Abstract:
A surface treatment system includes a pressure generator structured to generate air pressure; a spray head assembly coupled to the pressure generator; and a hopper coupled to the spray head assembly and structured to hold surface treatment material, the hopper including an extended portion disposed at a top front portion of the hopper that raises a front top edge of the hopper to be higher than a rear top edge of the hopper, wherein the hopper is configured to provide the surface treatment material to the spray head assembly and the spray head assembly is configured to use the air pressure to spray the surface treatment material onto a surface.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority under 35 U.S.C. §119(e) from U.S. provisional patent application No. 61/882,182, entitled “Surface Treatment System and Method” and filed on Sep. 25, 2013, the contents of which are incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    1. Field 
         [0003]    The disclosed concept relates generally to surface treatment systems and methods, and, more particularly, to a system and/or method for spraying treatment on a surface. 
         [0004]    2. Background 
         [0005]    Many surface treatments, and in particular, many deck treatments such as Rust-Oleum® Deck and Concrete Restore™ (manufactured by Rust-Oleum® Corporation) are designed to be applied to a surface with a roller applicator. However, applying a surface treatment using a roller applicator is a relatively time consuming process. 
         [0006]    It would thus be desirable to provide an improved surface treatment system and/or method that overcomes this and other shortcomings in the relevant art. 
       SUMMARY OF THE INVENTION 
       [0007]    In one embodiment, a surface treatment system includes a pressure generator structured to generate air pressure; a spray head assembly coupled to the pressure generator; and a hopper coupled to the spray head assembly and structured to hold surface treatment material, the hopper including an extended portion disposed at a top front portion of the hopper that raises a front top edge of the hopper to be higher than a rear top edge of the hopper, wherein the hopper is configured to provide the surface treatment material to the spray head assembly and the spray head assembly is configured to use the air pressure to spray the surface treatment material onto a surface. 
         [0008]    In another embodiment, a sprayer for treating a surface includes a spray head assembly structured to receive air pressure; and a hopper coupled to the spray head assembly and structured to hold surface treatment material, the hopper including tended portion disposed at a top front portion of the hopper that raises a front top edge of the hopper to be higher than a rear top edge of the hopper, wherein the hopper is configured to provide the surface treatment material to the spray head assembly and the spray head assembly is configured to use the air pressure to spray the surface treatment material onto a surface. 
         [0009]    In another embodiment, a method of applying treatment to a surface includes providing a sprayer including a spray head assembly structured to receive air pressure and a hopper coupled to the spray head assembly and structured to hold surface treatment material, the hopper including an extended portion disposed at a top front portion of the hopper that raises a front top edge of the hopper to be higher than a rear top edge of the hopper, wherein the hopper is configured to provide the surface treatment material to the spray head assembly and the spray head assembly is configured to use the air pressure to spray the surface treatment material onto a surface; providing air pressure to the sprayer; and spraying the surface treatment material on the surface using the sprayer. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    A further understanding of the disclosed and claimed concept can be gained from the following Description when read in conjunction with the accompanying drawing in which: 
           [0011]      FIG. 1  is a schematic diagram of a surface treatment system in accordance with an embodiment of the disclosed concept; 
           [0012]      FIG. 2  is a front view of a hopper used with a surface treatment system in accordance with an embodiment of the disclosed concept; 
           [0013]      FIG. 3  is a schematic diagram of a surface treatment system in use in accordance with an embodiment of the disclosed concept; and 
           [0014]      FIGS. 4A and 4B  are front views of nozzles used with a surface treatment system in accordance with embodiments of the disclosed concept. 
       
    
    
       [0015]    Similar numerals refer to similar parts throughout the specification. 
       DESCRIPTION 
       [0016]    Directional phrases used herein, such as, for example, left, right, front, back, top, bottom and derivatives thereof, relate to the orientation of the elements shown in the drawings and are not limiting upon the claims unless expressly recited therein. 
         [0017]    Referring to  FIG. 1 , a schematic diagram of a surface treatment system  1  in accordance with an embodiment of the disclosed concept is shown. The surface treatment system  1  includes a pressure generator  10 , a conduit  20 , a spray head assembly  30 , and a hopper  40 . Collectively, the spray head assembly  30  and the hopper  40  form a sprayer. 
         [0018]    The pressure generator  10  generates air pressure. The pressure generator  10  is coupled to the conduit  20  and supplies the generated air pressure to the conduit  20 . Any suitable device for generating air pressure (e.g., without limitation, an air compressor) may be employed as the pressure generator  10 . In some embodiments of the disclosed concept, the pressure generator  10  is capable of generating at least 60 psi of pressure. Furthermore, in some embodiments of the disclosed concept, the pressure generator  10  is configured to provide a relatively constant pressure of about 60 psi. In some other embodiments of the disclosed concept, the pressure generator  10  is capable of generating at least 100 psi of pressure. In some of other embodiments of the disclosed concept, the pressure generator  10  is capable of generating about 160 psi of pressure. 
         [0019]    The conduit  20  couples the pressure generator  10  to the spray head assembly  30  via a pressure regulator  21 . The pressure regulator  22  includes an adjustable valve  22  that can be operated to limit the amount of pressure provided to the spray head assembly  30 . The pressure regulator  21  also includes a gauge  23 . The gauge  23  allows a user to visibly verify the amount of pressure that is being provided to the spray head assembly  30  by the pressure generator  10 . It should be noted that the pressure regulator  21  may be omitted without departing from the scope of the disclosed concept. 
         [0020]    The hopper  40  is disposed on top of the spray head assembly  30  and is configured to hold surface treatment material  50 . The surface treatment material  50  is fed from the hopper  40  to the spray head assembly  30  where it is then sprayed out of a nozzle  32  of the spray head assembly  30  using the air pressure provided by the pressure generator  10 . 
         [0021]    The spray head assembly  30  includes a trigger  31  to control the spraying. Depressing the trigger  31  causes more air pressure to be used to spray the surface treatment material and thus allows more surface treatment material  50  to be sprayed out of the nozzle  32 . However, if the trigger  31  is depressed too far, too much surface treatment material  50  can spray at once leading to undesirable effects such as spattering. To reduce or eliminate such problems, the spray head assembly  30  includes an extended grip portion  33  disposed behind the trigger  31 . It is contemplated that the extended grip portion  33  may be integrated into the grip of the spray head assembly  30  in some embodiments of the disclosed concept. It is also contemplated that the extended grip portion  33  may be embodied as a spacer that is removable from the grip and may be interchanged with different sized spacers. The extended grip portion  33  is operable to limit the amount the trigger  31  may be depressed, and thus limit the amount of surface treatment material  50  that may be sprayed at once. 
         [0022]    Referring to  FIG. 4A , in some embodiments of the disclosed concept, the nozzle  32  includes a circular orifice  34  that allows the surface treatment material  50  to pass through it, The circular orifice  34  has a generally circular shape. If the circular orifice  34  is too large, too much surface treatment material  50  will pass through it at once, and if it is too small, not enough surface treatment material  50  will pass through it. In some embodiments of the disclosed concept, the orifice  34  has a diameter in a range of about 20-40 mm. In some other embodiments of the disclosed concept, the orifice  34  has a diameter of about 30 mm. 
         [0023]    Referring to  FIG. 4B , in some other embodiments of the disclosed concept, the nozzle  32  includes an oblong orifice  34 . The oblong orifice  34 ′ has a slat shape. In some embodiments of the disclosed concept, the length of the minor axis of the oblong orifice  34 ′ is within a range of about 20-40 mm. In some other embodiments of the disclosed concept, the length of the minor axis of the oblong orifice  34 ′ is about 30 mm. 
         [0024]    Referring back to  FIG. 1 , the front side of the hopper  40  includes an extended portion  41 . The extended portion  41  functions to increase the height of the front side of the hopper  40 . The increased height provided by the extended portion  41  of the hopper  40  makes it more difficult to spill the surface treatment material  50  out of the front side of the hopper  40 . In particular, when a user of the surface treatment system  1  leans forward with the spray head assembly  30  and hopper  40 , such as one might do when applying surface treatment to a deck, there is a risk of spilling surface material  50  out of the front side of the hopper  40 . However, the extended portion  41  of the front side of the hopper  40  reduces this risk. 
         [0025]    The rear side of the hopper  40  includes a rear handle  42  and the top side of the hopper  40  includes a top handle  43 . The rear handle  42  and the top handle  43  provide a user with places to hold the hopper  40  to provide it with more stability. Providing both the rear handle  42  and the top handle  43  allow the user to choose the most comfortable handle to hold the hopper  40  with. It is contemplated that the rear handle  42 , the top handle  43 , or both may be omitted without departing from the scope of the disclosed concept. 
         [0026]    A center line  34  of the spray head assembly  30  is shown in  FIG. 1 . The center line  34  of the spray head assembly  30  passes through the nozzle  32  in the direction that the spray head assembly  30  sprays the surface treatment material  50 . A center line  44  of the hopper  40  is also shown in  FIG. 1 . The center line  40  of the hopper  40  passes vertically through the hopper  40 . When the center line  44  of the hopper  40  is arranged vertically, the upper edge of the hopper  40  is arranged horizontally. The center line  34  of the spray head assembly  30  and the center line  44  of the hopper  40  are arranged at an angle A with respect to each other such that the spray head assembly  30  sprays in a downward direction when the center line  44  of the hopper  40  is arranged vertically. This allows a user of the surface treatment system  1  to comfortable spray a surface  60  (see  FIG. 3 ) such as a deck or driveway comfortably and without fear of spilling the surface treatment material  50  out of the hopper  40 . In some embodiments of the disclosed concept, angle A is within a range of about 20-70 degrees. It is also contemplated that the surface treatment system  1  may be used to apply surface treatment material to vertical or angled surfaces as well. 
         [0027]    in some embodiments of the disclosed concept, a Rust-Oleum® Restore™ product such as Rust-Oleum® Deck and Concrete Restore™ is used as the surface treatment material  50 . Rust-Oleum® Corporation instructs users of Rust-Oleum® Deck and Concrete Restore™ to apply it using a proprietary Restore™ Roller. However, the surface treatment system  1  of the present application applies Rust-Oleum® Deck and Concrete Restore™ to a surface more quickly and more effectively. For example, the inventor of the present application has found that the Rust-Oleum® Deck and Concrete Restore™ cannot be applied to vertical surfaces using a roller because it runs before drying. However, the inventor of the present application has discovered that spraying Rust-Oleum® Deck and Concrete Restore™ with the surface treatment system  1  allows it to be applied to vertical surfaces because the spraying causes it to dry more quickly, thus preventing it from running. 
         [0028]    Rust-Oleum® Deck and Concrete Restore™ is a relatively thick material, and thus one having ordinary skill in the art would generally determine that it should be applied using a brush or roller. In contrast with this viewpoint, the inventor of the present application has found that the surface treatment system  1  is capable of effectively applying the product. Moreover, the inventor has found that using relatively high r pressure in the surface treatment system  1  effectively applies the product. For example, in some embodiments of the disclosed concept, an air pressure of about 60 psi or more is provided to the spray head assembly  30 . In other embodiments, an air pressure of about 100 psi or more is provided to the spray head assembly  30 . In yet other embodiments, an air pressure between 100 and 200 psi is provided to the spray head assembly  30 . In contrast, many spray guns used for painting recommend using an air pressure below 60 psi, and high volume low pressure (HVLP) spray guns recommend using an air pressure below 10 psi. 
         [0029]    While using the surface treatment system  1  with Rust-Oleum® Deck and Concrete Restore™ to treat a deck or another similar surface is one application for the disclosed concept, it will be appreciated by those having ordinary skill in the art that the disclosed concept is not limited thereto. It will be appreciated by those having ordinary skill in the art that the surface treatment system  1  may he adapted to use a variety of different surface treatment materials without departing from the scope of the disclosed concept. It will also be appreciated by those having ordinary skill in the art that the surface treatment system  1  may also be adapted for use on a variety of different types of surfaces, as well as different orientations of surfaces (e.g., vertical, horizontal, angled, etc.), without departing from the scope of the disclosed concept. 
         [0030]    Although the foregoing discussion has presented specific embodiments, persons skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the embodiments to achieve similar functionality and utility to the exemplary embodiments disclosed herein. Moreover, it should be appreciated that features from a particular embodiment may be implemented in another embodiment disclosed herein to achieve a desired functionality. Accordingly, the specific embodiments described herein should be understood as examples and not limiting the scope of the disclosure.