Patent Publication Number: US-2007108233-A1

Title: Spray texturing system

Description:
RELATED APPLICATION  
      This patent claims the benefit of U.S. Provisional Patent Application Ser. No. 60/722,102 filed Sep. 30, 2005, which is incorporated herein by reference. 
    
    
     TECHNICAL FIELD  
      This invention relates to sprayer devices for applying a textured coating to a surface. Specifically, embodiments of the invention relate to spraying coatings for textured ceilings and/or walls; spraying stucco material; and spraying drywall compound.  
     BACKGROUND  
      Current designs of texture compound sprayers are handheld. Due to the weight of a volume of compound to be sprayed, a user may have difficulty holding and aiming the sprayer. Further, when larger surfaces are coated, current spray systems need to be frequently refilled. Another drawback to current systems is the need for labor intensive cleaning at the end of a work day in order to prevent the drying out of residue spray compound left on equipment surfaces and/or unused excess spray compound left in hoppers. Current systems are also optimized for a small range of potential compound viscosities. What is needed is an improved texture compound spray system that addresses these and other concerns. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  shows an isometric view of a spray texture gun and hopper according to the prior art.  
       FIG. 2A  shows a side view of a spray texture system according to an embodiment of the invention.  
       FIG. 2B  shows an isometric view of a reservoir component according to an embodiment of the invention.  
       FIG. 2C  shows a front view of the reservoir component according to an embodiment of the invention.  
       FIG. 3A  shows an isometric view of a spray texture system according to an embodiment of the invention.  
       FIG. 3B  shows another isometric view of a spray texture system according to an embodiment of the invention.  
       FIG. 4A  shows an isometric view of a spray texture system according to an embodiment of the invention.  
       FIG. 4B  shows a close up view of a spray texture system from  FIG. 4A  according to an embodiment of the invention.  
       FIG. 4C  shows an isometric view of a spray texture system according to an embodiment of the invention.  
       FIG. 4D  shows a top view of a spray texture system according to an embodiment of the invention.  
       FIG. 4E  shows a side view of the spray texture system of  FIG. 4D  according to an embodiment of the invention.  
       FIG. 5  shows an illustration of a user with a spray texture system according to an embodiment of the invention.  
       FIG. 6  shows a side view of a spray texture gun according to an embodiment of the invention.  
       FIG. 7  shows a side view of another spray texture gun according to an embodiment of the invention.  
       FIG. 8A  shows an isometric view of a spray texture system according to an embodiment of the invention.  
       FIG. 8B  shows another isometric view of a spray texture system according to an embodiment of the invention.  
    
    
     DETAILED DESCRIPTION  
      In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which is shown, by way of illustration, specific embodiments in which the invention may be practiced. In the drawings, like numerals describe substantially similar components throughout the several views. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments may be utilized and structural, mechanical or logical changes, etc. may be made without departing from the scope of the present invention.  
       FIG. 1  shows a spray texture assembly  100  similar to a number of designs currently available. A gun handle or base  110  is shown with a pressurized air coupling  112 . In some examples, the air coupling  112  includes a selectively actuated valve to control the supply of air. A hopper  120  is shown coupled to the top of the base  110 . In use, gravity feeds an amount of compound down through the hopper  120  into the base  110  where pressurized air sprays the compound out through a nozzle  114 . In the embodiment shown, the nozzle  114  includes a number of port selection sizes mounted on a wheel. Embodiments of the present invention can be used with a spray texture assembly such as spray texture assembly  100 , although the invention is not so limited. Other guns, hoppers, spray texture assemblies, etc. are compatible with embodiments of the invention as will be described below. For illustration purposes, the spray texture assembly  100  as shown in  FIG. 1  is used as an example in selected embodiments of the invention.  
       FIG. 2A  shows a spray texture system  200  according to an embodiment of the invention. A cart  210  is shown supporting a reservoir  230 . A spray texture assembly  100  such as the example shown in  FIG. 1  is included in  FIG. 2A  to illustrate use in conjunction with other components in  FIG. 2A . A support  218  shaped to accept the spray texture assembly  100  is shown coupled to the cart  210 . In use, the spray texture assembly  100  is placed on the support  218 , and the support  218  holds the hopper in a substantially upright position adjacent to the reservoir  230 . The reservoir contains a supply of spray texture compound (not shown) for use in periodically filling the hopper. One common spray texture compound includes compound for forming indoor ceiling or wall patterns such as “popcorn” texture, although the invention is not so limited. Other spray texture compounds include exterior stucco, and smooth texture interior drywall mud for spraying level five flat surfaces, etc.  
       FIG. 2A  includes a user controlled mechanism  232  to selectively release an amount of the spray texture compound from the reservoir  230  into the hopper.  FIG. 2A  shows an embodiment where the user controlled mechanism  232  includes a sliding door that opens or closes a port in the bottom of the reservoir  230 . Although a port and a door are shown other user controlled mechanisms are within the scope of the invention including, but not limited to rotating shutters, valves, etc. In  FIG. 2A , the spray texture assembly  100  is located substantially below the reservoir  230 . In alternative embodiments, the spray texture assembly  100  is located in front and below the reservoir  230  with a port directing spray texture compound into the hopper.  
      The cart  210  in  FIG. 2A  includes a number of frame members  212 . In one embodiment, the cart  210  includes a folding mechanism  214  such as a hinged frame member. Embodiments that include a foldable or otherwise collapsible cart have a benefit of being easy to transport and/or ship. In one embodiment, the cart  210  includes one or more wheels  216  to facilitate movement of the cart around a job site.  
      An optional height adjustment mechanism is also shown in  FIG. 2A . The particular height adjustment in  FIG. 2A  includes a first shaft  220  and a second shaft  222  that telescope together. A plurality of indexing features  224  such as holes provide a number of secure selectable height positions. A securing device such as a pin  226  is shown interfacing with holes  224  to secure the position shown in  FIG. 2A . In one embodiment, a spring  228  is included to counter the weight of the reservoir  230  and facilitate a height adjustment operation. One ordinary skill in the art having the benefit of the present disclosure will recognize that a number of height adjustment mechanisms are possible within the scope of the invention. For example, various springs other than a coil spring  228  such as a leaf spring or a compressed gas spring, etc. may be used. Other securing devices such as a ratchet, a clamp, etc. may also be used. In place of telescoping members, other linkages such as folding linkages or threaded extenders may be used.  
       FIG. 2B  shows one embodiment of the reservoir  230  from  FIG. 2A . In one embodiment, the user controlled mechanism  232  includes a handle for easy operation.  FIG. 2C  shows optional ledges  238  for holding the reservoir  230  above the cart  210 . A cover  234  is shown to selectively seal the reservoir.  FIG. 2B  shows a two door hinged cover, although variations such as a single removable lid, etc are within the scope of the invention. In one embodiment a port  236  is included in the reservoir  230  to permit equalization of pressure when an amount of compound is released from the reservoir  230 . Among other advantages, the cover  234  keeps the compound from drying out over extended periods of time. In one embodiment the cover  234  includes a rubberized seal to enhance the sealing properties. In one embodiment, the port  236  can be selectively closed overnight to further seal the reservoir. Using embodiments such as this, a user does not need to clean the reservoir and remove all compound at the end of a work day. Any unused compound can be sealed in the reservoir  230  and used the next day.  
       FIG. 3A  shows another spray texture system  300  according to an embodiment of the invention. Similar to embodiments described above, a cart  310  is shown supporting a reservoir assembly  330 . The reservoir assembly  330  shown in  FIG. 3A  includes a lower platform  332  and a side support  334 . A commercially available container such as a five gallon pail  320  of compound is placed on the platform  332  and secured in place. In one embodiment a user controlled mechanism includes a handle  336  and a rotation joint  338  to selectively release an amount of compound.  
      A spray texture assembly  100  such as the example shown in  FIG. 1  is included in  FIG. 3A  to illustrate use in conjunction with other components in  FIG. 3A . A support  318  shaped to accept the spray texture assembly  100  is shown coupled to the cart  310 . In use, the spray texture assembly  100  is placed on the support  318 , and the support  318  holds the hopper in a substantially upright position adjacent to the reservoir  330 . The reservoir contains a supply of spray texture compound (not shown) for use in periodically filling the hopper.  
      Similar to embodiments described above, the cart  310  in  FIG. 3A  includes a number of frame members  312 . The cart  310  includes one or more wheels  314  to facilitate movement of the cart around a job site. In one embodiment, the cart  310  includes a folding mechanism and/or a height adjustment mechanism.  FIG. 3B  is included to illustrate operation of the spray texture system  300 . By actuating the user controlled mechanism, an amount of compound is released as shown by arrow  322  into the hopper  120 . Although selected configurations of a reservoir and user controlled mechanism are shown, the invention is not limited to the specific configurations. One of ordinary skill in the art, having the benefit of the present disclosure will recognize that other variations are possible within the scope of the invention.  
       FIG. 4A  shows a spray texture system  400  according to an embodiment of the invention. A spray texture gun  110  similar to the configuration shown in  FIG. 1  is included in the system  400  shown in  FIG. 4A . The spray texture system  400  includes an extension pole  410  with a spray gun mount  420  attached at a distal end. In one embodiment, the extension pole  410  is adjustable to a number of pole lengths, although the invention is not so limited. In one length adjustable configuration, a first pole segment  412  and a second pole segment  414  telescope within one another to provide adjustability. A proximal end  416  of the extension pole  410  is shown having a ball shaped feature that will be discussed in more detail below.  
       FIG. 4B  shows the spray gun mount  420  utilizing at least one pin  422  to secure the spray texture gun  110  within the mount  420 , however the invention is not so limited. Other examples of possible mount configurations are discussed below. In one embodiment, a quick connect device is utilized to couple the spray texture gun  110  to the mount  420 . For example the pins  422  shown in  FIG. 4A and 4B  are quickly removed and re-inserted in contrast to more permanent fasteners such as threaded bolts or nuts. In one embodiment, an orientation joint  428  is located between the mount  420  and the extension pole  410 , as shown in  FIG. 4B . A user selectable lever  424  is shown that engages one of a number of slots  426  to select an angle for use. Other possible orientation joints include, but are not limited to, friction clamps, ratchets, etc.  
       FIGS. 4A and 4B  further illustrate a remote trigger device coupled to the trigger  116 . In one embodiment, the remote trigger device includes a flexible line  432  that is coupled between the trigger  116  and a remote lever  430 . One of ordinary skill in the art having the benefit of the present disclosure will recognize that a number of possible remote trigger configurations are within the scope of the present invention. Examples include a spring return trigger with a pull only cable; a push/pull cable and cable housing configuration; a rigid actuation rod and linkage, hydraulic operation, etc.  
      In selected embodiments, the flexible line  432  is connected directly to the trigger  116 . In other embodiments, the flexible line  432  is coupled to a trigger extension  434 . A trigger extension  434  is useful in selected embodiments to provide additional leverage when the flexible line  432  pulls the trigger  116 . In one embodiment, one or more trigger extensions  434  can be used, depending on the configuration and/or brand of spray texture gun being used in the system. One method of coupling the trigger extension  434  to the trigger  116  includes using a close fitting hole  436  in one end of the trigger extension  434 . Other fastening methods are also within the scope of the invention including clamps, screws, etc.  
       FIG. 4C  illustrates another possible spray gun mount  440  according to an embodiment of the invention. A first clamp portion  442  and a second clamp portion  444  form opposing surfaces with a clamping region  441  in between.  FIG. 4C  further shows front members  446  to further capture a handle of a spray texture gun. In one embodiment, a space is left open between the first clamp portion  442  and the second clamp portion  444  and the front members  446  to allow a spray texture gun trigger to fully collapse against the gun handle. The embodiment shown in  FIG. 4C  shows a clamping lever  448  including a cam  450 . In one embodiment, a threaded member  452  passes through the first clamp portion  442  and the second clamp portion  444  and couples to the cam  450 . In one configuration, a wingnut  456  or other suitable fastener is included to adjust the appropriate tension on the cam  450  and lever  448 .  
       FIG. 4D  illustrates another possible spray gun mount  460  according to an embodiment of the invention. A first clamp portion  462  and a second clamp portion  464  form opposing surfaces with a clamping region  461  in between.  FIG. 4D  further shows front members  466  to further capture a handle of a spray texture gun. Similar to embodiments described above, in one embodiment, a space is left open between the first clamp portion  442  and the second clamp portion  444  and the front members  446  to allow a spray texture gun trigger to fully collapse against the gun handle. A clamping lever  467  is shown with a cam  468  attached at one end. In one embodiment, the cam  468  presses against a plate  470  that in turn distributes force against a spray gun handle (not shown) along the direction shown by arrow  472 .  
      Use of a lever and cam, removable pins, etc. provides a quick connect function for clamping and release of a spray texture gun. Although a number of variations are illustrated, the invention is not so limited. Other configurations of clamps, or other quick connect clamps are included within the scope of the invention. Further, combinations of embodiments shown are also within the scope of the invention. For example, a side clamp similar to the configuration shown in  FIG. 4C  can be combined with a rear clamp configuration such as shown in  FIG. 4D and 4E .  
       FIG. 5  illustrates how selected embodiments of spray texture systems interact with a user. Prior spray texture product designs were heavy, and required considerable effort by a user to hold and point the gun during a job. As illustrated in  FIG. 5 , a spray texture system  400  similar to embodiments described above, directs a portion of the weight from the gun and/or hopper through the extension pole down to a harness  500  that is worn by a user. The harness  500  shown in  FIG. 5  includes a coupling  506  to accept an end of the extension pole. In one embodiment, a ball  416  is included on a proximal end of the extension pole to further facilitate movement of the extension pole in relation to the harness  500 . Although a number of configurations of harness  500  are possible,  FIG. 5  illustrates both a waist strap  504  and shoulder straps  502 . The use of multiple straps in the harness  500  further spreads the load of the spray texture gun and/or hopper over multiple portions of the user&#39;s body such as shoulders and waist.  
       FIG. 6  illustrates a spray texture system  600  according to an embodiment of the invention. A body portion  610  is shown with a handle  611 . A trigger  612  is used to selectively operate the gun. A removable chamber  620  is shown that is attachable to the body  610  in the direction of arrow  614 . A fastening system such as a number of screws  622  are shown to selectively couple the chamber  620  to the body  610 . Other fastening systems such as levers, cams, alternate fasteners, etc. are also within the scope of the invention. An advantage of having a removable chamber includes the ability to optimize flow rates for a variety of compounds. For example, higher viscosity compounds may require a larger chamber  620  with higher flow rates along direction  620  as illustrated. Further variations in replaceable chambers include chamber materials that are resistant to damage from other compounds such as abrasive stucco, or corrosive compounds, etc. By making the chamber replaceable or interchangeable, a number of possible compounds cam be sprayed with the same gun body  610 .  
       FIG. 7  illustrates another spray texture system  700  according to an embodiment of the invention. A body portion  710  is shown with a handle  711 . A trigger  712  is used to selectively operate the gun. In one embodiment, the spray texture system  700  includes a removable chamber as described above, however a one piece spray texture system  700  can be used as well. A nozzle assembly  714  is shown coupled to a chamber of the system  700 . In one embodiment, the nozzle assembly includes a wheel with a number of selectable nozzle diameters. In another embodiment, the nozzle assembly includes a single nozzle that is replaceable, Other nozzles such as permanent nozzles are included in the scope of the invention as well. A seal  720  is shown that matches the particular nozzle assembly and prevents drying out of compound material. The use of a seal allows a user to leave the spray gun at the end of a work day, without time consuming cleaning. The seal can be easily removed the next work day, and the compound will not be dried out, thus allowing the user to continue work. Examples of seals include polymers such as elastomer materials (silicone, etc.) that provide a sufficient seal to prevent drying of the compound.  
       FIG. 8A  further illustrates portions of a spray texture system that prevent drying out of compound overnight or otherwise during periods of inactivity. A hopper  810  is illustrated in  FIG. 8A . In one embodiment a top seal  830  is configured to cover a top opening in the hopper  810 . In one embodiment a flange  832  is included in the top seal to help position the top seal, and to more effectively seal the hopper. A bottom seal  834  is also illustrated. In one embodiment, the bottom seal  834  includes a flange  836  that also serves to locate the bottom seal  834  and improve the sealing function. A securing cord  838  is shown to hold the top seal  830  and the bottom seal  834  in place. In one embodiment, the securing cord includes a bungee or other elastic cord. Other embodiments include a length adjustable cord with a fastener, etc. The system illustrated in  FIG. 8A  can be used to seal a hopper by itself without cleaning at the end of a work day. The compound material remains moist, and can therefore be used again the next work day.  
       FIG. 8B  shows the spray texture system of  FIG. 8A  used in conjunction with a hopper  810  and spray gun  820 . As shown, the top seal selectively covers the top opening of the hopper, while the bottom seal  843  can be moved out of position and the cord  838  is held against the gun  820 . In one embodiment to further seal the system as shown in  FIG. 8B , a nozzle seal as described above such as in  FIG. 7  can be used.  
      Embodiments of spray texture systems, spray texture system components, and methods as described above have a number of advantages. One advantage includes the ability to easily refill a hopper. Another advantage includes a system that is easier to support and spreads the weight of system components to other parts of a user&#39;s body. Another advantage includes seals that prevent drying out of compound, allowing a user to clean equipment less frequently. Other improvements described allow spraying of multiple types of compound, and provide inexpensive devices with the flexibility to handle multiple types of compound spraying jobs.  
      While a number of advantages of embodiments of the invention are described, the above lists are not intended to be exhaustive. Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement which is calculated to achieve the same purpose may be substituted for the specific embodiment shown. This application is intended to cover any adaptations or variations of the present invention. It is to be understood that the above description is intended to be illustrative, and not restrictive. Combinations of the above embodiments, and other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention includes any other applications in which the above structures and methods are used. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.