Abstract:
A fan including blades for an actuator generally used with a pressurized aerosol spray can or air compressor sprayer that delivers surface texture materials to be sprayed onto a drywall or other supporting surface. The fan may be positioned inside or outside of the actuator orifice to create various patterns or textures of the sprayed product. The fan may come with an insert that is removably attachable to the actuator so that the same actuator may be used with different fans.

Description:
RELATED APPLICATIONS  
       [0001]     This application claims the benefit of U.S. Provisional Application No. 60/662,661 titled “FAN ACTUATOR,” filed Mar. 17, 2005, which is herein incorporated by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of Invention  
         [0003]     Embodiments of the present invention relate generally to an actuator for use with a pressurized aerosol spray can or air compressor sprayer that delivers surface texture materials, including a water-based pressurized substance in liquid or semi-liquid form that is storable and dispensable from an air-tight pressurized container, to be sprayed onto a drywall or other supporting surface. More particularly, embodiments of the present invention relate to an actuator, with a fan with blades positioned inside, that can create various patterns or textures of the sprayed product.  
         [0004]     2. Description of Related Art  
         [0005]     Aerosol spray cans and air compressor sprayers are generally used to atomize a pressurized liquid into a spray which can be delivered into a room or to coat an object with the atomized spray. The atomized spray is facilitated through the spray tip, or actuator in aerosols. A traditional actuator can be used to spray different materials. However, the practice of dispensing materials through traditional actuators generally yields only one pattern that generally does not differ significantly from one another.  
         [0006]     In order to achieve different sprayed patterns or textures, the aerosol industry has devised different surface texture materials and procedures used to create different desired patterns or textures. This generally requires obtaining specific surface texture materials for the desired texture, and different tools with which to apply the materials, in order to complete just one texture. Traditional procedures to create desired patterns also involve other complications. For example, in repairing stucco-covered surfaces, it is difficult to recreate the same stucco effect in the repaired areas. The conventional practice involves removing the damaged portions of the surface and filling in any holes, depressions, or the like with a prepared patch material. The patch material is applied by means of a trowel or other manipulating tool that will patch the hole or depression and prepare the surface area to receive a finish surface coating. After the patch material is cured and adhered to the original support material, the final coating is applied to the smoothed surface. However, this process leaves a smooth surface that is not matched to the surrounding stucco texture. Consequently, to obtain the desired stucco texture, a specialized composition needs to be applied as the final coating.  
         [0007]     There are some aerosol compositions known in the art for producing a surface having an abrasive grit that can be dispensed from a suitable aerosol container. Such compositions generally comprise a liquid propellant, an abrasive grit and a binder solution that can affix the abrasive grit onto the surface. However, because the abrasive grit can only be sprayed on in only one manner, and cannot be customized in any way, it does not provide the same surface texture to that of stucco. Consequently, the difference between the particulate sizes can still be distinguished. Furthermore, in contrast to the traditional stucco composition, the ingredients of compositions of this type, and the steps taken to use it, render the product and resulting method more costly and complicated.  
         [0008]     Therefore, there exists a long-standing need to provide an actuator or spray tip that may be used to readily disperse material from a container in aerosol form in a variety of patterns or textures.  
       BRIEF SUMMARY  
       [0009]     In accordance with an embodiment of the invention, a fan has been developed for use in association with the actuator or spray tip of aerosol spray cans or air compressor sprayers. An embodiment of the present invention provides an actuator including a fan inside the actuator that can be used to spray the material in the container in a wide variety of patterns and textures, without involving multiple surface texture materials or complicated and costly procedures. The actuator may be compatible for use with any generic aerosol spray can.  
         [0010]     The actuator according to an embodiment of the invention is equipped with a fan with blades inside the actuator. The fan may sit inside the orifice of the actuator where the sprayed product exits. When the actuator is engaged, the pressure forces out the material contained in the aerosol spray can and the released material hits the blades so that the blades spin. The sprayed material passes through the spinning blades as it is being expelled. As a result, a spray pattern is created that is different from the pattern that would have been created with a traditional actuator. The fan blades change the spray atomization to create a different surface effect.  
         [0011]     In another embodiment of the invention, the fan may be positioned outside of the actuator. This exterior fan operates similarly to the fan that is inside the actuator. When the actuator is engaged, the pressure releases the material from the aerosol container which spins the fan blades as the sprayed product is expelled. The resulting pattern and texture may differ from that created by the interior fan due to the change in distance that the sprayed product must travel before it is dispersed by the blades.  
         [0012]     The fan blades may have various embodiments. By changing the number of the blades, the spray pattern and texture will change accordingly. In one embodiment, a six-blade fan may be used. In another embodiment, the fan may include a 4-blade configuration. In yet another alternative, the fan may include a 3-blade configuration. Furthermore, the fan blades may also vary in their shape and size. In one embodiment of the invention, the fan may comprise blades that are linear and thin. In an alternative, the fan may comprise wide blades that are curved and angular, with larger surface area.  
         [0013]     In yet another embodiment, an insert may be provided that can be introduced or removed from the actuator orifice. The insert may include an opening, with a fan inside or outside of the insert opening. Depending on what pattern or texture is desired, the user may select a specific insert with the accommodating fan and introduce the insert into the actuator. This interchangeability allows the user to create entire array of spray patterns and textures, with one air compressor sprayer or aerosol spray can, that may fit the use of many different products. Additionally, the insert makes possible the use of one surface texture material to give different patterns and textures merely by changing the insert and fan to be used. Depending on the desired pattern or texture, the fan and insert may be composed of various materials, flexible or rigid. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]     A detailed description of embodiments of the invention will be made with reference to the accompanying drawings, wherein like numerals designate corresponding parts in the figures.  
         [0015]      FIG. 1  is a cross-sectional view of an actuator assembly with a fan in disassembled form according to an embodiment of the invention.  
         [0016]      FIG. 2  is a perspective view of an actuator assembly with an interior fan according to an embodiment of the invention.  
         [0017]      FIG. 3  is a perspective view of an actuator assembly with an exterior fan according to an embodiment of the invention.  
         [0018]      FIG. 4  is a cross-sectional view of an actuator assembly with a fan in an insert in disassembled form according to an embodiment of the invention.  
         [0019]      FIG. 5  is a perspective view of an actuator assembly with a fan in an insert according to an embodiment of the invention.  
         [0020]      FIG. 6  is a perspective view of an actuator assembly with an insert including an exterior fan according to an embodiment of the invention.  
         [0021]      FIG. 7  is a front-view of a fan with six blades according to an embodiment of the invention.  
         [0022]      FIG. 8  is a front-view of a fan with four blades according to an embodiment of the invention.  
         [0023]      FIG. 9  is a front-view of a fan with three blades according to an embodiment of the invention. 
     
    
     DETAILED DESCRIPTION  
       [0024]     In the following description, reference is made to the accompanying drawings which form a part hereof and which illustrate several embodiments of the present invention. It is understood that other embodiments may be utilized and structural and operational changes may be made without departure from the scope of the present invention.  
         [0025]     As shown in  FIG. 1  and  FIG. 2 , an actuator according to an embodiment of the invention, is illustrated schematically by the reference numeral  11 , for an aerosol spray can  7 .  FIG. 1  shows the actuator  11  in a disassembled form.  FIG. 2  shows the actuator  11  an assembled form. The actuator comprises a body  1  that includes an inlet  2 , a fan  4  that fits into the orifice  3  of the inlet  2 , and a main valve  5  that leads down into the cavity  6  of the can  7 . The actuator body  1  is mounted on a neck  8  that contains the main valve  5  that leads down into the cavity  6  of the can  7 . The top of the actuator body  1  forms a button tip  9  on which the user may push down upon to engage the actuator  11  and deliver an aerosol spray as any conventional aerosol spray containers known in the art. The lower part of the main valve  5  extends into a lower valve  10 . Once the actuator assembly  12  is engaged, the inlet  2  opens, and the main valve  5  and the lower valve  10  maintain fluid communication to dispense the fluid from the cavity  6  up through the inlet  2  and exiting from the orifice  3 , as with other aerosol spray cans known in the art. In an alternative embodiment, the container may include a propellant, such as compressed air or liquid gas, to further facilitate the force of expulsion and blast velocity with which the aerosol spray is released.  
         [0026]     The button tip  9  provides an area for a user to apply pressure to the actuator  11  in order to open the main valve  5  to which the actuator  11  is connected. By opening the main valve  5  the pressurized contents of the cavity  6  are released up through the main valve  5  and into the inlet  2  where it is delivered out.  
         [0027]     As seen in  FIGS. 1 and 2 , the fan  4  is placed in the orifice  3  of the inlet  2  so that the sprayed product passes through the fan  4  when the sprayed product exits. When the actuator  11  is engaged, the pressure from the aerosol container  7  releases the contents which hit the blades  4 A and  4 B so that the blades  4 A and  4 B spin. The sprayed material passes through the spinning blades  4 A and  4 B during the expulsion. As a result, a spray pattern is created that is different from the pattern that would have been created in a traditional actuator, without the fan  4 . The fan blades  4 A and  4 B change the spray atomization released by the aerosol can to create a different effect.  
         [0028]     In  FIG. 3 , an embodiment of the invention is shown wherein the actuator assembly  112  includes a fan  104  that is placed on the exterior of the actuator  111 . The fan  104  is positioned immediately outside of the orifice  103  of the inlet  102 . When the actuator  111  is engaged, the pressure releases the contents from the aerosol container  107  which spins the fan blades  104 A and  104 B as the sprayed product is expelled. While the fan  104  in this embodiment operates similarly to that of the previous embodiment, it can yield a resulting pattern and texture that differs from that created by the interior fan  4  (as shown in  FIGS. 1-2 ) due to the change in distance that the sprayed product must travel before it is dispersed by the blades.  
         [0029]      FIGS. 4-6  illustrate another embodiment of the invention wherein the actuator assembly  212  further includes an insert  213  in the orifice  203  of the inlet  202 . The insert may be permanently fixed in the orifice or the insert may be removably attached to the orifice. In such a case, the insert may be removed from the actuator and interchanged with another insert with a different fan. This allows the user to create a variety of patterns or textures without having to purchase an entire new aerosol spray can or surface texture material. The insert  213  may fit in the orifice  203  in a way that part of the insert  213  protrudes from the orifice  203  once the insert  213  is fully placed in the inlet  202 . In another embodiment, the insert may also fit in the orifice so that the insert is flush with the actuator body (not shown). As shown in  FIG. 4  and  FIG. 5 , the insert  213  may further include a fan  204  that is positioned within the insert  213 . Like the previous embodiments, once the actuator  211  is engaged, and the inlet  202  is opened, the pressure releases the contents from the container  207  and spins the fan blades  204 A and  204 B as the sprayed product is expelled. This may create yet another texture and pattern that is distinct from those created by the other embodiments.  
         [0030]     In  FIG. 6 , an alternative embodiment is shown of the actuator assembly  312  wherein the actuator  311  includes an insert  313  with a fan  304  on the exterior of the insert  313 . As with the other embodiments, the top of the actuator body  301  forms a button tip  309  on which the user may push down upon to engage the actuator  311  and deliver an aerosol spray. Once the actuator assembly  312  is engaged, and the inlet  302  opens, the main valve  305  and the lower valve  310  maintain fluid communication to dispense the fluid from the cavity  306  up to the inlet  302  and through the insert  313 . Due to the difference in distance that the sprayed product must travel to contact the fan blades  304 A and  304 B and the difference in position of the fan  304 , a different texture and pattern is again created.  
         [0031]     Without being limited, several other embodiments of the actuator fan comprising different blades, and the corresponding actuators and inserts, are described below.  
         [0032]     As shown in  FIG. 7 , one embodiment of the fan  404  includes six blades  404 B,  404 C,  404 D,  404 E, and  404 F. The blades  404 A,  404 B,  404 C,  404 D,  404 E and  404 F may be linear and thin in configuration.  
         [0033]     As shown in  FIG. 8 , one embodiment of the fan  504  includes four blades  504 B,  504 C and  504 D. The blades  504 A,  504 B,  504 C and  504 D may be curved and angular in configuration, with larger surface area.  
         [0034]     As shown in  FIG. 9 , another embodiment of the fan  604  may include three blades  604 A,  604 B and  604 C. The fan  604  is illustrated with blades  604 A,  604 B and  604 C that are curved and angular, with larger surface area.  
         [0035]     As demonstrated in the previous embodiments, the fan blades may have various embodiments. Each of the three previously described embodiments can be configured so that the fan may embody any combination of blade number, shape, and size. By changing the number and type of the blades, the spray pattern and texture will change accordingly. Depending on the desired pattern or texture, the fan and insert may also be composed of various materials, flexible or rigid. For example, metals, silicon, plastics, and rubber, are a few materials that may be used.  
         [0036]     While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention.  
         [0037]     The presently disclosed embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than the foregoing description. All changes that come within the meaning of and range of equivalency of the claims are intended to be embraced therein.