GB2487778A - Nozzle for delivering a flowable substance - Google Patents

Abstract

A nozzle 1 for applying a fillet of a flowable substance over a joint between two perpendicular surfaces. The nozzle comprises an elongate tube having an axial bore 2 through which the substance is dispensed, the bore having at one end an entrance aperture 3 through which the substance enters and at the other end a elliptical exit aperture 7 through which the substance is dispensed. First and second wings 13 are connected to the tube at, or in the region of, the elongate sides of the exit aperture and extend along different respective planes having an engagement angle of substantially 90 degrees, the wings being arranged, in use, to support the nozzle between respective perpendicular surfaces such that the exit is in a fixed position above the underlying void between the perpendicular surfaces. There may be a nozzle system arranged whereby different sizes of nozzle connect together (figure 8)

Description

NOZZLE FOR DELIVERING A FLOWABLE SUBSTANCE

The present invention relates to a nozzle for delivering a fillet of a flowable substance over a seam or joint between two surfaces, particularly ones perpendicular to one another such as S afloorand wall.

It is common in the building and DIY industry to apply a flowable substance, such as sealant (e.g. mastic or caulk) or plaster over a seam or joint between perpendicular surfaces. In the case of sealant, this type of seal is called a fillet seal' and Figure 1 indicates typical finishes.

Typically, a fillet seal provides a waterproof barrier, for example between the floor of a bathroom and the upright panel of the bath or shower unit.

Sealant is readily available in tubular containers from builder's merchants and DIY stores, the container including a conical nozzle that, in use, is attached to the dispensing end of the container. Prior to use, the nozzle tip is cut open, usually at a 45 degree angle or thereabouts, at a depth which depends on the required bead size. A hand-gun tool is applied to the opposite end of the container to force the sealant through the nozzle so that it can be applied onto the joint or seam.

There is little doubt that applying sealant using conventional equipment requires skill and experience in order to achieve a good finish in a reasonable period of time. This is because it is difficult to control the amount of sealant extruded to suit the speed at which the nozzle is moved along the joint. It is common for the resulting bead to include undulations and gaps due to too much or too little material being delivered for the speed of movement of the tool.

A common way of alleviating this, after the event, is to run a wet finger over the bead to achieve something approaching an acceptable finish. Alternatively, a specialised finishing tool may be used. These methods occasionally help but it is a cumbersome process and rarely results in a high quality finish. This is partly because the sealant begins to cure as soon as the outer surface of the bead is exposed to the air, and the resulting dragging of the bead can create further gaps and/or curtains of excess sealant that are clearly visible.

W02010/093490 discloses an injection sealing nozzle, i.e. a nozzle specifically adapted to apply sealant into a gap between laterally-adjacent panels, such as dry wall panels. This type of sealing may be likened to applying grout between tiles. The nozzle system is iather complex and comprises a reservoir which directs sealant out of two side apertures into a chamber behind a V-shaped nose. In use, the nose protrudes partly into the gap between panels and acts to drag the wet sealant backwards in the direction of travel, leaving a recessed bead between the panels where the nose cannot reach. The nozzle is not suitable for applying a fillet seal between perpendicular surfaces because the nose section would remove the deposited sealant from the joint as it is moved along. It is also a complicated structure and relatively expensive to produce.

According to a first aspect, there is provided a nozzle (1) for delivering a fillet of flowable substance over a seam or joint between two substantially perpendicular surfaces, the nozzle comprising: an elongate tube having a substantially axial bore (2) through which the substance is dispensed, the bore having at one end an entrance aperture (3) through which the substance enters the nozzle and at the other end an exit aperture (7) through which the substance is dispensed from the nozzle; and first and second wings (13) connected to the tube at, or in the region of, the exit aperture and extending along different respective planes, the wings being arranged, in use, to support the nozzle between respective perpendicular surfaces such that the exit aperture is in a substantially fixed position relative to an underlying seam or joint between the surfaces! The fixed position substantially maintained by the supporting wings helps ensure that a uniform bead of the substance can be applied into the underlying void, particularly as the nozzle is moved along the seam or joint longitudinally.

In the broad sense, the wings can be any form of substantially planar support surface.

Typically, the substance will be sealant, such as mastic or caulk, adhesive or plaster.

The wings may be connected to the tube such that their respective support planes have an engagement angle of between 90 and 110 degrees. In the preferred embodiment, the engagement angle is substantially 90 degrees.

The wings may be connected at one end to respective sides of the exit aperture, either side of a vertical plane extending through the longitudinal axis of the tube, and extend backwards in the direction of the entrance aperture.

The connection between the wings and the tube may be flexible to allow a degree of compression when said wings are supported between respective perpendicular surfaces.

The rear edge of each wing may comprises an overhang which, in use, makes contact with a respective one of the perpendicular surfaces.

The exit aperture may be defined by a perimeter wall cut at an angle relative to the tube's horizontal plane, the aperture having a distal beak portion and a proximal tail portion connected by side portions.

In use, when the nozzle is supported between respective perpendicular surfaces, the beak is preferably positioned lower than the tail portion. The part of the wall defining the tail portion may define a void section or space that has a greater area than that defined by the wall of the beak portion, so as to create a pressure release for the underlying chamber which results in the substance being forced towards the tail. The side portions may substantially touch respective ones of the perpendicular surfaces.

According to a second aspect, there is provided a nozzle system comprising a plurality of nozzles as defined in the first aspect, each nozzle's exit aperture having a different respective size and wherein the entrance aperture of one nozzle connects to the exit nozzle of a different nozzle.

According to a third aspect, there is provided a nozzle (1) for applying a fillet of a flowable substance over a seam or joint between two substantially perpendicular surfaces, the nozzle comprising: an elongate tube having a substantially axial bore (2) through which the substance is dispensed, the bore having at one end an entrance aperture (3) through which the substance enters the nozzle and at the other end a generally elliptical exit aperture (7) through which the substance is dispensed from the nozzle; and first and second wings (13) connected to the tube at, or in the region of, the elongate sides of the elliptical exit aperture and extending along different respective planes having an engagement angle of substantially 90 degrees, the wings being arranged, in use, to support the nozzle between respective perpendicular surfaces such that the exit aperture is in a substantially fixed position above the underlying void between the perpendicular surfaces.

The invention will now be described, by way of example, with reference to the accompanying drawings, in which: Figure 1 shows isometric views of three different types of fillet seal, applied between perpendicular surfaces; Figures 2 (a) -(c) are, respectively, a perspective, top plan and bottom plan view of a nozzle in accordance with a first embodiment of the invention; Figure 3 is a plan view of the nozzle of Figure 2 when oriented such that wing portions thereof are visible edge-on; Figure 4 is a plan view of the nozzle of Figure 3 when positioned between perpendicular surfaces; Figure 5 shows schematic views of the nozzle of Figure 2 when applied to a join between perpendicular surfaces, which is useful for understanding the invention; Figure 6 is an isometric view of the fillet seal deposited using the nozzle of Figure 2; Figure 7 is a schematic view showing different nozzle profiles and the resulting fillet seal S produced therewith.

Figure 8 is a perspective view of a nozzle system according to a further aspect of the invention; and Figures 9 (a) -(c) show different views of a nozzle in accordance with a further embodiment of the invention.

Referring to Figures 2 (a) -(c), a nozzle I arranged specifically for applying a fillet seal between perpendicular surfaces is shown. The nozzle I comprises a conical tube made of a plastics material, the tube having an internal bore 2 running end-to-end substantially along a central axis between an entrance aperture 3 at the proximal end and an exit aperture 7 at the distal end. Both the entrance and exit apertures 3, 7 are approximately centred on the longitudinal axis of the bore 2.

The entrance aperture 3 includes means (not shown) to connect the nozzle to a tube of sealant, for example by a push fit or screw thread connection. In use, sealant is forced into the entrance aperture 3 whereafter it travels down the bore 2 and is delivered to an underlying joint directly from the exit aperture 7.

The exit aperture 7, when viewed from below, is defined by a generally elliptical wall 5 formed effectively by cutting the cone at an angle of anywhere between 30 and 60 degrees, although 45 degrees is the preferred angle of the slice. In the preferred embodiment, this wall 5 is not a perfect ellipse and is specifically shaped at its front to produce a given bead profile and at its back, or tail, to ensure that excess sealant is directed in a particular direction for best results. The shape of the exit aperture 7 also allows for a correcting stroke to be applied.

More specifically, the wall 5 comprises: (i) side portions 6 disposed either side of the longitudinal axis of the nozzle I, (ii) a beak portion 9 at the distal, terminating end of the nozzle between the side portions and (iii) a tail portion 11 opposite the beak, between the side portions. The beak portion 9 in this case has an arcuate shape (when viewed end-on) so as to produce a rounded bead profile when sealant is deposited. The tail portion II has a similar profile but is raised with respect to the beak 9 for reasons that will be described below; as indicated in Figure 2 (a) the side portions 6 are arcuately cut so that the tail is raised above the notional straight-line connecting it to the beak.

First and second wings 13 are connected to the exit aperture 7, each wing extending S upwards and rearwards from a respective one of the side portions 6, along their full extent between the beak and tail portions 9, 11 which provides a useful sealing effect during operation, in the general direction of the entrance aperture 3 of the nozzle 1. Each wing 13 is substantially planar, at least on its outermost surface. In this embodiment, the wings 13 are connected directly to a respective side portion 6 of the exit wall 5 and hence have an arcuate lower edge. The respective planes of the wings 13 are separated by an engagement angle a of approximately 90.

The angular arrangement of the wings 13 in use serves to support the nozzle 1 between perpendicular work surfaces X and Y, for example between a floor and wall, bath or shower unit (hence the approximate 90 separation angle a between the wing planes). This is indicated in Figures 3 and 4. When the nozzle I is located between such surfaces, as indicated in Figure 4, the wings 13 ensure that the exit aperture 7 is supported in a substantially fixed position with respect to the corner-wise joint 20 to be fillet sealed. In other words, the distance between the various parts of the exit wall 5 and the apex of the joint 20 remains substantially constant as the nozzle is moved along the gap, as is the angular orientation of the nozzle 1.

In Figure 3, it will be seen that the angle a of the wings 13 is in fact slightly greater than 90, in this case 92.5. The connection between the wings 13 and the exit aperture 7 is made slightly flexible so that, when the nozzle 1 is positioned between work surfaces X and Y, the wings compress to conform to the actual angle between said surfaces. In practise, these may not be exactly perpendicular. The compression force, together with the extent of the wings 13 between the beak and tail portions 9, 11 also ensures a tight seal between each wing 13 thereby preventing sealant from moving across the surfaces.

Referring to Figure 5, the nozzle 1 is shown from one side when positioned at the joint between work surfaces X and Y. The wings 13, as indicated above, ensure the positioning of the nozzle 1, particularly the exit aperture 7, in the manner indicated. In this condition, the tail 11 is raised relative to the beak 9 and, by virtue of this and/or its shaped profile, provides a larger opening relative to that of the beak. This ensures that, as sealant is delivered down the bore 2, any excess sealant is directed backwards due to the pressure differential ensuring a constant flow of the sealant. Initially, when the operator sees that the excess sealant is coming through the tail 11, they know that the void beneath the exit 7 is filled and can then move the nozzle 1 in the direction indicated. As the nozzle 1 is moved, the beak 9 shapes the deposited sealant to the appropriate profile (a rounded profile in this case due to the arcuate sectional profile) and any excess is forced backwards.

S

Figure 6 shows, in isometric view, the deposited bead of sealant as the nozzle I moves along the joint to be fillet sealed.

Thus, the nozzle I described above ensures that a neat bead of sealant can be deposited in a single stroke along the gap 20. In the event, however, that the bead is broken, which may occur if the operator moves the nozzle I too quickly, the nozzle I allows for a correcting stroke. More particularly, the user applies additional sealant in the already-described manner into the break and re-positions the beak 9 in front of the freshly-applied sealant; without necessarily delivering more sealant, the user then moves the nozzle 1 back over the fresh sealant. The raised position of the tail 11 ensures that it will pass over this sealant, which might otherwise drag the curing surface backwards, and the beak 9 shapes the fresh sealant accordingly.

Thus, there is shown and described a sealant or caulking nozzle which provides for improved application of a fillet seal using a relatively simple structure. The nozzle, like existing nozzles, is a simple tube-like structure (usually conical) having a single axial bore and with no complicated add-on parts needed. The novel modifications involve appropriate shaping of the exit aperture 7 which can be formed integrally by injection moulding, and the wings can be formed integrally or made separately and fixed to the sides of the aperture during production. Production costs are relatively low compared with prior art methods.

The nozzle I may be provided with an end cap which is inserted within the exit aperture 7.

The cap may take the form of a plug which is simply pulled out prior to use and can be reinserted afterwards.

Alternative bead profiles can be made by using different beak profiles. Referring to Figure 7, both rounded and straight beaks 9 are shown, with the resulting bead profiles.

To cater for different sizes or shapes of bead profile, in a further embodiment, a nozzle system 30 is provided and comprises a plurality of interlocking nozzles. Figure 8 shows such a nozzle system 30, in this case a system providing a plurality of interlocking nozzles 32, 34, 36 each catering for different bead diameters. A first nozzle 32 has an entrance aperture arranged for connection to a sealant container outlet 40 and a narrower exit aperture 33. A second nozzle 34 has a cylindrical connection part 35 which acts both as a connector to the first nozzle's exit aperture 33 and defines the entrance aperture to said second nozzle 34. The exit aperture of the second nozzle 34 is narrower in diameter than S that of the first. The same connection arrangement is provided between the second nozzle 34 and a third nozzle 36. The connector parts 35, 37 are arranged so as fit tightly within the interior of the adjacent nozzle's exit aperture. An end cap 38 can be provided for the smallest nozzle 36. Typical bead diameters are indicated on the Figure and can also be stamped on the outer surface of each nozzle to provide a visual indication to the operator.

Referring to Figures 9 (a) -(c) a third embodiment will now be described. In this embodiment, the nozzle I is identical with that of the first, other than the fact that each wing 13 is modified to include an overhang portion 52 on the rear edge 50 thereof. To clarify, the rear edge 50 of the wing 13 is the edge nearest to the entrance aperture 3. Given the backwards motion of the nozzle I in use, this edge might be considered the leading edge' but for the sake of clarity it is considered the rear edge by virtue of it being furthest away from the beak 9.

The overhang portion 52 comprises a narrow strip or layer of material that protrudes or projects downwards from the rear edge 50 in the general direction of the wings' outer surface. In use, the overhang portion 52 makes contact with the adjacent work surface and acts to provide an additional seal as the nozzle I is drawn along the work surfaces X and Y. This is found to provide improved application of the sealant with a substantially constant flow.

The nozzle can be supplied as a separate item or integrally formed together with a sealant dispensing system, e.g. a tube of mastic. In the embodiment described above, an arcuate or elliptical nozzle cross section is employed. However, the nozzle could, in theory have a different cross section, including rectangular with the wings extending from straight side edges.

Claims (11)

1. CLAIMS1. A nozzle (1) for applying a fillet of a flowable substance over a seam or joint between two substantially perpendicular surfaces, the nozzle comprising: an elongate tube having a substantially axial bore (2) through which the substance is dispensed, the bore having at one end an entrance aperture (3) through which the substance enters the nozzle and at the other end an exit aperture (7) through which the substance is dispensed from the nozzle; and first and second wings (13) connected to the tube at, or in the region of, the exit aperture and extending along different respective planes, the wings being arranged, in use, to support the nozzle between respective perpendicular surfaces such that the exit aperture is in a substantially fixed position relative to an underlying seam or joint between the surfaces.
2. 2. A nozzle according to claim 1, wherein the wings are connected to the tube such that their respective planes have an engagement angle of between 90 and 110 degrees.
3. 3. A nozzle according to claim 2, wherein the engagement angle is substantially 90 degrees.
4. 4. A nozzle according to any preceding claim, wherein the wings are connected at one end to respective sides of the exit aperture, either side of a vertical plane extending through the longitudinal axis of the tube, and extend backwards in the direction of the entrance aperture.
5. 5. A nozzle according to any preceding claim, wherein the connection between the wings and the tube is flexible to allow a degree of compression when said wings are supported between respective perpendicular surfaces.
6. 6. A nozzle according to any preceding claim, in which the rear edge of each wing comprises an overhang which, in use, makes contact with a respective one of the perpendicular surfaces.
7. 7. A nozzle according to any preceding claim, wherein the exit aperture is defined by a perimeter wall cut at an angle relative to the tube's horizontal plane, the aperture having a distal beak portion and a proximal tail portion connected by side portions.
8. 8. A nozzle according to claim 7, wherein, in use when the nozzle is supported between respective perpendicular surfaces, the beak is positioned lower than the tail portion.
9. 9. A nozzle according to claim 8, wherein, in use, the side portions substantially touch respective ones of the perpendicular surfaces.
10. 10. A nozzle system comprising a plurality of nozzles as claimed in any preceding claim, each nozzle's exit aperture having a different respective size and wherein the entrance aperture of one nozzle connects to the exit nozzle of a different nozzle.
11. II. A nozzle (I) for applying a fillet of a flowable substance over a seam or joint between two substantially perpendicular surfaces, the nozzle comprising: an elongate tube having a substantially axial bore (2) through which the substance is dispensed, the bore having at one end an entrance aperture (3) through which the substance enters the nozzle and at the other end a generally elliptical exit aperture (7) through which the substance is dispensed from the nozzle; and first and second wings (13) connected to the tube at, or in the region of, the elongate sides of the elliptical exit aperture and extending along different respective planes having an engagement angle of substantially 90 degrees, the wings being arranged, in use, to support the nozzle between respective perpendicular surfaces such that the exit aperture is in a substantially fixed position above the underlying void between the perpendicular surfaces.