fit, or threads). The supply tube  304  can effectively extend the fill port  316  to a location proximate the bottom of the container  332 . To fill the reservoir  104 , the supply tube  304  can be coupled to the fill port  316  and the lid portion  302  can be secured to the container  332  such that a bottom end of the supply tube  304  can be disposed below the upper level of the liquid in the container  332 . 
         [0037]    With reference to  FIGS. 7 ,  8 ,  9 , and  10 , the piston assembly  114  can be urged upwardly in the cylinder  110  toward the upper cap member  122  to purge air from the interior of the cylinder  110 . When the valve element  180  is not biased into the closed position (e.g.: with a spring), the reservoir  104  can be oriented in an upright condition (i.e., with the coupling neck  144  pointing upwardly) while the piston assembly  114  is moved toward the upper cap member  122 . Additionally or alternatively, the reservoir  104  can be equipped with a vent system (not shown) that permits the operator to move the valve element  180  away from the valve seat  184  ( FIG. 3 ) or to open another valve (not shown), such as a valve that is incorporated into the piston  190  to relieve air from the interior of the cylinder  110  as the piston assembly  114  is moved toward the upper cap member  122 . 
         [0038]    With reference to  FIGS. 7-10 , the coupling neck  144  of the reservoir  104  can be inserted into and engaged to seal with the fill port  316 . The handle  194  of the piston assembly  114  can be drawn at an applicable pace away from the upper cap member  122 . This in turn can draw liquid in the container  332  up through the supply tube  304  ( FIG. 6 ), the fill port  316 , the coupling neck  144 , and into the interior of the cylinder  110 . It will be appreciated in light of the disclosure that some air may be drawn into the cylinder  110  as the reservoir  104  is filled. In situations where the valve element  180  is not biased into the closed position, the weight of the liquid in the reservoir  104  can close the valve element  180  against the valve seat  184  so the reservoir  104  can be removed from the fill port  316  and turned upright to permit the air to be purged from the interior of the cylinder  110 . The air can be purged by urging the piston assembly  114  toward the upper cap member  122 . In instances where the valve element  180  is biased into the closed position, the vent system can be employed to open the valve element  180  and/or another valve to permit air to be purged from the interior of the cylinder  110 . 
         [0039]    The reservoir  104  can be coupled to the sprayer body  102  to provide paint to the sprayer  100 . During operation, blowback (from the pumping action) can be routed to a supply conduit to maintain a relatively high degree of suction at the coupling neck  144 , which in turn tends to draw the piston assembly  114  upward in the cylinder  110  as liquid is drawn from the cylinder  110 . The seal members  192  on the piston assembly  114  can wipe (or wipe clean) the interior surface of the cylinder  110  as the piston assembly  114  translates so as to permit the operator of the sprayer to visually determine the amount of liquid within the cylinder  110 . 
         [0040]    It will be appreciated that the container adapter  300  can have utility beyond its use with the sprayer  100  and as such, it may be modified somewhat from that which is illustrated in  FIGS. 5-10 . Specifically, the fill port  316  can be omitted from the lid portion  302  and the supply tube  304  can be omitted altogether, as applicable. 
         [0041]    The reservoir  104  has been described as being removably coupled to the sprayer body  102  using a threaded connection. Additional examples of other means for coupling a reservoir to a sprayer body can be employed, as illustrated in  FIGS. 11-16 . A latch system  400 , for example, can be employed to couple a reservoir  402  to a sprayer body  404 , as shown in  FIGS. 11-14 . The latch system  400  can comprise a first latch portion  410 , which can be coupled to the sprayer body  404 , and a second latch portion  412  that can be coupled to the reservoir  402 . 
         [0042]    With continuing reference to  FIGS. 11-14 , the first latch portion  410  can comprise a yoke  420 , a first sealing flange  422 , and a first latch member  424 . The yoke  420  can comprise a saddle  430  having an arcuate saddle surface  432 . The first sealing flange  422  can be coupled between the yoke  420  and the first latch member  424 . In one example, the first latch member  424  comprises a tab that defines having a latch aperture  438 . 
         [0043]    The second latch portion  412  can comprise a pivot  440 , a second sealing flange  442 , and a second latch member  444 . The pivot  440  can be a cylindrically shaped structure that can be coupled to the second sealing flange  442  via a pair of arms  450 . The yoke  420  can be received between the arms  450  such that the arcuate saddle surface  432  can pivot or rotate on the exterior surface of the pivot  440 . The second sealing flange  442  can be configured to engage the first sealing flange  422  and when desired, a gasket (not shown) can be disposed between the first and second sealing flanges  422  and  442  to form a seal therebetween. The second latch member  444  can comprise a resilient tab member  460  that can be deflected to be received through the latch aperture  438  and thereafter released to abut against the first latch member  424  to inhibit relative pivoting movement about the pivot  440  between the first and second latch portions  410  and  412 . 
         [0044]    With reference to  FIGS. 1 ,  2 ,  15 , and  16 , another example of a means for coupling a reservoir to a sprayer body is illustrated. The means for coupling can comprise a collar  150 , a sprayer adapter  500 , and a coupler  502  that can be configured to be mounted to the reservoir  104  ( FIG. 2 ). The sprayer adapter  502  can comprise a plate member  510 , a coupling nipple  512 , and a pair of coupling arms  514 . The plate member  510  can comprise a plurality of threads  516  that can be threadably engaged to the threads of the collar  150  to fixedly but removably attach the sprayer adapter  500  to the sprayer body  102  ( FIG. 1 ). The coupling nipple  512  can be configured to engage an inlet  162  of the pump assembly  164  ( FIG. 1 ) when the sprayer adapter  500  is coupled to the sprayer body  102 . The coupling arms  514  can be hook-like in shape and can extend from the plate member  510  on a side opposite the collar  150 . 
         [0045]    The coupler  502  can comprise a coupler body  520 , a coupler member  522 , and a means for biasing the coupler member  522  relative to the coupler body  520 , such as a pair of helical compression springs  524 . The coupler body  520  can be an annular structure that can be fixedly coupled to the upper cap member  122  ( FIGS. 2 and 3 ) of the reservoir  104 . The coupler body  520  can comprise a bottom plate  530 , and an annular wall  532  that is coupled to and extends circumferentially around the bottom plate  530 . The coupler body  520  can also comprise a slotted aperture  534  that can be formed in the annular wall  532 , and a pair of guide pins  536 . The annular wall  532  can be configured to engage the perimeter of the plate member  510  to align the coupling neck  144  ( FIGS. 2 and 3 ) to the coupling nipple  512 . The coupler body  520  and the sprayer adapter  500  can be keyed to one another to control and fix the orientation of the coupler  502  as it is installed to the sprayer adapter  500 . Additionally or alternatively, indicia can be employed on the sides of the coupler body  520  and the sprayer adapter  502  to assist the user of the sprayer to properly orient the coupler  504  to the sprayer adapter  502 . 
         [0046]    The coupler member  522  can comprise a body  540 , a pair of mating coupling arms  542 , and a tongue  544 . The body  540  can define a pair of apertures  550  for receiving the guide pins  536 , and a pair of spring apertures  552  that can be configured to receive the helical compression springs  524 . The mating coupling arms  542  can be fixedly coupled (e.g., integrally formed with) the body  540  and can be configured to be engaged to or disconnected from the coupling arms  514  of the sprayer adapter  500  to fix the coupler member  522  to the sprayer adapter  500 . The tongue  544  can be received through the slotted aperture  534 . The guide pins  536  of the sprayer adapter  502  can be received in the apertures  550 . The helical compression springs  524  can be fitted over the guide pins  536  and can be disposed in the spring apertures  552 . The helical compression springs  524  can urge the coupler member  522  in a direction relative to the sprayer adapter  500  such that the tongue  544  can extend (or extend further) out of the slotted aperture  534 . 
         [0047]    To couple the reservoir  104  to the sprayer body  102 , the annular wall  532  can be fitted to the perimeter of the plate member  510  to align the coupling neck  144  ( FIGS. 2 and 3 ) to the coupling nipple  512 . The tongue  544  can be pressed toward the coupler body  520  to retract the coupler member  522  within the coupler body  520 . In the retracted position, the coupler  502  can be fitted to the sprayer adapter  500  such that the mating coupling arms  542  do not engage the coupling arms  514 . 
         [0048]    In one example, the coupling neck  144  ( FIGS. 2 and 3 ) can engage the coupling nipple  512  prior to the point at which the mating coupling arms  542  can contact the coupling arms  514 . The mating coupling arms  542  and the coupling arms  514  can include tapered surfaces  560  that can engage one another to urge the coupler member  522  relative to the sprayer adapter  500  to permit the mating coupling arms  542  to pass beyond the coupling arms  514 . When the coupler  502  is fully inserted to sprayer adapter  500 , the coupler member  522  can be released to permit the helical coil springs  524  to urge the coupler member  522  outwardly from the coupler body  520  such that confronting surfaces  570  on the coupling arms  514  and the mating coupling arms  542  engage one another. In this arrangement, the coupler member  522  can also inhibit rotation of the coupler  504  relative to the sprayer adapter  502  to inhibit the removal of the reservoir  104 ,  402  from the sprayer body  102 ,  404 . 
         [0049]    The foregoing description of the various aspects of the present teachings has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the present teachings. Individual elements or features of a particular aspect of the present teachings are generally not limited to that particular aspect, but, where applicable, are interchangeable and can be used in various selected aspects, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the present teachings, and all such modifications are intended to be included within the scope of the present teachings. 
         [0050]    The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed. 
         [0051]    When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. 
         [0052]    Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer, or section from another region, layer, or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of the example embodiments. 
         [0053]    Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.