TWI531414B - Portable airless sprayer - Google Patents

Description

Portable airless spraying machine

This invention relates to portable fluid dispensing systems. In particular, the present invention relates to portable paint sprayers.

Paint sprayers are well known and widely used in the surface of paints such as building structures, furniture and the like. In conventional sprayer systems, airless paint sprayers provide the highest quality finishes due to their ability to finely atomize liquid paint. In particular, the airless paint sprayer presses the liquid paint up to 3000 psi [pounds per square inch] (about 20.7 MPa) and discharges the paint through small shaped holes. However, typical airless spray systems require a large stationary power unit (such as an electric motor, a gasoline motor or an air compressor) and a large stationary pumping unit. The power unit is coupled to a stationary paint source (such as a 5 gallon bucket) and a spray gun. Therefore, these units are ideal for large areas where paint requires high quality finishes.

However, it is generally desirable to paint a small area that does not meet the requirements or that cannot be set up with an airless spray system. For example, it may be desirable to provide a repair and decorative area having a topcoat that matches the original paint zone. Various types of hand-held spray systems and units have been developed to address this situation. For example, the so-called buzzer or cup-type spray gun includes a small hand-held device that is powered by being connected to a power outlet. These units are not capable of providing professional grade topcoats, especially because of the low pressures produced and the need to use low pressure secondary nozzles. Therefore, there is a need for a portable hand-held spray device that produces a professional grade topcoat.

The invention relates to a hand-held airless fluid dispensing device comprising a pump, a driving element and a nozzle element. The pump directly pressurizes a fluid. The drive element supplies power to the pump. The orifice element is coupled to the pump and atomizes the undiluted architectural coating to a particle size of no greater than about 70 microns, depending on Dv (50). The pump pressurizes the fluid to about 2.48 MPa at the orifice element and the orifice has an area of about 18.7 square millimeters. In one embodiment, the pump, drive element and orifice element are integrated into a hand held housing. In an embodiment, the pump includes a reciprocating piston fluid pump including at least two pumping chambers configured to be actuated by at least one piston out of phase. In another embodiment, the reciprocating piston fluid pump includes two pistons having different displacements that are linearly actuated by a wobble plate driven by a gear reducer and an electric motor.

1 shows a block diagram of a portable airless fluid dispensing device 10 of the present invention. In the illustrated embodiment, apparatus 10 includes a portable airless spray gun that includes a housing 12, a showerhead assembly 14, a fluid reservoir 16, a pumping mechanism 18, and a drive element 20. In various embodiments of the invention, the showerhead assembly 14, fluid container 16, pumping mechanism 18, and drive member 20 are packaged together in a portable spray system. For example, the showerhead assembly 14, fluid container 16, pumping mechanism 18, and drive element 20 can each be mounted directly to the outer casing 12 to include an integrated hand-held device, as described with reference to Figures 2-15. In other embodiments, the fluid container 16 can be separate from the outer casing 12 and coupled to the showerhead assembly 14, the pumping mechanism 18, and the drive element 20 via a hose, as shown in Figures 16-17. In still other embodiments, the showerhead assembly 14 can be separate from the outer casing 12 and coupled to the fluid container 16, the pumping mechanism 18, and the drive element 20 via a hose, as shown in Figures 18-22.

In all embodiments, sprayer 10 includes an airless dispensing system in which pumping mechanism 18 draws fluid from container 16 and utilizes power from drive element 20 to pressurize the fluid for passage through nozzle assembly 14 Chemical. In various embodiments, the pumping mechanism 18 includes a gear pump, a piston pump, a plunger pump, a vane pump, a rolling diaphragm pump, a ball pump, a rotating multi-leaf pump, a diaphragm pump or has a tooth One of the servo motors for the pin and pinion drive. In various embodiments, drive element 20 includes an electric motor, a pneumatic motor, a linear actuator, or a gas engine that can be used to drive a cam, a wobble plate, or a rocker arm. In one embodiment, when driven by drive element 20, pumping mechanism 18 produces an orifice of about 360 psi [psi] (about 2.48 MPa) up to about 500 psi (about 3.4 MPa) or higher. Spray or operating pressure. However, in other embodiments, the pumping mechanism 18 is capable of producing pressures of up to about 1,000 psi (about 6.9 MPa) to about 3,000 psi (about 20.7 MPa). In combination with the showerhead assembly 14 (which includes a spray orifice having an area of from as little as about 0.005 square inches (about 3.23 square millimeters) to about 0.029 square inches (about 18.7 square millimeters)), the sprayer 10 enables fluid construction Coatings such as paints, pigments, varnishes, and quick-drying paints are atomized to a Dv (50) scale of about 150 microns or less, or about 70 microns or less.

2 shows a side perspective view of the spray gun 10 having a housing 12, a showerhead assembly 14, a fluid container 16, a pumping mechanism 18 (mounted within the housing 12), and a drive member 20 (positioned within the housing 12). The spray gun 10 also includes a pressure relief valve 22, a trigger 24 and a battery 26. The showerhead assembly 14 includes a shield 28, a spray head 30, and a connector 32. Drive element 20 and pumping mechanism 18 are disposed within housing 12. The outer casing 12 includes an integrated handle 34, a container lid 36 and a battery cartridge 38.

The fluid container 16 has a fluid that is desired to be ejected from the lance 10 . For example, the fluid container 16 is filled with a paint or varnish that is fed to the showerhead assembly 14 by coupling with the cover 36. Battery 26 is inserted into battery cartridge 38 to provide power to drive element 20 within housing 12. The trigger 24 is coupled to the battery 26 and the drive element 20 such that a power input is provided to the pumping mechanism 18 after actuation of the trigger 24. Pumping mechanism 18 draws fluid from container 16 and provides pressurized fluid to showerhead assembly 14. Connector 32 couples showerhead assembly 14 to pump 18. The spray head shield 28 is coupled to the connector 32 to prevent objects from contacting the high speed output of the fluid from the spray head 30. The spray head 30 is inserted through the nozzle guard 28 and the bore in the connector 32 and includes one of the pressurized fluids received from the pumping mechanism 18. The showerhead assembly 14 provides a highly atomized fluid stream to produce a high quality finish. Pressure relief valve 22 is coupled to pumping mechanism 18 to open the mechanism to atmospheric pressure.

3 shows an exploded view of the spray gun 10 having a housing 12, a showerhead assembly 14, a fluid reservoir 16, a pumping mechanism 18, and a drive member 20. The spray gun 10 also includes a pressure relief valve 22, a trigger 24, a battery 26, a clamp 40, a switch 42 and a circuit board 44. The showerhead assembly 14 includes a shield 28, a spray head 30, a connector 32, and a barrel 46. The pumping mechanism 18 includes a suction tube 48, a return line 50, and a valve 52. Drive component 20 includes a motor 54, a transmission assembly 56, and a connection assembly 58. The outer casing 12 includes an integrated handle 34, a container lid 36 and a battery cartridge 38.

Pumping mechanism 18, drive element 20, transmission 56, connection assembly 58 and valve 52 are mounted within housing 12 and supported by various brackets. For example, the transmission 56 and the connection assembly 58 include a bracket 60 that is coupled to the bracket 62 of the pumping mechanism 18 using fasteners 64. The valve 52 is screwed into the bracket 62 and the connector 32 of the spray head 30 is screwed onto the valve 52. The spray head 30, the valve 52, the pumping mechanism 18 and the drive element 54 are supported within the outer casing 12 by ribs 66. In other embodiments of the spray gun 10, the outer casing 12 includes ribs or other features that are used to directly support the transmission 56 and the attachment assembly 58 without the use of the bracket 60. The switch 42 is positioned above the handle 34 and the circuit board 44 is positioned below the handle 34 such that the trigger 24 is ergonomically positioned on the housing 12. The switch 42 includes terminals for connection to the drive element 20, and the battery 26 is supported by the turns 38 of the housing 12 in a manner that is connected to the circuit board 44. Circuit board 44 can be programmed to vary the voltage supplied to drive element 20 to vary the flow from pumping mechanism 18 and to limit current and voltage. Additionally, circuit board 44 can be programmed to use pulse width modulation (PWM) to slow the output of drive element 20 when drawing high currents. In another embodiment, a temperature sensor is incorporated into the plate 44 to monitor the temperature in the electrical system of the spray gun 10, such as the temperature of the battery 26. Battery 26 can include a lithium battery, a nickel battery, a lithium ion battery, or any other suitable rechargeable battery. In one embodiment, battery 26 includes an 18V DC battery, although other lower or higher voltage batteries may be used. The fluid container 16 is screwed into the cover 36 of the outer casing 12. The suction tube 48 and the return line 50 extend from the pumping mechanism 18 into the fluid container 16. The clamp 40 allows the spray gun 10 to be conveniently loaded, for example, on one of the operator's belts or a storage rack.

To operate the spray gun 10, the fluid container 16 is filled with a liquid to be ejected from the spray head 30. The trigger 24 is actuated by an operator to activate the drive element 20. Drive element 20 draws power from battery 26 and causes rotation to one of the shafts of transmission 56. The transmission 56 causes the linkage mechanism 58 to provide uncoordinated motion to the pumping mechanism 18. The pumping mechanism 18 draws liquid from the container 16 using a suction tube 48. Excess fluid that cannot be handled by the pumping mechanism 18 is returned to the vessel 16 by actuating the injection valve 22 and the return conduit 50. The pressurized fluid from the pumping mechanism 18 is provided to the valve 52. After reaching a threshold pressure level, valve 52 is opened to allow pressurized fluid to enter bobbin 46 of spray head 30. The barrel 46 includes a spray orifice that atomizes the pressurized fluid as it exits the spray head 30 and the spray gun 10. The bobbin 46 can include a removable spray head that can be removed from the spray head guard 28 or a reversible spray head that rotates into the spray head retainer 28.

4 shows an exploded view of the pumping mechanism 18 and drive member 20 of FIG. The pumping mechanism 18 includes a bracket 62, a fastener 64, an inlet valve assembly 68, an outlet valve assembly 70, a first piston 72, and a second piston 74. The driving component 20 includes a driving shaft 76, a first gear 78, a first bushing 80, a second gear 82, a shaft 84, a second bushing 86, a third bushing 88, a third gear 90, and a fourth bushing 92. The fourth gear 94. The coupling mechanism 58 includes a connecting rod 96, a bearing 98, a rod 100, and a sleeve 102. The first piston 72 includes a first piston sleeve 104 and a first piston seal 106. The second piston 74 includes a second piston sleeve 108 and a second piston seal 110. The inlet valve 68 includes a first valve cartridge 112, a seal 114, a seal 116, a first valve stem 118, and a first spring 120. The outlet valve 70 includes a second valve barrel 122, a seat portion 124, a second valve stem 126, and a second spring 128.

The drive shaft 76 is inserted into the sleeve 80 such that the gear 78 rotates when the drive element 20 is activated. In various embodiments of the invention, the sleeve 80 and the gear 78 are integrally formed as an assembly. The sleeves 86 and 88 are inserted into one of the receiving holes in the bracket 60, and the shaft 84 is inserted into the sleeves 86 and 88. Gear 82 is coupled to one of the first ends of shaft 84 for engagement with gear 78, and gear 90 is coupled to a second end of shaft 84 for engagement with gear 94. In various embodiments of the invention, gear 82, shaft 84, gear 90, and bushing 92 are integrally formed as an assembly. The sleeve 102 is inserted into one of the receiving holes in the bracket 62 and the rod 100 is inserted into the sleeve 102 to support the coupling mechanism 58. Bearing 98 connects rod 100 to connecting rod 96. The connecting rod 96 is coupled to the first piston 72. The first piston 72 and the second piston 74 are respectively inserted into the piston sleeves 102 and 108 installed in the pumping chamber in the bracket 62. Valve seal 106 and sleeve 108 seal the pumping chambers. The fastener 64 is inserted through the hole in the bracket 62 and the sleeve 130 and screwed into the bracket 60. The first valve cartridge 112 is inserted into one of the receiving holes of the bracket 62. The first spring 120 biases the valve stem 118 against the barrel 112. Similarly, the second valve cartridge 122 is inserted into one of the receiving apertures of the bracket 62 such that the spring 128 biases the valve stem 126 against the bracket 62. The valve cartridges 112 and 122 can be removed from the bracket 62 such that the valve stems 118 and 126 can be easily replaced. The seals 114 and 116 prevent fluid from leaking from the valve 68 and the seat 124 prevents fluid from leaking from the valve 70. Valve 22 is inserted into one of the receiving bores of bracket 62 to intercept fluid flow from pistons 72 and 74.

Figure 5 shows a perspective view of one of the attachment mechanisms 58 of Figure 4. The coupling mechanism 58 includes a rod 100 to which the lands 132, the bearing 98, the connecting rod 96 and the gear 94 are attached. The connection mechanism provides a connection between the drive element 20 and the pumping mechanism 18. The piston 72 is coupled to the connecting rod 96 by a ball and socket joint or a plug and protrusion configuration. The coupling mechanism 58 converts the rotational shaft from the drive member 20 into a reciprocating motion of the piston 72. As best shown in Figures 6A and 6B, rotation of the rod 100 via the gear 94 produces a rocking of the connecting rod 96 through the lands 132 having a surface that is offset from the axis of rotation. In various embodiments of the invention, the rod 100 is integrally formed with the lands 132 as an assembly. However, in other embodiments, the attachment mechanism 58 can include a Scotch yoke or another system for converting rotational motion into linear motion.

Figure 6A shows a cross-sectional view of the attachment mechanism 58 of Figure 5 with the connecting rod 96 in an advanced position. Figure 6B shows a cross-sectional view of the attachment mechanism 58 of Figure 5 with the connecting rod 96 in a retracted position. The coupling mechanism 58 includes a gear 94, a connecting rod 96, a bearing 98, a rod 100, a sleeve 102, a lands 132, and a sleeve 134. In this configuration, the attachment mechanism 58 includes a rocking assembly. Figures 6A and 6B, which are discussed at the same time, illustrate the reciprocating motion produced by the lands 132 when subjected to a rotational motion. One of the first ends of the rod 100 is supported by a sleeve 102 that is supported in a bracket 62 of the pumping mechanism 18. The second end of one of the rods 100 is supported by a sleeve 134 through a lands 132 that are supported in the bracket 60. The lands 132 are disposed about the rod 100 and include a sleeve seat for the sleeve 134, a gear holder for the gear 94, and a rocking seat 136 for the connecting rod 96. The connecting rod 96 includes a ball 138 disposed in a socket in the piston 72.

The gear 94 rotates the lands 132 and the rod 100, and the rod 100 rotates within the sleeve 102 and the sleeve 134. The rocking seat 136 includes a cylindrical structure having a surface that rotates about an axis that is offset from the axis about which the lands 132 and the rod 100 rotate. As the lands 132 rotate, the shaft of the rocking seat 136 spirals about the axis of the rod 100, producing a conical scan. The bearing 98 is disposed in a plane transverse to the axis of the rocking seat 136. Therefore, the bearing 98 fluctuates or oscillates with respect to a plane that crosses the rod 100. The connecting rod 96 is attached to the outer diameter end of the bearing 98, but the connecting rod 96 is prevented from rotating about the rod 100 by the ball 138. Ball 138 is coupled to piston 72 (which is disposed within one of the piston seats 62) to prevent rotation. However, the ball 138 is allowed to move in the axial direction as the bearing 98 swings. Thus, the swirling motion of the rocking seat 136 produces a linear motion of the ball 138 to drive the pumping mechanism 18.

FIG. 7 shows a cross-sectional view of the pumping mechanism 18 assembled with the drive member 20. Drive element 20 includes a mechanism or motor for generating rotation of drive shaft 76. In the illustrated embodiment, drive element 20 includes a DC (direct current) motor that receives an electrical input from battery 26 or another power source. In other embodiments, the drive element includes an AC (alternating current) motor that receives an electrical input by being plugged into a power outlet. In various other embodiments, the drive element can include a pneumatic motor that receives compressed air as an input, a linear actuator, a gas engine, or a brushless DC motor. A compressed air motor or a brushless DC motor provides an essentially safe drive element that eliminates or significantly reduces electrical and thermal energy from the drive components. This allows the spray gun 10 to be used with flammable or flammable liquids or in environments where flammable, flammable or other hazardous materials are present. The first gear 78 is mounted on the drive shaft 76 and held in place by the sleeve 80. The sleeve 80 is secured to the shaft 76 using a set screw or another suitable member.

The first gear 78 meshes with a second gear 82 that is coupled to the shaft 84. The shaft 84 is supported in the bracket 62 by bushings 86 and 88. The gear 90 is placed on a reduced diameter portion of the shaft 84 and secured in place using the sleeve 92. The sleeve 92 is secured to the shaft 84 using a set screw or another suitable member. Gear 90 meshes with gear 94 to rotate rod 100. The rod 100 is supported by the sleeve 102 and the sleeve 134 in the brackets 62 and 60, respectively. Gears 78, 82, 90 and 94 provide a gear reduction member that slows the input from the lever 100 from the input provided by drive member 20. Depending on the type of pumping mechanism used and the type of drive components used, various sizes of gears and gear reductions can be provided as needed to produce the desired operation of the pumping mechanism 18. For example, the pumping mechanism 18 needs to operate at a rate sufficient to produce the desired fluid pressure. In particular, it is advantageous to provide a highly desirable fine topcoat using sprayer 10 at a pressure of from about 1,000 psi (about 6.9 MPa) to about 3,000 psi [about 20.7 MPa]. In one embodiment of the pumping mechanism 18, one of the gear reduction mechanisms of about 8 to 1 is used with a typical 18V DC motor. In another embodiment of the pumping mechanism 18, a DC to AC bridge is used, with a gear reduction system of about 4 to 1 being used with a typical 120V DC motor.

As described with reference to Figures 6A and 6B, rotation of the rod 100 produces a linear motion of the ball 138 of the connecting rod 96. Ball 138 is mechanically coupled to socket 140 of piston 72. Thus, the connecting rod 96 directly actuates the piston 72 in both the advanced and retracted positions. The piston 72 is advanced and retracted within the piston sleeve 104 in the bracket 62. When the piston 72 is retracted from the advanced position, fluid is drawn into the valve 68. Valve 68 includes a stem 142 that is coupled to a suction tube 48. The straw 48 is immersed in one of the liquids inside the fluid container 16 (Fig. 3). Fluid is drawn into the pumping chamber 144 by bypassing the valve stem 118 and through the inlet 146. The valve stem 118 is biased against the valve barrel 112 by a spring 120. The seal 116 prevents fluid from passing between the barrel 112 and the rod 118 when the rod 118 is closed. The seal 114 prevents fluid from passing between the barrel 112 and the bracket 62. The valve stem 118 is pulled away from the barrel 112 by the suction generated by the piston 72. As the piston 72 advances, fluid within the pumping chamber 144 is pushed through the outlet 148 toward the valve 70.

The pressurized fluid in chamber 144 is pushed into pressure chamber 150 by bypassing valve stem 126 of valve 70. The valve stem 126 is biased against the bracket 62 by a spring 128. When the lever 126 is closed, the seat 124 prevents fluid from passing between the lever 126 and the bracket 62. The valve stem 126 is forced away from the bracket 62 as the piston 72 moves toward the advanced position, while the spring 120 and the pressure created by the piston 72 close the valve 68. Pressurized fluid from pumping chamber 144 fills pressure chamber 150 (including the space between barrel 122 and bracket 62) and pumping chamber 152. The pressurized fluid also forces the piston 74 to retract to the retracted position. The barrel 122 reduces the volume of the pressure chamber 150 such that less fluid is stored within the pumping mechanism 18 and increases the velocity of the fluid passage mechanism 18, which aids in cleaning. The volume of the pumping chamber 144 and the amount of displacement of the piston 72 are greater than the amount of displacement of the piston 74 and the volume of the pumping chamber 152. In one embodiment, the amount of exhaust of the piston 72 is twice as large as the displacement of the piston 74. In another embodiment, the piston 72 has a 0.4375 inch (about 1.1 cm) diameter and a 0.230 inch (about 0.58 cm) stroke, and the piston 74 has a diameter of 0.3125 inches (about 0.79 cm) and a 0.150. Miles (about 0.38 cm) of the trip. Thus, one of the pistons 72 provides sufficient fluid to fill the pumping chamber 152 and maintain the pressure chamber to fill the pressurized fluid. Additionally, the piston 72 has a volume that is large enough to push pressurized fluid through the outlet 154 of the bracket 62. In contrast to providing suction by two smaller pistons, providing suction by only a single larger piston provides improved suction capability.

When the piston 72 is retracted to draw additional fluid into the pumping chamber 144, the piston 74 is pushed forward by the connecting rod 96. The piston 72 is disposed within the piston sleeve 108 in the bracket 62 and the piston seal 110 prevents pressurized fluid from escaping the pumping chamber 152. The piston 72 is advanced to evacuate fluid that is pushed into the pumping chamber 152 by the piston 72. The fluid is pushed back into the pressure chamber 150 and through the outlet 154 of the bracket 62. Pistons 72 and 74 operate out of phase with each other. For the particular embodiment shown, the piston 74 is out of phase with the piston 72 by one hundred and eighty degrees such that when the piston 74 is in its maximum advanced position, the piston 72 is in its maximum retracted position. Due to the out-of-phase operation, the pistons 72 and 74 operate synchronously to provide a continuous flow of pressurized fluid to the pressure chamber 150 while also reducing vibration in the sprayer 10. In one embodiment, the pumping mechanism operates at approximately 4,000 pulses per minute and each piston operates at approximately 2,000 strokes per minute. The pressure chamber 150 acts as a liquid trap to provide a constant flow of pressurized fluid to the outlet 154 such that a continuous flow of liquid can be provided to the valve 52 and the showerhead assembly 14 (Fig. 3). In other embodiments, additional mechanical components can be coupled to the pressure chamber 150 to provide an auxiliary liquid trap device. For example, the pressure chamber 150 can be coupled to a bladder, diaphragm, hose or telescoping tube to provide external pressure to the fluid passing through the chamber 150 to the outlet 154. In particular, a hose can be used to connect the pumping mechanism 18 to the showerhead assembly 14 to provide a liquid trap function, such as shown, for example, in FIG.

In another embodiment, the pumping mechanism 18 can include a dual displacement single piston pump in which a single piston applies pressure to the two cylinders 180 degrees out of phase. In other embodiments, three or more pumping chambers may be pressurized out of phase to provide an even smoother spray profile. For example, a triple plunger or piston pump can be used. In still other embodiments, a oscillating pump (generated by a rotor), a gear pump, or a rotating multi-leaf pump can be used.

FIG. 8 shows a side cross-sectional view of valve 52 and showerhead assembly 14. Figure 9, which is discussed concurrently with Figure 8, shows a bottom cross-sectional view of valve 52 and showerhead assembly 14. Valve 52 includes cylinder 156, shaft cap 158, ball head 160, seal 162, needle 164, spring 166, seal 168, spring shock absorbers 170 and 172, seal 174, seal 176, stop 178, fluid passage 180 and filter 182. The showerhead assembly 14 includes a shield 28, a connector 32, a spray head 30 (which includes a barrel 46), a seat 184, and an orifice 186.

The cylinder 156 of the valve 52 is screwed into one of the sockets 62 of the pumping mechanism 18. Seal 168 prevents fluid from leaking between bracket 62 and cylinder 156. Spring shock absorber 172, spring 166, and spring shock absorber 170 are positioned about needle 164, and filter 182 is positioned about needle 164 and spring 166. The stopper 178 is inserted into the axial bore 188 in the cylinder 156. Needle 164 and filter 182 are inserted into cylinder 156 and needle 164 extends into axial bore 188 within cylinder 156. Seal 176 prevents fluid from leaking into the axial bores within cylinder 156. The filter 182 connects the shaft cap 158 with the cylinder 156 to extend the fluid passage 180 in an annular flow path toward the shaft cap 158. The shaft cap 158 is inserted into the fluid passage 180 of the cylinder 156. Seal 174 prevents fluid from leaking between cylinder 156 and shaft cap 158. The seal 162 is inserted into the shaft cap 158 to enclose the integrated ball head 160 of the needle 164. The connector 32 is screwed onto the cylinder 156 to maintain the seal 162 engaged with the shaft cap 158 and to maintain the needle 164 within the cylinder 156.

The orifice 186 is inserted into the bore 190 in the barrel 46 of the spray head 30 and abuts the shoulder 192. The seat 184 is inserted into the bore 190 and maintains the orifice 186 against the shoulder 192. Inserting the spray head 30 into the transverse bore 194 in the shaft cap 158 causes the seat 184 to align with the needle 164. The ball head 160 is biased against the seat 184 by a spring 166. The seat 184 includes a contoured surface for engaging the ball head 160 such that pressurized fluid flow is prevented from entering the showerhead 30. The shield 28 is positioned about the shaft cap 158.

After the pumping mechanism 18 is activated, such as by operating the trigger 24, pressurized fluid is provided to the outlet 154. The fluid from the pumping mechanism 18 is pushed into the valve 52 through the outlet 154. Fluid travels through fluid passage 180, surrounding filter 182 to engage shaft cap 158. At the shaft cap 158, the pressurized fluid can pass through the passage 196 between the shaft cap 158 and the needle 164 (as shown in FIG. 9) to be positioned between the seal 162 and the lands 198 of the needle 164. The pressure of the fluid against the front surface of the lands 198 and the needle 164 forces the needle 164 back into the cylinder 156. The spring 166 compresses between the shock absorbers 170 and 172, which inhibit the spring 166 from vibrating during the pulsation of the pressurized fluid from the pumping mechanism 18. The stopper 178 inhibits the needle 164 from moving too far and reduces the impact force of the needle 164 against the cylinder 156. In one embodiment, the spring 166 is fully compressed at about 1,000 psi (about 6.9 MPa) and the spring 166 is closed at about 500 psi (about 3.4 MPa). After the needle 164 is retracted, pressurized fluid can enter the seal 162 and into the bore 200 of the seat 184. From the orifice 200, the pressurized flow system is atomized by the orifice 186. In one embodiment, the orifice 186 uses an aperture diameter of about 0.029 square inches (about 0.736 square millimeters) to atomize the undecimated (e.g., no water to reduce viscosity) building coating to about 150 microns. In another embodiment, the orifice 186 atomizes the pressurized architectural coating to about 70 microns on a Dv (50) scale.

In other embodiments of the invention, valve 52 may include an assembly in which seat 184 is integrated into cylinder 156 as discussed with respect to Figure 13B and discussed in greater detail below. For example, using a pressure-actuated shut-off valve, such as available from Minneapolis, Minnesota Graco Minnesota company of a shut-off valve Cleanshot ^TM. Such a valve is described in U.S. Patent No. 7,025,087 to the name of U.S. Pat. For example, after the valve seat 184 is placed in the cylinder 156, the needle 164 does not extend all the way to the barrel 46. Thus, the spatial extension between the extension orifice 186 and the ball head 160 allows the aperture 200 to be effectively extended. This leaves a significant fluid volume within the bore 200 after the pumping mechanism 18 is activated and the valve 52 is closed. After one of the pumping mechanisms 18 is subsequently activated, the liquid is still not atomized, which may result in unwanted splashing or splashing of the fluid. Such a showerhead includes a conventional design and an exemplary embodiment is described in U.S. Patent No. 3,955,763 to the name of U.S. Pat.

However, the embodiments of Figures 8 and 9 achieve advantages over such designs. The seat 184 and the orifice 186 are integrated into the barrel 46 such that the seat 184 and the orifice 186 are also removed when the nozzle 30 is removed from the nozzle assembly 14. This reduces the number of parts compared to previous designs. For example, no additional seals and fastening elements are required. Additionally, integrating the orifice 186 into the barrel 46 reduces the volume of the non-atomized fluid ejected from the orifice 186. Specifically, the space between the orifice 186 and the ball head 160 is shortened by moving the seat 184 into the barrel 46 and extending the needle 164 to reach the seat 184 in the barrel 46. Therefore, the volume of the hole 200 is reduced.

Figure 10 shows a cross-sectional view of the pressure relief valve 22 used in the pumping mechanism 18 of Figure 4. The pressure relief valve 22 includes a body 202, a plunger 204, a spring 206, a seat 208, a ball 210, a seal 212, and an operating rod 214. The body 202 is threaded into the bore 216 of the bracket 62 to engage the aperture 218. The bore 218 extends into the bracket 62 to engage the pressure chamber 150 (Fig. 7). The body 202 also includes a transverse bore 220 that extends through the body 202 to align with the vent 222 in the bracket 62. Vent 222 receives return conduit 50 (Fig. 3) that extends into fluid reservoir 16 (Fig. 3). Therefore, a complete circuit is formed between the fluid container 16, the suction tube 48, the pumping mechanism 18, the pressure chamber 150, the pressure relief valve 22, and the return tube 50. Inserting the plunger 204 into the body 202 causes the rod 224 to extend through the body 202 and the flange 226 engage the interior of the body 202. Seal 228 is positioned between body 202 and flange 226 to prevent fluid from within bore 220 from entering body 202. The spring 206 is positioned within the body 202 and urged against the flange 226 to bias the plunger 204 toward the seat 208. The ball 210 is positioned between the plunger 204 and the seat 208 to prevent flow between the aperture 218 and the aperture 220. The seal 212 prevents fluid from leaking through the ball 210.

Valve 22 prevents pumping mechanism 18 from becoming excessively pressurized. Depending on the spring rate of the spring 206, the plunger 204 will be displaced when the pressure within the pressure chamber 150 reaches a desired threshold level. At this level, the aperture 218 is coupled to the aperture 220 to allow liquid within the pressure chamber 150 to travel into the vent 222. Thus, the liquid is returned to the vessel 16 and recycled by the pumping mechanism 18. For example, in one embodiment, valve 52 is configured to open at 1,000 psi (about 6.9 MPa) while valve 22 is configured to open at 2,500 psi (about 17.2 MPa). In various embodiments of the invention, the plunger 204 can have an adjustment mechanism to set the distance the plunger 204 is withdrawn from the seat 208 such that the valve 22 can be used to automatically or manually adjust the flow rate of the pumping mechanism 18.

The valve 22 will also be supplied to the pumping mechanism 18 in conjunction with the mechanism. After a new use of the sprayer 10 is initiated, it may be desirable to purge air from the sprayer 10 to prevent splashing or inconsistent ejection of fluid from the sprayhead 10 before the fluid has filled the pumping mechanism 18. Thus, an operator can push or pull the lever 214 that is coupled to the lever 224 by the hinge 230 to withdraw the ball 210 from engagement with the seat 208. Thus, after the pumping mechanism 18 is activated, air from the sprayer 10 is displaced by the fluid from the container 16 and the air is removed from the sprayer 10 through the vent 222. Thus, when the operating lever 214 is released, the valve 52 will open after the fluid is pressurized instead of the pressurized air and the initial flow of atomizing fluid will be uniform.

Valve 22 also provides a means for depressurizing sprayer 10 in later use. For example, after the sprayer 10 is operated, the pressurized fluid is still within the sprayer 10 when the drive element 20 has ceased to operate the pumping mechanism 18. However, it may be desirable to depressurize the sprayer 10 to allow the sprayer 10 to be detached and cleaned. Accordingly, displacement of the operating lever 214 opens the valve 22 to discharge pressurized fluid within the pumping mechanism to the container 16.

Figure 11 shows a cross-sectional view of a first embodiment of one of the fluid containers 16 of Figure 3. The fluid container 16 includes a generally cylindrical container 232 having a perimeter 234 and a contoured bottom 236. The peripheral edge 234 is coupled to the sprayer 10 by a helical engagement with a cover 36 of the outer casing 12 (Fig. 3). The bottom 236 has a base 238 that is coupled to the container 232 to provide a flat bottom surface on which the container 232 can rest while standing upright. The straw 48 extends from the pumping mechanism 18 to the interior of the container 16. In the illustrated embodiment, the straw 48 includes a fixed tube that reaches the bottom of the bottom 236 of the container 232. The straw 48 is bent to reach the center of the container 232 with the bottom 236 being flat. The straw 48 includes an inlet 240 (which faces the flat portion of the bottom 236) and a filter 242. The inlet 240 extends over approximately the entire surface area of the flat portion of the bottom portion 236. The bottom 236 includes a curved portion 246 that injects fluid within the container 232 toward the inlet 240. Thus, the straw 48 can evacuate most of the volume of liquid provided in the container 232 when the sprayer 10 is placed in an upright position.

12A and 12B show cross-sectional views of a second embodiment of a fluid container 16 of Fig. 3. The fluid container 16 includes a cylindrical container 248 having a perimeter 250 and a flat bottom 252. The straw 48 extends into the interior of the container 248. In the illustrated embodiment, the straw 48 includes a two piece tube having an upper portion 254 and a lower portion 256. Upper portion 254 includes a curved portion to reach the center of container 248. Lower portion 256 extends from upper portion 254 at an angle to reach bottom portion 252. The lower portion 256 is rotatably attached to the upper portion 254 such that the inlet 258 containing the filter 260 can be placed around the entire perimeter of the cylindrical wall of the container 248. The lower portion 256 includes a coupling member 262 that fits over the lower end of the upper portion 254. Seal 264 is positioned between coupling 262 and upper portion 254 to prevent fluid from escaping tube 48. Thus, the lower portion 256 can be rotated to a forward position (as shown in Figure 12A) for injection along a downward orientation (e.g., a floor). Additionally, the lower portion 256 can be rotated to a rearward position (as shown in Figure 12B) for injection in an upward orientation (e.g., ceiling). The lower portion 256 can be rotated in a variety of ways. An operator can manually move the lower portion 256, such as prior to providing the liquid to the container 248. In another embodiment, a magnetic knob is disposed on the bottom of the container 248 to move the inlet 258.

13 shows an exploded view of a second variation of one of the embodiments of the hand-held sprayer of one of the dispensing devices 10 of FIG. The spray gun 10B includes components similar to the spray gun 10 of FIG. 3, such as the outer casing 12B, the spray head assembly 14B, the fluid container 16B, the pumping mechanism 18B, the drive element 20B, the pressure relief valve 22B, the battery 26B, the guard 28B, the spray head 30B, Valve 52B, transmission assembly 56B and connection assembly 58B. Pumping mechanism 18B includes a dual piston pumping assembly wherein each piston system is directly coupled to vessel 16B and provides pressurized fluid to nozzle 14B. The pumping mechanism 18B includes a first piston 72B and a second piston 74B, both of which have the same amount of exhaust. Pistons 72B and 74B reciprocate within piston cylinders in housings 266 and 268 by direct coupling with connection assembly 58B. Pistons 72B and 74B reciprocate out of phase to reduce vibration and pulsation of the liquid atomized by showerhead assembly 14B. Pistons 72B and 74B draw fluid from container 16B through inlet valves 270 and 272 disposed in outer casing 274, respectively. The outer casing 274 includes an inlet 276 that draws fluid from the lower portion 280 of the container 16B. Pistons 72B and 74B push fluid into outlet valves 282 and 284 disposed in outer casing 286, respectively. Housing 286 includes an outlet 288 that is coupled to valve 52B. Valve 52B includes a mechanically actuated valve that is coupled to one of operating levers 290. The lever 290 withdraws the needle 292 from a valve seat in the cylinder 294 to allow pressurized fluid to enter the showerhead assembly 14B. The lever 290 is also electrically coupled to a switch 296 that activates a drive element 20B that includes an electric motor in the illustrated embodiment. Drive element 20B provides input through transmission assembly 56B (which provides a gear reduction function) and connection assembly 58B (which converts rotational input power from drive element 20B into reciprocating linear motion for driving pistons 72B and 74B) Power is supplied to the pumping mechanism 18B. For example, transmission assembly 56B can include a planetary gear set and connection assembly 58B can include a wobble plate assembly. In another embodiment of the invention, piston 72B and piston 74B can be coupled to different fluid containers to provide mixing within spray gun 10B.

Figure 13B shows a cross-sectional assembly view of various components of the spray gun 10B of Figure 13A. The spray gun 10B includes a spray head assembly 14B, a pumping mechanism 18B, a shut-off valve 52B, and a connection assembly 58B. As discussed with respect to Figure 13A, the coupling mechanism 58B receives input from the drive element 20B to provide power to the pumping mechanism 18B. Pumping mechanism 18B is coupled to shut-off valve 52B to control the flow of pressurized fluid from pumping mechanism 18B to showerhead assembly 14B. Both the shut-off valve 52B and the drive element 20B are activated by actuating the operating lever 290. In particular, the lever 290 is configured to pivotally abut against the housing 12B at the rocker point P. Thus, retraction of the lower portion of the lever 290 (such as by an operator's hand) retracts the lever 297 to pull the pin 292 away from the valve seat 184B to allow pressurized fluid to enter the showerhead assembly 14B. Additionally, the lever 290 is retracted to contact the switch 296, which is coupled to the drive member 20B to provide input power to the pumping mechanism 18B. Therefore, the mechanical actuation of the operating lever 290 simultaneously activates the drive element 20B and the shut-off valve 52B.

The shut-off valve 52B includes a mechanically actuated valve wherein the valve seat 184B is coupled to the cylinder 294 via a connector 32B and a shaft cap 158B. Specifically, the connector 32B is screwed onto the cylinder 294 to sandwich the valve seat 184B and the sleeve 298 between the shaft cap 158B and the cylinder 294. The showerhead assembly 14B also includes seals 199A and 199B that are positioned between the seat 184B and the sleeve 298 and between the sleeve 298 and the shaft cap 158, respectively. The shield 28B is coupled to the shaft cap 158B. The shield 28B and the shaft cap 158B are formed to receive a bore 194B having a nozzle assembly of one of the bobbins, the bobbin containing one of the orifices for atomizing the pressurized fluid. Thus, the barrel and the nozzle assembly of the orifice can be easily inserted and removed from the aperture 194B, such as to change the orifice size or to clean the orifice. These orifices are always known and easy to manufacture. An example of such a nozzle assembly is described in U.S. Patent No. 6,702,198 to the name of U.S. Pat. However, the pressurized fluid must extend from the seat 184B, across the seal 199A, the seal 199B, and the collar 298 to the bore 194B before being atomized and discharged from the sprinkler assembly 14B that may be splashed. Spray hole. The area between the seat 184B and the orifice can be reduced by incorporating the valve seat into the nozzle assembly barrel as described with reference to Figures 8 and 9.

Figure 14 shows a perspective view of a third variation of one of the embodiments of the hand sprayer of the dispensing device 10 of Figure 1 utilizing a gravity fed fluid container. Sprayer 10C includes a housing 12C, a showerhead assembly 14C, a fluid cup 16C, a pumping mechanism 18C, and a drive element 20C. The showerhead assembly 14C includes a pressure actuated valve that releases fluid pressurized by the pumping mechanism 18C. The pumping mechanism 18C is supplied with input power by the drive element 20C to pressurize fluid from one of the cups 16C. Drive element 20C includes an AC motor having a power cable 300 that can be plugged into any conventional power outlet, such as a 110 volt outlet. In other embodiments, drive element 20C can be configured to operate from about 100 volts to about 240 volts. However, any embodiment of the present invention can be configured to operate with DC or AC power via a power line or a battery. Pumping mechanism 18C and drive element 20C are integrated into housing 12C such that sprayer 10C includes a portable hand held unit. The fluid cup 16C is mounted to the top of the outer casing 12C such that the flow system is fed into the pumping mechanism 18C via gravity. Thus, sprayer 10C does not require a suction tube 48 to draw fluid from cup 16C because fluid is directly discharged from cup 16C into one of the inlets of pumping mechanism 18C within housing 12C.

Figure 15 shows a perspective view of a fourth variation of one of the embodiments of the hand sprayer of the dispensing device 10 of Figure 1 utilizing an electric drill as a drive member. The sprayer 10D includes a housing 12D, a showerhead assembly 14D, a fluid cup 16D, a pumping mechanism 18D, and a drive element 20D. The showerhead assembly 14D includes a pressure actuated valve that releases fluid pressurized by the pumping mechanism 18D. The pumping mechanism 18D is supplied with input power by the drive element 20D to pressurize fluid from one of the fluid cups 16D. Drive element 20D includes a hand held drill. In the illustrated embodiment, the drill includes a pneumatic drill that receives compressed air at an inlet 302. However, in other embodiments, the drill can include an AC or DC electric drill. Pumping mechanism 18D includes a shaft that can be inserted into one of the drills to drive the pumping element. The pumping mechanism 18D is integrated into the outer casing 12D while the drive element 20D and the fluid container 16D are mounted to the outer casing 12D. The outer casing 12D also includes a suitable reduction gear to match the rate of the drill to the desired rate of the pumping mechanism 18D to produce the desired pressure. The pumping mechanism 18D and the fluid cup 16D are mounted to the drill using the bracket 304. The bracket 304 includes an anti-rotation mechanism that prevents the pumping mechanism 18D from rotating relative to the drive member 20D when actuated by the drill. The bracket 304 also pivotally connects the fluid cup 16D to the drill. The fluid cup 16D can be rotated on the carriage 304 to adjust the angle at which the fluid in the cup 16D is gravity fed into the outer casing 12D. In an embodiment, the fluid cup 16D can be rotated about 120 degrees. Therefore, the spray gun 16D can be used to spray in both the upward and downward directions.

Figure 16 shows a perspective view of a fifth variation of one of the embodiments of the hand-held sprayer of the dispensing device 10 of Figure 1 utilizing a one-arm bag fluid reservoir. The sprayer 10E includes a housing 12E, a showerhead assembly 14E, a fluid cup 16E, a pumping mechanism 18E, and a drive element 20E. Sprayer 10E includes a sprayer similar to the sprayer of the embodiment of sprayer 10C of FIG. However, the fluid container 16E includes a flexible bag that is coupled to the outer casing 12E via a tube 306. The flexible pouch includes an enclosure similar to the closure of an IV (intravenous) pouch and can be conveniently attached to one of the sprayers 10E by the strap 308. For example, the strap 308 can be conveniently attached to one of the upper arms or the biceps of an operator. Therefore, an operator does not need to directly lift the weight of the fluid container 16E to operate the sprayer 10E, thereby reducing fatigue.

Figure 17 shows a perspective view of a sixth variation of one of the embodiments of the hand-held sprayer of the dispensing device 10 of Figure 1 utilizing a waist pack fluid reservoir. Sprayer 10F includes a housing 12F, a showerhead assembly 14F, a fluid cup 16F, a pumping mechanism 18F, and a drive element 20F. Sprayer 10F includes a sprayer similar to the sprayer of the embodiment of sprayer 10C of FIG. However, the fluid container 16F includes a rigid container that is coupled to the outer casing 12F via a tube 306. The container includes an enclosure that is shaped to be ergonomically attached to an operator of the sprayer 10F by a waistband 310. For example, the waistband 310 can be conveniently attached to one of the operator's torso or waist.

Figure 18 is a perspective view showing one of the first variations of one embodiment of the hose connection airless spray gun of the dispensing device 10 of Figure 1 utilizing a waist mounted sprayer package. Sprayer 10G includes a housing 12G, a showerhead assembly 14G, a fluid cup 16G, a pumping mechanism 18G, and a drive element 20G. The outer casing 12G of the sprayer bag 10G is attached to the waist of one of the operators by the waist belt 312. The outer casing 12G provides a platform on which the fluid container 16G, the pumping mechanism 18G and the drive element 20G are mounted. The showerhead assembly 14G is coupled to the pumping mechanism 18G via a hose 314. The hose 314 acts as a liquid trap to slow the pulsation and vibration of the fluid pressurized by the pumping mechanism 18G. The showerhead assembly 14G includes an airless spray gun having a mechanically actuated spray valve 316 that provides pressurized fluid to an orifice in an ergonomically shaped handheld device 318. Device 318 includes a trigger that opens one of valves 316. The pumping mechanism 18G operates to pressurize the fluid stored in the container 16G and pump the pressurized fluid to the device 318 through the hose 314. The pumping mechanism 18G is powered by a drive element 20G that includes a wireless electric motor powered by a battery 319. The drive element 20G can be continuously operated by activating a switch located on the outer casing 12G. In this embodiment, a pressure relief valve or bypass circuit is provided in conjunction with the pumping mechanism 18G until an operator actuates the valve 316. In another embodiment of the invention, device 318 includes a switch for operating drive element 20G by extending a cable along hose 314. Separating the heavier and larger components of sprayer 10G from device 318 eliminates the need for an operator to continuously lift all of the components of sprayer 10G during operation. The fluid container 16G, the pumping mechanism 18G, and the driving member 20G can be conveniently supported by the waist belt 312 to reduce fatigue when the sprayer 10G is operated.

Figure 19 shows a perspective view of a second variation of one of the hose connection airless spray gun embodiments of the dispensing device 10 of Figure 1 utilizing a back mounted sprayer package. Sprayer 10H includes a housing 12H, a showerhead assembly 14H, a fluid cup 16H, a pumping mechanism 18H, and a drive element 20H. Sprayer 10H includes a sprayer similar to the sprayer of the embodiment of sprayer 10G of FIG. However, drive element 20H includes an AC electric motor having a power cable 320 that is configured to be plugged into any conventional power outlet, such as a 110 volt outlet. Additionally, fluid container 16H, pumping mechanism 18H, and drive element 20H are integrated into housing 12H that is configured for mounting to a backpack configuration. The outer casing 12H includes a belt 322 that allows the fluid container 16H, the pumping mechanism 18H, and the drive element 20H to be ergonomically mounted to the back of one of the operators. Thus, the sprayer 10H is similar to the sprayer of the sprayer 10G, but the backpack configuration increases the capacity of the fluid container. In other embodiments, drive element 20H operates using battery power to increase the mobility of sprayer 10H.

Figure 20 is a perspective view showing one of the third variations of one embodiment of the hose connection airless spray gun of the dispensing device 10 of Figure 1 using a sprayer package for installing a hopper. The sprayer 10I includes a housing 12I, a showerhead assembly 14I, a fluid cup 16I, a pumping mechanism 18I, and a drive element 20I. Sprayer 10I includes a sprayer similar to the sprayer of the embodiment of sprayer 10G of FIG. However, the fluid container 16I of the sprayer 10I includes a hopper. Therefore, an operator can quickly and easily set the sprayer 10I. In addition, multiple operators can operate a single container. The tray surface also provides a direct access point for the liquid within the container 16I to extend the use of the sprayer 10I in different situations. For example, a roller can be placed on the surface of the tray of the container 16I while the nozzle assembly 14I is used to eliminate the use of multiple containers. Further, even if the power to the pumping mechanism 18I and the driving element 20I disappears, the liquid in the container 16I can be used. Thus, container 16I reduces fluid waste and cleaning time in a variety of situations and in a variety of ways. Further, the container 16I can be separated from the outer casing 12I to enable easy cleaning of the container 16I. The container 16I is designed to remain stationary while an operator is moving around with the device 318. Therefore, an operator does not need to carry the container 16I to reduce fatigue and increase productivity. The fluid container 16I allows a large amount of liquid to be stored to reduce the number of refills. The hose 314 has an extra length to increase operator mobility.

Figure 21 is a perspective view showing one of the first variations of one of the embodiments of the barrel sprayer package of the dispensing device 10 of Figure 1 using a capped pump. The sprayer 10J includes a housing 12J, a nozzle assembly 14J, a fluid cup 16J, a pumping mechanism 18J, and a drive element 20J. Sprayer 10J includes a sprayer similar to the embodiment of sprayer 10G of FIG. However, the fluid container 16J includes a tub 324 having a cover 326 on which the pumping mechanism 18J and the drive member 20J are mounted. Drive element 20J includes an AC electric motor having a power cable 328 that is configured to be plugged into any conventional power outlet, such as a 110 volt outlet. The lid 326 is configured to be mounted on a standard five gallon drum or a standard one gallon drum to facilitate rapid set up spraying operations and reduce waste. One of the sprayer 10J operators can start operation only by opening a bucket of new paint and replacing the original lid with the lid 326 of the present invention. The pumping mechanism 18J is completely submerged in the barrel 324 so no priming is required. Additionally, the fluid in vessel 16J provides cooling to pumping mechanism 18J and drive element 20J.

Figure 22 shows a perspective view of a second variation of one of the embodiments of a barrel sprayer package of the dispensing device 10 of Figure 1 utilizing an immersion pump. The sprayer 10K includes a housing 12K, a nozzle assembly 14K, a fluid cup 16K, a pumping mechanism 18K, and a drive element 20K. Sprayer 10K includes a sprayer similar to the embodiment of sprayer 10J of FIG. The pumping mechanism 18K includes a hand-held device mounted to the cover 330 that is similar to the hand-held device of the device 10C of FIG. However, unlike the feeding of the pumping mechanism 18K from a hopper, the inlet 332 is connected to the interior of the tub 324. Thus, the inlet 332 is connected to a feed tube that extends to the bottom of the barrel 324. A priming valve 334 is disposed between the feed tube and the inlet 332. In other embodiments, the tub 324 is pressurized to facilitate feeding liquid to the inlet 332.

Figure 23 shows a block diagram of the dispensing device 10 of Figure 1 utilizing an air assist assembly. Apparatus 10 includes a portable airless spray gun that includes a housing 12, a showerhead assembly 14, a fluid reservoir 16, a pumping mechanism 18, and a drive element 20, as described with reference to FIG. However, the apparatus 10 also has an air assist assembly 336 that provides compressed air to the showerhead assembly 14. The air assist assembly 336 includes an air line 338, a valve 340, and an air nozzle 342. Compressed air from the air assist assembly 336 is provided to the showerhead assembly 14 via line 338. Line 338 has a pressure valve 340 to limit the flow of air into the showerhead assembly 14. In an embodiment, the air assist assembly 336 includes a compressor. For example, a small portable battery operated compressor can be used to provide air to the showerhead assembly 14. In another embodiment, air assist assembly 336 comprises a tank or a cylinder of compressed air, such as CO _2, nitrogen or air. The showerhead assembly 14 has an air nozzle 342 that includes a passage within the spray head 14 that enables pressurized air from the air assist assembly 336 to merge with pressurized fluid from the pumping mechanism 18. In one embodiment, the showerhead assembly 14 includes a conventional air-assisted spray head (as is known in the art) that further has an inlet for receiving external pressurized air rather than internal pressurized air. An air-assisted showerhead is described in U.S. Patent No. 6,708,900 to the name of U.S. Pat. The compressed air assists in propelling the pressurized fluid produced by the pumping mechanism 18 through the showerhead assembly 14 to further atomize the fluid and provide one of the fluids to improve application. The showerhead assembly 14 can be equipped with a mechanism for adjusting the position of the needle 164 in the valve 52 to control atomization of the fluid. Additionally, the orifice 186 can be configured or replaced with another orifice to optimize air assisted spraying. Thus, the air assist assembly 336 increases the versatility of the fluid dispensing device 10 to achieve more control over the spray parameters and can be used with a wider variety of fluids.

24 shows a perspective view of a trolley-mounted airless sprayer system 350 having a storage reservoir 352 for a portable hand-held sprayer 356 and a battery charger 354. The airless sprayer system 350 mounted to the cart is mounted to an airless spray system 358 that includes a trolley cart 360, a motor 362, a pump 364, a suction tube 366, a hose 368, and a nozzle 370. The airless spray system 358 includes a conventional airless spray system that is configured for large scale industrial or professional use. System 358 includes a heavy duty motor 362 and pump 364 that are designed to apply a large volume of liquid or paint during each use. Such a motor and pump is described in U.S. Patent No. 6,752,067 to the name of U.S. Pat. For example, the straw 366 is configured to be inserted into a five gallon paint bucket suspended from the available hooks 372 on the wheelbarrow 360. Motor 362 is configured to connect to a conventional power outlet using a power cord to provide input power to pump 364. Nozzle 370 is coupled to pump 364 using a hose 368 that provides sufficient length to allow an operator to walk around at will. Thus, system 358 includes a portable spray system that, when an operator uses nozzle 370, can use the cart 360 to push the portable spray system around and then set it to remain stationary. Therefore, system 358 is well suited for large jobs, but is not easy to move and reset, especially for small jobs.

System 358 has a hand-held spray system 350 mounted to the cart to provide an operator with a convenient and fast system for replenishing system 358. The hand-held spray system 350 is mounted to the shuttle cart 360 using the receptacle 352. The reservoir 352 includes a container that is threaded to the cart 360 or otherwise coupled to the cart 360. The reservoir 352 includes a hood for receiving the sprayer 356. In one embodiment, the reservoir 352 includes a molded plastic container shaped to securely hold the sprayer 356 and includes a hinged lid. The reservoir 352 is sufficiently large to encapsulate the sprayer 356 and the rechargeable battery 374A. The reservoir 352 also provides a platform to mount a battery charger 354 on the platform. Battery charger 354 can be disposed inside of reservoir 352 or external to reservoir 352. Battery charger 354 includes one of the chargers for recharging rechargeable batteries 374A and 374B. Battery charger 354 includes an adapter 376 to which battery 374B is coupled to be charged while battery 374A is used with sprayer 356. Power is supplied to the battery charger 354 by connection to a power line that supplies power to the motor 362. Thus, battery charger 354 provides charging capabilities such that batteries 374A and 374B are readily usable with spray system 358.

Spray system 358 and sprayer 356 provide an airless spray system that provides a high quality finish. Spray system 358 is used to apply a large amount of liquid or paint. Sprayer 356 is readily available to an operator in locations or spaces where system 358 is not accessible due to, for example, power cord or spray hose 368 limitations. Sprayer 356 includes any of these embodiments of a portable airless sprayer described herein. Thus, sprayer 356 provides an airless spray finish that is comparable in quality to the airless spray finish produced by spray system 358. Thus, for a single job, an operator can switch between the use system 358 or the sprayer 356 without significant differences in spray quality.

In various embodiments of the invention, the present invention enables high quality spray topcoats for building materials. For example, using a Dv (50) technique in which at least 50% of the spray droplets meet the atomization target, the present invention achieves the atomization listed in the table below.

Thus, the fluid dispensing device of the present invention achieves a nozzle operating pressure of about 360 psi (about 2.48 MPa) or greater in a handheld portable configuration, in accordance with Underwriters Laboratories Specifications UL1450.

While the invention has been described with respect to the preferred embodiments of the embodiments of the present invention, it is understood that various modifications may be made without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the scope of the invention. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed herein, and the invention is intended to cover all embodiments within the scope of the appended claims.

10. . . Fluid dispensing device

10B. . . spray gun

10C. . . Sprayer

10D. . . Sprayer

10E. . . Sprayer

10F. . . Sprayer

10G. . . Sprayer

10H. . . Sprayer

10I. . . Sprayer

10J. . . Sprayer

10K. . . Sprayer

12. . . shell

12B. . . shell

12C. . . shell

12D. . . shell

12E. . . shell

12F. . . shell

12G. . . shell

12H. . . shell

12I. . . shell

12J. . . shell

12K. . . shell

14. . . Nozzle assembly

14B. . . Nozzle assembly

14C. . . Nozzle assembly

14D. . . Nozzle assembly

14E. . . Nozzle assembly

14F. . . Nozzle assembly

14G. . . Nozzle assembly

14H. . . Nozzle assembly

14I. . . Nozzle assembly

14J. . . Nozzle assembly

14K. . . Nozzle assembly

16. . . Fluid container

16B. . . Fluid container

16C. . . Fluid cup

16D. . . Fluid cup

16E. . . Fluid cup

16F. . . Fluid cup

16G. . . Fluid cup

16H. . . Fluid cup

16I. . . Fluid cup

16J. . . Fluid cup

16K. . . Fluid cup

18. . . Pumping mechanism

18B. . . Pumping mechanism

18C. . . Pumping mechanism

18D. . . Pumping mechanism

18E. . . Pumping mechanism

18F. . . Pumping mechanism

18G. . . Pumping mechanism

18H. . . Pumping mechanism

18I. . . Pumping mechanism

18J. . . Pumping mechanism

18K. . . Pumping mechanism

20. . . Drive component

20B. . . Drive component

20C. . . Drive component

20D. . . Drive component

20E. . . Drive component

20F. . . Drive component

20G. . . Drive component

20H. . . Drive component

20I. . . Drive component

20J. . . Drive component

20K. . . Drive component

twenty two. . . Pressure relief valve

22B. . . Pressure relief valve

twenty four. . . trigger

26. . . battery

26B. . . battery

28. . . Guard

28B. . . Guard

30. . . Nozzle

30B. . . Nozzle

32. . . Connector

32B. . . Connector

34. . . handle

36. . . Container lid

38. . . Battery pack

40. . . Fixture

42. . . switch

44. . . Circuit board

46. . . Bobbin

48. . . straw

50. . . Return pipe

52. . . valve

52B. . . valve

54. . . motor

56. . . Transmission assembly

56B. . . Transmission assembly

58. . . Connection assembly

58B. . . Connection assembly

60. . . bracket

62. . . bracket

64. . . fastener

66. . . rib

68. . . Inlet valve assembly

70. . . Outlet valve assembly

72. . . First piston

72B. . . First piston

74. . . Second piston

74B. . . Second piston

76. . . Drive shaft

78. . . First gear

80. . . First bushing

82. . . Second gear

84. . . axis

86. . . Second sleeve

88. . . Third bushing

90. . . Third gear

92. . . Fourth sleeve

94. . . Fourth gear

96. . . Connecting rod

98. . . Bearing

100. . . Rod

102. . . casing

104. . . First piston sleeve

106. . . First piston seal

108. . . Second piston sleeve

110. . . Second piston seal

112. . . First valve barrel

114. . . Seals

116. . . Seals

118. . . First valve stem

120. . . First spring

122. . . Second valve cartridge

124. . . Seat

126. . . Second valve stem

128. . . Second spring

130. . . Bushing

132. . . Land

134. . . Bushing

136. . . Swing seat

138. . . ball

140. . . Bearing socket

142. . . Rod

144. . . Pumping chamber

146. . . Entrance

148. . . Export

150. . . Pressure chamber

152. . . Pumping chamber

154. . . Export

156. . . cylinder

158. . . Shaft cap

158B. . . Shaft cap

160. . . Ball head

162. . . Seals

164. . . needle

166. . . spring

168. . . Seals

170. . . Spring shock absorber

172. . . Spring shock absorber

174. . . Seals

176. . . Seals

178. . . Stopper

180. . . Fluid channel

182. . . filter

184. . . Seat

184B. . . Seat

186. . . Spray hole

188. . . Axial hole

190. . . hole

192. . . Shoulder

194. . . Transverse hole

196. . . aisle

198. . . Land

200. . . hole

202. . . main body

204. . . Plunger

206. . . spring

208. . . Seat

210. . . ball

212. . . Seals

214. . . Joystick

216. . . hole

218. . . hole

220. . . Transverse hole

222. . . Vent

224. . . Rod

226. . . Flange

228. . . Seals

230. . . Hinge

232. . . container

234. . . Periphery

236. . . bottom

238. . . Pedestal

240. . . Entrance

242. . . filter

246. . . Curved part

248. . . container

250. . . Periphery

252. . . bottom

254. . . Upper

256. . . Lower part

258. . . Entrance

260‧‧‧Filter

262‧‧‧ coupling parts

264‧‧‧Seal

266‧‧‧ Shell

268‧‧‧Shell

270‧‧‧ inlet valve

272‧‧‧Inlet valve

274‧‧‧ Shell

276‧‧‧ entrance

280‧‧‧ lower

282‧‧‧Export valve

284‧‧‧Export valve

286‧‧‧ Shell

288‧‧‧Export

290‧‧‧Operator

292‧‧ needle

294‧‧ ‧ cylinder

296‧‧‧ switch

297‧‧‧ rod

298‧‧‧ bushings

199A‧‧‧Seal

199B‧‧‧Seal

300‧‧‧Power cable

302‧‧‧ entrance

304. . . bracket

306. . . Pipe fittings

308. . . band

310. . . belt

312. . . belt

314. . . hose

316. . . valve

318. . . Device

319. . . battery

320. . . power cable

322. . . band

324. . . barrel

326. . . cover

328. . . power cable

330. . . cover

332. . . Entrance

334. . . Start injection valve

336. . . Air assist assembly

338. . . Air line

340. . . valve

342. . . Air nozzle

350. . . Airless sprayer system installed on the trolley

352. . . Storage reservoir

354. . . battery charger

356. . . Sprayer

358. . . Airless spray system

360. . . Small wheelbarrow

362. . . motor

364. . . Pump

366. . . straw

368. . . hose

370. . . Nozzle

372. . . hook up

374A. . . rechargeable battery

374B. . . rechargeable battery

376. . . Adapter

Figure 1 is a block diagram showing one of the main components of a portable airless fluid dispensing device of the present invention;

Figure 2 is a side perspective view showing one of the embodiments of the hand sprayer of the dispensing device of Figure 1; 3 shows an exploded view of the hand held sprayer of FIG. 2 showing a housing, a showerhead assembly, a fluid cup, a pumping mechanism, and a drive component.

Figure 4 shows an exploded view of the pumping mechanism and drive member of Figure 3; Figure 5 shows a perspective view of one of the wobble plates used with the drive member and pumping mechanism of Figure 4; Figure 6A shows the view at a push position Figure 5B shows a cross-sectional view of the wobble plate of Figure 5 in a retracted position; Figure 7 shows a cross-sectional view of an assembled pumping mechanism and drive element; Figure 8 shows Figure 3 A side cross-sectional view of one of the nozzle assemblies; Figure 9 shows a bottom cross-sectional view of the valve of Figure 8; Figure 10 shows a cross-sectional view of one of the pressure relief valves used in the pumping mechanism of Figure 4; Figure 11 shows Figure 3 is a cross-sectional view of a first embodiment of one of the fluid cups; Figure 12A and Figure 12B are cross-sectional views of a second embodiment of one of the fluid cups of Figure 3; Figure 13A shows Figure 1 using a dual piston pump One of the second variations of one of the hand-held sprayer embodiments of the dispensing device; FIG. 13B shows a cross-sectional assembly view of one of the various components of the hand-held sprayer of FIG. 13A; FIG. 14 shows the use of a gravity feed One of the third variations of one of the embodiments of the hand-held sprayer of one of the dispensing devices of Figure 1 of the fluid cup Figure 15 is a perspective view showing one of the fourth variations of one embodiment of the hand-held sprayer of the dispensing device of Figure 1 using an electric drill as a drive member; Figure 16 shows the use of a one-arm bag fluid reservoir. Figure 1 is a perspective view of one of the fifth variations of one of the embodiments of the hand-held sprayer of the dispensing device of Figure 1;

Figure 17 is a perspective view showing one of the sixth variations of one embodiment of the hand-held sprayer of the dispensing device of Figure 1 utilizing a waist pack fluid reservoir;

Figure 18 is a perspective view showing one of the first variations of one embodiment of the hose connection airless spray gun of the dispensing device of Figure 1 using a waist mounted sprayer package;

Figure 19 is a perspective view showing one of the second variations of one embodiment of the hose connection airless spray gun of the dispensing device of Figure 1 using a back mounted sprayer package;

Figure 20 is a perspective view showing one of the third variations of one embodiment of the hose connection airless spray gun of the dispensing device of Figure 1 using a sprayer bag for installing a hopper;

Figure 21 is a perspective view showing one of the first variations of one of the embodiments of the barrel sprayer package of the dispensing device of Figure 1 using a capped pump;

Figure 22 is a perspective view showing one of the second variations of one of the embodiments of the barrel sprayer package of the dispensing device of Figure 1 using an immersion pump;

Figure 23 shows a block diagram of one of the air assist assemblies for use with the fluid dispensing device of Figure 1;

Figure 24 shows a perspective view of a trolley-mounted airless sprayer system having a storage reservoir and a battery charger for a portable hand-held sprayer.

10. . . Fluid dispensing device

12. . . shell

14. . . Nozzle assembly

16. . . Fluid container

18. . . Pumping mechanism

20. . . Drive component

twenty two. . . Pressure reducing valve

twenty four. . . trigger

26. . . battery

28. . . Guard

30. . . Nozzle

32. . . Connector

34. . . handle

36. . . Container lid

38. . . Battery pack

40. . . Fixture

42. . . switch

44. . . Circuit board

46. . . Bobbin

48. . . straw

50. . . Return pipe

52. . . valve

54. . . motor

56. . . Transmission assembly

58. . . Connection assembly

60. . . bracket

62. . . bracket

64. . . fastener

66. . . rib

Claims (31)

A hand held airless fluid dispensing device comprising: an outer casing; a reciprocating piston fluid pump disposed within the outer casing and including at least two pumping chambers configured to be actuated by at least one piston out of phase a fluid pump comprising: a first cylinder having a first chamber; a first piston disposed in the first chamber; a second cylinder having a second chamber; a second piston disposed in the second chamber; a primary drive member coupled to the outer casing and coupled to the reciprocating piston fluid pump to actuate the at least one piston; and a showerhead coupled to the An outlet of at least one of the pumping chambers; and a rocking assembly connecting the primary drive member to the first piston and the second piston of the fluid pump; wherein the rocking assembly comprises: an axle, It is for receiving a rotational input from the main drive element along a rotational axis of a drive element; a lands disposed on the shaft to surround the rotational axis, the lands having an axis offset about one of the rotational axes of the drive a cylindrical shape Surface; a bearing mounted to the connecting plate; a connecting rod, which is mounted to the bearing; and at least one projecting member, connected to the connecting rod and configured to cross over Placed in a recess in one of the pistons. The fluid dispensing device of claim 1, wherein the spray head comprises: a spray hole; a seal seat; a needle configured to be mated with the seal seat to close the spray hole; and a spring that causes the The needle is biased against the seal seat. The fluid dispensing device of claim 2, wherein the pressure generated by the fluid pump opens the orifice. The fluid dispensing device of claim 2, further comprising a trigger that activates the primary drive element and retracts the needle. The fluid dispensing device of claim 2, wherein the spray head further comprises a spray head tube, wherein the spray hole and the seal seat are mounted to the spray head tube. The fluid dispensing device of claim 2, wherein at least one of the pumping chambers comprises an inlet connected to a fluid source by a straw. The fluid dispensing device of claim 6, wherein the fluid source comprises a cylindrical cup having a constant wall, and the straw includes a rotatable rod configured to position a different portion of the straight wall. The fluid dispensing device of claim 6, wherein the straw comprises a fixed rod and the fluid source comprises a contoured wall for injecting fluid into the cup toward the fixed rod. The fluid dispensing device of claim 6, wherein the straw comprises a flexible hose. The fluid dispensing device of claim 9, wherein the fluid source comprises a volume A device configured to be tied or hung on one of the operator's arms, a back or a hip. The fluid dispensing device of claim 9, wherein the fluid source comprises a hopper. The fluid dispensing device of claim 1, wherein the spray head is coupled to the fluid pump through a flexible hose. The fluid dispensing device of claim 1, wherein the primary drive component comprises a portable drill and the housing system is configured to be mounted to the portable drill. The fluid dispensing device of claim 1, further comprising: a pressure chamber disposed between the spray head and the fluid pump, the pressure chamber being coupled to the first chamber and the second chamber; An inlet valve disposed between the first chamber and a fluid source; and an outlet valve disposed between the first chamber and the pressure chamber. The fluid dispensing device of claim 14, wherein the first cylinder has a displacement that is greater than a displacement of the second cylinder. The fluid dispensing device of claim 1, further comprising first and second inlet valves and first and second outlet valves coupled to the first cylinder and the second cylinder, respectively. The fluid dispensing device of claim 1, further comprising a liquid trap for temporarily storing fluid pressurized by the pumping mechanism. The fluid dispensing device of claim 1, wherein the reciprocating piston fluid pump and the showerhead atomize the undiluted building material to one of 70 microns or less within a Dv (50) scale. A hand-held airless fluid dispensing device comprising: a pump for directly pressurizing a building paint, the pump comprising: a first cylinder having a first chamber; a first piston; Positioned in the first chamber; a second cylinder having a second chamber; and a second piston disposed in the second chamber; wherein the first cylinder has a larger exhaust volume than the second chamber a displacement of one of the second cylinders; a drive element for supplying power to the pump; and a orifice element coupled to the pump for atomizing the pressurized architectural coating to one of no more than about 150 microns Particle size; wherein the pump, the drive element and the orifice element are integrated into a hand-held housing. The fluid dispensing device of claim 19, wherein the orifice element has an area of about 0.029 square inches (about 18.7 square millimeters) or less. The fluid dispensing device of claim 19, wherein the pump produces a pressure of about 360 psi (about 2.48 MPa) or greater at the orifice element. The fluid dispensing device of claim 19, wherein the driving component is selected from the group consisting of a pneumatic system, an AC electric motor having a power line, a DC electric motor powered by a battery, a power supply, and a linear actuation The group of components. The fluid dispensing device of claim 19, wherein the fluid pump is selected from the group consisting of a multi-piston pump, a dual piston pump, a dual displacement single piston pump, a triple plunger, a oscillating pump, and a gear pump And a group of diaphragm pumps. An integrated hand-held sprayer comprising: a housing; a motor mounted to the housing; a reciprocating pumping element mounted to and driven by the housing, wherein the reciprocating pumping element includes a roll a diaphragm; and a showerhead for receiving pressurized fluid from the reciprocating pumping element to atomize the fluid to a particle size of no greater than 70 microns within a Dv (50) scale. The integrated hand-held sprayer of claim 24, further comprising: a gear reduction system coupled to the reciprocating pumping element. The integrated hand-held sprayer of claim 26, further comprising: a rechargeable battery; and wherein the motor includes an electric DC motor configured to receive power from the rechargeable battery. The integrated hand-held sprayer of claim 26, further comprising: a rocking assembly that connects the gear reduction system to the reciprocating pumping element. The integrated hand-held sprayer of claim 27, further comprising a collector volume for receiving pressurized fluid from the pumping element. The integrated hand-held sprayer of claim 24, wherein the reciprocating pumping element comprises a piston pump. The integrated hand-held sprayer of claim 29, wherein the reciprocating pumping element comprises: First and second pistons reciprocating out of phase in the first and second piston chambers respectively; an inlet valve allowing fluid to flow from the liquid container into the first piston chamber; and an outlet valve, It is used to connect the first piston chamber to the spray head. The integrated hand-held sprayer of claim 29, wherein the reciprocating pumping element comprises: a pair of pistons that reciprocate out of phase and discharge an equal volume of fluid, each piston containing an inlet for receiving fluid from a liquid container a valve and an outlet valve for providing pressurized fluid to the spray head.