Abstract:
The subject invention relates to a power sprayer that offers flexibility of movement because it can be battery operated and is designed to eliminate the need for cleaning its spray nozzle after being used. Paint colors can be changed quickly by simply changing the media cartridges that are adapted for simple attachment to the sprayer. The media cartridges used in conjunction with the sprayers of this invention can also eliminate the inconvenience associated with refilling conventional power sprayers with a desired media. The present invention more specifically discloses a sprayer media cartridge system comprising: (a) a media container, (b) a self-cleaning nozzle, (c) a media shut-off means, (d) a primary media atomizing aperture in a configuration relative to the self-cleaning nozzle, (e) a movable media containment member within the media container, (f) a gas transfer interface, and (g) a power unit engagement means.

Description:
[0001]    This application is a divisional of U.S. patent application Ser. No. 12/502,577, filed on Jul. 14, 2009 (presently pending) which claims benefit of U.S. Provisional Patent Application Ser. No. 61/080,406, filed on Jul. 14, 2008. The teachings of U.S. Provisional Patent Application Ser. No. 61/080,406 and U.S. patent application Ser. No. 12/502,577 are incorporated herein by reference in their entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    A wide variety of consumer products are frequently packaged in aerosol cans. These products include paints, hair spray, insecticides, herbicides, air fresheners, perfumes, fragrances, antimicrobial agents, cleaners, anti-sticking agents, and the like. Even though packaging these types of products in aerosol cans has been well accepted by consumers for decades, the continued use of aerosol cans for packaging consumer products is coming under greater and greater scrutiny. Most of the criticism relating to the use of aerosol cans originates from the thesis that aerosols are harmful to the environment. Additionally, the aerosol cans themselves are typically discarded after being used and generally end up in landfills as solid waste. In actual practice the steel of which aerosol cans are made is seldom recycled. 
         [0003]    Aerosol cans also have the drawback of potentially exploding and causing personal injury and/or property damage if they are exposed to high temperatures during storage or transportation. This danger of explosion limits the manner in which products that are packaged in aerosol cans are transported, stored, and utilized. 
         [0004]    Power sprayers that can be used to apply liquid compositions, such as paints, insecticides, lubricants, and the like to substrates are a viable alternative to aerosols. In fact, power sprayers circumvent many of the problems associated with the use of aerosols. For instance, the use of power sprayers does not present the explosion hazard or the environmental concerns associated with aerosol products. However, power sprayers are frequently awkward to handle and difficult to clean after being used. 
       SUMMARY OF THE INVENTION 
       [0005]    The subject invention relates to a power sprayer that can be conveniently used by both professionals and amateurs. This power sprayer offers flexibility of movement because it can be battery operated. It also is designed to eliminate the need for cleaning its spray nozzle after being used. The media being sprayed can also be easily changed quickly and easily. For instance, paint colors can be changed quickly and repeatedly by simply changing the media cartridges that are adapted for simple attachment to the sprayer. The media cartridges used in conjunction with the sprayers of this invention also eliminate the inconvenience associated with refilling conventional power sprayers with a desired media. Even more importantly, it eliminates the need for extensive clean-up and cleaning materials, such as solvents, rags, paper towels, etc., which is time-consuming and has a negative impact on the environment. One of the most important benefits of the present invention is the ability to deliver virtually any media, including waterborne systems, without compromising the spray quality and flexibility of a spray can. In fact, the power sprayer of this invention offer even better flexibility than conventional sprayers or spray cans by virtue of being capable of being used while in any orientation. 
         [0006]    The present invention more specifically discloses a media cartridge system for a sprayer comprising: (a) a media container, (b) a self-cleaning nozzle, (c) a media shut-off means, (d) a primary media atomizing aperture in a configuration relative to the self-cleaning nozzle, (e) a movable media containment member within the media container, (f) a gas transfer interface, and (g) a power unit engagement means. 
         [0007]    The subject invention further discloses a sprayer which is comprised of ( 1 ) an electrical power source, ( 2 ) an electric motor, ( 3 ) a pump which is driven by the motor, ( 4 ) an output, ( 5 ) an electrical control switch, ( 6 ) a media cartridge air transfer interface, ( 7 ) a media cartridge engagement means, and ( 8 ) a media cartridge which is comprised of (a) a media container, (b) a self-cleaning nozzle, (c) a media shut-off means, (d) a primary media atomizing aperture in a configuration relative to the self-cleaning nozzle, (e) a movable media containment member within the media container, (f) a gas transfer interface, and (g) a power unit engagement means. 
         [0008]    The present invention also reveals a sprayer which is comprised of ( 1 ) a power unit which includes (a) an electrical power source, (b) an electric motor, (c) a pump which is driven by the motor, (d) an output control, and (e) an electrical control switch, ( 2 ) a nozzle unit which includes (a) a media cartridge air transfer interface, (b) a power unit engagement means, (c) a gas transfer interface, and ( 3 ) a media container wherein the media container includes (a) a media cartridge engagement means, (b) a movable media containment member within the media container, (c) a media container air transfer interface and (d) a media supply line interface. 
         [0009]    The subject invention further discloses a sprayer having a configuration which comprises a media outlet, a storage device/energy source (such as a capacitor, a fuel cell or a battery), at least one primary atomization outlet, and at least one spray pattern shaping/secondary outlet that minimizes power usage, wherein the primary outlet utilizes higher pressure than the secondary outlet, wherein the higher pressure utilized by the primary outlet is at least 2 times the pressure of the pressure utilized by the secondary outlet and wherein the primary atomization aperture is configured in a convex shape relative to the media aperture to provide enhanced self-cleaning as well as increased gas flow by entrainment of ambient gases through a coanda effect. The objective of this sprayer system is to deliver and shape a higher level of media at the same level of power consumption as compared to conventional spraying technology. This is accomplished by separating the need for high energy atomization air flow from the lower pressure needed to attain a desired spray pattern. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a perspective view of a power sprayer of this invention. 
           [0011]      FIG. 2  is a partial exploded view of the power sprayer depicted in  FIG. 1  showing the media cartridge detached from the power unit. 
           [0012]      FIG. 3  is a cross-sectional view of the power sprayer depicted in  FIG. 1  as cut along section line  3 - 3 . 
           [0013]      FIG. 4  is a partial section view showing one embodiment of this invention depicting an electro-magnetic vibrator for media agitation. 
           [0014]      FIG. 5  is a partial section view showing one embodiment of this invention depicting an acoustical/electro-magnetic vibrator for media agitation. 
           [0015]      FIG. 6  is a cross-sectional view of another embodiment of the power sprayer of this invention. 
           [0016]      FIG. 7  is a cross-sectional view of the power-sprayer of  FIG. 6  highlighting the internal components of the nozzle portion of the media cartridge in a “closed/not spraying” mode. 
           [0017]      FIG. 8  is an orthographic view of the media cartridge. 
           [0018]      FIG. 9  is a cross-sectional view of the power-sprayer of  FIG. 6  highlighting the internal components of the nozzle portion of the media cartridge in an open spraying mode depicting the flow pattern of both the spray media and primary and secondary air. 
           [0019]      FIG. 10  is a cross-sectional view of the power-sprayer of  FIG. 6  highlighting the internal components of the nozzle portion of the media cartridge in an open spraying mode depicting an oval spray pattern that can be attained due to positioning of the tip guard.  FIG. 10  illustrates both a vertical flat pattern  61  and a horizontal flat pattern  62  either of which can be attained via appropriate orientation of the secondary air pattern shaping outlet port  40 . 
           [0020]      FIG. 11  is a cross-sectional view of the power-sprayer of  FIG. 6  highlighting the internal components of the nozzle portion of the media cartridge in an open spraying mode depicting a round spray pattern that can be attained due to positioning of the tip guard.  FIG. 11  depicts a shut media nozzle  63  before and after spraying occurs and further depicts an open media nozzle  64  utilized to attain a round spray pattern  65 . 
           [0021]      FIG. 12  is a schematic view of another embodiment of the power sprayer of this invention. 
           [0022]      FIG. 13  is a schematic view of another embodiment of the power sprayer of this invention showing a wand hand extension. 
           [0023]      FIG. 14  is a schematic view of the power sprayer of  FIG. 13  showing an optional pivot arm with a wheel attachment. 
           [0024]      FIG. 15  is a schematic view of a media cartridge adaptor depicting a nozzle and a power unit interface  66  and an external media supply connector  67 . 
           [0025]      FIG. 16  is a schematic view of a media cartridge equipped with a piston  59  as the movable media containment member. 
           [0026]      FIG. 17  is a schematic view of a media cartridge equipped with a bellows  60  as the movable media containment member depicts the media as partially expended. 
           [0027]      FIG. 18  is a schematic view depicting a media cartridge wherein an air bladder  68  indirectly activates the media containment bladder  36 . 
           [0028]      FIG. 19  is a schematic view depicting a media cartridge having two movable media containment members which in this embodiment of the invention are bellows  60 . In this embodiment of the invention, there are two media shutoff means  29 . In this figure the movable media containment member depicts the media as partially expended. 
       
    
    
     REFERENCE NUMERALS USED IN FIGURES 
       [0029]    The reference numerals used in the drawings to identify various parts or elements of the power sprayer and media cartridge used in the practice of this invention are as follows:
     1 . media cartridge     2 . power unit     3 . power unit handle     4 . nozzle     5 . flexible bladder (moveable media containment member)     6 . media container     7 . agitation sphere (media preparation device)     8 . trigger     9 . batteries (electrical power source)     10 . electric motor     11 . gear train     12 . pump     13 . constant output control     14 . power unit gas transfer line     15 . media cartridge (air) gas transfer interface     16 . electromechanical vibrator     17 . acoustical plate     18 . electromagnetic drive     19 . power unit engagement means     20 . power unit mounting bracket     21 . power unit gas transfer interface (gas transfer interface)     22 . control switch (electrical)     23 . media flow control means     24 . tip guard     25 . air inlet     26 . secondary air blower     27 . primary air aperture (primary media atomizing aperture)     28 . media aperture     29 . media needle (media shut-off means)     30 . mechanical interference     31 . mechanical interference seat     32 . shut-off spring     33 . media supply valving needle     34 . diaphragm     35 . secondary air supply     36 . bladder (movable media containment member)     37 . media     38 . access port     39 . seals     40 . secondary air pattern shaping outlet port     41 . secondary air outlet     42 . convex nozzle tip     43 . media nozzle tip     44 . trigger/nozzle engagement member     45 . spray pattern     46 . atomized media     47 . secondary air     48 . primary atomization air     49 . pattern shaping air     50 . wand     51 . handle     52 . wand trigger     53 . pivot arm     54 . wheel     55 . power sprayer     56 . wand sprayer     57 . media cartridge engagement means     58 . power unit identification means     59 . piston     60 . bellows     61 . vertical flat pattern     62 . horizontal flat pattern     63 . shut media nozzle     64 . open media nozzle     65 . round spray pattern     66 . nozzle and power unit interface     67 . external media supply connector     68 . air bladder     69 . external media container   
 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0099]    The power sprayers of this invention can be made utilizing a wide variety of designs wherein the power unit and media cartridge can be of a variety of different shapes and orientations to each other.  FIG. 1  depicts one typical design for such a power sprayer  55 . As can be seen, the power sprayer depicted in  FIG. 1  includes a media cartridge  1  which attaches to the top of a power unit  2 . This sprayer includes a power unit handle  3  which connects the power unit  2  to the media cartridge  1 . The media cartridge includes a nozzle  4  which extends forwardly from the media cartridge  1 . 
         [0100]      FIG. 2  depicts the power sprayer of  FIG. 1  wherein the media cartridge  1  is disengaged from the power unit  2 . The media cartridge can be affixed to the power unit via the power unit mounting bracket  20  to which the power unit engagement means  19  attaches. 
         [0101]    In the design shown, this attachment is effectuated by the interlocking edges which taper in one direction to engage the media cartridge to the power unit at the desired orientation. In this orientation, the power unit gas transfer interface  21  which is a port that aligns with a media cartridge gas transfer interface  15  (as shown in  FIG. 3 ). 
         [0102]      FIG. 3  is a cross-sectional view of the power sprayer of  FIG. 1  showing the media cartridge affixed to the power unit. As can be seen, the media cartridge includes a media container  6  which is filled with media  37 . In cases where the media is a liquid it is highly preferred from the movable media containment member to be essentially free of gases. In any case, the media is contained in the media container  6  with a movable media containment member  5 . The media container also includes an agitation sphere  7  for preparing the media for application to a substrate by agitating the media to attain a homogeneous mixture. As can be seen, the media cartridge includes a nozzle  4  through which the media passes while being sprayed. The media cartridge also includes a media cartridge gas transfer interface  15  which mates with the power unit gas transfer interface  21  to provide a pressurized gas such as air which provides force to compress the movable media containment member  5  to force the media  37  there from and ultimately out through nozzle  4  into a desired spray pattern. 
         [0103]    The gas from the power unit is compressed by pump  12  which is typically powered by an electric motor  10  having an appropriate gear train  11 , if necessary. The electric motor is typically powered with DC batteries  9  which provide DC current to the electric motor. This supply of electricity optimally is through an output control  13  which is capable of providing the electric motor with constant voltage to attain consistent motor speed (constant revolutions per minute). In other embodiments of this invention, the output control  13  can be designed to provide variable output motor speed to attain desired spray patterns or can be designed to provide controllable output. For instance, the output of the motor can be automatically set by the device to attain a desirable spray pattern predicated upon the distance of the spray nozzle from a substrate surface as could be automatically determined utilizing an infrared, radar, or ultrasonic distance measurement system. 
         [0104]    The operation of the unit can be controlled via switch  22  which toggles between an open and closed position via trigger  8  to provide power to the unit as desired. In one embodiment of this invention the switch can be a variable control which will allow the motor to increase or decrease in speed depending upon the degree to which the trigger is pulled. The variable control can be a rheostat, a pot, or any other device capable or providing a variable signal to the output control  13 . 
         [0105]      FIG. 4  depicts a media cartridge having a nozzle of convex shape. This device shows an electro-mechanical vibrator  16  for agitating the media to attain a homogeneous mixture.  FIG. 5  also depicts such a media cartridge wherein an acoustical plate  17  or an electromagnetic device  18  is utilized to agitate the media wherein such agitation can optionally be carried out with the aid of an agitation sphere  7 . It should be noted that a convex nozzle shape provides enhanced resistance to air nozzle clogging. 
         [0106]      FIG. 6  depicts another embodiment for a spray gun  55  in accordance with this invention. This design includes a tip guard  24  which protects the tip of the nozzle from damage which could occur during mishaps such as dropping the spray gun which would adversely affect the quality of the spray. In this design, inlet air  25  is drawn in by the power unit  2  by a secondary air blower  26 . The inlet air acts to cool the electric motor  10  and the pump  12 . The compressed air exiting the secondary air blower moves through the power unit assembly and enters into the media cartridge as depicted in  FIG. 7 .  FIG. 6  shows a trigger  8  which is integrated with a media flow control means  23 . The media flow control means can be a valve that limits the gas (air) pressure in the media container  6  to moderate the amount of pressure applied to the bladder  36  in the embodiment of the invention. In an alternative embodiment of this invention the media flow control means  23  can also limit the travel of the trigger to a desired stop point which also limits the travel of the needle  29  to limit the amount of atomized media  46  spray (as shown in  FIG. 10  and  FIG. 11 ). In still another embodiment of this invention the trigger is used to control the ratio of media flow to gas (air) flow. The trigger  8  can further be used to operate the control stitch  22  to activate the output control  13  and to attain the desired electric motor  10  operating speed (rpm output) desired. As can be seen in  FIG. 6  and  FIG. 7 , the trigger  8  has a flexible element that engages the trigger/nozzle engagement member  44 . In one embodiment of this invention, the trigger/nozzle engagement member  44  is phased to allow the control switch to activate gas flow before media flow. On trigger  8  the media  37  flow can be terminated before gas flow (primary atomization air  48  flow and secondary air  47  flow) is terminated to enhance the self-cleaning feature of the nozzle  4 . 
         [0107]    The secondary air flows through the nozzle of the media cartridge and is the source of the secondary air supply  35  can change the desired spray pattern and the secondary air supply  35  can result in augmented secondary air  47  through the coanda effect (as illustrated in  FIG. 10  and  FIG. 11 ). The pump provides pressurized air which flows through a power unit gas transfer line  14  through the power unit gas transfer interface  21  (as shown in  FIG. 7 ) and into the media cartridge gas transfer interface  15  and through the nozzle as primary atomizing air  48  and ultimately through the primary air aperture  27  of the nozzle. The primary atomizing air  48  and the secondary air  47  converge to provide an atomized media  46  as shown in  FIG. 10  and  FIG. 11 . 
         [0108]      FIG. 7  is a cross-sectional view of the power-sprayer of  FIG. 6  highlighting the internal components of the nozzle portion of the media cartridge in a “closed position” depicting the typical resting position of the mechanical interference  30  when the nozzle  4  is not spraying atomized media. In this position the mechanical interference  30  closes the nozzle  4  by moving forward to form a seal by contact with the mechanical interference seat  31 . In this position the media supply valve needle  53  is not penetrating through the diaphragm  34  to allow media  37  to flow from the moveable media containment member  5  to the nozzle  4 . The power unit identification means  58  can be a mechanical or electrical device that identifies the cartridge and optionally its contents. It typically also adjusts output parameters to attain a desired result. These parameters can include but are not limited to a fine, medium or heavy spray output and coverage or quality. This is accomplished through control by varying the output of the primary and secondary air supplies, motor, pump and/or media output. 
         [0109]      FIG. 9  is a cross-sectional view of the power-sprayer of  FIG. 6  highlighting the internal components of the nozzle portion of the media cartridge in an “open position” depicting the position of the mechanical interference  30  when the nozzle  4  is spraying atomized media. In this position the mechanical interference  30  is pulled back to open the nozzle  4  by to allow media to flow through the media aperture  28 . In this open position the media shut off needle is pulled away from the mechanical interference seat  31  to allow media  37  to flow around it and out of the primary aperture  27 . In this position the media supply valve needle  53  penetrates through the diaphragm  34  to allow media  37  to flow from the media bladder  36  to the nozzle  4 .  FIG. 9  also shows the flow pattern of the atomized spray media  46 , the primary atomizing air  48 , and secondary air  47 . 
         [0110]      FIG. 10  is a cross-sectional view of the power-sprayer of  FIG. 6  highlighting the internal components of the nozzle portion of the media cartridge in an open spraying mode depicting an oval spray pattern that can be attained by appropriate positioning of the tip guard  24 .  FIG. 11  is a cross-sectional view of the power-sprayer highlighting the internal components of the nozzle portion of the media cartridge in an open spraying mode depicting a round spray pattern that can be attained by positioning the tip guard  24  in a different orientation. As can be seen in  FIG. 10  and  FIG. 11 , the atomized media  46  can be sprayed into a variable and desired spray pattern  45 . It should be noted that the gas flow acts to both cause media atomization and media flow. Media flow is caused by a force differential which can be mechanical, vacuum, and/or positive pressure. For instance, a pressure can be applied upon the moveable media containment member  5  to attain an adequate pressure differential to cause the desired level of media flow.  FIG. 10  also depicts that secondary air pattern shaping outlet ports  40  cause a convergence of the secondary air supply  35  onto the primary atomization air  48 . The pattern shaping air  49  acts in concert with the secondary air  47  to provide the desired spray pattern  45 . 
         [0111]      FIG. 12  is a schematic view of another embodiment of the power sprayer of this invention. In this embodiment of the invention the power sprayer  55  is affixed to a folding power unit handle  3 . As illustrated in  FIG. 13  the power sprayer  55  can be affixed to a wand  50  (an extension handle) having a handle  51  and a wand trigger  52  to facilitate spraying objects that would ordinarily be difficult to reach. For instance, the wand could be affixed to the power sprayer  50  to spray substrates that ordinarily could not be reached without using a ladder.  FIG. 14  is a schematic view that depicts another embodiment of the invention in the form of a ward sprayer  56  wherein an optional pivot arm  53  with a wheel  54  is attached to the power sprayer  55 . This embodiment of the invention can be conveniently be used to spray lines on a highway, parking lot, or field. 
         [0112]    While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the subject invention.