Patent Publication Number: US-2021178416-A1

Title: Paint Stream Director for Paint Sprayer

Description:
This application claims priority to U.S. Provisional Patent Application Ser. No. 62/946,530 filed on Dec. 11, 2019, which is incorporated herein in its entirety by this reference thereto. 
    
    
     FIELD OF THE INVENTION 
     The disclosed device concerns paint spraying with compressed and airless sprayers. More particularly, it relates to a removably engageable housing for containing paint spray from a paint spraying gun to a desired area to be painted. The distal edge of the overspray housing may be configured with a brush or roller material thereon, to enable the housing to brush paint sprayed on a surface into uneven areas. 
     BACKGROUND OF THE INVENTION 
     In the field of painting, an airless or compressed air sprayer is frequently used to cover large or uneven areas in place of brushes and rollers. Such spray painting generally accomplishes the painting tasks in an expedited fashion. 
     However, during the task of spray painting, frequently there can occur wind which will cause portions of the airborne paint from the sprayer to miss the intended surface for the paint being sprayed. Further, in many instances, spray painting surfaces near trim or objects which are not to be painted, causes a problem, especially for non professional painters who may lack the accuracy needed to direct the spray only to surfaces needing paint and to miss those areas and objects not requiring paint. 
     The device and method herein provide a solution to the perils of wind driven overspray and targeting of paint to adhere only to surfaces needing it. 
     The forgoing examples of spray painting, and issues regarding such, are intended to be illustrative and not exclusive and they do not imply any limitations on the invention described and claimed herein. Various other limitations of the related art are known or will become apparent to those skilled in the art upon a reading and understanding of the specification below and the accompanying drawings. 
     SUMMARY OF THE INVENTION 
     The device herein, in various preferred modes, provides a solution to overspray and precise targeting issues during spray painting of various surfaces. The device features a housing which has a first end configured to engage either around the discharge of a spray gun or a distal end of an extension conduit which operatively engages the spray gun at a first end thereof. 
     The housing is preferably formed of fabric, paper, a polymeric material, or a mesh to provide a protective surrounding for the liquid droplets exiting a spray gun during their travel toward and to the surface to be painted. The housing if formed by a sidewall, and in all preferred modes of the device herein, has a first end having a diameter significantly narrower than a distal end thereof. The first end of the housing has a diameter forming a circumference thereof, which is larger than a cross section of the paint spray projected from the fluid nozzle or jet of a paint spraying gun. This allows the spray pattern projecting under pressure from the sprayer fluid nozzle to form the desired linear or other shaped spray pattern upon contact with the surface to be painted adjacent the distal end of the engaged housing. 
     The housing may be configured at the first end for removable engagement to the spray gun in a manner surrounding the fluid spray nozzle thereof with the sidewall of the housing. In all modes of the device, it is configured for engagement to the spray gun or to a conduit extending therefrom, to surround a conventional fluid spray nozzle which engages with a spray gun. By conventional fluid spray nozzle is meant, for example, those fluid spray nozzles from the BINKS company, which employ a widely used industry standard threaded or bayonet engagement, of the fluid spray nozzle components, with a nozzle connector of a spray gun. 
     Where not directly engaged to the spray gun, in a mode of the device particularly preferred for painting elevated or hard to reach surfaces, a conduit at a first end may be engaged with the pressurized discharge opening with the paint gun and operatively connected at a second end of the conduit with the housing. The conduit can have the fluid spray nozzle operatively connected at the second end thereof, such that the engagement of the first end of the housing of the device to the second end of the conduit locates the sidewall of the housing of the device to surround the paint spray exiting the fluid spray nozzle at the second end of the conduit 
     The sidewall of the device herein, forms and defines the shape of the protective housing. The housing is preferably formed in a configuration wherein it widens from the first end thereof, toward the second end. The housing, thus, may be formed in a conical form or a pyramidic form or other configurations forming the first end which is narrow and which expands to a wider second or distal end. 
     As noted, this configuration forms a passage within the sidewall for communication of the paint from the fluid nozzle of the gun or the conduit, to the surface to be painted. The sidewall, thus in all modes and shapes, protects the pressurized paint exiting the nozzle in a pattern, from wind which will alter the paint pattern causing overspray and waste of paint from wind driven droplets which miss their mark. A skeletal structure can be engaged with the sidewall to hold the sidewall in the desired shape during use where the sidewall is formed of paper or lightweight material. 
     In a particularly preferred mode of the device, a brush component, such as that formed by horse hair or synthetic bristles, or by a roller having a chosen nap, can be engaged to the sidewall to surround the passage at the distal end of the housing. This mode enables the user to both spray, and concurrently brush or roll the paint reaching the surface being painted. Such a brush component is particularly useful for surfaces such as stucco or uneven wood or the like, which may be uneven or have recesses and ridges. The brush component will allow the user to use the brush component to contact the surface being painted, and to urge the paint to areas which would normally be left uncovered by the liquid spray. 
     This brush component may be permanently engaged to the distal end of the housing in modes of the device which are disposable. Alternatively, the brush component may be formed in a shape and with a fastener which is complimentary in shape to the sidewall of the housing, at the distal end of the housing. So formed, the brush component can be removably engaged to the housing. This allows for a kit of different brush components formed of differing bristle types or fabric naps, whereby the user can attach one of the brush components from a kit thereof, to the sidewall at the distal end of the housing. 
     Formation of the sidewall of the housing of a mesh fabric is also preferred to allow the user to view the surface being painted while still protecting the shape of the spray pattern from wind. This mode is especially well suited for painting of surfaces adjacent other surface which are not to be painted since the user can view the surface being painted and paint contact therewith, through the mesh formed sidewall. Such a mesh fabric, for example, is available in insect screen form and other coated mesh fabrics, from the Phifer company of Tuscaloosa, Ala. 
     With respect to the above description, before explaining at least one preferred embodiment of the paint spray stream protector invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangement of the components in the following description or illustrated in the drawings. The invention herein described and shown is capable of other embodiments and of being practiced and carried out in various other ways by those skilled in the art upon reading this disclosure. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. 
     As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for designing of other paint spray surrounding housings, and for carrying out the several purposes of the present disclosed device. It is important, therefore, that the claims be regarded as including such equivalent construction and methodology insofar as they do not depart from the spirit and scope of the present invention. 
     As used in the claims to describe the various inventive aspects and embodiments, “comprising” means including, but not limited to, whatever follows the word “comprising”. Thus, use of the term “comprising” indicates that the listed elements are required or mandatory, but that other elements are optional and may or may not be present. By “consisting of” is meant including, and limited to, whatever follows the phrase “consisting of”. Thus, the phrase “consisting of” indicates that the listed elements are required or mandatory, and that no other elements may be present. By “consisting essentially of” is meant including any elements listed after the phrase, and limited to other elements that do not interfere with or contribute to the activity or action specified in the disclosure for the listed elements. Thus, the phrase “consisting essentially of” indicates that the listed elements are required or mandatory, but that other elements are optional and may or may not be present depending upon whether or not they affect the activity or action of the listed elements. The term “substantially” when employed herein, means plus or minus twenty percent unless otherwise designated in a different range. 
     It is an object of the present invention to provide an easily removably engageable paint spray device which eliminates or minimizes overspray of a pressurized paint stream. 
     It is a further object of this invention to provide such an overspray prevention device, which also includes a permanent or removable distal end which enables the brushing or spreading of paint being sprayed. 
     These and other objects, features, and advantages of the present overspray protection system, as well as the advantages thereof over existing prior art, which will become apparent from the description to follow, are accomplished by the improvements described in this specification and hereinafter described in the following detailed description which fully discloses the invention, but should not be considered as placing limitations thereon. 
    
    
     
       BRIEF DESCRIPTION OF DRAWING FIGURES 
       The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate some, but not the only or exclusive examples of embodiments and/or features of the disclosed paint overspray protection system and method herein. It is intended that the embodiments and figures disclosed herein are to be considered illustrative of the invention herein, rather than limiting in any fashion. 
       In the drawings: 
         FIG. 1  depicts the device in a particularly preferred mode having an overspray housing component which is directly engageable at a first end with a spray gun as in  FIG. 1A  or which may be engaged to the distal end of a conduit which has a connector thereon to operatively engage a first end with a spray gun. 
         FIG. 1A  shows the device herein in the simplest mode wherein a first end of the overspray housing is connected to a body or component of a spray gun having a nozzle, to position the sidewall to surround the fluid stream emitted by the nozzle of the spray gun which is shown in a cut out portion of the sidewall for clarity. 
         FIG. 2  shows a perspective view of the housing having a first end engaged with the distal end of the conduit which has a connector at a first end which is operatively engageable to a spray gun. 
         FIG. 3  shows a mode of the housing body formed by a sidewall with a diameter which widens from a first end to a distal end of the housing, and showing a brush component which may be engaged or removably engageable to the distal end of the body of the housing. 
         FIG. 4  shows a mode of the device wherein the sidewall of the housing is formed of a mesh material. 
         FIG. 5  shows the device having a skeletal support engaged with the sidewall. 
         FIG. 6  depicts a mode of the device in a rectangular shape at the distal end of the sidewall forming the body of the housing. 
         FIG. 7  shows a view of the sidewall having a secondary layer on an interior surface to absorb paint and prevent dripping. 
         FIG. 8  shows the sidewall of the device formed in a fan like configuration for additional rigidity and strength during use. 
         FIG. 9  depicts the device herein in another particularly preferred mode wherein a paint roller is additionally provided and engaged adjacent the distal end of the housing. 
         FIG. 10  shows the device herein in a similar fashion to that of  FIG. 9 , wherein the roller is positioned adjacent and parallel to the sidewall forming the housing. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In this description, the directional prepositions of up, upwardly, down, downwardly, front, back, top, upper, bottom, lower, left, right and other such terms refer to the device as it is oriented and appears in the drawings and are used for convenience only and such are not intended to be limiting or to imply that the device has to be used or positioned in any particular orientation. 
     Now referring to drawings in  FIGS. 1-10 , wherein similar components are identified by like reference numerals, there is seen in  FIG. 1  and  FIG. 1A , the overspray device  10  herein. The device  10  in all modes features a housing  12  having an interior cavity  28 , defined by a sidewall  22 . This housing  12 , has a connector  11  which is either directly engageable at a first end  13 , to an area of a body of the spray gun  15  in a mounted engagement, such that the sidewall  22  surrounds the paint stream emitted from the gun-mounted nozzle  14 , which disburses paint from a spray gun  15  as in  FIG. 1A . In the alternative, the connector  11  at the first end  13  of the housing  12  may be engaged at or to the distal end  16  of an elongated conduit  18 , in the mounted engagement, where the interior cavity  28  surrounds the paint stream projected from the fluid nozzle  14  which is also operatively positioned at the distal end of the conduit  18 . 
     In all modes of the device  10 , the interior cavity  28  of the housing  12  defines a pathway for paint sprayed from a fluid nozzle  14 . The sidewall  22  protects paint projected from the nozzle  14  through this pathway from communication with wind which might alter the trajectory of the stream of paint as it travels through the pathway of the interior cavity  28  from the first end  13  of the housing  12 , to an exit of the paint stream through a second opening  21  at the distal end  25  of the housing  12 . 
     The mode of the device  10  in  FIG. 1  provides additional utility through the provision of the extension provided by the conduit  18  for spraying above the head of the user, or for spraying over impediments. However, in some instances, in narrow confines, the mode of the device of  FIG. 1A  may be preferable. 
     Where the housing  12  is directly engaged to a spray gun  15 , a housing connector  11  at the first end  13  of the housing  12  is configured for a removable engagement of the housing  12  to the gun  15 , or as noted below, to a second end of an elongated member  18 . That removable engagement using the housing connector  11  will position the housing  12  such that the sidewall  22  surrounds the paint stream dispensed by the fluid nozzle  14  which is connected to the conventional fluid nozzle connector  29  of the spray gun  15  in the conventional fashion. This housing connector  11  for example, and in now way limiting, can be a collar which fractionally engages around an exterior of the conventional nozzle connector  29  at the nozzle end of the gun  15 , or may be a housing connector  11  attached to the housing  12  which is complimentary to and connects with a mating connector, on the gun  15 , or could be a housing connector  11  which is threaded and operatively engages with a mating threaded connection surrounding the nozzle  14 , or it can be any configuration of housing connector  11  as would occur to those skilled in the art, which will removably engage the first end  13  of the housing  12 , to the gun  15 , and concurrently position the sidewall  22  to surround the paint dispensed by the nozzle  14 . 
     In the particularly preferred mode of the device  10 , of  FIG. 1 , providing the user an extension length for spraying heights and for reaching over impediments to the surface being painted, the first end  13  of the conical or pyramidic housing  12  formed by the sidewall  22 , may be configured with a connector  24  to operatively engage the housing first end  13  to the distal end  16 , of an elongated conduit  18 . This connector  24  may be the same configuration and operation as the above noted housing connector  11 , and such would be preferable to allow the user to employ the device easily, with or without the conduit  18 . 
     In this mode of the device  10 , the first end  20  of the conduit  18  is configured with a mating connector  27 , to operatively engage with the nozzle connector  29  which conventionally operatively engages a fluid nozzle  14 , of the spray gun  15  such as the spray fluid nozzles  14  from BINKS company for example. 
     In this extended mode, the nozzle  14  is operatively positioned at the distal end  16  of the conduit  18  and a mating connector  27 , at the first end  20  of the conduit  18 , engages with the conventional gun nozzle connector  29  directly or with an adapter. Of course the gun  15  could be modified with a new nozzle connector  29  to engage with one end of a conduit  18 , and such is anticipated within the scope of this invention. 
     Using this engagement of the first end  20  of the conduit  18  to the gun nozzle connector  29 , a sealed connection is formed with the pressurized fluid from the spray gun  15 , which feeds paint under pressure to the conventionally mounted fluid nozzle  14 . With the nozzle  14  removed from the gun  15 , the pressurized paint or fluid then communicates through an axial passage of the conduit  18 , to the nozzle  14  operatively connected to the distal end  16  of the conduit  18 . 
     The nozzle  14  in this configuration of the device  10  is preferably in a removable engagement to the conduit  18  at the distal end  16  thereof. By removable engagement is meant that the nozzle  14  forms a sealed engagement at the distal end of the conduit  18 , such as with a threaded connector or a connector  24  which is configured the same as the gun nozzle connector  29  on the gun  15 , so that the nozzle  14  can be connected in a conventional fashion to either the conduit  18  or gun  15 , and whereby conventional paint nozzles  14  may be used. 
     By fluid nozzle  14  herein is meant, those spray nozzle assemblies conventionally employed in the spray painting industry, such as where the nozzle  14  includes a threaded air cap or collar, which threadably connects to a threaded mount such as the nozzle connector  29 , and thereby holds a centrally located fluid nozzle component operatively in place. Such an industry standard configuration for example is employed spray guns  15  manufactured by the BINKS company, as well as a number of other manufactures of conventional paint sprayers. 
     Thus, in the mode of the device  10  of  FIG. 1 , the gun nozzle  14  is engaged to the conduit  18  at the distal end thereof  16 . Preferably, it is a removable engagement where the connector  24  is configured the same as the fluid nozzle connector  29  and is located at the distal end of the conduit  18 . Should a replacement be required during use, conventional nozzles  14  used by such spray guns  15 , can be placed at the distal end of the conduit  18 . 
     The device, as in  FIG. 1 , for example, with the conduit  18  engaged between the gun  15  and the nozzle  14 , will spray paint from the distal end mounted nozzle  14 . The fluid or paint is communicated from the gun  15  through the axial passage (not shown but well known) within the conduit  18 . The fluid spray from the nozzle  14  will be disbursed from the nozzle  14  at the distal end  16  of the conduit  18 , and will be surrounded by the sidewall  22  forming the housing  12 . 
     In all modes of the device  10  including the conduit  18 , complimentary fasteners  24 , such as threaded connector, bayonet type connectors, twist and slide connectors, frictional connectors, or other complimentary fasteners  24  that would occur to those skilled in the art, on both the first end  13  of the housing  12  and the distal end  16  of the conduit  18 , allow for a removable engagement therebetween which is preferable to allow for replacement. As noted above, where the first end  20  of the conduit  18  connects with the fluid nozzle connector  29  of the spray gun  15  feeding the nozzle  14 , the nozzle  14  is operatively engaged to the distal end  16  of the conduit  18 . In this engagement at the distal end  16  of the conduit  18 , that conduit  18  will preferably have a connector  24  thereon configured the same as the fluid nozzle connector  29  to sealably engage the conventional spray nozzle  14  thereto. 
     Shown in  FIG. 2  is a perspective view of the housing  12  in the mode of the device  10  employing a conduit  18  engaged between the spray gun  15  and the housing  12  in the manner noted above. As shown, the interior cavity  28  at or adjacent a first opening  19  ( FIG. 3 ) at the first end  13  of the housing  12  formed by the sidewall  22 , has a first diameter D 1  ( FIG. 3 ). This first diameter D 1  is significantly smaller than a second diameter D 2  ( FIG. 3 ) of the cavity  28 , at or adjacent a second opening  21  ( FIG. 3 ) also communicating with the interior cavity  28  at the distal end  25  of the housing  12 . 
     In all preferred modes of the device  10 , this housing  12  has such a first diameter D 1  of the cavity  28  at or adjacent a first opening  19  at the first end  13  of the housing  12 , which is sized to surround the nozzle  14 , and which is large enough in the first diameter D 1  so as to prevent any interference with the liquid spray pattern being emitted by the nozzle  14 . The size or length of this first diameter D 1  of course can vary depending on the fluid disbursement pattern emitting from the nozzle  14 . Currently, a first diameter D 1  of the cavity  28  between 1-4 inches, depending on the spray pattern emitted has been used and worked well. Because the spray patterns of the conventionally commercially sold nozzles  14  are known, the device  10  can easily be configured in multiple sizes to accommodate both the nozzles  14  and their spray pattern in advance for easy sale and use. 
     In all modes of the device  10 , from the first diameter at the first opening at the narrower first end  13  of the housing  12  formed by the sidewall  22 , the sidewall  22  will extend in a funnel like shape, such as a cone or pyramid type shape, to the wider second diameter at the second opening at the distal end  25  of the housing  12 , which communicates with the interior cavity  18 . Thus, the formed housing  12  is preferably of a funnel-like shape and can be frustoconical or pyramidic or some other funnel type shape. By funnel type shape is meant that the sidewall  22  forming the housing  22  defines an interior cavity  28  which is narrower in diameter at or adjacent the first opening at the first end  13  and the cavity  28  has a wider diameter at or adjacent a second opening communicating with the cavity  28 , the distal end  25  of the housing  12 . 
     As shown in the figures, to enable the user to brush and spray the surface being painted, it is also preferred to include a brush component  30  engaged with the distal end  25  of the sidewall  22  forming the housing  12 . The brush component  30  may be formed of bristles such as from horse hair or synthetic bristles or can be a nap type material as employed on paint rollers or can be another natural or synthetic material adapted to spread sprayed paint on the surface being painted. This brush component  30  can be permanently engaged, or a brush component connector  32  engaged to the brush component  30  on one side can be adapted on the opposite side to connect to the distal end  25  of the housing  12 . 
     For example, the connector  32  can be formed with a recess therein which has a circumference substantially equal to the circumference of the sidewall  22  at the opening to the cavity  28  at the distal end  25  of the housing  12 . It can then slide onto position with the sidewall  22  positioned into the recess which can friction fit or have adhesive therein. If formed to removably engage using such a connector  32 , the brush component  30  can be provided in a kit form, with a plurality of brush components  30  with differing bristles and nap material therein. This will allow the user to choose and engage the most appropriate brush component  30  for the job at hand, to the housing  12 . 
     Shown in  FIG. 3 , is a mode of the housing  12  having a body formed by the sidewall  22  with the interior cavity  28  having a diameter which continually widens from a diameter of the cavity  28  at the first end  13  of the housing  12 , toward the distal end  25  of the housing  12 . Also shown is an detached depiction of the brush component  30  which may be in fixed engagement or removably engageable to the distal end  25  of the body of the housing  12 . The sidewall  22  of the housing  12  can be formed of paper or fiberboard or other materials where the device  10  is disposable and may preferably be formed of a mesh or transparent or see-through material as noted herein. 
     In  FIG. 4  is depicted the mode of the device  10  wherein the sidewall  22  of the body of the housing  12  is formed of a see-through material. By see through material is meant a material which has holes or gaps therein or is sufficiently transparent, to allow a user to view the surface being painted, through the sidewall  22 . 
     Such see through material for example includes a sidewall  22  of mesh material such as insect screen or loosely woven material. The housing  12  sidewall  22  can also be formed of substantially transparent polymeric material, such as polyethylene sheeting or a similar polymeric material, to provide increased wind blockage and concurrently provide a see-through sidewall  22  for the user to view the surface being painted during spraying. 
     Shown in  FIG. 5 , the device  10  can also have a housing  12  which is formed with a frame  34  or skeletal support for the sidewall  22  forming the housing  12 . The frame  34  supports can be adhered to the sidewall  22  or engaged in formed passages on, or running the length of the sidewall  22 . The frame  34  would work especially well when the device  10  is employed to spread paint using a brush component  30 , positioned on the end, or where a roller  40  is located adjacent the sidewall  22  as in  FIGS. 9-10 . In such situations, the frame  34  will impart stiffness and support to keep the sidewall  22  from deforming. 
     As noted above, in all modes of the device  10  is preferred that the housing  12  have a body formed by a sidewall  22  which defines a funnel-like shape extended from the first diameter of the cavity  28  at the first end  13 , to the a second diameter of the cavity at or adjacent the distal end  25  of the housing  12  where an opening communicates with the internal cavity  28 . To note that the shape can be funnel-like and not just frustoconical, such a differing funnel-like shape is shown in  FIG. 6 . As shown, the sidewall  22  forms a housing  12  which is substantially rectangular in the shape of the opening to the internal cavity  28  at the distal end  25  of the sidewall  22  forming the body of the housing  12 . 
     In some modes of the device  10  the sidewall  22  may be formed in multiple layers. As shown in  FIG. 7 , the sidewall  22  can include a secondary layer on an interior surface such as one formed of material to absorb paint and prevent dripping. 
     Where additional strength for the sidewall  22  to resist bending and collapse is desired, and where a frame is not employed, forming the sidewall  22  in a zig-zag or fan configuration will give it more stability against bending and collapse during use. 
     Shown in  FIGS. 9-10 , is a mode of the device  10  herein, which operates in the same fashion as the above noted configurations, but which includes a paint roller  40 . As shown in  FIG. 9 , the paint roller  40  is rotationally engaged in a position adjacent the housing  12 . Such might be directly to the housing  12  if a frame  34  is included, or to a mount  42  connected to the member  18  where the member  18  is included. By rotationally engaged is meant that the paint roller  40  is formed in a conventional fashion by a sleeve which slides onto a member  44 , which has a rotational connection  46  to the mount  42 . Such a rotational connection for example can be a bearing or similar engagement of the member  44  to the mount  42 . In the mode of the device of  FIGS. 9-10 , the user can roll the roller  40  in contact upon the surface being painted to spread the sprayed paint into cavities and nooks, which may not have adequately received it from the spray. The roller  40  being formed of sleeve which is removably connected to the rotating member  44 , allows it to be replaced when worn, or where a larger or smaller nap is needed to spread the paint. 
     It should be noted that any of the different depicted and described configurations and components of the paint overspray protection device herein, can be employed with any other configuration or component shown and described as part of the device herein. Additionally, while the present invention has been described herein with reference to particular embodiments thereof and/or steps in the method of production or use, a latitude of modifications, various changes and substitutions are intended in the foregoing disclosure, and it will be appreciated that in some instance some features, or configurations, of the invention could be employed without a corresponding use of other features without departing from the scope of the invention as set forth in the following claims. All such changes, alternations and modifications as would occur to those skilled in the art are considered to be within the scope of this invention as broadly defined in the appended claims.