U.S. patent application number 11/398271 was filed with the patent office on 2006-08-17 for multiple side-feeding aerosol valve assembly.
Invention is credited to John R. Woods.
Application Number | 20060180616 11/398271 |
Document ID | / |
Family ID | 36814659 |
Filed Date | 2006-08-17 |
United States Patent
Application |
20060180616 |
Kind Code |
A1 |
Woods; John R. |
August 17, 2006 |
Multiple side-feeding aerosol valve assembly
Abstract
A valve assembly is disclosed for use in an aerosol spray can
capable of spraying viscous materials or materials with large
particulates with increased atomization and without clogging or
packing like traditional aerosol spray cans designed for spraying
texture materials. The valve opening may be located at
substantially any point between the bottom and the top of the
container. The valve assembly may include a plurality of
side-fitting dip tubes, a side-feeding mechanism, a side release
tube and at least one storage member connected, respectively, to at
least one of the dip tubes, whereby texture material is dispensed
when a central channel is aligned with a side conduit that is in
flow communication with the dip tubes.
Inventors: |
Woods; John R.; (Woodland
Hills, CA) |
Correspondence
Address: |
PILLSBURY WINTHROP SHAW PITTMAN LLP
P.O BOX 10500
McLean
VA
22102
US
|
Family ID: |
36814659 |
Appl. No.: |
11/398271 |
Filed: |
April 4, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10832126 |
Apr 26, 2004 |
7059497 |
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11398271 |
Apr 4, 2006 |
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|
10174264 |
Jun 18, 2002 |
6726066 |
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10832126 |
Apr 26, 2004 |
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09760990 |
Jan 16, 2001 |
6415964 |
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10174264 |
Jun 18, 2002 |
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09656247 |
Sep 5, 2000 |
6382474 |
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09760990 |
Jan 16, 2001 |
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09312133 |
May 14, 1999 |
6112945 |
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09656247 |
Sep 5, 2000 |
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Current U.S.
Class: |
222/402.1 ;
222/464.2 |
Current CPC
Class: |
B65D 83/752 20130101;
B65D 83/48 20130101; B65D 83/32 20130101 |
Class at
Publication: |
222/402.1 ;
222/464.2 |
International
Class: |
B65D 83/14 20060101
B65D083/14 |
Claims
1. A valve assembly for use in an aerosol system, said valve
assembly comprising: an upper housing defining a first opening
through the periphery thereof; a side conduit having a free end,
and an end connected to said first opening at an angle sloping
downward from the horizontal; a lower housing divided into a first
vertical passageway for receiving a first dip tube, a second
vertical passageway for receiving a second dip tube, and a vertical
compartment, wherein each of said first and second passageways has
an upper end and a lower end and said upper ends are in flow
alignment with the free end of the side conduit so as to provide
flow communication between the lower end of each said passageway
and said first opening; an actuating mechanism having a spool
defining a length-wise channel through a portion thereof, wherein
said spool is configured to move vertically within said upper
housing and said vertical compartment, and wherein a lower portion
of said channel is angled so as to be in flow alignment with said
conduit through said first opening when the actuating mechanism is
in an actuated position, thereby allowing a sprayable material to
flow through at least one of said passageways and said conduit and
channel; and a side release tube attached to the actuating
mechanism, the side release tube having an upper portion and a
lower portion, wherein the lower portion includes an opening and
the upper portion and lower portion provide flow communication from
the opening to the actuating mechanism.
2. The valve assembly of claim 1, wherein the lower portion of the
side release tube is positioned inside the container and the upper
portion of the side release tube is positioned outside of the
container, the upper portion being attached to the actuating
mechanism.
3. The valve assembly of claim 1, wherein the opening of the side
release tube is positioned above the sprayable material without
contact with the sprayable material.
4. The valve assembly of claim 1, wherein the side release tube
provides flow communication of the gas from the inside of the
container to the actuating mechanism.
5. The valve assembly of claim 1, wherein the gas is released
through the side release tube to provide added atomization to the
sprayable material as the sprayable material exits the actuating
mechanism.
6. The valve assembly of claim 5, wherein the gas does not contact
the sprayable material until the sprayable material is exiting the
actuating mechanism.
7. The valve assembly of claim 1, wherein the gas is released at
the same time as the sprayable material when the actuating
mechanism is depressed.
8. The valve assembly of claim 1, wherein for each of the first and
second dip tubes, an upper portion of the dip tube is housed by its
respective vertical passageway such that an upper end of the dip
tube is disposed adjacent and in flow communication with the free
end of the side conduit.
9. The valve assembly of claim 8, wherein the lower end of the
first dip tube is in direct communication with a first fraction of
sprayable material housed within an aerosol container, and the
lower end of the second dip tube is connected to a storage member
within the aerosol container, the storage member housing a second
fraction of sprayable material.
10. The valve assembly of claim 9, wherein the first and second
fractions are portions of the same material.
11. The valve assembly of claim 9, wherein the first and second
fractions are portions of different materials.
12. The valve assembly of claim 1, wherein in the actuated
position, the angled lower portion of the channel is parallel to
the conduit.
13. The valve assembly of claim 1 further including resilient means
to bias the actuating mechanism towards an unactuated position, the
resilient means engaging an undersurface of the spool's middle
portion.
14. An aerosol system for applying sprayable material comprising: a
container holding a gas and sprayable material, wherein the gas is
positioned over the sprayable material; and a valve assembly
attached to the container comprising an upper housing defining a
first opening through the periphery thereof, a side conduit having
a free end, and an end connected to said first opening at an angle
sloping downward from the horizontal, a lower housing divided into
a first vertical passageway for receiving a first dip tube, a
second vertical passageway for receiving a second dip tube, and a
vertical compartment, wherein each of said first and second
passageways has an upper end and a lower end and said upper ends
are in flow alignment with the free end of the side conduit so as
to provide flow communication between the lower end of each said
passageway and said first opening, an actuating mechanism having a
spool defining a length-wise channel through a portion thereof,
wherein said spool is configured to move vertically within said
upper housing and said vertical compartment, and wherein a lower
portion of said channel is angled so as to be in flow alignment
with said conduit through said first opening when the actuating
mechanism is in an actuated position, thereby allowing a sprayable
material to flow through at least one of said passageways and said
conduit and channel, and a side release tube attached to the
actuating mechanism, the side release tube having an upper portion
and a lower portion, wherein the lower portion includes an opening
and the upper portion and lower portion provide flow communication
from the opening to the actuating mechanism.
15. The system of claim 14, wherein the lower portion of the side
release tube is positioned inside the container and the upper
portion of the side release tube is positioned outside of the
container, the upper portion being attached to the actuating
mechanism.
16. The system of claim 14, wherein the opening of the side release
tube is positioned above the sprayable material without contact
with the sprayable material.
17. The system of claim 14, wherein the side release tube provides
flow communication of the gas from the inside of the container to
the actuating mechanism.
18. The system of claim 14, wherein the gas is released through the
side release tube to provide added atomization to the sprayable
material as the sprayable material exits the actuating
mechanism.
19. The system of claim 18, wherein the gas does not contact the
sprayable material until the sprayable material is exiting the
actuating mechanism.
20. They system of claim 14, wherein the gas is released at the
same time as the sprayable material when the actuating mechanism is
depressed.
Description
RELATED APPLICATION DATA
[0001] This application is a Continuation-in-part of Ser. No.
10/832,126, filed on Apr. 26, 2004, which is a Continuation-in-part
of Ser. No. 10/174,264, filed Jun. 18, 2002, now U.S. Pat. No.
6,726,066, which is a Continuation-in-part of Ser. No. 09/760,990,
filed Jan. 16, 2001, now U.S. Pat. No. 6,415,964, which is a
Continuation-in-part of Ser. No. 09/656,247, filed Sep. 5, 2000,
now U.S. Pat. No. 6,382,474, which is a Continuation-in-part of
Ser. No. 09/312,133, filed May 14, 1999, now U.S. Pat. No.
6,112,945.
FIELD OF INVENTION
[0002] This invention relates to valve assemblies for use in an
aerosol spray can that is capable of spraying viscous materials or
materials with large particulates with increased atomization and
without clogging or packing like traditional aerosol spray cans
designed for spraying texture materials.
BACKGROUND OF THE INVENTION
[0003] The practice of dispensing heavy and particulate materials
through traditional aerosol spray can valve assemblies in the
aerosol industry has presented problems in which the heavy and
particulate materials to be dispensed clog up the valve assemblies.
These heavy and particulate materials may include exterior stucco,
heavy sand finishes, drywall and acoustic ceiling patching
materials, fire suppressant materials, adhesive and bonding
materials, and even culinary sauces.
[0004] A traditional aerosol spray can may be filled with these
heavy and particulate materials for spraying. In the traditional
aerosol spray can, the material to be dispensed must pass through
an orifice that is normally sealed off (with a seal or gasket,
e.g.) in the unactuated position. When the actuator is depressed,
the orifice is exposed to allow the material to pass through.
However, when heavy and particulate materials are used, they tend
to clog up the valve assemblies (e.g., by clogging up or sticking
to the seal, the orifice, and/or the area therebetween) and render
the aerosol spray cans inoperative. Constant operation of these
aerosol spray cans in spraying heavy and particulate materials is
not possible due to the inconsistent ability of these traditional
valve assemblies to dispense these materials without clogging.
[0005] U.S. Pat. No. 5,715,975, issued to Stern et al., discloses
an aerosol spray texturing device that is comprised of a container,
a nozzle, a valve assembly, and an outlet. The valve assembly in
the '975 patent is located in the upper section of the container
near the nozzle. Although the nozzle tube of the device in the '975
patent may be configured to spray texture materials, the device in
the '975 patent still has the problem of clogging or packing of the
valve assembly by the particulates contained in the texture
material for spraying, especially if the particulates are large,
like those found in stucco or other heavy and particulate materials
mentioned above.
[0006] U.S. Pat. No. 5,037,011, issued to the present Applicant,
discloses a spray apparatus for spraying a texture material through
a nozzle. Although sufficient for its intended purpose, this
apparatus also cannot spray texture materials having large
particulates, such as stucco, because the particulates clog up the
valve opening within the spray apparatus.
[0007] Therefore, a long-standing need has existed to provide an
apparatus that may be used to readily apply heavy and particulate
materials in aerosol form, such as exterior stucco, heavy sand
finishes, drywall and acoustic ceiling patching materials, fire
suppressant materials, adhesive and bonding materials, and culinary
sauces. Furthermore, the heavy and particulate materials to be
applied should be contained in a hand-held applicator so that the
materials may be conveniently stored, as well as dispensed, in a
simple and convenient manner without clogging or packing the valve
assembly of the applicator.
BRIEF SUMMARY OF THE INVENTION
[0008] An object of the present invention, therefore, is to provide
a valve assembly for use in an aerosol spray can capable of
spraying viscous materials or materials with large particulates
without clogging or packing like traditional aerosol spray cans
designed for spraying texture materials.
[0009] Another object of the present invention is to provide an
inexpensive and economical means for matching surface texture of a
repaired or patched surface area on a drywall panel, acoustic
ceiling, or stucco-covered surface.
[0010] Another object of the present invention is to improve the
appearance of patched or repaired areas on a textured surface by
employing a spray-on hardenable texture material that covers the
repaired or patched area and visually assumes the surface texture
of the surrounding patched or repaired surface.
[0011] Another object of the present invention is to provide a
hand-held dispensing unit containing a pressurized texture surface
material for spray-on and direct application of the material in a
liquid or semi-liquid form onto a repaired or patched area so that
the surrounding patched or repaired surface will be visually and
mechanically matched.
[0012] Another object of the present invention is to provide a
valve assembly for use in an aerosol spray can capable of spraying
highly-viscous materials, such as fire suppressant materials,
adhesive and bonding materials, and culinary sauces, as well as
colored agents, resins, catalysts, blowing agent, urethane-type
products, and the like, including the ability to spray two
different materials from a single can, without clogging or packing
like traditional aerosol spray cans when spraying these
materials.
[0013] One embodiment of the valve assembly comprises a dip tube
disposed inside a container. A rod is disposed inside the dip tube
so that it may move lengthwise within the dip tube. A sealing
member is coupled to the bottom end of the rod, so as to form a
tight-seal with the bottom opening of the dip tube when the rod is
in an up position, and it exposes the bottom opening of the dip
tube to the heavy and particulate material inside the container
when the rod is in a down position. A bushing is also coupled to
the top opening of the dip tube. Finally, an actuator is coupled to
the top end of the rod and the bushing, allowing the user to
depress the actuator, thus lowering the rod to its down position
and exposing the bottom opening of the dip tube to the material
within the container, and allowing the heavy and particulate
material to move up the dip tube and out of the container.
[0014] Another embodiment of the valve assembly comprises a dip
tube disposed inside the container. An interior tube is disposed
inside the dip tube so that it may move lengthwise within the dip
tube. There is at least one orifice at the bottom end of the
interior tube. A top O-ring is coupled to the interior tube
adjacent the at least one orifice to prevent any bypass of the
heavy and particulate material into the dip tube, and a bottom
O-ring is coupled to the bottom end of the interior tube to seal
off the valve assembly when not actuated. The top opening of the
dip tube is coupled to a bushing. Finally, an actuator is coupled
to the top end of the interior tube, allowing the user to depress
on the actuator, thus lowering the interior tube to its down
position and exposing the at least one orifice on the interior tube
to the material inside the container and allowing the heavy and
particulate material to flow up the interior tube and out of the
container.
[0015] In yet another embodiment of the invention, a valve assembly
is described wherein the valve opening may be located at
substantially any point between the bottom and the top of the
container. The valve assembly includes a side-fitting dip tube and
a side-feeding mechanism, whereby texture material is dispensed
when a central channel is aligned with a side conduit that is in
flow communication with the dip tube. The valve assembly also
includes a guiding mechanism to ensure alignment of the central
channel and the side conduit in the actuated position. The
embodiment just described provides for a much simpler and faster
assembly, as well as a reduction in the amount of gas that is lost.
In addition, placement of the dip tube on the side (within the
container) eliminates the need to build different sizes of valve
assemblies to fit a range of container sizes. Thus, a single size
of the valve assembly may be produced and dip tubes of various
lengths may be used to fit the intended container size. As such,
this embodiment also provides a reduction in size and costs
associated with the use of multiple container sizes.
[0016] In another embodiment of the invention, the valve assembly
described immediately above includes two or more side-fitting dip
tubes, wherein one of the tubes extends towards the bottom of the
container and is in direct contact with the material housed within
the container (as described above). Each one of the one or more
additional dip tubes, on the other hand, is connected to a storage
member, such as a sack or a pouch, which, in turn, is housed within
the container. In this way, when the actuating mechanism is
activated, a first material (or fraction of material) is drawn
through the first dip tube, and a second material (or second
fraction of the same material) is drawn through the second dip
tube, thereby allowing two different materials (or fractions of
material) to be sprayed from a single container. When more than two
dip tubes are present, the aerosol container may be used to spray
as many different materials (or fractions of materials) from a
single container as there are dip tubes by connecting each
additional dip tube to a separate storage member within the
container.
[0017] The invention prevents clogging or packing of the valve
assembly by eliminating the need for a seal or gasket which, as was
described above, is required in traditional aerosol spray cans.
However, the elimination of the gasket, without more, would simply
allow the contents near the top of the container to leave. That is,
provisions must be made to ensure that the entire contents of the
container can be dispensed. To this end, in embodiments of the
present invention, the valve opening may be at the bottom of the
container, as opposed to being at the top, as in traditional
aerosol spray cans. In other embodiments, the valve assembly may
still be placed near the top of the container, with a dip tube that
receives sprayable material from the bottom of the container and
feeds the material through a side conduit and an angled channel.
The placement of the valve opening as described with respect to the
embodiments herein greatly reduces the clogging or packing of the
valve by texture materials having large particulates. This
improvement allows the efficient and low-cost spraying of more
highly-textured materials, because there is no longer the problem
of clogging or packing of the valve opening by the particulates
suspended within the texture material.
[0018] In still another embodiment of the invention, the valve
assembly includes a side release tube which is attached to the
actuator. The side release tube is disposed partly inside the
container and may be parallel with the dip tube. The side release
tube extends through the top of the container and continues
externally to the actuator. The side release tube provides a
pathway for gas in the container to reach and exit from the
actuator. When the actuator is depressed, the sprayable material is
released at the same time that the gas is released, separate from
the sprayable material, through the side release tube. The
additional gas hits the sprayable material as the material exits
the actuator and thus provides an added level atomization to the
dispensed material.
[0019] Other features and advantages of the invention will become
apparent from the following detailed description, taken in
conjunction with the accompanying drawings that illustrate, by way
of example, various features and embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a perspective view of a valve assembly in
accordance with an embodiment of the present invention;
[0021] FIG. 2 is a cross-sectional view of a valve assembly in
accordance with an embodiment of the present invention;
[0022] FIG. 3 is a perspective view of a valve assembly in
accordance with an embodiment of the present invention;
[0023] FIG. 4 is a cross-sectional view of a valve assembly in
accordance with an embodiment of the present invention;
[0024] FIG. 5 is a perspective view of a valve assembly in a closed
position in accordance with an embodiment of the present
invention;
[0025] FIG. 6 is a cross-sectional view of a valve assembly in a
closed position in accordance with an embodiment of the present
invention;
[0026] FIGS. 7A and 7B illustrate perspective views of a portion of
a valve assembly in accordance with an embodiment of the present
invention;
[0027] FIG. 8 is a cross-sectional view of a valve assembly in an
opened position in accordance with an embodiment of the present
invention;
[0028] FIG. 9 is a perspective view of a valve assembly in an
opened position in accordance with an embodiment of the present
invention;
[0029] FIG. 10 is a cross-sectional view of a valve assembly in
accordance with an embodiment of the present invention;
[0030] FIG. 11 is a cross-sectional view of a valve assembly in
accordance with an embodiment of the present invention;
[0031] FIG. 12 is a side elevational view of a valve assembly in
accordance with an embodiment of the present invention;
[0032] FIG. 13 is an exploded view of the valve assembly depicted
in FIG. 12;
[0033] FIG. 14A is a side cross-sectional view of a valve assembly
in an unactuated position in accordance with an embodiment of the
present invention;
[0034] FIG. 14B is a rear cross-sectional view of the valve
assembly depicted in FIG. 14A;
[0035] FIG. 14C is a top cross-sectional view of the valve assembly
depicted in FIG. 14A;
[0036] FIG. 15A is a cross-sectional view of a valve assembly in an
actuated position in accordance with an embodiment of the present
invention;
[0037] FIG. 15B is an enlarged view of the top portion of the valve
assembly shown in FIG. 15A;
[0038] FIG. 16A is a perspective view of a lower housing according
to an embodiment of the present invention;
[0039] FIG. 16B is a perspective view of a lower housing according
to another embodiment of the present invention;
[0040] FIG. 17 is a cross-sectional view of a valve assembly in an
actuated position in accordance with an embodiment of the present
invention; and
[0041] FIG. 18 is a cross-sectional view of a valve assembly
including a side release tube according to an embodiment of the
present invention.
DETAILED DESCRIPTION
[0042] FIGS. 1 and 3 are perspective views of a valve assembly in
accordance with an embodiment of the present invention. A dip tube
1 is coupled to a bushing 4, which may also be coupled to a cup 5.
An actuator 6 is also coupled to the bushing 4.
[0043] In FIGS. 2 and 4, an aperture on the actuator 6 forms a
nozzle opening 7, in which a dispersing apparatus, such as a nozzle
cap or a dispensing tube, may be attached or screwed. A rod 2 is
disposed inside the dip tube 1 in a way that allows the rod 2 to
move within the dip tube 1 along its length. The actuator 6 is
coupled to the top end of the rod 2, so that when the actuator 6 is
depressed, the rod 2 moves downward within the dip tube 1. A
sealing member 3 is coupled to the bottom end of the rod 2, so that
when the rod 2 is in an up position, i.e., the actuator 6 is not
depressed, the sealing member 3 forms a tight-seal with the bottom
opening of the dip tube 1. However, when the rod 2 is in a down
position, i.e., the actuator 6 is depressed, the sealing member 3
exposes the bottom opening of the dip tube 1 to the heavy and
particulate material inside the container, and the aerosol within
the container will force the texture material through the bottom
opening of the dip tube 1, up through the dip tube 1, and out of
the container through the nozzle opening 7. The heavy and
particulate material may be a variety of sprayable materials,
including viscous materials or materials having large particulates,
like that of stucco.
[0044] The cup 5 acts as a guide to limit how far down the actuator
6 may be depressed, and in turn how far down the rod 2 may travel
within the dip tube 1. If the actuator 6 is depressed too far, the
bottom end of the rod 2 may come in contact with the bottom surface
of the container, which may result in damage to the container. The
cup 5 is also adapted to fit securely over the top portion of an
aerosol spray can and may also provide a surface for attaching the
valve assembly to the aerosol spray can.
[0045] The placement of the valve opening at the bottom of the
container, as opposed to near the top of the container, as
described in the prior references, drastically reduces the clogging
and packing of the valve opening as experienced by traditional
aerosol spray cans when spraying texture materials containing large
particulates, such as stucco. Further description of an example of
a heavy and particulate material is disclosed in U.S. Pat. No.
6,225,393, entitled, "Hardenable Texture Material in Aerosol Form,"
incorporated herein by reference. In addition to being capable of
spraying stucco-like materials, the valve assembly is also
particularly useful in spraying other types of materials having
large particulates or high viscosities, including fire suppressant
materials. These materials having large particulates or high
viscosities may be dispensed directly from the valve system of an
aerosol dispensing container. The aerosol dispensing container is
preferably a size that allows it to be hand held and may be
operated with one hand.
[0046] Ideally, the actuator 6 is made out of an elastic material,
such as rubber, so as to allow the retention of the rod 2 in the up
position when the actuator 6 is not depressed. The actuator 6 may
also be made of a non-elastic material, but there may be a
resilient member, such as a spring, coupled to the bushing 4 and
engaging the actuator 6 so as to spring-load the actuator 6. The
sealing member 3 should be made of a material, such as rubber, that
will allow the sealing member 3 to form a tight-seal with the
bottom opening of the dip tube 1 so as to prevent any entry of the
texture material and the aerosol carrier into the dip tube 1 when
the rod 2 is in the up position, i.e., when the actuator 6 is not
being depressed.
[0047] FIGS. 5 to 9 show another embodiment of the present
invention. A dip tube 1 is coupled to a bushing 4, which may also
be coupled to a cup 5. A spring member 9 may be coupled to the
bushing 4 to spring-load the actuator 6 engaging the spring member
9 on the bushing 4.
[0048] An interior tube 10 with a top end and a bottom end is
disposed inside the dip tube 1 in a way that allows the interior
tube 10 to move within the dip tube 1 along its length. The
actuator 6 is coupled to the top end of the interior tube 10, so
that when the actuator 6 is depressed, the interior tube 10 moves
downward within the dip tube 1. There is at least one orifice 13 at
the bottom end of the interior tube 10 so as to allow the heavy and
particulate material from inside the container to flow up through
the interior tube 10 and out of the nozzle opening. A top O-ring 11
is coupled to the interior tube 10 adjacent to and just above the
at least one orifice 13 so as to form a seal to prevent any bypass
of the heavy and particulate material from the container into the
dip tube 1 when the interior tube 10 is in a down position. A
bottom O-ring 12 is coupled to the bottom end of the interior tube
10 so as to seal off and close the valve assembly when the interior
tube 10 is in an up position.
[0049] As described above, the cup 5 may act as a guide so as to
limit how far down the actuator 6 may be depressed, as well as
provide a surface for attaching the valve assembly to the
container.
[0050] FIGS. 7A and 7B illustrate perspective views of a portion of
a valve assembly in accordance with an embodiment of the present
invention. As may be seen in FIG. 7B, when orifice 13 is aligned
with orifice 14, an opening is created.
[0051] FIG. 10 shows yet another embodiment of the present
invention. There is at least one exterior orifice 14 on the dip
tube 1 that is adapted to be in flow alignment with the at least
one orifice 13 of the interior tube 10. Therefore, when the
actuator 6 is depressed and the interior tube 10 is lowered to its
open position, the at least one orifice 13 of the interior tube 10
aligns with the at least one orifice 14 on the dip tube 1 so that
the material inside the container 17 may flow through the exterior
orifice 14 and into the at least one orifice 13 of the interior
tube 10 and up through the interior tube 10 and out of the
container through the nozzle opening 7. Similarly, there is a top
O-ring 11 and a bottom O-ring 12, as described above, for sealing
off the dip tube 1 to prevent any bypass of the heavy and
particulate material from the container and for closing the valve
assembly.
[0052] FIG. 11 shows yet another embodiment of the present
invention. In this embodiment, a resilient member 16, shown here as
a spring, is located at the bottom of the container 17. One end of
the resilient member 16 is adjacent to the bottom of the container.
The resilient member 16 may be attached to, or may abut, the bottom
of the container 17. The second end of the resilient member 16 may
be attached to, or may abut, the inner tube 10. This resilient
member 16 will serve to spring-load the actuator and will prevent
the inner tube 10 from remaining in its lowered position beyond the
time required by the user. The resilient member 16 may also serve
as a type of anchor or stabilizer for the inner tube 10 and dip
tube 1. This will help to prevent any movement of the inner tube 10
and dip tube 1 that may cause a leakage where the inner tube 10 and
the dip tube 1 meet the top of the container 17. While FIG. 11
shows the resilient member 16 being used with the embodiment of the
present invention that has a inner tube 10 and a dip tube 1, it
should be understood that the spring could be used with any
embodiment of the present invention to center the tube extending
into the container, to provide support to the tube in the
container, and to push the tube back towards the top of the can and
spring-load the actuator.
[0053] The resilient member 16 is depicted in FIG. 11 as a coil or
spring. However, it should be understood by one skilled in the art
that this resilient member may be made from a rubber cylinder, a
metal coil or any other means as are known in the art.
[0054] FIGS. 12-15 show another embodiment of the present
invention. A valve assembly 100 includes an upper housing 102 and a
lower housing 104. The lower housing 104 is divided into a vertical
passageway 114 and a vertical compartment 116. The upper housing
102 may be generally cylindrical and includes a transverse opening
106 through the wall of the housing. The upper housing 102 also
includes a side conduit 108 where, at one end 112, it is connected
to the opening 106 and, at the other (free) end 110, it is in flow
alignment and communication with the upper end 118 of the vertical
passageway 114. Thus, the side conduit 108 is disposed between the
upper housing 102 and the lower housing 104 at an angle sloping
downwards from the horizontal. In a preferred embodiment, the upper
and lower housings are coupled together by snap means 128A, 128B,
or other similar coupling means. In an alternative embodiment,
upper housing 102 and lower housing 104 may be made as a unitary
structure.
[0055] As shown in FIGS. 13 and 14A-B, a spool 122 having a middle
portion 130, an upper elongated member 132, and a lower elongated
member 134 moves vertically within the upper housing 102 and the
vertical compartment 116 of the lower housing 104. The middle
portion 130 is generally cylindrical and defines a transverse
opening 138 through its wall. A channel 124 having a straight upper
portion 136 and an angled lower portion 126 is defined through a
length-wise portion of the upper elongated member 132. The upper
housing 102 includes a bushing 152 on its top surface, such that
the bushing 152 is concentric with, and disposed around, the
channel's straight upper portion 136.
[0056] In a preferred embodiment, the straight upper portion 136 of
the length-wise channel 124 is concentric with and, as such,
constitutes the upper elongated member 132. As illustrated in FIGS.
14A and 15B, the lower portion 126 of the length-wise channel 124
is angled, so that it extends radially outwards in a
downward-sloping manner, such that it connects to, and is in flow
alignment and communication with, the opening 138 in the wall of
the spool's middle portion 130. A first seal 140, such as an
O-ring, is coupled to the exterior of the middle portion 130 of the
spool 122 just below the point where the angled lower portion 126
meets the opening 138 so as to prevent passage of the sprayable
material from the container 17 into the opening 138 or channel 124
when the spool 122 is up, i.e., when the actuating mechanism is in
an unactuated position (see FIGS. 14A-B). Similarly, a second seal
142 (e.g., an O-ring) is coupled to the exterior of the middle
portion 130 of the spool 122 just above the point where the angled
lower portion 126 meets the opening 138 so as to prevent passage of
the sprayable material from the container 17 into the upper housing
102 when the spool 122 is down, i.e., when the actuating mechanism
is in an actuated position (see FIGS. 15A-B).
[0057] The valve assembly 100 further includes a resilient member
148 to bias the actuating mechanism, including the spool 122
towards an unactuated position, i.e., in an up position. In one
embodiment, the resilient member 148 is a spring that is disposed
around the spool's lower elongated member 134. In this embodiment,
one end of the spring engages an undersurface 150 of the spool's
middle portion 130, and the other end engages the bottom surface
144 of the vertical compartment 116. In this manner, the spool 122
is normally spring-loaded towards an unactuated position, and its
vertical movement is restricted as determined, e.g., by the
properties of the spring.
[0058] Embodiments of the invention include a guiding mechanism to
ensure that, in an actuated position, the openings 106 and 138 line
up, so that the side conduit 108 and the angled lower portion 126
of the channel 124 are in flow alignment and communication. This,
in effect, requires that the spool 122 be prevented from twisting,
or rotating around its longitudinal axis. In one embodiment, this
is achieved by including, in the bottom surface 144 of the vertical
compartment 116, an aperture 146 having generally a non-circular
shape. In addition, the spool's lower elongated member 134 has a
cross-section in the shape of the aperture 146 and rides within the
aperture. Thus, in the example shown in FIG. 14C, the aperture 146
is in the shape of a plus sign, although any other non-circular
geometry may also be used. In operation, the lower elongated member
134 extends through, and is engaged by, the aperture 146, so that
the latter guides the movement of the former.
[0059] FIG. 15A shows a cross-sectional view of a valve assembly in
an actuated position within a container 17. As depicted more
clearly in FIG. 15B, a dip tube 154 is inserted through a lower end
120 of the vertical passageway 114 such that an upper portion of
the dip tube is housed within the vertical passageway 114, and the
upper end 156 of the dip tube is disposed adjacent and in flow
alignment and communication with the free end 110 of the side
conduit 108.
[0060] In operation, to initiate spraying of the texture material,
the upper elongated member 132 of the spool 122 is depressed until
the openings 106 and 138 are aligned, and the side conduit 108 and
angled lower portion 126 are parallel and in flow communication.
The guiding mechanism described above ensures that the spool 122 is
lowered without twisting. Once the openings 106 and 138 are
aligned, the propellant within the container 17 forces the texture
material through the bottom opening of the dip tube 154, up through
the dip tube and the side conduit 108, and out of the container
through the angled lower portion 126 and the upper straight portion
136 of the channel 124. As was noted with respect to the
embodiments previously described, the heavy and particulate texture
material may be a variety of sprayable materials, including viscous
materials or materials having large particulates, such as stucco.
To terminate spraying of the texture material, the upper elongated
member is released, at which time the resilient member 148 forces
the spool 122 upwards and towards the unactuated position, where
the openings 106 and 138 are no longer aligned.
[0061] Although embodiments shown in FIGS. 12-15 depict a valve
assembly that is placed near the top of container, the invention
may be practiced by placing the valve assembly at substantially any
point between the top and bottom of the container. This flexibility
in placement of the valve assembly is made possible because the
side-feeding feature of the invention, in combination with the
side-fitting dip tube, allows elimination of the gasket that is
required by traditional aerosol spray cans, and yet provides for
uptake of the texture material from the bottom of the can.
[0062] Nevertheless, placement of the valve assembly near the top
of the container may be desirable, and preferred. For example, such
placement provides for a much simpler and faster assembly, as well
as a reduction in the amount of gas that is lost. In addition,
placement of the dip tube on the side eliminates the need to build
different sizes of valve assemblies to fit a range of container
sizes. In effect, the invention allows for production of a single
size of the valve assembly, wherein dip tubes of various lengths
can be used according to the intended container size. As such, the
invention also provides a reduction in size and costs associated
with the use of a multiplicity of container sizes.
[0063] As shown in FIG. 16A, the lower housing 104 may include two
(or more) vertical passageways 114A, 114B. The passageways may be
situated side by side, and in various orientations. Thus, FIG. 16A
shows passageways 114A and 114B oriented in one direction, while
FIG. 16B shows passageways 114C and 114D, oriented about 90 degrees
from the position depicted in FIG. 16A. It should be understood
that FIGS. 16A and 16B depict illustrative examples only, and that
the vertical passageways may have any other orientation within the
lower housing 104. In addition, while, in a preferred embodiment,
each of the vertical passageways 114A-114D has a circular cross
section, the present invention may also be practiced with these
passageways having non-circular cross sections.
[0064] FIG. 17 shows a cross-sectional view of a valve assembly in
an actuated position within the container 17, wherein a lower
housing 104 according to FIG. 16B has been employed for
illustrative purposes. Here, a first dip tube 154 is inserted
through a lower end 120A of the first vertical passageway 114C such
that an upper portion of the dip tube is housed within the first
vertical passageway 114C, and the upper end of the dip tube is
disposed adjacent and in flow alignment and communication with the
free end 110 of the side conduit 108. The lower end 155 of the
first dip tube 154 extends generally downwards and is directly in
contact/communication with the interior of the container 17.
[0065] Similarly, a second dip tube 254 is inserted through a lower
end 120B of the second vertical passageway 114D such that an upper
portion of the dip tube is housed within the second vertical
passageway 114D, and the upper end of the dip tube is disposed
adjacent and in flow alignment and communication with the free end
110 of the side conduit 108. Here, however, the lower end 255 of
the second dip tube 254 is connected to a storage member, such as a
sack or a pouch, 200, which is contained within the container
17.
[0066] The above configuration allows for two different materials,
or two portions (or fractions) of the same material, to be sprayed
out of the same container. Thus, in operation, to initiate
spraying, the upper elongated member 132 of the spool 122 is
depressed, as before, until the openings 106 and 138 are aligned,
and the side conduit 108 and angled lower portion 126 are parallel
and in flow communication. The guiding mechanism described above
ensures that the spool 122 is lowered without twisting. Once the
openings 106 and 138 are aligned, the propellant within the
container 17 forces material through the bottom openings of the
first dip tube 154 and second dip tube 254, up through the
respective dip tubes and the side conduit 108, and out of the
container through the angled lower portion 126 and the upper
straight portion 136 of the channel 124.
[0067] The storage member 200 connected to the second dip tube 254
may include its own propellant. Thus, compressed gasses functioning
as propellants may be introduced into the container 17 and storage
member 200 by, e.g., undercapping the propellant into the container
(i.e., filling the container with the propellant and then sealing
it quickly) and/or filling the storage member 200 and the container
17 with propellant through the valve mechanism atop the
container.
[0068] As was noted with respect to the embodiments previously
described, the heavy and particulate texture material may be a
variety of sprayable materials, including viscous materials or
materials having large particulates, such as stucco. In addition,
the container 17 may be filled with an oil-based material having a
first color, while the storage member 200 is filled with a
water-based material having a second color. In this way, when the
actuating mechanism is operated, the two materials are sprayed
without mixing, thereby creating separate color patterns on the
sprayed area. Moreover, the container may be filled with a resin,
while the storage member is filled with a catalyst, or the
container may be filled with a urethane-type product (such as,
e.g., plastic or rubber), while the storage member is filled with a
blowing agent (such as, e.g., water or a hydrocarbon material).
[0069] It is noted that the relative lengths of the dip tubes shown
in FIG. 17 are for illustrative purposes only, and either dip tube
may be of various lengths, depending, e.g., on the overall
dimensions of the container 17, the dimensions of the storage
member 200, etc. In addition, the diameter of each of the dip tubes
may be selected based, e.g., on the material(s) being sprayed.
Finally, the invention described herein may be used to spray more
than two (fractions of) materials from a single container by
including multiple vertical passageways, dip tubes, and storage
members.
[0070] In FIG. 18, a cross-sectional view of a valve assembly
including a side release tube 300 according to an embodiment of the
present invention. In this embodiment, the valve assembly includes
a side release tube 300 which is attached to the actuator 302. The
side release tube 300 is disposed partly inside the container and
may be parallel with the dip tube 304. The internal portion of the
side release tube extends to top layer of gas 306 above the
sprayable material 308 inside the container, without touching the
material. The side release tube 300 extends through the top of the
container and continues externally to the actuator 302. The side
release tube 300 provides a pathway for gas 306 in the container to
enter from an opening 310 on the lower portion of the side release
tube 300 and then reach and exit from the actuator 302. When the
actuator 302 is depressed, the sprayable material 308 is released
at the same time that the gas 306 is released through the side
release tube 300. The additional gas 306 is released separately and
not brought into contact with the sprayable material 308 until the
gas 306 enters the actuator 302 where the gas 306 exits with the
sprayable material 308. The additional gas 306 hits the sprayable
material 308 as the material exits the actuator 302 and thus
provides an added level atomization to the dispensed material.
[0071] While the description above refers to particular embodiments
of the present invention, it will be understood that many
modifications may be made without departing from the spirit
thereof. The accompanying claims are intended to cover such
modifications as would fall within the true scope and spirit of the
present invention.
[0072] The presently disclosed embodiments are therefore to be
considered in all respects as illustrative and not restrictive, the
scope of the invention being indicated by the appended claims,
rather than the foregoing description, and all changes that come
within the meaning and range of equivalency of the claims are
therefore intended to be embraced therein.
* * * * *