U.S. patent application number 10/192470 was filed with the patent office on 2004-01-15 for handle for a paint sprayer.
Invention is credited to Valls, William H., Whitaker, Robert Kyle, Williams, Mary Lynn, Yan, Kinshun.
Application Number | 20040007631 10/192470 |
Document ID | / |
Family ID | 28454321 |
Filed Date | 2004-01-15 |
United States Patent
Application |
20040007631 |
Kind Code |
A1 |
Williams, Mary Lynn ; et
al. |
January 15, 2004 |
HANDLE FOR A PAINT SPRAYER
Abstract
A paint sprayer for sprayer a fluid includes a pump housing, an
electrical housing having a motor and a switch, a handle coupled to
the pump housing, a paint cup coupled to the handle, and a
mechanical actuator coupled to the pump housing for operating the
motor. The actuator has a first portion positioned in the vicinity
of the exterior of the pump housing and a second portion that
extends into the pump housing. The second portion is configured to
engage the switch in the electrical housing to operate the motor.
The handle is an elongated member having a top end and a bottom
end, with a generally rectangular cross-section at the top end and
a generally circular cross-section at the bottom end.
Inventors: |
Williams, Mary Lynn;
(Brentwood, TN) ; Whitaker, Robert Kyle; (Mt.
Juliet, TN) ; Yan, Kinshun; (New York, NY) ;
Valls, William H.; (Loveland, OH) |
Correspondence
Address: |
Lorri W. Cooper
Jones, Day, Reavis & Pogue
North Point
901 Lakeside Avenue
Cleveland
OH
44114
US
|
Family ID: |
28454321 |
Appl. No.: |
10/192470 |
Filed: |
July 10, 2002 |
Current U.S.
Class: |
239/332 ;
239/375 |
Current CPC
Class: |
B05B 9/0861 20130101;
Y10T 16/48 20150115 |
Class at
Publication: |
239/332 ;
239/375 |
International
Class: |
B05B 009/03 |
Claims
What is claimed is:
1. An airless paint sprayer for spraying a fluid comprising: a main
housing that comprises: an electrical housing having a motor and a
switch; and a pump housing comprising a pump and a fluid passage,
with the pump being configured to pump a fluid through the fluid
passage and the motor configured to operate the pump; a handle
coupled to the main housing; a paint cup coupled to the handle for
the storage of a fluid, said paint cup in communication with the
fluid passage; and a mechanical actuator coupled to the pump
housing for operating the motor, the actuator having a first
portion positioned in the vicinity of the exterior of the pump
housing and a second portion that extends into the pump housing,
said second portion configured to engage the switch in the
electrical housing to operate the motor.
2. The paint sprayer of claim 1, wherein the handle is positioned
between the main housing and the paint cup and is attached to the
pump housing, with the pump housing being fluidly isolated from the
electrical housing so that fluid is deterred from entering the
electrical housing through the pump housing.
3. The paint sprayer of claim 1, wherein the handle comprises an
elongated member having a top end and a bottom end, said elongated
member having a generally rectangular cross-section at the top end
and a generally circular cross-section at the bottom end, with a
first transition zone positioned between the top and bottom ends
where the cross-section transitions from the generally rectangular
cross-section to the generally circular cross-section.
4. The paint sprayer of claim 1, wherein the first portion of the
actuator comprises a button that is movable by a user, the second
portion comprises an arm that is movable in concert with the
button, and the switch comprises a microswitch.
5. The paint sprayer of claim 1, further comprising a seal coupled
to the switch for deterring the passage of fluid between the pump
housing and the electrical housing in the vicinity of the
switch.
6. A mechanical actuator for an airless paint sprayer having a pump
housing, an electrical housing, and a handle, with the pump housing
coupled to the electrical housing and the electrical housing
comprising a motor and a switch, the mechanical actuator
comprising: an actuator first portion positioned outside the pump
and electrical housings; and an actuator second portion having a
first end and a second end, with the first end coupled to the
actuator first portion and the second end extending into the pump
housing for communication with the switch of the electrical
housing, wherein the actuator first portion is movable from a first
position to a second position and movement of the actuator first
portion moves the actuator second portion from a first position to
a second position in the pump housing, and the actuator second
portion engages the electrical switch of the electrical housing
when in the second position to activate the motor.
7. The mechanical actuator of claim 6, wherein the first portion is
a button and the second portion is an arm.
8. The mechanical actuator of claim 7, further comprising a pivot
bar positioned between the actuator button and the first end of the
actuator arm, and the pivot bar is configured to be pivotally
positioned in a slot in the airless paint sprayer, wherein the
mechanical actuator pivots around the pivot bar such that the
actuator button moves from its first position to its second
position and the actuator arm moves from its first position to its
second position.
9. The mechanical actuator of claim 7, wherein the actuator button
is positioned adjacent the handle such that when a user grips the
handle, the users' hand engages the button.
10. A handle for an airless paint sprayer comprising: an elongated
member having a top end and a bottom end, said elongated member
having a generally rectangular cross-section at the top end and a
generally circular cross-section at the bottom end, with a first
transition zone positioned between the top and bottom ends where
the cross-section transitions from the generally rectangular
cross-section to the generally circular cross-section.
11. The handle of claim 10, further comprising attachment points at
at least the top end thereof, wherein the attachment points are for
mating the handle to a housing of an airless paint sprayer.
12. The handle of claim 10, further comprising a second transition
zone in the vicinity of the top end of the handle, the second
transition zone having a larger cross-section at the top of the
second transition zone than at the bottom of the second transition
zone, both cross-sections of which are generally rectangular.
13. The handle of claim 12, further comprising a third transition
zone in the vicinity of the bottom end of the handle, the third
transition zone having a larger cross-section at the bottom of the
third transition zone than at the top of the third transition zone,
both cross-sections of which are generally circular.
14. The handle of claim 10, further comprising a third transition
zone in the vicinity of the bottom end of the handle, the third
transition zone having a larger cross-section at the bottom of the
third transition zone than at the top of the third transition zone,
both cross-sections of which are generally circular.
15. The handle of claim 10, wherein the generally rectangular
cross-section is rectangular and the generally circular
cross-section is circular.
16. The handle of claim 14, wherein a lid portion having a rim is
positioned at the bottom end of the elongated member and the rim of
the lid portion is for attaching the handle to a paint cup, with
the larger generally circular cross-section of the third transition
zone being positioned at the rim of the lid portion.
17. The handle of claim 10, further comprising at least one
attachment point at the bottom end of the elongated member for
coupling with a paint cup.
18. The handle of claim 17, wherein the attachment point at the
bottom end of the elongated member includes a lid portion with a
rim, and screw threads are positioned on the rim for mating with
screw threads of a paint cup to attach a paint cup to the
handle.
19. The handle of claim 16, wherein the lid portion includes a
frustoconical upper portion and a generally cylindrical lower
portion, with the screw threads being positioned on the lower
portion.
20. The handle of claim 10, wherein the lid is integral with the
handle.
Description
FIELD OF THE INVENTION
[0001] The claimed invention relates to a paint sprayer. In
particular, the invention concerns a hand-held airless paint
sprayer having an ergonomically designed handle and a mechanical
actuator.
BACKGROUND OF THE INVENTION
[0002] Currently known hand-held paint sprayers exert extensive
stress on muscles of the arm, particularly on the weaker muscles of
the arm, such as those in the wrist. An airless paint sprayer
typically utilizes several parts, including an electrical housing
and motor, a pump housing and pump, a paint tank (also commonly
referred to as a paint cup), a handle, a tip, an internal fluid
passage through which paint or cleaning solutions may flow, and
controls for triggering and controlling the flow of paint through
the fluid passage. A typical prior art hand-held airless paint
sprayer is shown in FIG. 1.
SUMMARY
[0003] According to one embodiment of the invention, an airless
paint sprayer for spraying a fluid comprises a main housing, a
handle, a paint cup and a mechanical actuator. The main housing
comprises an electrical housing having a motor and a switch, and a
pump housing comprising a pump and a fluid passage. The pump is
configured to pump a fluid through the fluid passage and the motor
is configured to operate the pump. The handle is coupled to the
main housing and the paint cup is coupled to the handle for the
storage of a fluid, with the paint cup being in communication with
the fluid passage. The mechanical actuator is coupled to the pump
housing for operating the motor. The actuator has a first portion
positioned in the vicinity of the exterior of the pump housing and
a second portion that extends into the pump housing. The second
portion is configured to engage the switch in the electrical
housing to operate the motor.
[0004] In another embodiment, a mechanical actuator for an airless
paint sprayer having a pump housing, an electrical housing, and a
handle comprises an actuator first portion and an actuator second
portion. The pump housing of the paint sprayer is coupled to the
electrical housing and the electrical housing comprises a motor and
a switch. The actuator first portion is positioned outside the pump
and electrical housings. The actuator second portion has a first
end and a second end, with the first end coupled to the actuator
first portion and the second end extending into the pump housing
for communication with the switch of the electrical housing. The
actuator first portion is movable from a first position to a second
position and movement of the actuator first portion moves the
actuator second portion from a first position to a second position
in the pump housing. The actuator second portion engages the
electrical switch of the electrical housing when in the second
position to activate the motor.
[0005] According to yet another embodiment, a handle for an airless
paint sprayer comprises an elongated member having a top end and a
bottom end. The elongated member has a generally rectangular
cross-section at the top end and a generally circular cross-section
at the bottom end. A first transition zone is positioned between
the top and bottom ends where the cross-section transitions from
the generally rectangular cross-section to the generally circular
cross-section.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0006] FIG. 1 is a side view of a prior art paint sprayer;
[0007] FIG. 2 is a side view of a paint sprayer according to the
invention;
[0008] FIG. 3 is a perspective view of the paint sprayer of FIG.
2;
[0009] FIG. 4 is an expanded perspective view of the housing and
handle of the paint sprayer shown in FIG. 2;
[0010] FIG. 5 is an exploded view of the housing of the paint
sprayer shown in FIG. 4;
[0011] FIG. 6 is an exploded view of the actuator assembly and drip
guard of the paint sprayer shown in FIG. 4;
[0012] FIG. 7 is a perspective view of a drip guard for use with
the paint sprayer shown in FIG. 2; and
[0013] FIG. 8 is a side view of an alternative embodiment of the
invention where an accessory hose is used with the paint
sprayer.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The paint sprayer of the present invention is utilized in
spraying paint, stain, or other viscous materials onto a surface,
while directing stresses related to holding and activating the
applicator to stronger muscles of the arm, including the bicep and
tricep muscles. This redirection of stress, in turn, significantly
reduces the fatigue of the user during use and allows for better
control during the paint application process. The invention is
primarily directed to airless paint spray gun applications,
although it may have uses in other paint applications. The paint
sprayer of the invention creates a number of ergonomic benefits,
including: 1) changing the center of gravity of the spray gun
relative to the current art so that the sprayer's weight acts on
the larger and stronger muscles of the arm (bicep, tricep) versus
the wrist muscles, as is done in the current art; 2) evenly
distributing and balancing the weight of the sprayer, whereas the
current art distributes the paint at a great distance from the
handle and the center of gravity; 3) and shaping the handle for a
comfortable formed fit to the hand of a user, whereas the prior art
tends to be rectangular in shape and has uncomfortable edges.
[0015] As shown in FIG. 1, prior art paint sprayers 10 typically
utilize a paint cup 12 and a handle 14 that are positioned directly
under a main housing 16, with the paint cup 12 being positioned at
a forward end 18 of the main housing 16 and the handle 14 being
positioned at a rear end 20 of the main housing 16. The center of
gravity Cg tends to be positioned in the vicinity of the forward
end 18 of the housing 16, both when the paint cup 12 is full and
when the paint cup 12 is empty. The position of the Cg is driven in
part by the location of the components under the housing 16,
including the electric motor 22 and pump 24, which tend to be
distributed toward the forward end 18 of the housing 16. The user
grasps the handle 14 of the paint sprayer 10 at the rear end 20 of
the housing 16 in a gripping zone 26, which is defined by the
user's hand 28 and wrist 30 when in engagement with the handle 14.
As is evident, since the center of gravity Cg is positioned toward
the forward end 18 of the paint sprayer 10, the user is required to
exert a rotational force on the paint sprayer 10 to maintain it in
proper position for spraying. Such exertion can cause weariness of
the user, particularly in the muscles of the hand 28 and wrist
30.
[0016] The present invention, as shown in FIGS. 2 and 3,
reconfigures the parts of the paint sprayer 10 so that the main
housing 16, paint cup 12, and handle 14 are vertically aligned with
one another. This vertical alignment distributes the weight so that
it more closely aligns with the sprayer's center of gravity Cg. As
a result, stresses on the user are minimized as compared to prior
art paint sprayers, since the user is not required to constantly
exert a force to keep the paint sprayer housing level.
[0017] As shown in FIG. 2, a gripping zone 26 for the present
invention is defined by the user's hand when it grasps the handle
14 of the paint sprayer 10. The gripping zone 26 comprises the
entire hand and wrist area under the main housing 16. In a
preferred embodiment, the paint sprayer 10 of the present invention
is designed so that the center of gravity Cg of the paint sprayer
10, whether empty or full, vertically aligns with the gripping zone
26. The gripping zone 26 is preferably designed so that all user's
hand sizes are encompassed within the zone.
[0018] Referring to FIGS. 2 and 3, the main housing 16 of the
present invention includes an electrical housing 17 that houses an
electric motor 22. The motor 22 is powered by a power cord 32 that
extends outwardly from the housing 16. As shown in FIG. 3, in a
preferred embodiment, the power cord 32 extends outwardly from the
side of the housing 16, although placement of the cord 32 is not
critical to the invention. It may be positioned at any number of
places, as long as it does not interfere with operation of the
sprayer 10.
[0019] The main housing 16 also includes a pump housing 19. The
pump housing 19 houses a pump 24 that comprises a cylinder 78, a
piston 80, and a fluid passage 34 through which paint or other
fluids may flow. A tip 36 is connected to the pump housing 19 at
one end of the fluid passage 34. Paint is pumped through the fluid
passage 34 by the pump 24, which is operated by the electric motor
22, and is sprayed through the tip 36 in a pattern, as is typical
of paint sprayers. A tip guard 37 surrounds the tip in a
conventional manner and is utilized to deter injury to the
operator, for example, from injection of paint into the skin.
[0020] A handle 14 is attached to the bottom 38 of the main housing
16 and a paint cup 12 is attached to the bottom 40 of the handle.
In a preferred embodiment, the handle 14 is attached to the pump
housing 19.
[0021] A control knob 42 is positioned at a rear end of the housing
16. This knob 42 can be used to adjust the amount of paint that
flows through the fluid passage 34. The knob 42 may be rotatable,
is preferably easy to operate, and maintains its position after
being set.
[0022] An actuator 46 is coupled to the handle 14 and/or the
housing 16. The actuator 46 is preferably a mechanical actuator
coupled to an electrical switch 136. The mechanical actuator
extends through the pump housing to the electrical housing. The
electrical switch 136 is positioned inside the electrical housing
17 and sealed from the pump housing 19. The mechanical actuator 46
includes a button 48 that extends outwardly from the main housing
16 so that the user may press the button to operate the motor 22
and the pump 24. The actuator 46, in a preferred embodiment, is
positioned between the tip 36 and the handle 14 below the pump
housing 19, and is configured to be easily and ergonomically
operable by a user in the gripping zone 26.
[0023] A lid structure 50 is coupled to the lower end 40 of the
handle 14. The lid 50 has a generally frustoconical shape, with the
larger portion of the cone being at the bottom. A rim 52 is formed
at the bottom of the cone and includes an attachment mechanism (not
shown) for coupling to the paint cup 12. The attachment mechanism
may include a screw thread, a snap fixture, or any other attachment
mechanism suitable for use in connecting the paint cup 12 to the
handle 14.
[0024] The paint cup 12 has an open upper end 54 that is removable
from the lid structure 50 of the handle. An outer wall surrounds
the paint cup 12 and a base surface 58 is positioned at the bottom
of the paint cup. A preferred attachment technique is to screw the
cup 12 onto the rim 52 of handle 14, although other attachment
techniques known to those of skill in the art may also be utilized.
The wall 56 of the paint cup 12 may be cylindrical, frustoconical,
or the like, as long as it has an opening at the top and a base
surface 58 at the bottom. The paint cup 12 also serves as a base
for the entire sprayer 10, so that the sprayer can rest on an
underlying surface. In addition, the paint cup 12 preferably has a
base surface 58 upon which the cup may rest during filling (after
the cup 12 has been removed from the remainder of the sprayer). In
a preferred embodiment, as shown in FIGS. 2 and 3, the base surface
58 is slightly enlarged relative to the wall 56 of the paint cup.
The base surface 58 may be formed as a separate piece that is
connected to the wall 56 by press fit, wedge fit, gluing, welding,
or other known attachment techniques. For example, in a preferred
embodiment, as shown in FIGS. 2 and 3, the paint cup 12 may be
formed having an upper part that forms the wall 56 and a separate
lower part 60 that is connected to the base surface 58 of the wall
56. The separately formed lower part 60 also has an upwardly
extending wall 62 and a base surface 64 is attached to the base
surface 58 of the upper part to form a two part paint cup. In a
preferred embodiment, the wall 56 of the paint cup is transparent
while the base 60 of the paint cup 12 is made of a differently
colored opaque material.
[0025] The paint cup 12 may be made of a polymer, such as a low
density polyethylene or polypropylene. Other materials may also be
used in making the cup 12, the invention not being limited to a
particular material. Screw threads or other attachment mechanisms
(not shown) are preferably positioned around the upper end 54 of
the paint cup 12 for mating with the screw threads on the lid 50 of
the handle 14. As shown, the paint cup upper end 54 preferably
seats within the rim 52 of the lid 50.
[0026] Referring to FIG. 3, the handle 14 is preferably hollow. An
intake suction tube 66 extends from the fluid passage 34 in the
pump housing 19, through the handle 14, and into the paint cup 12.
The intake tube 66 may be rigid or flexible, as long as the tube
extends to the bottom of the paint cup 12 and does not curl
upwardly. A filter 68 is shown positioned at the bottom end of the
intake tube 66 in the paint cup 12 for use in filtering out any
debris in the fluid in the paint cup 12. The intake tube 66 is
preferably removable from the handle 14 and paint cup 12 for
cleaning purposes and may be positioned in an intake opening (not
shown) in the bottom of the housing. The intake opening is at one
end of the fluid passage 34 through the pump housing 19. A return
opening (not shown) may also be positioned inside the handle 14 for
handling any fluid that bypasses the components of the pump 24 and
does not exit the tip 36. This bypass flow is returned to the paint
cup 12 by the return opening, as known by those of skill in the
art. The return opening may be positioned in the vicinity where the
handle 14 meets the pump housing 19, or an additional tube may be
positioned in the return opening (not shown) to extend into and/or
through the handle 14 for assisting in directing the fluid back to
the paint cup 12.
[0027] FIGS. 4 and 5 depict the main housing 16 in greater detail.
In a preferred embodiment, as discussed above, the main housing 16
includes an electrical housing 17 and a pump housing 19. The
electrical housing includes a motor cover 70, a motor carriage 72,
and a motor 22. The motor 22 is positioned on the motor carriage
72. In one embodiment, the motor 22 is an E-Mag motor, such as a 60
watt or higher E-Mag. The cover 70 is preferably fastened to the
motor carriage 72 with screws 84 in a conventional manner.
[0028] The pump housing 19 includes a cylinder 78 and a piston 80.
The motor 22 is coupled to the cylinder 78 and moves the piston 80
back and forth to pump fluid through the fluid passage 34, which
extends through the pump housing 19. The pump housing 19 is
attached to the electrical housing 17 by screws or other known
fastening means. The pump housing 19 and electrical housing 17 are
configured and oriented so that the "wet" part of the sprayer (the
pump housing 19) is maintained separately from the "dry" part of
the sprayer (the electrical housing 17). It is preferred that the
housings are maintained separately from one another to deter fluid
in the pump housing 19 from entering into and possibly damaging the
electrical components in the electrical housing 17. In addition,
the pump housing 19 is removable from the electrical housing 17 for
cleaning purposes. The pump housing 19 can be submerged in a
cleaning solution while the electrical housing 17 is maintained
dry. While a particular configuration for the main housing is
depicted herein, other embodiments of the main housing 16 are also
applicable to the present invention.
[0029] As shown in FIG. 6, the handle 14 is positioned beneath the
pump housing 19 such that the intake tube 66 from the paint cup 12
communicates fluid to the pump 24 through the opening 88 in the
handle 14. In a preferred embodiment, the paint cup 12 is centered
beneath the handle 14 and the paint cup 12 and/or handle 14 may be
symmetrically shaped. The handle 14 includes attachment points 90
for connecting the handle 14 to the main housing 16. As shown in
FIG. 6, the handle 14 may be connected directly to the pump housing
19. The handle 14 may be attached by other means, as long as the
intake tube 66 from the paint cup 12 is in communication with the
fluid passage 34.
[0030] The actuator 46, shown in FIGS. 4 and 6, is a mechanical
actuator that extends through the pump housing 19 to the electrical
housing 17. The actuator 46 has a button 48 at one end that is
connected to a pivot bar 92, and an extension arm 94 that extends
outwardly toward the rear end 20 of the housing from the pivot bar
92. The pivot bar 92 is seated in a channel 96 defined in the upper
end of the handle 14. The extension arm 94 extends through the pump
housing 19 and is configured to engage a switch 136 in the
electrical housing 17 for activating the motor 22. The switch 136
may be a microswitch that pivots or rocks when engaged by the
extension arm 94. The switch 136 may include a seal for sealing the
electrical housing 17 from the pump housing around the switch. The
actuator 46 pivots or rocks when the button 48 is engaged by a user
to operate the switch 136. While one embodiment of the actuator is
shown and described, other configurations of the actuator are also
within the scope of the claimed invention.
[0031] FIGS. 4 and 6 also depict a drip guard 86 according to the
invention. A drip guard 86 is preferably positioned under the tip
36 for deterring paint from contacting the handle 14 and the
actuator 46. In particular, drip guard 86 is used to deter paint
from contacting any of the electrical components of the paint
sprayer 10. The drip guard 86 is coupled to the main housing 16
and/or the handle 14. The drip guard 86 has two separate flanges
98, 100, a first 98 of which extends under the tip 36 and a second
100 of which is positioned over the actuator 46 so that the button
48 of the actuator 46 extends through a hole 102 in the second
flange 100. The drip guard 86 includes a circular attachment hole
104 for positioning around the cylinder 78 of the pump housing 19.
In addition, the drip guard 86 includes an appendage 106 which
extends outwardly below the circular hole 104. The appendage 106 is
engaged within a slot 108 in the handle 14. The combination of the
appendage 106 and the circular attachment hole 104 assist in
maintaining the drip guard 86 in position on the paint sprayer 10.
As discussed, the first flange 98 of the drip guard 86 is curved
and extends outwardly from the housing 16 under the tip 36 adjacent
the actuator 46 and assists in deterring paint from contacting the
handle area of the paint sprayer 10. The second flange 100 of the
drip guard 86 extends around the actuator button 48 and assists in
deterring paint from entering the actuator 46.
[0032] An alternative embodiment of the drip guard 86 is shown in
FIG. 7 as only comprising the first flange portion 98. This drip
guard 86 is similarly positioned beneath the tip 36 and is designed
to deter paint from dripping from the tip 36 and contacting the
handle 14 (and thus the user's hand and actuator 46 during paint
application. Other drip guards may also be designed for use with
the present invention, the invention not being limited to the
designs shown herein. The drip guard is designed to be positioned
between the tip 36 and the actuator 46 and is preferably positioned
below the tip 36 and adjacent the actuator 46, handle 14, or main
housing 16 for deterring the flow of paint onto the handle 14 and
actuator 46.
[0033] Referring again to FIG. 6, the handle 14 of the present
design is ergonomically engineered for comfort to both male and
female users during both use and transport. In addition, the
actuator 46 on the handle 14 is ergonomically designed to allow
operators of many sizes ease in operating the actuator 46 without
requiring strain, unusual motion, or unnecessary finger extension.
The handle 14 is also conducive to use by both left and
right-handed users, and may include a foam cushion (not shown).
[0034] In particular, the handle 14 has a varied cross-section that
has a generally rectangular shape 118 at the upper end 110 that
transitions to a circular shape at the lower end 112. The
rectangular shape 118 transitions to a circular shape 120 in a
first transition zone 114, as shown in FIGS. 4 and 6. In addition,
the generally rectangular cross-section 118 at the upper end 110
has a varying-sized cross-section. The generally rectangular
cross-section 118 at the upper end 110 of the handle 14 has a
larger cross-sectional shape than the generally rectangular
cross-section 118 below the upper part. The larger cross-section
transitions to a smaller cross-section in a second transition zone
116, as shown in FIGS. 4 and 6.
[0035] Furthermore, the circular cross-sectional shape 120 at the
lower end 112 of the handle 14, where the handle 14 joins with the
lid 50, also includes a transition zone--referred to as the third
transition zone 122, as shown in FIG. 4. This third transition zone
122 transitions from the lower end 112 of the handle 14 to the rim
52 of the lid 50, with the smaller-diameter circular cross-section
occurring toward the lower end 112 of the handle 14 and the larger
diameter circular cross-section 120 occurring toward the rim 52 of
the lid 50. These transition zones 114, 116, 122 assist in
providing a comfortable handle 14 for the varying hand sizes of the
user. For example, a smaller handed user would likely only contact
the lower part of the rectangular cross-section and the
intermediate part of the handle where the circular cross-section
has a generally constant diameter. A very large-handed user may
contact the entire length of the handle 14, including the upper
part of the lid 50. As a result, both the smaller and larger handed
user's are comfortably accommodated. In addition, the handle 14 is
a mirror image of itself on either side, so that no variation is
provided based upon left or right handed users. Thus, both users
may use the handle in comfort. It should be noted that while a
specific configuration for the handle 14 is shown and described,
variations of the transition zones 114, 116, 122 are also within
the scope of the claimed invention. In particular, the size and
location of the transition zones 114, 116, 122 may vary along the
length of the handle 14. In addition, the shape of the handle may
vary.
[0036] FIG. 8 shows an alternative embodiment of the invention
utilizing the main housing 16 and handle 14, as described above in
connection with FIGS. 2-7. This embodiment, however, does not
utilize a paint cup 12. Instead, it utilizes a hose structure that
connects the intake tube 66 to a separate paint bucket 124. The
intake tube 66 is coupled to an intake hose 126 that extends from
the intake tube 66 to a paint bucket 124, or other paint source. A
rigid tube 128 and filter structure 68 may be coupled to the end of
the intake hose 126 and preferably extend to the bottom of the
paint bucket 124. In addition, a return hose 130 is shown extending
from a return tube 132 that extends through the handle. The return
hose is used to return paint from the return opening back to the
paint bucket 124. The return hose 130 is shown as connected to a
rigid tube 132 that extends through the handle 14 to the return
opening. Other types of attachments may also be utilized. For
instance, the return tube 132 can be removable, or a permanently
affixed return tube 132 can be attached to the return outlet so
that the return hose 130 may couple to the end of the tube 132. The
return hose 130 and intake hose 126 may be formed as a single hose
that is joined together, as shown, or may be two separate hoses.
Furthermore, in one embodiment, the sprayer does not utilize a
return opening.
[0037] Referring again to FIG. 2, the center of gravity Cg of the
paint sprayer 10 is preferably maintained in a Cg region 134 that
is positioned over or within the gripping zone 26. In a preferred
embodiment, represented by the X in FIG. 2, the center of gravity
Cg is aligned with a longitudinal axis Y-Y of the handle 14 and
paint cup 12. The paint cup 12 may have an axis Z-Z other than the
longitudinal axis Y-Y and the handle 14 may have an axis V-V other
than the longitudinal axis Y-Y, and these axes may also be aligned
with the center of gravity Cg of the paint sprayer 10. In addition,
the main housing 16 has a longitudinal axis L-L that extends front
to back. In a preferred embodiment, the axis Z-Z of the paint cup
12 and the axis V-V of the handle 14 are perpendicular to the
longitudinal axis L-L of the housing. Even more preferably, the
axis Y-Y of the paint cup 12 and handle 14 are perpendicular to the
longitudinal axis L-L of the main housing 16.
[0038] The center of gravity will vary within the Cg region 134
depending upon whether the paint cup 12 is full of fluid or empty.
The Cg may vary slightly as the paint is used from the paint cup
12. It is preferred that the Cg is positioned so that there will be
little variation in Cg as paint is used from the cup 12. The Cg of
the paint sprayer 10 may be manipulated by moving the components
within the main housing 16. For instance, the motor 22 may be moved
around within the electrical housing 17 to modify the position of
the Cg. Other components may also be moved around to alter Cg, if
so desired.
[0039] In a preferred embodiment, the center of gravity of the
sprayer 10 is designed so that the sprayer 10 may sit on a flat
surface without tipping over, regardless of the amount of paint in
the paint cup 12, and is resistant to tipping caused by accidental
bumping. The center of gravity may take into account accessories,
including the sprayer 10 itself, a hose 126, 130 (should the
sprayer 10 be used with an accessory hose instead of the paint cup
12), and the power cord 32. In addition, the center of gravity is
preferably positioned so that the paint sprayer 10 is balanced when
in the hand of a user.
[0040] It is preferred that the pump 24 is designed to prime on the
first try with every use. In addition, it is preferred that the
internal fluid passage 34 is smooth and has no trap points. A
smooth internal fluid passage 34 will make it easier to clean the
sprayer 10 and result in greater overall customer satisfaction
since the sprayer 10 will be more likely to operate properly during
subsequent uses.
[0041] In use, the user unscrews the paint cup 12 from the sprayer
10 and fills it with paint. After plugging the power cord 32 into
an electrical outlet, the user grips the handle 14 and activates
the sprayer 10 by pressing the actuator button 48. The actuator 46
pivots to activate the switch 136 and the motor 22. Spray intensity
may be adjusted by turning the control knob 42 on the rear end 20
of the sprayer housing 16. While pressing the actuator button 48,
the user moves his/her arm back and forth to spray paint onto the
desired surface.
[0042] The sprayer 10 may be cleaned by removing and emptying the
paint cup 12 from the lid 50, filling the paint cup 12 with clean
water or cleaning solution, reattaching the paint cup 12 to the lid
50, and spraying the water or solution through the fluid passage 34
out the tip 36. Alternatively, the pump housing 19 can be removed
from the main housing 16 and soaked or run under water. Typical
cleaning solutions include water, paint thinner (mineral spirits),
lacquer thinner, denatured alcohol, turpentine, and other paint
solvents.
[0043] The various parts of the paint sprayer 10, such as the tip
guard 37, housing 16, drip guard 86, handle 14, power cord 32, and
other parts are shown as having a particular configuration. The
configurations shown are for illustration purposes only, the scope
of the invention being defined by the appended claims and not
limited to any of the particularly shown embodiments.
[0044] While various features of the claimed invention are
presented above, it should be understood that the features may be
used singly or in any combination thereof. Therefore, the claimed
invention is not to be limited to only the specific embodiments
depicted herein.
[0045] Further, it should be understood that variations and
modifications may occur to those skilled in the art to which the
claimed invention pertains. The embodiments described herein are
exemplary of the claimed invention. The disclosure may enable those
skilled in the art to make and use embodiments having alternative
elements that likewise correspond to the elements of the invention
recited in the claims. The intended scope of the invention may thus
include other embodiments that do not differ or that
insubstantially differ from the literal language of the claims. The
scope of the present invention is accordingly defined as set forth
in the appended claims.
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