U.S. patent application number 13/446918 was filed with the patent office on 2012-10-11 for aerosol spray texture apparatus for a particulate containing material.
This patent application is currently assigned to HOMAX PRODUCTS, INC.. Invention is credited to Donald J. Stern, James A. Tryon.
Application Number | 20120255974 13/446918 |
Document ID | / |
Family ID | 27578083 |
Filed Date | 2012-10-11 |
United States Patent
Application |
20120255974 |
Kind Code |
A1 |
Stern; Donald J. ; et
al. |
October 11, 2012 |
Aerosol Spray Texture Apparatus for a Particulate Containing
Material
Abstract
An outlet system for a hardenable acoustic texture material
aerosol dispensing system. The outlet system comprises a discharge
assembly movably supported such that a first return member
automatically returns the discharge assembly to a first position
when the discharge assembly is displaced a predetermined distance
from the first position.
Inventors: |
Stern; Donald J.;
(Clackamas, OR) ; Tryon; James A.; (Seattle,
WA) |
Assignee: |
HOMAX PRODUCTS, INC.
Bellingham
WA
|
Family ID: |
27578083 |
Appl. No.: |
13/446918 |
Filed: |
April 13, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12360833 |
Jan 27, 2009 |
8157135 |
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13446918 |
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10991611 |
Nov 18, 2004 |
7481338 |
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12360833 |
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10691897 |
Oct 22, 2003 |
7014073 |
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10991611 |
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10047041 |
Jan 14, 2002 |
6641005 |
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10691897 |
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09703409 |
Oct 31, 2000 |
6352184 |
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10047041 |
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09203547 |
Dec 1, 1998 |
6152335 |
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09703409 |
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08950202 |
Oct 14, 1997 |
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09203547 |
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Current U.S.
Class: |
222/402.1 |
Current CPC
Class: |
B65D 83/20 20130101;
B65D 83/206 20130101; E04F 21/12 20130101; B05B 1/02 20130101; B05B
1/34 20130101; B65D 83/752 20130101; B05D 1/02 20130101; B65D 83/42
20130101; B65D 83/30 20130101; B65D 83/62 20130101; B05B 7/2435
20130101; B65D 83/303 20130101; B05B 1/12 20130101; B65D 83/525
20130101; B05D 5/061 20130101; B65D 83/54 20130101; B05B 1/1654
20130101; B65D 83/201 20130101; B05B 1/1645 20130101; B65D 83/60
20130101; B05B 1/26 20130101; B65D 83/64 20130101; B65D 83/48
20130101; B65D 83/46 20130101; B05B 1/04 20130101 |
Class at
Publication: |
222/402.1 |
International
Class: |
B65D 83/00 20060101
B65D083/00 |
Claims
1. An outlet system for a hardenable acoustic texture material
aerosol dispensing system comprising a discharge assembly movably
supported such that a first return member automatically returns the
discharge assembly to a first position when the discharge assembly
is displaced a predetermined distance from the first position.
2. The outlet system as recited in claim 1, further comprising a
release member detachably attached to the discharge assembly as the
discharge assembly moves the predetermined distance, where the
release member is detached from the discharge assembly when the
discharge assembly begins to return to the first position.
3. The outlet system as recited in claim 2, further comprising a
second return member for displacing the release member to
detachably attach the release member to the discharge assembly
after the discharge assembly returns to the first position.
4. The outlet system as recited in claim 1, further comprising a
first biasing member arranged automatically to displace the
discharge assembly at least a portion of the first predetermined
distance from the first position.
5. The outlet system as recited in claim 1, further comprising a
lever member for facilitating displacement of the displacement of
the discharge assembly the predetermined distance from the first
position, where the lever member is released from the discharge
assembly after the discharge assembly moves the predetermined
distance.
Description
RELATED APPLICATIONS
[0001] This application (Attorney's Ref. No. P216936) is a
continuation of U.S. application Ser. No. 12/360,833, filed Jan.
27, 2009.
[0002] U.S. application Ser. No. 12/360,833 is a divisional of U.S.
application Ser. No. 10/991,611, filed Nov. 18, 2004, now U.S. Pat.
No. 7,481,338, which issued Jan. 27, 2009.
[0003] U.S. application Ser. No. 10/991,611 is a continuation of
U.S. application Ser. No. 10/691,897, filed Oct. 22, 2003, now U.S.
Pat. No. 7,014,073, which issued Mar. 21, 2006.
[0004] U.S. application Ser. No. 10/691,897 is a continuation of
U.S. application Ser. No. 10/047,041, filed Jan. 14, 2002, now U.S.
Pat. No. 6,641,005, which issued Nov. 4, 2003.
[0005] U.S. application Ser. No. 10/047,041 is a continuation of
U.S. application Ser. No. 09/703,409, filed Oct. 31, 2000, now U.S.
Pat. No. 6,352,184, which issued Mar. 5, 2002.
[0006] U.S. application Ser. No. 09/703,409 is a continuation of
U.S. application Ser. No. 09/203,547, filed Dec. 1, 1998, now U.S.
Pat. No. 6,152,335, which issued Nov. 28, 2000.
[0007] U.S. application Ser. No. 09/203,547 is a
continuation-in-part of U.S. application Ser. No. 08/950,202, filed
Oct. 14, 1997, now abandoned.
[0008] The contents of all related applications listed above are
incorporated herein by reference.
TECHNICAL FIELD
[0009] The present invention relates to a texture spraying
apparatus for discharging a texture material onto a surface, and
more particularly to an aerosol spray texture apparatus
particularly adapted to discharge a texture material having
particulate matter contained therein.
BACKGROUND
[0010] Buildings are commonly comprised of a frame to which a roof,
exterior walls, and interior walls and ceilings are attached. The
interior walls and ceilings are commonly formed using sheets of
drywall material that are attached to frame, usually by screws.
Gaps are normally formed between adjacent sheets of drywall
material. In addition, the screws are countersunk slightly, and the
screw heads are visible.
[0011] To hide the gaps and screw heads, they are covered with tape
and/or drywall compound and sanded so that the interior surfaces
(wall and ceiling) are smooth and continuous. The interior surfaces
are then primed for further finishing.
[0012] After the priming step, a texture material is often applied
to interior surfaces before painting. The texture material forms a
bumpy, irregular surface that is aesthetically pleasing. The
textured interior surface also helps to hide irregularities in the
interior surface.
[0013] Some interior surfaces, especially ceilings, are covered
with a special type of texture material referred to as acoustic
texture material. Acoustic texture material contains particulate
material that adheres to the interior surface. The purpose of the
particulate material is partly aesthetic and partly functional. The
particles absorb rather than reflect sound and thus can reduce echo
in a room. The term "acoustic" texture material is used because of
the sound absorptive property of this type of texture material.
[0014] When repairs are made to interior walls and ceilings, the
texture material often must be reapplied. The newly applied texture
material should match the original texture material.
[0015] A number of products are available that allow the
application of texture material in small quantities for the purpose
of matching existing texture material. In addition to hopper based
dispensing systems, texture material may be applied in small
quantities using aerosol systems. With conventional texture
material that does not include particles, a variety of oil and
water based texture materials in aerosol dispensing systems are
available.
[0016] Acoustic texture materials pose problems that have
heretofore limited the acceptance of aerosol dispensing systems. In
particular, most acoustic texture materials contain polystyrene
chips that dissolve in commercially available aerosol propellant
materials. Thus, conventional aerosol propellant materials are not
available for use with acoustic texture materials.
[0017] The Applicants have sold since approximately 1995 a product
that employs compressed inert gas, such as air or nitrogen, as the
propellant. The compressed gas does not interact with the particles
in the acoustic texture material. The compressed air resides in the
upper portion of the aerosol container and forces the acoustic
texture material out of the container through a dip tube that
extends to the bottom of the container.
[0018] While commercially viable, the use of compressed inert gas
to dispense acoustic texture material from an aerosol container
assembly presents several problems. First, if the aerosol system is
operated while inverted, the compressed inert gas escapes and the
system becomes inoperative. Second, the compressed inert gas can
force all of the acoustic texture material out of the aerosol
container in a matter of seconds. An inexperienced user can thus
inadvertently and ineffectively empty the entire container of
acoustic texture material.
[0019] The Applicants are also aware of an aerosol product that
sprays a foam material instead of a true acoustic texture material.
The foam material does not contain particulate material, and thus
the resulting texture formed does not match an existing coat of
true acoustic texture material.
[0020] The need thus exists for a system for dispensing acoustic
texture material that provides the convenience of an aerosol
dispensing system, employs true acoustic texture material, and is
easily used by inexperienced users.
RELATED ART
[0021] There are in the prior art various devices to spray a
texture material onto a wall surface or a ceiling. Depending upon
the nature of the composition and other factors, the material that
is sprayed onto the surface as a coating can have varying degrees
of "roughness".
[0022] In some instances, the somewhat roughened texture is
achieved by utilizing a textured composition that forms into
droplets when it is dispensed, with the material then hardening
with these droplets providing the textured surface. In other
instances, solid particulate material is mixed with the liquid
texture material so that with the particulate material being
deposited with the hardenable liquid material on the wall surface,
these particles provide the textured surface. However, such prior
art aerosol spray texture devices have not been properly adapted to
deliver a texture having particulate matter therein to provide the
rougher texture.
[0023] In particular, the Applicants are aware of prior art spray
texture devices using an aerosol container which contains the
texture material mixed with a propellant under pressure and from
which the textured material is discharged onto a surface. Such
aerosol dispensers are commonly used when there is a relatively
small surface area to be covered with the spray texture material.
Two such spray texture devices are disclosed in U.S. Pat. No.
5,037,011, issued Aug. 6, 1991, and more recently U.S. Pat. No.
5,188,263, issued Feb. 23, 1993 with John R. Woods being named
inventor of both of these patents.
[0024] Additionally, the Assignee of the present invention has
since approximately 1983 manufactured and sold manually operated
devices for applying spray texture material onto walls and
ceilings. These spray texture devices are described in one or more
of the following U.S. Pat. Nos. 4,411,387; 4,955,545; 5,069,390;
5,188,295.
[0025] Basically, these spray texture devices comprised a hopper
containing hardenable material, a manually operated pump, and a
nozzle. By pointing the device at the area being patched and
operating the manual pump, the hardenable material and pressurized
air generated by the pump were mixed in the nozzle and subsequently
sprayed onto the area being patched.
[0026] When applied to a ceiling, the hardenable material employed
by these prior art spray texture devices basically comprised a
mixture of the following ingredients: [0027] a. water to form a
base substance and a carrier for the remaining ingredients; [0028]
b. a filler substance comprising clay, mica, and/or calcium
carbonate; [0029] c. an adhesive binder comprising natural and/or
synthetic polymers; and [0030] d. an aggregate comprising
polystyrene particles.
[0031] The filler, adhesive binder, and aggregate are commercially
available from Hamilton Materials, Inc. under the tradename
PurTex.
[0032] The hardenable material employed by these prior art spray
texture devices further comprised one or more of the following
additional ingredients, depending upon the circumstances:
thickeners, surfactants, defoamers, antimicrobial materials, and
pigments.
SUMMARY
[0033] The present invention is a dispensing system that allows a
predetermined, metered quantity of material to be dispensed from an
aerosol container. The dispensing system is particularly adapted to
dispense acoustic texture material including particles of
polystyrene mixed throughout.
[0034] The present invention comprises a container system for
containing the texture material and a compressed inert gas as a
propellant, a valve assembly operable in an open and close
configuration for allowing or preventing fluid flow from the
container assembly, an outlet assembly for dispersing the texture
material dispensed thereby, and a metering assembly that interacts
either with the valve assembly or the outlet assembly to allow the
user to control the amount of texture material dispensed.
[0035] The metering system may be as simple as a collar that limits
the outlet assembly to limit the flow rate of the texture material
exiting the system and thus provide the user with more control over
the amount of texture material dispensed.
[0036] A more complex system requires the user to depress an
actuator member fully at which point the metering assembly will
release the valve assembly and cause the valve assembly to return
to its closed position without any interaction by the user.
[0037] An even more complex system may require the user to press an
actuator member to energize the system. After the actuator member
has been depressed by a predetermined amount, the valve is
triggered open and then released to close without further input
from the user. In this case, the user has no control over the
amount of texture material dispensed and thus cannot inadvertently
dispense the entire contents of the can.
[0038] The metering assembly can be mounted within the container
assembly or above the container assembly around the valve stem.
Another type of metering assembly is located completely outside of
the container and simply acts on a conventional valve assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] FIG. 1 is a highly schematic view depicting the major
components of an aerosol dispenser for acoustic texture material
constructed in accordance with, and embodying, the principles of
the present invention.
[0040] FIG. 1A is an isometric view showing a first embodiment the
present invention being held in a person's hand in a manner to
operate the apparatus to dispense the textured material
therefrom;
[0041] FIG. 2 is a longitudinal sectional view showing the valve
assembly of the first embodiment and a small portion of the aerosol
container, with the valve assembly in its closed position;
[0042] FIG. 3 is a view similar to FIG. 2, but showing the valve
assembly in its open position;
[0043] FIG. 4 is a view similar to FIG. 3, but showing a second
embodiment of the present invention, where the valve assembly has a
different arrangement for the vent openings of the valve assembly;
and
[0044] FIG. 5 is a drawing similar to FIG. 3, but drawn to an
enlarged scale, and giving various dimensions which in a prototype
have been proved to be suitable in the present invention.
[0045] FIG. 6 is a longitudinal sectional view of a third
embodiment of the present invention;
[0046] FIG. 7 is an isometric view of an upper portion of the valve
assembly of the third embodiment;
[0047] FIG. 8 is a longitudinal sectional view of that portion of
the valve assembly illustrated in FIG. 7;
[0048] FIG. 9 is a longitudinal sectional view of the lower and
middle portion of the valve assembly of the third embodiment of
FIG. 6, with the valve in the closed position;
[0049] FIG. 10 is a view similar to FIG. 9, but showing the valve
in the open position;
[0050] FIG. 11 is a longitudinal sectional view, similar to FIG. 6,
of a fourth embodiment of the present invention;
[0051] FIG. 12 is a longitudinal sectional view of the lower part
of the valve assembly of the fourth embodiment of FIG. 11;
[0052] FIG. 13 is a longitudinal sectional view of a fifth
embodiment of the present invention;
[0053] FIG. 14 is a longitudinal sectional view of a sixth
embodiment of the present invention;
[0054] FIG. 15 is an enlarged longitudinal section view of a
portion of the seventh embodiment of FIG. 16, with a broken line
circle showing that portion of FIG. 16 enlarged as FIG. 15;
[0055] FIG. 16 is a longitudinal sectional view of a seventh
embodiment of the present invention;
[0056] FIG. 17 is a longitudinal sectional view of an eighth
embodiment of the present invention;
[0057] FIG. 18 is a top plan view of an actuator assembly that may
be used with the present invention;
[0058] FIG. 19 is a longitudinal section view taken along lines
19-19 of FIG. 18;
[0059] FIG. 20 is a top plan view of another actuator assembly that
may be used with the present invention;
[0060] FIG. 21 is a front elevational view of the actuator assembly
of FIG. 20;
[0061] FIG. 22 is a longitudinal section view taken along lines
22-22 in FIG. 21;
[0062] FIG. 23 is a top plan view of yet another actuator assembly
that may be used with the present invention;
[0063] FIG. 24 is a longitudinal section view taken along lines
24-24 of FIG. 23;
[0064] FIG. 25 is a top plan view of still another actuator
assembly that may be used with the present invention;
[0065] FIG. 26 is a top plan view of another actuator assembly that
may be used with the present invention;
[0066] FIG. 27 is a longitudinal section view taken along lines
27-27 in FIG. 26;
[0067] FIG. 28 is a top plan view of yet another actuator assembly
that may be used with the present invention;
[0068] FIG. 29 is a longitudinal section view taken along lines
29-29 in FIG. 28;
[0069] FIG. 30 is a top plan view of another actuator assembly that
may be used with the present invention;
[0070] FIG. 31 is a longitudinal section view taken along lines
31-31 in FIG. 30.
[0071] FIGS. 32A-D depict a ninth embodiment of a dispensing system
of the present invention having a metering assembly to facilitate
application of a predetermined quantity of acoustic texture
material;
[0072] FIG. 33A-D are section views depicting a tenth embodiment of
a dispensing system of the present invention;
[0073] FIGS. 34A-G are section views of an eleventh embodiment of a
dispensing system of the present invention;
[0074] FIGS. 35A-G are section views taken along a different plane
and corresponding to FIGS. 34A-G;
[0075] FIG. 36 is a section view taken along lines 36-36 in FIG.
34A;
[0076] FIG. 37 is a section view taken along lines 37-37 in FIG.
34A;
[0077] FIG. 38 is a section view of a twelfth embodiment of the
present invention;
[0078] FIG. 39 is a partial section view of a dispensing system of
a thirteenth embodiment of the present invention;
[0079] FIG. 40 is a section view of a dispensing system of a
fourteenth embodiment of the present invention;
[0080] FIG. 41 is a section view taken along lines 41-41 in FIG.
40;
[0081] FIG. 42 is a section view taken along lines 42-42 in FIG.
40;
[0082] FIG. 43 is a section view of a fifteenth embodiment of a
dispensing system of the present invention;
[0083] FIG. 44 is a side elevational view of the dispensing system
of FIG. 43;
[0084] FIG. 45 is a section view taken along lines 45-45 in FIG.
43;
[0085] FIG. 46 is a side elevational view of a dispensing system of
the sixteenth embodiment of the present invention;
[0086] FIG. 47 is a section view of the dispensing system depicted
in FIG. 46; and
[0087] FIG. 48 is a partial section view taken along lines 48-48 in
FIG. 46.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0088] As schematically depicted in FIG. 1, the present invention
is an aerosol dispensing system 1 comprising a number of individual
components that are designed to work together in a manner that
allows acoustic texture material to be applied to a surface to be
coated.
[0089] The aerosol dispensing system 1 comprises a fluid portion 2
and a mechanical portion 3. The fluid portion 2 comprises a
hardenable acoustic texture material 4 containing particles 5 and a
propellant material 6. The mechanical portion 3 comprises a
container assembly 7, a valve assembly 8, and an actuator assembly
9.
[0090] Each of these individual components will be described in
general below, and following that will be described a number of
specific embodiments of the present invention that illustrate how
these components work together to obtain an aerosol system or
method for dispensing acoustic texture material.
I. Fluid Portion
[0091] The fluid portion 1 of the dispensing system and method of
the present invention comprises the material 4 to be dispensed,
hereinafter the acoustic texture material or hardenable material,
and the propellant material 6.
[0092] Referring initially to the hardenable acoustic texture
material 4, the Applicants determined that, in the context of
applying ceiling texture material to an interior surface such as a
ceiling, the composition of the hardenable material was limited by
the result desired. In particular, the Applicants determined that
the hardenable acoustic texture material 4 must, at a minimum,
include polystyrene chips or beads as the particles 5 in order to
obtain a textured surface that would satisfactorily match the
surrounding original textured surface.
[0093] In general, the particles may be polystyrene, cork or other
types of foam material, such as 88% polyethylene and 12% ethylene
vinyl acetate, natural or synthetic rubber, elastomer, etc.
[0094] When particulate material comprising particles other than
expanded polystyrene were used, however, either the spray texture
material would not spray properly (i.e., the particles would bounce
off the ceiling), the spray texture material would not match the
original texture on the ceiling, and/or it would clog or bridge in
the pick-up opening in the tube.
[0095] Accordingly, the Applicants determined that, in order to
develop an aerosol product that would obtain acceptable results for
patching a textured ceiling, commercially available ceiling spray
texture material as has long been used by prior art non-aerosol
spray texture devices is preferably used as part of the hardenable
material.
[0096] The hardenable material 4 may include:
[0097] (a) water as a base and carrier;
[0098] (b) PurTex, a commercially available acoustical ceiling
texture material; and
[0099] (c) Foammaster 1119A, a commercially available defoamer.
[0100] The PurTex product basically comprises a calcium carbonated,
mica, and/or clay as filler material, natural and/or synthetic
binder, a preservative, and polystyrene chopped beads.
[0101] In addition to the ingredients recited above, the hardenable
material may also comprise the following ingredients:
[0102] (a) a thickener that controls the film integrity of the
composition;
[0103] (b) a surfactant;
[0104] (c) an antimicrobial component; and
[0105] (d) a pigment compound (often a whitener).
[0106] Of the foregoing ingredients, the commercially available
ceiling texture material could not be eliminated or altered without
materially altering the appearance of the texture pattern formed
thereby. This texture material is a mixture that comprises a
carrier fluid component and a particulate material having particles
which are mixed throughout the carrier fluid. The particulate
material is made from an expanded polystyrene having a
predetermined particle size. Commonly, the particles of the mixture
have a variety of sizes to provide a texture surface having
different particle sizes.
[0107] One preferred formulation of the texture mixture is
comprised of the following ingredients: [0108] a. a thickener that
controls the film integrity of the composition; [0109] b. a
surfactant; [0110] c. a defoamer to facilitate the processing and
minimize bubbles when spraying; [0111] d. an antimicrobial
component; [0112] e. a pigment component (often a whitener); [0113]
f. a commercially available ceiling texture material with the
particles distributed therein. [0114] g. water.
[0115] The commercially available ceiling texture material
basically comprises calcium carbonate, mica, and/or clay as a
filler, a synthetic or natural binder, a preservative, and
polystyrene chopped beads.
[0116] Attached hereto in Appendix A are Tables A-F. These tables
contain the formulas employed by the Applicants to obtain the
hardenable material dispensed by the present invention. Currently,
the formula contained in Table F describes the preferred commercial
form of the hardenable material dispensed by the present
invention.
[0117] In the attached tables, trade names are used to identify
certain commercially available ingredients. The ingredient PureTex
was described above. The purpose of each of the remaining
ingredients will be described below: PMO 30 is a preservative;
BENTONE LT is a thickener; NUOSEPT 95 is a preservative; KTPP is a
surfactant; COLLOIDS 648 is a defoamer; BUSAN 11M1 is a filler,
preservative, antifoamant, dispersant; TITAN 2101 is a white
pigment, MINUGEL 400 is a thickener; BENTONE EW is a thickener; and
FOAMASTER 1119A is a defoamer.
[0118] The other major component of the fluid portion 2 is the
propellant material 6. The propellant employed may be a compressed
inert gas such as air or nitrogen that is separate from and acts on
the hardenable material. The propellant may also be comprised of
50% propane and 50% isobutane, but the particles, or aggregate,
cannot be formed of polystyrene in this case.
[0119] As discussed above, in the preferred case the hardenable
acoustic texture material 4 should, for aesthetic purposes, include
the polystyrene chips or beads 5. Accordingly, in the preferred
case the propellant material 6 is preferably a compressed inert
gas. Appropriate inert gasses include air, nitrogen, or a
combination thereof. The compressed inert gas will not adversely
affect the hardenable material 4 and, in particular, will not
dissolve or otherwise cause the deterioration of the polystyrene
chips or beads 5 contained therein.
II. Mechanical Portion
[0120] A shown in FIG. 1, the valve assembly 8 is mounted within
the container assembly 7, and the actuator assembly 9 is mounted on
the valve assembly 8. The valve assembly 7 is normally in a closed
configuration in which fluid, namely the hardenable material 4, is
prevented from exiting the container assembly 7. The operator
depresses the actuator assembly 9 to place the valve assembly 7
into its open configuration. When the valve assembly 7 is in its
open configuration, an exit passageway is created that allows fluid
to flow out of the container assembly 7 through the actuator
assembly 9.
[0121] The container assembly 7 is generally conventional, except
that it may be modified slightly as necessary to mount the valve
assembly 8 and actuator assembly 9.
[0122] The valve assembly 8 and actuator assembly 9 are unique to
the present invention and will be described as necessary below in
the discussion of the preferred embodiments.
III. First Embodiment
[0123] In FIG. 1A, it can be seen that the apparatus 10 of the
present invention comprises an aerosol container 12 defining a main
pressure chamber 13, and having at its upper end 14 a valve
assembly 16. The container 12 has an overall cylindrical
configuration, comprising a cylindrical sidewall 17, a top wall 18
(either integral with the sidewall 17 or made separately), and a
bottom wall (not shown for ease of illustration). The valve
assembly 16 is mounted at the center of the top wall 18.
[0124] The valve assembly 16 comprises a valve housing 20 mounted
to the top container wall 18, and a valve stem or element 22
positioned within the housing 20 for movement between the closed
position of FIG. 2 to the open position of FIG. 3. Fixedly attached
to the upper end of the valve element 22 is a manually operable
actuating and discharge portion 24, comprising a mounting portion
26, a cross bar 28, a discharge nozzle 30 extending upwardly from
the mounting portion of 26, and a pair of positioning legs 32
extending downwardly from the mounting portion 26 and positioned
diametrically opposite from one another.
[0125] The valve housing 20 comprises an annular mounting collar 34
having an outer circumferential mounting lip 36, having in cross
section a semi-circular configuration so as to provide a downwardly
facing circular recess to be attached to a matching circular lip
formed in the top wall 18 of the container 12. The collar 34
extends downwardly a short distance from the lip 36 as a side wall
38 and has a lower inwardly extending annular wall portion 40.
[0126] The valve housing 20 also comprises a lower cylindrical
housing portion 42 which defines a lower valve chamber 44 located
at the lower end of the valve stem 22, and a lower wall 45.
[0127] Extending downwardly from the housing portion 42 is a lower
intake tube 46. It will be noted that there is formed in the lower
wall 45 of the housing portion 42 a plurality of vent openings 47
positioned radially outwardly of a tube 46 and leading from the
main chamber 13 in the container 12 into the lower valve chamber
44. The function of these vent openings 47 will be discussed later
herein in connection with the overall operation of the apparatus 10
of the present invention.
[0128] The tube 46 has an upper end 48 connecting to the center
part of a lower wall 45 of the housing portion 42 and a lower end
52 that is positioned at the lower end of the container 12. This
tube 46 defines a vertical passageway 54 extending from the lower
intake opening 56 of the tube 46 upwardly to an upper outlet
opening 58 leading into the lower valve chamber 44. The lower
housing portion 42 has a downwardly extending stub 60 that fits
within the upper end of the tube 46 and defines the upper opening
58.
[0129] There is an intermediate flexible fitting 62 which is
operably connected and positioned between the valve housing 20 and
the valve element 22. As can be seen in FIG. 5, this fitting 22
comprises an upper tubular portion 64, a lower seal portion 66 and
a middle connecting portion 68 interconnecting the upper tubular
portion 64 and lower seal portion 66.
[0130] This intermediate fitting 62 can be made of a moderately
flexible rubber or synthetic rubber material, and it performs a
number of functions. First, the upper tubular portion 64 serves as
a resilient spring member which urges the valve element 22 toward
its upper closed position of FIG. 2. The lower seal portion 66, as
its name implies, serves to create a seal between the valve element
22 and the valve housing 20 in the closed position of FIG. 2. The
connecting portion 68 functions to position the valve element 22
relative to the housing 20, and also interconnects portion 64 and
66.
[0131] Before describing this flexible fitting 62 in more detail,
there will be a further description of the valve stem or element
22. The valve element 22 has an overall cylindrical configuration
and defines a central vertical discharge passageway 70 that leads
to the nozzle 30 that defines the upper portion 72 of the
passageway 70. The upper part of the valve element 22 has exterior
threads 73 which interconnect with the interior threads formed in
the mounting portion 26 of the actuating and discharge portion 24.
The lower middle portion 74 of the valve element has the same
cylindrical configuration as the upper portion, with a smooth outer
surface, and the upper tubular portion 64 of the flexible fitting
62, in the closed position of FIG. 2, fits snugly around the outer
surface of this lower cylindrical portion 74.
[0132] At the lower end of the valve element 22 there is fixedly
attached thereto a circular horizontal closure disc or plate 76
that closes the lower end of the discharge passageway 70. The upper
perimeter surface of this closure planar disc 76 fits against a
lower circumferential seal surface 78 of the seal portion 66 of the
fitting 62. There is a plurality of side openings 80 formed in the
side wall at the lower end of the valve element 22, at a location
immediately above the lower closure plate 76. In the preferred
configuration shown herein, there are two such openings 80,
positioned diametrically opposed to one another.
[0133] To describe further the intermediate flexible fitting 62,
the upper circular edge of the tubular portion 64 bears against an
annular protrusion 82 of the valve element 22. The lower end of the
tubular portion 64 has a moderately expanded circumferential lip 84
that extends over and engages the inner edge of the lower housing
wall 40 that defines an opening that receives the flexible fitting
62 and the valve element 22. Thus, it can be seen from observing
FIGS. 2, 3 and 5 that as the actuating and discharge portion 24
(fixedly connected to the valve element 22) is pushed downwardly,
the tubular portion 64 of the flexible fitting 62 is compressed
axially (see FIGS. 3 and 5) so as to urge the valve element 22 with
the actuating and discharge portion upwardly to the position of
FIG. 2. At the same time, the connecting portion 68 of the flexible
fitting 62 continues to position the valve element 22 centrally
within the collar 34 of the valve housing 20.
[0134] With regard to the seal portion 66 of the flexible fitting
62, this has in cross section a generally frusto conical
configuration, with an inner cylindrical wall that fits around the
lower part of the valve element 22. The upper circumferential
surface 86 of the seal portion 66 fits against the lower surface of
the inner lower wall 40 of the housing collar 34. In the position
of FIG. 2, the aforementioned seal surface 78 is in sealing
engagement with the upper surface of the closure plate 76 of the
valve element 22 so as to form a seal so that the texture material
that is positioned in the valve chamber 44 is sealed from the
discharge passageway 70 in the valve element 22.
[0135] However, when the actuating and discharge portion 24 with
the valve element 22 is depressed to the position of FIGS. 3 and 5,
it can be seen that the lower closure plate 76 moves away from the
seal surface 78 of the seal portion 66 to open the two intake
openings 80 at the bottom of the valve element 22 so that the
texture material in the valve chamber 44 is able to move through
the openings 80 upwardly through the discharge passageway 70 and
out the upper nozzle portion 72 of the discharge passageway 70 to
pass outwardly therefrom in a spray pattern against a wall or
ceiling surface or the like.
[0136] The texture material within the container 12 is a mixture
that comprises a carrier fluid component and a particulate material
having particles which are mixed throughout the carrier fluid. The
mixture is contained within the container 12 at a predetermined
pressure level which is above ambient pressure. At this
predetermined pressure level a propellant portion of the carrier
fluid remains liquid. Normally, there will be gas in the form of
vaporized propellant in the upper portion of the container 12 in
pressure equilibrium with the liquid phase. However, when the
pressure is reduced to a predetermined lower level, this propellant
component vaporizes.
[0137] The particulate material is made from a polystyrene material
having a predetermined maximum particle size (e.g. an eighth of an
inch), with each particle being compressible to a smaller particle
size dimension. Commonly, the particles of the mixture will have a
variety of sizes, to provide a varying texture surface. Other
compressible materials, such as cork, that are compatible with the
fluid components could be used.
[0138] To describe the operation of the present invention, the
apparatus 10 is provided to the end user with the pressurized
texture material mixture contained within the container 12, and
with the particulate material distributed throughout the liquid
component. The actuating and discharge portion 24 remains in the
closed position of FIG. 2, where the valve element 22 is in the
closed position. When it is desired to use the spray texture
apparatus 10, the apparatus 10 is grasped in a person's hand as
indicated in FIG. 1A, with two of the person's fingers engaging the
opposite sides of the cross bar 28 to depress the cross bar 28 so
as to move the valve element 22 downwardly, against the urging of
the tubular portion 64 of the intermediate flexible fitting 62 so
as to open the intake openings 80 of the valve element 22.
Obviously, other types of handles and triggering mechanisms could
be used.
[0139] With the valve element 22 in the open position of FIG. 3 or
5, it can be seen that the lower valve chamber 44 becomes exposed
to ambient pressure through the valve element openings 80. When
this occurs, the pressurized material in the main chamber 13 forces
the texture material upwardly through the tube 46 into the valve
chamber 44, with the material flowing from this chamber 44 into the
openings 80 and thence out the discharge passageway 70. At the same
time, the vaporized propellant portion of the fluid component of
the texture material passes upwardly through the vent openings 47
into the valve chamber 44 and mixes and/or atomizes. This increases
the percentage of the gaseous component of the carrier fluid that
is passing into and through the valve chamber 44 and out the
passageway 70.
[0140] It has been found that the particular arrangement of the
present invention functions to reliably pass the particles in the
mixture through the intake openings 80 to be discharged out the
passageway 70. In addition to the propellant gas passing upwardly
through the vents 47, the fluid component of the mixture is able to
have at least the vaporizable portion thereof pass upwardly through
the tube 46 into the chamber 44, with this component vaporizing at
least partially to form gaseous bubbles in the texture mixture.
Within the broader scope of the present invention, a propellant in
gaseous form or dissolved in a medium at higher pressure could be
utilized. By empirical testing, it is believed that the vaporizable
portion or propellant serves at least two functions. First, it adds
gas to the mixture to some extent so that as it passes from the
discharge nozzle opening portion 72, it is in a desired spray
pattern to be distributed on the wall or ceiling surface. Further,
even though the particles in the mixture are close to the same size
as the diameters of the openings 80, these particles pass reliably
through these openings 80 and outwardly through the passageway 70
and the nozzle end opening 72. It is surmised that the action of
the vaporizable fluid component or propellant being transformed at
least partially into the gaseous state or as expanded gas cause a
certain turbulence and localized pressure variations to jostle or
move or force any particles loose that may temporarily be caught in
the openings 80, or possibly in other parts of the valve chamber
44.
IV. Second Embodiment
[0141] A second embodiment of the present invention is shown in
FIG. 4. This is substantially the same as the first embodiment,
except that the vent openings (designated 47a) are positioned in
the sidewall of the housing 42a so that these direct flow laterally
into the chamber 44a at the location of the intake openings 80a. It
is surmised that this location of the vent openings 47a are able to
be oriented to effect a tangential swirling pattern, or oriented
more radially to provide a more direct force, in the vicinity of
the openings 80a to enhance proper movement of the particles.
[0142] FIG. 5 is an enlarged view giving in inches the dimensions
of a prototype built in accordance with the teachings of the
present invention, and also to show the components more clearly. It
is to be recognized, of course, that these dimensions could be
increased or decreased within certain limits (e.g. ten percent,
twenty percent, or possibly as high as fifty percent or higher, and
in some instances changed to provide different proportional
relationships in these dimensions) to obtain certain design
objectives. Further, the openings 80 could be made moderately
larger than the maximum dimension of the particles, or in some
instances even smaller than the particle dimension, if the
particles are sufficiently compressible.
V. Third Embodiment
[0143] FIG. 6 illustrates at 110 of the third embodiment of the
present invention which is particularly adapted to apply an
acoustic texture material to the surface of a ceiling. This
apparatus 110 comprises a container 112 and a discharge assembly
114. The container 112 defines a chamber 116 having a texture
material containing portion 118 and a propellant containing portion
120. In this third embodiment, the texture material containing
portion 118 is located in the bottom part of the chamber 116 since
the apparatus 110 is normally operated in a vertically aligned
position so that the texture material 122 is positioned by gravity
in the lower part of the chamber 116. The propellant containing
portion 120 is in the upper part of the chamber 116, and the
propellant 124 is a gaseous substance which is substantially inert,
such as nitrogen or atmospheric air, relative to the texture
material 122. There is a pressure interface 126 between the upper
surface 28 of the texture material 122 and the gaseous propellant
124 that is immediately above, with the propellant 124 being (in
this third embodiment) in direct contact with the texture material
122.
[0144] The container 112 comprises a cylindrical side wall 130,
having an upper frusto-conical wall section 132, and a bottom wall
134. The discharge assembly 114 comprises an infeed section 136 and
a valve section 138.
[0145] The infeed section 136 comprises a feed tube 140 having a
lower open end 142 positioned adjacent to and just above the bottom
wall 134, and an upper end 144 which fits within a downwardly
extending stub 146 that is part of an entry chamber housing 148
that defines an entry chamber 150. To describe briefly the function
of this infeed section 136, in operation the texture material 122
is forced by pressure from the propellant 124 to flow into the
lower open end 142 of the tube 140 and into the entry chamber 150.
From this chamber 150, the texture material flows into the valve
section 138.
[0146] The valve section 138 comprises a mounting collar 152
(sometimes referred to as a "cup"), a flexible valve seal and
mounting member 154, a valve stem 156, a valve handle portion 158,
a positioning spring 159, and an end nozzle section 160.
[0147] With reference to FIGS. 9 and 10, the valve mounting collar
152 has a perimeter portion 162 which extends upwardly from the
collar side wall 163 to curve upwardly and outwardly and then
downwardly in approximately a 180.degree. curve. This perimeter
portion 162 is positioned over a circumferential lip 164 that is
formed from an inner circumferential edge of the upper wall 132 and
extends in a circle around the inside edge of the frusto-conical
upper wall 132. This lip 164 at its inner edge is curved (as seen
in cross section) upwardly, outwardly and then downwardly in a
curved configuration so as to fit within the curved perimeter
portion 162 of the mounting collar 152.
[0148] A significant feature of the present invention is the manner
in which this mounting collar 152 forms a seal with the upper
container wall 132 and also forms a seal with the aforementioned
entry chamber housing 148. More particularly, the entry chamber
housing 148 comprises a bottom wall 166 and a cylindrical side wall
168. The walls 166 and 168 are made integrally of a semi-rigid
plastic material which is able to yield moderately.
[0149] As can be seen in FIG. 9, the upper edge 170 of the side
wall 168 has its thickness dimension reduced to a very small
thickness so as to be reasonably flexible. Then the upper edge
portion is formed in a curve 170 that extends upwardly and
inwardly, and then outwardly in a somewhat downward curve, this
curved portion being indicated at 174, so that this upper curved
portion 174 of the chamber member side wall 168 fits snugly between
the collar perimeter portion 162 of the collar 152 and the circular
lip 164 of the upper container wall 132.
[0150] In addition, by initially forming the edge portion 174 of
quite thin material (which then can be formed in a circular curve),
stresses that might be created in thus attaching the upper edge
portion 174 to the container lip 164 are not transmitted into the
side wall 168 of the entry chamber housing 148.
[0151] This connection of the perimeter portion 162, circular lip
164 and the curved section 174 can conveniently be provided as
follows. The inner edge of the container upper wall 132 is
preformed to form the circular lip 164, and the collar 152 is also
preformed with its semi-circular perimeter portion 162. The upper
curved section of the entry housing 148 can either be preformed
with its upper curved section 174, or this curve 174 can be made at
the time of assembly.
[0152] Initially, the entry housing 148 with the tube 140 already
mounted therein is positioned within the container 112 with the
upper edge portion 174 of the housing sidewall 168 overlying the
container lip 164. Then the mounting collar 152, with the seal and
mounting member 154 and the valve stem 156 already mounted thereto
is positioned in the opening at the upper end of the container 112,
with the collar perimeter portion 162 overlying the curved portion
174. After this, an expanding tool is positioned within the collar
152 and is operated to push radially outwardly against the sidewall
163 of the collar 152 at approximately the location 175 to expand
the collar sidewall at the location outwardly a short distance so
that it forms a slanted wall section that engages part of the
underside of the container lip 164. This secures the collar 152 in
place. Also, this makes a tight fit between the collar perimeter
portion 162, the container lip 164 and the curved portion 174 so
that a proper seal is formed. This seal is formed not only with
respect to the chamber 116, but also this forms a seal within the
entry chamber 150.
[0153] The valve seal and mounting member 154 in terms of function
has two portions, namely a lower seal portion 178, and second a
mounting portion 180. The mounting portion 180 has a center opening
181 and fits within the inner circular edge of a lower wall 182 of
the mounting collar 152. The mounting portion 180 has a lip or
shoulder 183 that extends over the inner edge of the wall 182, and
the seal portion 178 fits against the lower surface of the wall
182.
[0154] In this manner, the mounting portion 180 serves to support
the valve stem 156 in the opening 181, with the valve stem
supporting the valve handle portion 158 and the end nozzle section
160. The seal portion 178 forms a seal not only for the inlets of
the valve stem 156, but also forms a seal with the lower collar
wall 182.
[0155] The describe the valve stem 156, there is a vertical tubular
portion 184 that has as its lower end a closure disk or plate 186
which in the closed position abuts against the lower circular edge
188 of the seal portion 178. The lower part of the tubular portion
184 of the stem 156 has two laterally extending openings 189. In
the closed position of FIG. 6, the seal portion 178 closes these
two openings 189. The upper end portion 190 of the tubular stem
portion 184 has external threads so that it can be connected to the
handle portion 158.
[0156] The valve handle portion 158 has a lower cylindrical
mounting portion 192 which is internally threaded and fits in
threaded engagement onto the upper end 190 of the valve stem
tubular portion 184. This handle portion 158 has two outwardly
extending actuating members or handle members 194 extending in
opposite directions from one another, each of these members 194
having an upwardly concavely curved surface 196 to be engaged by
the fingers of the person.
[0157] A circumferential shoulder 198 on the valve stem 156 engages
the upper end of the positioning spring 159, and the lower end of
the positioning spring 159 bears against the upper surface of the
collar wall 182. Thus, when the handle portion 158 is depressed
downwardly, the spring 59 is deformed downwardly so as to provide a
restoring force to move the handle portion 158 upwardly when the
handle portion 158 is released. The upper part of the handle
portion 158 comprises a tubular extension 200 that is connected to
the end nozzle section 160.
[0158] The tubular portion 184 of the valve stem 156 defines an
upwardly extending through passageway 202 which lead into an
expanded passageway section (generally designated 204) formed in
the upper end portion 200 of the handle portion 158 in conjunction
with the upper nozzle section 160. With reference to FIG. 8, the
valve handle portion 158 is formed so that immediately above the
threaded mounting portion 192, there is an initial lower passageway
portion 206 which receives the very upper end of the valve stem
176, and defines an upper passage entry portion 208. This
passageway portion 208 lead into an upwardly and outwardly
expanding passageway portion 210 which in turn leads into an inside
surface portion 212 of a greater diameter, the surface portion 212
in effect defining an expansion chamber 214 which is part of the
expanded passageway portion 204. From the chamber 214, the
passageway portion 204 diminishes in cross-sectional area in an
upward direction, and this uppermost converging passageway section
is formed by the nozzle section 160.
[0159] This nozzle section 160 is made of two molded parts which
are half sections which fit within the valve handle upper portion
200 and are joined to one another along a vertical center plane as
two side by side sections. There is a lowermost circular portion
216 having its diameter smaller than the diameter of the chamber
surface portion 212. Immediately above the section 216 there is a
further necked down section 218, and this connects to an upwardly
and inwardly slanted portion 219 to a further upward portion 220
which defines a yet smaller cylindrical passageway section 222 that
leads into an end nozzle portion 224.
[0160] This end nozzle section 224 comprises two plate sections or
flanges 226 which define therebetween an elongate laterally
extending slot 228. These two plate sections 226 converge toward
one another to form the end slot 228. In addition, as can be seen
in FIG. 6, at opposite ends of the two flanges 226 there are
laterally and outwardly extending connecting portions 230 which
have outwardly slanting upwardly facing surface portions 232. Thus,
it can be seen that this passageway at 222 is transformed in an
upward direction from a cylindrical passageway to a passageway
which converges in one direction (caused by the plates 226 slanting
toward one another), and expands in a direction 90.degree. from the
first direction (caused by the outward slant of the surfaces 232 of
the connecting portions 230).
[0161] The texture material 122 within the container 112 is a
mixture that comprises a carrier fluid component and a particulate
material having particles which are mixed throughout the carrier
fluid. The gaseous propellant 124 in the upper chamber portion 120
is at a predetermined pressure level which is above ambient
pressure (e.g. 100 PSI).
[0162] The particulate material is made from an expanded
polystyrene having a predetermined maximum particle size (e.g. the
larger particles averaging about 1/8 of an inch across), with each
particle being compressible to a smaller particle size dimension.
(A compression test of a preferred form of the material indicates
that under 100 PSI pressure, the volume is decreased from 100% down
to 25% of the original volume). Commonly, the particles of the
mixture has a variety of sizes to provide a texture surface having
different particle sizes. While this polystyrene material is the
preferred material, within the broader scope of the present
invention other materials (desirably compressible materials) could
be used.
[0163] To describe the operation of the present invention, the
apparatus 110 is provided to the end user with the texture material
mixture contained within the container, and with the particulate
material distributed throughout the fluid component. The texture
material 22 occupies at least approximately one half of the volume
of the chamber 116 or possibly somewhat more than half the volume
of the chamber 116. Since the apparatus 110 is commonly operated in
a vertical position to apply the spray texture material upwardly to
a ceiling, the texture material 122 is normally positioned in the
bottom of the container 112. In use, the apparatus 110 is grasped
in a person's hand, with two of the person's fingers engaging the
upper surfaces 196 of the handle members 194 to depress the handle
portion 158 and the valve stem 156 against the urging of the spring
159. This moves the closure disk or plate 186 downwardly to expose
the openings 188. The pressurized gas 124 pushes the texture
material 122 upwardly through the tube 140 into the entry chamber
150. It has been found that the particular arrangement as shown
herein functions to reliably pass the particles in the mixture
through the lateral valve openings 188 and into the passageway 202
defined by the valve stem 156.
[0164] The texture material 124 flows through the passageway 202 of
the valve stem 156 into the expansion chamber 204, and thence
upwardly through the converging passageway portion defined by the
nozzle portion 160. As the texture material flows into the upper
nozzle portion, the texture material expands laterally in the end
nozzle portion 224 in one direction, while the passageway is
diminished in the direction 90.degree. to the first direction. The
material exiting from this elongate nozzle opening 228 is disbursed
upwardly and somewhat laterally to be applied to the surface
(which, as indicated previously, would usually be a ceiling to
which an acoustic texture material is applied.
[0165] As described above, the texture mixture may comprise one or
more the following ingredients: [0166] a. a thickener that controls
the film integrity of the composition; [0167] b. a surfactant;
[0168] c. a defoamer to facilitate the processing and minimize
bubbles when spraying; [0169] d. an anti-microbial component;
[0170] e. a pigment component (often a whitener); [0171] f. a
commercially available ceiling texture material with the particles
distributed therein; [0172] g. water.
[0173] When deposited on the surface, the texture material hardens
to form the finished textured surface.
VI. Fourth Embodiment
[0174] A fourth embodiment of the present invention is illustrated
in FIGS. 11 and 12. Components of this fourth embodiment which are
similar to components of the third embodiment will be given like
numerical designations, with an "a" suffix distinguishing those of
the second embodiment.
[0175] In this fourth embodiment, the apparatus 110a comprises a
container 112a and a discharge assembly 114a. However, the
discharge assembly 114a does not have the feed tube 140 and the
entry chamber housing 148 that are present in the third embodiment
110, shown in FIGS. 6 through 10.
[0176] Another difference in this fourth embodiment is that the
texture material 122a, instead of being positioned by gravity in
the bottom of the container 112a, is contained in a flexible
sack-like container 240 that forms the texture material chamber
118a immediately adjacent to the valve section 138. Further, the
propellant 124a is separated from the texture material 122a by the
flexible container 240, and this propellant 124a is a vaporizable
liquid which when under pressure in the container remains liquid,
but with a small pressure reduction vaporizes to form a gas which
pushes against the texture material 122a.
[0177] In order to prevent the flexible sack-like container 240
from deforming in a manner to close off the intake openings to the
valve, there is provided an elongate spring 242a which is
positioned vertically in the texture material chamber 118a. The
upper edge of the flexible container 240 is placed in a curve over
the inner rounded edge 164a of the container upper wall 132a, and
beneath the curved perimeter portion 162a of the collar 152a, in
the same manner as the rounded portion 174 of the entry chamber
housing of the third embodiment.
[0178] As in the third embodiment, there is the valve section 138a
which comprises a mounting collar 152a, the seal and mounting
member 154a, the valve stem 156a, the valve handle portion 158a,
and the end nozzle section 160a. All of these components 152a
through 160a are substantially the same as in the third embodiment,
except that the positioning spring 159 of the third embodiment is
omitted. In its place, the seal and mounting member 154 is provided
with an upwardly extending resilient tube portion 244 that is made
integral with the seal and mounting member 154. When the handle
portion 158a is depressed, this deforms this resilient tubular
portion 244 outwardly so as to be axially compressed.
[0179] In operation, when the valve section 138a is moved to the
open position, the propellant 124a pushes the texture material 118a
into the valve openings 188a and out and upwardly through the
passageway 202a, to exit out the nozzle opening 228a. The manner in
which this occurs is believed to be evident from the description in
the third embodiment, so this will not be repeated in connection
with this fourth embodiment.
[0180] As indicated above, as the volume of the texture material
122a decreases, the flexible container 240 collapses, with the
propellant 124a expanding in the propellant chamber 120a.
VII. Fifth Embodiment
[0181] Referring now to FIG. 13 of the drawing, depicted therein at
320a is a spray texturing device constructed in accordance with of,
and embodying, the principles of a fifth embodiment of the present
invention. This device 320a is adapted to contain and dispense a
hardenable material 322. The hardenable material 322 comprises a
commercially available ceiling texture material 324 containing
polystyrene particles 326.
[0182] The aerosol device 320a basically comprises a container 328,
a cap 330, and a collection tube 332. The cap 330 mounts the
collection tube 332 within an opening 334 in the container 328 such
that a first end 336 of the collection tube 332 is within the
container 328 and a second end 338 of the collection tube 332
extends out of the container 328. The hardenable material 322 is
contained within a chamber 340 defined by the container 328. The
collection tube first end 336 extends into the hardenable material
322.
[0183] A port 342 is formed in the container 328 to allow
pressurized air to be introduced into the chamber 340. When the
container 328 is in the upright position shown in FIG. 13, the
introduction of pressurized air through the port 342 into the
chamber 340 forces the hardenable material 322 into the collection
tube first end 336, through the collection tube 332, and out of the
collection tube second end 338. Accordingly, the aerosol device
320a in its most basic form employs a compressed inert gas such as
air to force a hardenable material containing particulates upwardly
out of the container 328.
VIII. Sixth Embodiment
[0184] Referring now to FIG. 14, depicted therein at 320b is sixth
embodiment of an aerosol device constructed in accordance with, and
embodying, the present invention. The aerosol device 320b is
constructed and operates in the same basic manner as the device
320a above. However, the device 320b further comprises a manifold
344 at which a vapor tap tube 346 is connected to the dispensing
tube 332. Compressed air injected into the tube 346 will mix with
the hardenable material 322 exiting the dispensing tube 322 near
the dispensing tube second end 338 to atomize the hardenable
material 322 as it leaves the tube 332. By vaporizing the
hardenable material 322 as it leaves the dispensing tube 332, the
hardenable material 322 sprays as it leaves the device 320b as is
the tendency with the material 322 as it leaves the aerosol device
320a described above. While a stream of hardenable material 322 can
be used to patch a ceiling, the spray developed by the aerosol
device 320b more evenly and effectively distributes the hardenable
material onto the ceiling. A valve 348 was employed to vary the
amount of air used to atomize the hardenable liquid 322.
IX. Seventh Embodiment
[0185] Referring now to FIGS. 15 and 16, depicted therein is yet
another exemplary aerosol device 320c constructed in accordance
with, and embodying, the principles of a seventh embodiment of the
present invention. Elements of the aerosol device 320c that are the
same as those of the device 320a are assigned the same reference
character and will be described herein only to the extent that they
differ from the corresponding element of the device 320a.
[0186] The aerosol device 320c fundamentally differs from the
devices 320a and 320b described above in that the device 320c
employs a vaporizable liquid 350 to propel the hardenable material
322 from the container 328. The vaporizable liquid 350 can be a
hydrocarbon material as is well known in the art.
[0187] The device 320c further comprises a valve assembly 352 for
allowing the operator to open or close a dispensing passageway 354
through which the hardenable material 322 is discharged.
[0188] When the valve assembly 352 is operated to establish the
discharge passageway 35, the vaporizable material 350 vaporizes and
becomes a gas which collects in an upper portion 356 of the chamber
340. This gas acts on the hardenable material 322 to force this
material through the discharge passageway 354 and out of the
container 328.
[0189] In this case, with a liquid hydrocarbon used as a
propellant, a texture material 354 comprising particles 356 of
material other than polystyrene should be used. The liquid
hydrocarbon will dissolve polystyrene particles. Accordingly, the
particles 356 should be formed of cork or other materials that will
not be dissolved by the liquid hydrocarbons. In this case, the
aerosol device 320c is not optimized for use as a ceiling texture
material dispenser because the particles 356 will either bounce off
of the ceiling or will not adequately match the texture of the
surrounding ceiling.
[0190] The valve assembly 352 is constructed and operates in the
same basic manner as the valve section 138 described above with
reference to FIG. 6 and will be described herein only briefly. The
valve assembly 352 basically comprises a housing 362, a valve seat
364, and a valve member 366 having a valve stem 368.
[0191] The discharge tube 332 is connected to the valve housing
362. The valve assembly 352 is opened by downwardly pressing the
valve stem 368. When the valve is so opened, the discharge
passageway 354 is defined by the discharge tube 332, valve housing
362, and valve member 366.
X. Eighth Embodiment
[0192] Referring now to FIG. 17, depicted at 320d therein an eighth
embodiment of an aerosol device constructed in accordance with, and
embodying, the principles of the present invention. The aerosol
device 320d is constructed in a manner basically similar to that of
the device 320a described above. Components of the device 320d that
are the same as those of the device 320a described above will be
assigned the same reference character and described below only to
the extent necessary for a complete understanding of the operation
of the device 320d.
[0193] The aerosol device 320d comprises a piston member 370
arranged within the container 328 such that the chamber 340 is
divided into a first portion 372 and a second portion 374. The
hardenable material 322 including the ceiling texture material 324
comprising polystyrene particles 326 is arranged in the first
portion 372 of the chamber 340. The chamber second portion 374
contains a propellant material such as a vaporizable hydrocarbon
liquid or a compressed inert gas such as air or nitrogen.
[0194] A valve assembly 378 is mounted to the cap 330 within the
opening 334 in the canister 328. This valve assembly 378 comprises
a valve seat 380 and a valve member 382 having a valve stem 384.
Depressing the valve stem 384 downwardly allows the hardenable
material 324 within the chamber first portion 372 to flow through
an exit passageway 386 to the exterior of the container 328. The
discharge passageway 386 is defined by the valve member 382. When
the valve assembly 378 is opened, the propellant material 376 in
the chamber second portion 374 is allowed to expand. As it expands,
the propellant material 376 acts on the piston member 370 to force
the hardenable material 324 out of the canister 328.
[0195] The piston member 370 thus separates the hardenable material
324 from the propellant material 376, allowing the use of liquid
hydrocarbons as a propellant material. However, it should be
recognized that a perfectly fluid-tight seal around the perimeter
of the piston member 370 cannot be maintained; thus, over time, the
propellant material 376 may seep into the chamber first portion 372
and, if the propellant material 376 is a liquid hydrocarbon and the
particles 326 are polystyrene, dissolve these particles 326.
XI. Dispersion Means
[0196] With conventional texture material without polystyrene
particles, the liquid propellants used gassify as the exit the
aerosol device with the texture material; the gassifying liquid
propellant causes the texture material to exit the aerosol device
in the form of a conical spray rather than a stream.
[0197] Because the acoustic texture material dispensed by any of
the various dispensing assemblies described herein uses compressed
inert gas as a propellant rather than a conventional liquid
propellant, the texture material is not broken up into a spray and
thus tends to exit the aerosol device in a stream rather than a
spray.
[0198] Accordingly, dispersion means are preferably employed to
disperse the texture material as it exits the aerosol device such
that the texture material exits in a fan-shaped or conical spray.
Dispersion means such as are depicted in FIGS. 18-31 and as
described below may be used with any of the dispensing assemblies
or aerosol devices described herein to prevent the acoustic texture
material from being deposited in the form of a narrow stream.
[0199] Referring to FIGS. 18 and 19, depicted therein at 420a is an
exemplary dispersion assembly constructed in accordance with, and
embodying, the principles of the present invention. Referring
initially to FIG. 19, depicted at 422 is a hollow tube
corresponding either to a second end of a discharge tube such as
the discharge tube 322 shown and described in relation to FIGS. 13
and 14, or a stem portion of a valve assembly such as the valve
assembly 352 and 378 described and shown in FIGS. 16 and 17. This
hollow tube 422 defines a discharge axis A shown by broken lines in
FIG. 19.
[0200] The dispersion assembly 420a is mounted on this tube 422.
The dispersion assembly 420a comprises a mounting member 424 and a
deflecting member 426. A discharge opening 428 is formed in the
mounting member 424.
[0201] The mounting member 424 is attached to the tube 422 such
that the discharge opening 428 is aligned with a discharge
passageway 430 defined by the tube 422. The discharge opening 428
comprises a cylindrical upper portion 432 and a frustoconical lower
portion 434. The lower portion 434 reduces the diameter of the
discharge passageway 430 from the inner diameter of the tubular
member 422 to the diameter of the opening upper portion 432. The
discharge opening 428 thus forms a nozzle that accelerates the
hardenable material flowing along the discharge passageway.
[0202] The deflection member 426 is generally hook-shaped and
connected to the attachment member such that a portion 436 thereof
coincides with the discharge axis A.
[0203] Accordingly, as the hardenable material passes through the
discharge opening 428, it contacts the deflection member 426 such
that at least a portion of the hardenable material has a vector
component that radially extends outward from the discharge axis
A.
[0204] The dispersion assembly 420a thus causes the hardenable
material to form a spray rather than a stream. This makes it easier
for the user to apply hardenable material to a surface in an even
pattern.
[0205] Handles 425 are formed on the attachment member 424 to allow
the user to displace the tubular member 422 downwardly along the
discharge access A.
[0206] Referring now to FIGS. 20-22, depicted at 420b therein is
yet another exemplary dispersion assembly constructed in accordance
with, and embodying, the principles of the present invention. The
dispersion assembly 420b is constructed and operates in the same
basic manner as the dispersion assembly 420a described above;
accordingly, the dispersion assembly 420b will be described herein
only to the extent that it differs from the dispersion assembly
420a.
[0207] The dispersion assembly 420b comprises a deflection member
438 extending from the attachment member 424 above the discharge
opening 428. The deflecting member 438 has a deflecting surface 440
formed thereon. The deflecting surface 440 is arranged such that it
intersects the discharge axis A. Accordingly, as hardenable
material flows along this axis A, the material will contact this
deflecting surface 440. After it has been so deflected, at least a
portion of the hardenable material will have a vector component in
a direction radially extending from the discharge axis A. As with
the dispersion assembly 420a described above, the dispersion
assembly 420b will thus generate a spray of hardenable material
that facilitates the application of this material on the surface to
be textures.
[0208] FIGS. 23 and 24 depict an exemplary dispersion unit 420c
that is constructed in accordance with, and embodies, the
principles of the present invention. This dispersion unit 420c
operates in the same basic manner as the dispersion assembly 420a
and will be described herein only to the extent that it differs
therefrom.
[0209] The dispersion unit 420c comprises a dispersion member 424.
The dispersion member 424 has formed therein a nozzle passageway
442 comprising a vertical portion 444 aligned with the discharge
access A and a radial portion 446 arranged at an angle to the
discharge access A. A dispersion surface 448 is arranged at the end
of the vertical portion 444 and forms a part of the radial portion
446. As the hardenable material flows along the discharge access A,
it will be redirected such that it has a vector component radially
extending from the discharge access A.
[0210] The radial passageway 446 is further defined by a lower
surface 450. As shown in FIG. 24, the deflecting surface 448
terminates approximately midway along the bottom surface 450.
[0211] In FIG. 25, there is depicted yet another exemplary
dispersion member 420d constructed in the same basic manner as the
dispersion member 420c described above. In the dispersion member
420d, the radial passageway 446 is defined by divergent sidewalls
452 and 454. These diverging sidewalls 452 and 454 allow the
hardenable material to fan out as it exits the discharge opening
428.
[0212] In FIGS. 26 and 27, there is depicted yet another exemplary
dispersion member 420e constructed in the same basic manner as the
dispersion member 420d described above. The dispersion member 420e
further comprises a deflecting member 456 arranged to partially
cover the discharge opening 428. The deflecting member 456 is
generally triangular in shape, with a point being formed
substantially equidistant between the diverging sidewalls 452 and
454 defining the radial passageway 446. Configured as just
described, the deflecting member 456 deflects at least a portion of
the hardenable material coming out of the discharge opening 428
such that at least a portion of the hardenable material has a
vector component that radially extends from an access B of the
radial passageway 446. This results in a wider dispersal of
hardenable material throughout the spray pattern formed by the
dispersion member 424.
[0213] Referring now to FIGS. 28 and 29, depicted at 420f therein
is yet another exemplary dispersion member constructed in
accordance with, and embodying, the principles of the present
invention. The dispersion member 420f operates in a manner similar
to the dispersion assembly 420b described above.
[0214] In particular, a dispersion member 458 is arranged adjacent
to the upper portion 432 of the discharge opening 428. In the
discharge member 420f, the exit opening 428 is rectangular in shape
and the deflecting member 458 is arranged with a deflecting surface
464 formed thereon arranged to deflect all of the hardenable
material exiting through the discharge opening 428. However, the
deflecting surface 464 does not overhang an upper surface 466 of
the dispersion member 424f; accordingly, the hardenable material is
not channeled in a direction radial to the discharge access A and
is allowed to develop into a spray that facilitates application of
the hardenable material to the surface to be covered.
[0215] Referring now to FIGS. 30 and 31, depicted therein at 420g
is yet another exemplary dispersion member constructed in
accordance with, and embodying, the principles of the present
invention. This dispersion member 420g defines a passageway 468
comprising a short vertical portion 470 and a fan-shaped radial
portion 472. The radial portion 472 has diverging sidewalls 474 and
476 and parallel upper and lower walls 478 and 480. Extending
between the upper and lower walls 478 and 480 are a plurality of
deflecting member 482 designed to deflect and slow down at least a
portion of the hardenable material exiting through the discharge
opening 428. The fan-shaped arrangement of the radial passageway
472 along with the deflecting member 482 results in a spray of
hardenable material that facilitates the application of this
material onto a surface.
XII. Ninth Embodiment
[0216] Referring now to FIG. 32a, depicted at 500 therein is a
ninth embodiment of a dispensing system constructed in accordance
with, and embodying, the principles of the present invention. In
addition to a fluid portion as generally described above, the
dispensing system 500 includes a mechanical portion 502 that allows
the acoustic texture material of the fluid portion to be dispensed
in predetermined metered amounts.
[0217] The mechanical portion 502 comprises a container assembly
504, a valve assembly 506, an actuator member 508, and a metering
assembly 510.
[0218] A container assembly 504 comprises a container 512, a cap
514, and a mounting flange 516.
[0219] The valve assembly 506 comprises a valve housing 518, a
valve stem 520, a valve spring 522, and a valve seal 524.
[0220] The metering assembly 510 comprises a metering member 526
and a plurality of guide flanges 528 extending from the valve
housing 518.
[0221] The actuator member 508 is attached to the valve stem 520 by
threads, adhesives, or the like. The actuator member is configured
such that the user can depress downwardly on the actuator member
508 and cause the valve stem 520 to move downwardly along a
longitudinal axis x of the mechanical portion 502.
[0222] The cap 514 and mounting flange 516 are attached to the
container 512 in a conventional manner. The valve housing 518 is
attached to the mounting flange 516 such that the valve housing 518
resides within the container 512. The valve housing 518 is
connected to a pick-up tube such as the tube 46 described above,
which creates a fluid path from the bottom of the container 512 to
the valve housing 518 as will be described in further detail
below.
[0223] The valve seal 524 is mounted to the cap 514, and the valve
stem 520 is mounted to the valve seal 524 such that the valve stem
520 moves along the axis x as generally described above. The valve
spring 522 is arranged to oppose motion of the valve stem 520
downward along the axis x.
[0224] The metering member 526 is an annular or ring shaped member
that is arranged about a lower portion of the valve stem 520
between a stem portion 520a of the valve stem 520 and the valve
seal 524. A release flange 530 extends from an upper portion of the
metering member 526.
[0225] A release projection 532 is formed on a lower inner portion
of the metering member 526. A similarly shaped release groove 534
is formed about the valve stem 520 adjacent to the stem portion
520a. The release projection 532 is designed to engage the release
groove 534, but can be disengaged therefrom by deliberate
application of manual force that tends to move the metering member
526 away from the stem portion 520a.
[0226] The metering member 526 further defines a metering surface
536 that has substantially the same cross-sectional area as an
outer surface of the stem member 520.
[0227] Referring again to FIG. 32A, the mechanical portion 502 is
shown in what will be referred to as a storage state. In the
storage state, the metering member 526 engages the valve seal 524
to prevent fluid from exiting the container 512 through the valve
assembly 506.
[0228] The propellant within the container 512 acts on the texture
material there within to force the texture material through a
housing inlet 538 in the valve housing 518 and into a housing
chamber 540.
[0229] To dispense texture material from the mechanical portion
502, the actuator member 508 is displaced downwardly along the axis
x such that the metering member 526 disengages from the valve seal
524. When this occurs, pressurized fluid within a housing chamber
540 defined within the valve housing 518 may flow through a stem
inlet 542 in the valve stem 520, into a stem passageway 546 in the
valve stem 520, and out of the mechanical portion 502 through an
outlet chamber 548.
[0230] Because the release projection 532 is engaged with the
release groove 534 to begin with, the metering member 526 moves
downward with is the valve stem 520 creating the dispensing path DP
along which the texture material passes as it exits the container
512. At the point depicted in FIG. 32B, the release flange 530
engages an upper portion of the guide flanges 528 such that the
metering member 526 can no longer move downward along the axis
x.
[0231] Referring now to FIG. 32C, continued displacement of the
actuator member 508 such that the valve stem 520 moves further
downward along the axis x results in the release projection 532
leaving the release groove 534 such that the metering member 526 no
longer moves in tandem with the valve stem 520. The valve stem 520
thus moves relative to the metering member 526 to a point shown in
FIG. 32C in which the stem inlet 542 is completely covered by the
metering surface 536. At this point, texture material is prevented
from flowing from the housing chamber 540 through the stem inlet
542. This effectively stops texture material from flowing out of
the container 512.
[0232] During the downward movement of the stem member 520, the
valve spring 522 is compressed. Accordingly, releasing the actuator
member 508 allows the valve spring 522 to urge the valve stem 520
upward. Friction between the valve stem 520 and the metering
surface 536 causes the metering member 526 to move upward with the
valve stem 520 until the metering member 526 again comes in contact
with the valve seal 524. This configuration is shown in FIG.
32D.
[0233] At this point, the metering member 526 can no longer move
upward with the valve stem 520. The valve spring 522 continues to
move the valve stem 520 upward until the stem portion 520a thereof
engages the metering member 526 as shown in FIG. 32A. At this
point, the release projections 532 engage the release groove 534
such that, if the valve stem 520 again is moved downward, the
metering member 526 will be carried therewith. Accordingly, the
mechanical portion 502 is returned to its predispensing state shown
in FIG. 32A and is ready to be used again.
[0234] The mechanical assembly 502 described above requires no
special skill by the user for dispensing the texture material
within the container 512. The user must simply press downwardly on
the actuator member 508 until the valve stem 520 bottoms out as
shown in FIG. 32C, then releases the actuator member 508. If these
minimal directions are followed, the mechanical portion 502 will
dispense a quantity of texture material that is a function of the
pressure and volume of the inert gas used as a propellant, the
speed at which the stem member 520 is moved downward, the size of
the stem inlet 542, and the amount the stem member 520 is allowed
to travel before its stem inlets 542 are covered by the metering
surface 536. These parameters can be adjusted so that a reasonably
consistent amount of texture material is dispensed by even an
inexperienced user.
XIII. Tenth Embodiment
[0235] Referring now to FIGS. 33A-D, depicted therein at 550 is a
tenth embodiment of a dispensing system constructed in accordance
with, and embodying, the principles of the present invention. This
dispensing system 550 comprises a fluid portion as described above,
and a mechanical portion 552. The mechanical portion 552 is
designed to dispense a controlled, metered amount of texture
material.
[0236] In particular, the mechanical portion 552 comprises a
container assembly 554, a valve assembly 556, an outlet assembly
558, and a metering assembly 560. A container assembly 554 is
adapted to contain the fluid portion as described above. The valve
assembly 556 is mounted on the container assembly 554 and operates
in a closed configuration in which fluid may not exit the container
assembly 554 and an open configuration in which fluid is allowed to
exit the container assembly 554. The outlet assembly 558 disperses
the texture material exiting the container assembly 554 through the
valve assembly 556. The metering assembly 560 engages the valve
assembly 556 to control the opening and closing of the valve
assembly such that only a limited amount of texture material is
released when the valve assembly is used as intended.
[0237] The container assembly 554 comprises a container 562 and a
cap 564 mounted on the container 562 along a longitudinal axis x
thereof.
[0238] The valve assembly 556 comprises a valve housing 566, a
valve stem 568, a valve spring 570, and a valve seal 572. The valve
housing 566 is mounted to the container 562 and cap 564 such that
the interior of the container 562 is divided into two separate
chambers. As with the ninth embodiment discussed above, a pick-up
tube is connected to the valve housing 566 to allow fluid at the
bottom of the container assembly 554 to enter the valve housing
566.
[0239] The valve seal 572 is mounted on the cap 564, and the valve
stem 568 extends through the valve seal 572. The valve seal
prevents fluid from flowing out of the valve housing 566 between
the valve stem 568 and the cap 564.
[0240] The valve spring 570 is mounted between the cap 564 and the
valve stem 568 such that the spring 570 urges the valve stem
upward. When no force is applied to the valve stem 568, the valve
spring 570 urges the valve stem 568 upward such that the valve stem
568 engages the valve seal 572, in which case the valve assembly
556 is in its closed position.
[0241] The outlet assembly 558 comprises an actuator member 574,
and outlet member 576, an outlet cap 578, and an actuator return
spring 580. The outlet member 576 is rigidly attached to the valve
stem 568 by threading and/or adhesives, such that movement of the
outlet member 576 is transferred to the valve stem 568.
[0242] The outlet member extends through the actuator member 574
such that relative movement between the outlet member 576 and the
actuator member 574 is possible.
[0243] The outlet cap 578 is attached to the outlet member 576 to
form a dispersing means as texture material exits the mechanical
portion 552.
[0244] The actuator return spring 580 is arranged between the cap
564 and the actuator member 574 to oppose downward movement of the
actuator member 574.
[0245] The metering assembly 560 comprises a metering member 582
and a release member 584. The metering member 582 is attached to
the outlet member 576. Accordingly, movement of the metering member
582 will be transmitted through the outlet member 576 to the stem
member 568. It should be noted that, in the exemplary dispensing
system 550 described herein, the valve stem 568, outlet member 576,
outlet cap 578, and metering member 582 all form a rigid assembly
and can be made as one piece. For manufacturing reasons, however,
this assembly comprises four separate molded plastic parts in the
exemplary dispensing system 550.
[0246] The release member 584 is fixed relative to the cap 564. In
the exemplary assembly 550, the actuator return spring 580
physically engages the release member 584 at its lower end and thus
holds the release member 584 against the cap 564. Again, this is
convenient for manufacturing purposes, but the cap 564 and release
member 584 could conceivably be formed by one integrally formed
part.
[0247] Formed on the actuator member 574 is an actuator surface
586. Extending from the metering member 582 are metering
projections 588. These projections 588 are canted outwardly from
the longitudinal axis x, but are sized, dimensioned, and made of a
material that allows these projections 588 to deflect inwardly
towards the axis x.
[0248] Formed on the release member 584 is a release surface 590.
The release surface 590 is spaced directly below the actuator
surface 586.
[0249] FIG. 33A shows the mechanical portion 552 in a predispensing
state in which the valve assembly 556 is closed. Applying a
downward force on the actuator member 574 causes the actuator
surface 586 to engage the metering projections 588 and force the
valve stem 568 downward as perhaps best shown in FIG. 33B. When the
valve stem 568 moves downward, it disengages from the valve seal
572 and forms a dispensing path DP. This dispensing path DP allows
pressurized texture material within the valve housing 566 to enter
a stem inlet 592 formed in the valve stem 568, flow through a stem
passageway formed in the valve stem 568, and enter an outlet
chamber 596 defined by the outlet member 576 and outlet cap 578.
The outlet chamber 596 is in communication with the exterior of the
container 562 through an outlet opening 598 defined by the outlet
cap 578. The outlet opening 598 is sized and dimensioned to
disperse the texture material as it leaves the mechanical portion
552.
[0250] As shown in FIG. 33B, as the valve stem 568 moves downward,
it carries the metering projections 588 with it such that these
projections 588 come in contact with the release surface 590 on the
release member 584.
[0251] Referring now to FIG. 33C, it can be seen that continued
downward movement of the valve stem 568 causes the release surface
590 to displace the metering fingers 588 towards the longitudinal
axis x such that these fingers 588 are disengaged from the actuator
surface 586. At this point, the actuator surface 586 comes into
contact with the release surface 590.
[0252] As the valve stem 568 moves downward, it compresses the
valve spring 570. Accordingly, when the metering fingers 588 become
disengaged with the actuator surface 586, the valve spring 570
urges the valve stem 568 upward. The metering projections 588 slide
along the actuator member 574 as shown in FIG. 33D and allow the
valve spring 570 to force the valve stem 568 back into its
original, uppermost position in which it engages the valve seal 572
to prevent fluid from flowing out of the container 562.
[0253] During this process, the actuator member 574 has compressed
the actuator member return spring 580. Accordingly, the user need
only release the actuator member 574, and the actuator return
spring 580 will force the actuator member 574 up relative to the
valve stem 568 and metering member 582. The actuator member 574
thus returns to its initial position in which the actuator surface
586 is located above the metering projections 588. The metering
projections 588 are thus allowed to return to their original
position in which they are more severely canted outwardly relative
to the longitudinal axis x. The mechanical portion 552 is thus
ready to dispense another metered portion of texture material.
[0254] As with the ninth embodiment discussed above, the dispensing
system 550 of the tenth embodiment allows the user to press firmly
and continuously down to dispense a limited, controlled, and
metered amount of texture material.
[0255] The amount of texture material released is determined by the
same factors discussed above with reference to the ninth
embodiment.
XIV. Eleventh Embodiment
[0256] Referring now to FIGS. 34-37, depicted therein at 600 is a
eleventh embodiment of the dispensing system constructed in
accordance with, and embodying, the principles of the present
invention. The dispensing system 600 comprises a fluid portion as
described above and a mechanical portion 602, a portion of which is
depicted in the drawing.
[0257] The mechanical portion 602 comprises a container assembly
604, a valve assembly 606, an outlet assembly 608, and a metering
assembly 610.
[0258] The valve assembly 606 is mounted on the container assembly
and operable in open and close configurations. When the valve
assembly 606 is in its closed configuration, fluid is prevented
from leaving the container assembly 604. The outlet assembly 608 is
mounted onto the valve assembly 606 such that, when the valve
assembly 606 is in its open configuration fluid, and in particular
acoustic texture material, is allowed to flow out of the container
assembly 604 through the outlet assembly 608.
[0259] The metering assembly 610 controls the valve assembly 606
such that a predetermined, metered amount of texture material is
dispensed.
[0260] The container assembly 604 comprises a container 612 and a
cap 614. The valve assembly 606 comprises a valve housing 616, a
valve stem 618, a valve spring 620, and a valve seal 622. The cap
614 is mounted on the container 612 and the valve seal 622 is
mounted on the cap 614. The valve stem 618 extends through the
valve seal 622. The valve seal 622 is made of a resilient material
that engages the cap 614 and the valve stem 618 such that fluid is
not able to flow out of the container 612 between the cap 614 and
the valve stem 618.
[0261] The valve housing 616 is mounted to the container assembly
604 such that it is within the container 612 below the cap 614. As
with the valve housings of the ninth and tenth embodiments
described above, the valve housing 616 is connected to a pick-up
tube that extends to the bottom of the container 612. As generally
discussed above, the pressurized propellant material is located at
the top of the container 612 and the texture material at the bottom
of the container 612. Accordingly, the pressurized propellant
material forces the texture material through the pick-up tube such
that pressurized texture material is present in the valve housing
616.
[0262] The valve spring 620 is arranged between the cap 614 and the
valve stem 618 such that the valve spring 620 urges the valve stem
618 upward such that the valve assembly 606 is normally biased into
its closed position. When the valve assembly 606 is in its closed
position, the valve stem 618 engages the valve seal 622 as shown in
FIG. 34A.
[0263] The outlet assembly 608 comprises an actuator member 624,
and outlet member 626, and an actuator return spring 628. The
outlet member 626 is rigidly attached to the valve stem 618 by
threads, adhesive, or the like such that movement of the outlet
member 626 causes movement of the valve stem 618. The actuator
member 624 is free to move relative to the valve stem 618 and
outlet member 626, with the outlet member 626 extending through the
actuator member 624. The actuator return spring 628 is arranged to
urge the actuator member 624 upward; when the actuator member 624
is moved downward, the actuator return spring 628 is
compressed.
[0264] The metering assembly 610 comprises a trigger assembly 630
and a release assembly 632. The trigger assembly 630 comprises a
trigger member 634 and a trigger spring 636. The release assembly
632 comprises a release member 638 configured as will be described
below.
[0265] The trigger member 634 comprises a plurality of guide
fingers 640, a plurality of trigger fingers 642, and a plurality of
release fingers 644 that extend downwardly from a trigger plate
646. The guide finger 640 and trigger finger 642 are shown in FIG.
34 and in the horizontal section view of FIG. 36. The release
fingers 644 are shown in FIG. 35 as well as in the horizontal
section view of FIG. 36. The exemplary mechanical portion 602
comprises three each of these guide fingers 640, trigger finger
642, and release finger 644. More or fewer of these fingers 640-644
may be used, but the use of three each represents a desirable blend
of balance during operation and manufacturability.
[0266] As shown in FIGS. 34, 35, and 37, an intermediate flange 648
is formed on the outlet member 626.
[0267] The release member 638 comprises a guide cylinder 650, a
plurality of support posts 652, and a plurality of release posts
653 that extend upwardly from a base plate 654. The base plate 654
is configured to snugly be received within the cap 614. The guide
cylinder 650 extends upwardly a distance slightly greater than the
height of the support posts 652 and release posts 653.
[0268] An actuator surface 656 is formed on the actuator member
624. As shown in FIG. 34, a trigger surface 658 is formed on each
of the trigger fingers 642. FIG. 35 shows that a cam surface 660 is
formed on each of the release fingers 644. And in FIG. 34, it can
be seen that a support surface 662 and release surface 664 are
formed on each of the support posts 652.
[0269] The actuator member 624 comprises first and second bearing
surfaces 666 and 668 and an actuator cylinder 670.
[0270] The metering assembly 610 is assembled together with the
container assembly 604, valve assembly 606, and outlet assembly 608
as follows. After the valve assembly 606 has been mounted onto the
container assembly 604 and the outlet member 626 attached to the
stem member 618 as described above, the release member 638 is
displaced such that the base plate 654 thereof is snugly received
by the cap 614 such that the guide cylinder 650 is aligned with the
axis x. At this point, the intermediate flange 648 will rest on the
support surfaces 662 on the support posts 652. The trigger spring
636 is then placed over the outlet member 626 such that spring 636
is supported at its lower end by the intermediate plate 648. The
trigger member 634 is then placed over the outlet member 626 such
that the trigger spring 636 is arranged between the trigger plate
646 and the intermediate plate 648. Importantly, the trigger
fingers 642 must be aligned with the support posts 652 and the
release finger 644 must be aligned with the release posts 653.
[0271] The first bearing surface 666 defines a hole in the trigger
plate 646 through which the outlet member 626 passes. In addition,
the first bearing surface 666 engages the guide member 626 and the
second bearing surfaces 668 on the guide fingers 640 engage the
intermediate flange 648 such that the trigger member 634 also can
move only along the longitudinal axis x.
[0272] The actuator return spring 628 is then placed around the
trigger member 634 until it rests on the base plate 654 of the
release member 638. The outlet member 624 is then placed over the
trigger member 634 such that the actuator cylinder 670 engages the
guide cylinder 650 such that the actuator member 624 moves only
along the system axis x. In this configuration, the actuator return
spring 628 opposes downward motion of the actuator member 624 as
generally discussed above.
[0273] The purpose of the metering assembly 610 is generally to
allow the user to pull down on the actuator member 624 and initiate
a sequence of events that open and close the valve assembly 606
substantially independent from the actions of the user. In
particular, in the ninth and tenth embodiments it would be possible
for the user to pull down on the actuator member halfway and place
the valve assembly in a state in which texture material may freely
flow out of the container assembly. In those ninth and tenth
embodiments, the valve assembly will automatically be closed only
if the user pulls the actuator member down past a predetermined
point.
[0274] In this eleventh embodiment described in FIGS. 34-37, the
trigger assembly 630 controls the opening of the valve assembly 606
while the release assembly 632 controls the closing of the valve
assembly 606. The user merely energizes the metering assembly 610
by compressing various springs and then triggers the automatic
sequence of events that opens and closes the valve assembly 606.
The user is thus prevent from placing the valve assembly 606 in an
intermediate configuration in which texture material is allowed to
freely flow from inside the container assembly 604.
[0275] The sequence of events initiated by the user's pulling of
the actuator member 624 will now be described with reference to
FIGS. 34A-G and 35A-G.
[0276] In FIGS. 34A and 35A, the mechanical portion 602 is shown in
its predispensing state in which the actuator member 624 is in its
uppermost position and the valve assembly 606 is closed. The user
then applies a downward force on the actuator member 624 as shown
by arrows in FIGS. 34B and 35B. As shown best in FIG. 35B, the
actuator surface 656 engages the trigger member 634 such that the
trigger member 634 moves down with the actuator member 624. The
mechanical portion 602 is in a pretriggering state in FIGS. 34B and
35B in which the actuator return spring 628 and trigger spring 636
are both compressed. At this point, the valve spring 620 is not
compressed and the valve assembly 606 is still in its closed
configuration. Then, as shown in FIGS. 34C and 35C, the trigger
surfaces 658 on the trigger fingers 642 engage the release surfaces
664 on the support posts 652. The trigger fingers 642 are supported
by the intermediate plate 648 at this point, so the interaction of
the trigger surfaces 658 with the release surfaces 664 causes the
support posts 652 to deflect slightly away from the system axis x.
The situation depicted in FIGS. 34C and 35C will be referred to as
the triggering state.
[0277] Referring now to FIGS. 34D and 35D, when the support posts
652 deflect far enough outward, the support surface 662 is removed
from underneath the intermediate flange 648. At this point, the
trigger spring 636, which is fully compressed in the pretriggering
state, and which also is stronger than the valve spring 620,
expands, forcing the intermediate plate 648 downward and
compressing the valve spring 620. This state is shown in FIGS. 34D
and 35D and will be referred to as the open state.
[0278] In this open state, the valve assembly has been placed in
its open configuration, and fluid is free to flow into a stem inlet
672 and through a stem passageway 674 formed in the valve stem 618.
Fluid then flows into an outlet chamber 676 formed in the outlet
member 626 and subsequently out of the mechanical portion 602. A
dispensing path DP is thus formed.
[0279] Referring now to FIG. 35D, it can be seen that the release
posts 653 begin to engage the cam surfaces 660 when the mechanical
portion 602 is in this open state.
[0280] When the trigger spring 636 forces the intermediate flange
648 downward to open the valve assembly 606, resistance to downward
movement of the actuator member 624 is substantially decreased.
Accordingly, the user who is applying a downward force on the
actuator member will quickly move the actuator member into the
position shown in FIGS. 34E and 35E. The state shown in FIGS. 34E
and 35E will be referred to as the release state. In this release
state, the release posts 653 have acted on the cam surfaces 660 to
deflect the release fingers 644 inwardly towards the system axis x.
The actuator surface 656 no longer engages the trigger member 634.
At this point, the valve spring 620 is fully compressed and will
exert a fairly strong upward force on the valve stem 618. Because
the trigger member 634 has been released from the actuator surface
656, nothing opposes upward motion of the valve stem 618.
Accordingly, the valve spring 620 forces the valve stem 618, and
thus the intermediate flange 648 upward until the valve stem again
engages the valve seal 622 to place the valve assembly 606 in its
closed configuration. This is shown in FIGS. 34F and 35F and will
be referred to as the released state.
[0281] As the intermediate flange 648 moves up with the valve stem
618, it will force the trigger member 634 up through the trigger
spring 620.
[0282] The operator then releases the actuator member 624. As
described above, the downward motion of the actuator member 624 has
compressed the actuator return spring 628, so, when the actuator
member 624 is released, the actuator return spring 628 forces the
actuator member back up to its uppermost position as shown in FIGS.
34G and 35G. At this point, the release fingers 644 are free to
spring back into their nondeformed state as perhaps best shown in
FIG. 35G. And as shown in FIG. 34G, the support posts 652 spring
back to their original configuration with the support surfaces 62
again supporting the intermediate flange 648. The mechanical
assembly 602 thus returns to its predispensing state as shown in
FIGS. 34A and 35A. As described above, the user need only energize
this system by compressing various springs and trigger the system
by moving the actuator member 624 passed a predetermined point.
Once these actions have taken place, the metering assembly 610
automatically opens and closes the valve assembly 606 such that
only a predetermined amount of texture material is allowed to flow
out along the dispensing path DP. Again, the amount of texture
material released during the short period of time that the valve
assembly is opened is determined by various factors such as the
initial pressure of the propellant material, and volume of the
propellant material, the amount that the valve stem moves when it
is placed into its open position, the sizes of the various orifices
and restrictions involved in forming the dispensing path DP, the
relative sizes of the trigger spring 636 and the valve spring 620,
and the exact physical locations of the actuator surface 656,
trigger 658, cam surface 660, support surface 662, release surface
664, and release post 653.
XV. Twelfth Embodiment
[0283] Referring now to FIG. 38, depicted at 700 therein is a
twelfth embodiment of a dispensing system constructed in accordance
with, and embodying, the principles of the present invention. This
twelfth embodiment includes a fluid portion as described above and
a mechanical portion 702 for dispensing acoustic texture material
forming part of the fluid portion.
[0284] The mechanical portion 702 comprises a container assembly
704, a valve assembly 706, an actuator assembly 708, and a metering
member 710.
[0285] The container assembly 704 comprises a container 712 and a
cap 714. The valve assembly 706 comprises a valve housing 716, a
valve stem 718, a valve spring 720, and a valve seal 722.
[0286] The cap 714 and valve housing 716 are attached to the
container 712. The valve seal 722 is mounted to the cap 714, and
the valve stem 718 passes through the valve seal 722. The valve
spring 720 is arranged between the cap 714 and the valve stem 718
to bias the valve stem 718 upward such that the valve assembly 706
is normally in a closed configuration.
[0287] The actuator assembly 708 comprises an outlet cap 726 and an
actuator member 728. The actuator member 728 is rigidly connected
to the valve stem 718, and the outlet cap 726 is rigidly connected
to the actuator member 728.
[0288] The metering member 710 is rigidly connected to the cap 714
around the valve stem 718 immediately below the actuator member
728.
[0289] A stop surface 730 is formed on a bottom portion of the
actuator member 728. A limiting surface 732 is formed on an upper
portion of the metering member 710. The stop surface 730 and
limiting surface 732 both have a generally frustoconical shape. In
the exemplary mechanical portion 702, the surfaces 730 and 732
match each other.
[0290] The valve housing 716 defines a valve chamber 734 within the
container 704. As with the embodiments discussed above, a pick-up
tube is used to allow fluid communication between a bottom portion
of the container 704 and the valve chamber 734. The pressurized
propellant material accumulates at the top of the container 704 and
forces acoustic texture material at the bottom of the container 704
through the pick-up tube and into the valve chamber 734.
Accordingly, pressurized acoustic texture material is present in
the valve chamber 734.
[0291] In use, the actuator member 728 is depressed downward
against the force of the valve spring 720 such that the valve stem
734 disengages from the valve seal 722 and creates a dispensing
path through which texture material may exit the mechanical portion
702. In particular, when the valve stem 718 disengages from the
valve seal 722, texture material within the valve chamber 734 flows
into a stem inlet 736 and a stem passageway 738 in the valve stem
718. The texture material then flows through an outlet chamber 740
defined by the actuator member 728 and outlet cap 726. Finally, the
acoustic texture material exits through an outlet opening 742
formed in the outlet cap 726.
[0292] The metering member 710 performs two basic functions. First,
the stop surface 730 on the actuator member 728 engages the
limiting surface 732 on the metering member 710 to limit the
distance the valve stem 718 travels relative to the valve seal 722.
This effectively restricts the size of the opening through which
the texture material must pass as it exits the mechanical portion
702 and thus assists the user in controlling the amount of texture
material released.
[0293] The interaction of the stop surface 730 with the limiting
surface 732 also prevents cocking of the valve stem 718 relative to
the longitudinal axis of the container 712. This aids the user in
aiming the device while dispensing the texture material.
[0294] The metering member 710 thus assists the user in operating
the valve assembly 706 in a manner that allows the texture material
to be applied properly.
XVI. Thirteenth Embodiment
[0295] Referring now to FIG. 39, depicted at 750 therein is a
thirteenth embodiment of the dispensing system constructed in
accordance with, and embodying, the principles of the present
invention. The dispensing system 750 comprises a fluid portion 752
and a mechanical portion 754.
[0296] In the dispensing system 750, the fluid portion 752 is
initially stored at two locations as indicated by the suffix a and
b. The texture material to be dispensed is shown at 756 along with
air at ambient pressures as indicated at 758. Pressurized
propellant material is stored as shown by the reference character
760.
[0297] The mechanical portion 754 comprises a hopper assembly 762
and a propellant assembly 764.
[0298] The hopper assembly 762 comprises a hopper container 766 and
a hopper seal 768. The propellant assembly 764 comprises a
propellant container 770, a propellant nozzle 772, and an actuator
button 774.
[0299] The propellant assembly 764 is conventional and is adapted
to contain a pressurized, gaseous fluid such as air or nitrogen.
Similar assemblies are used to dispense inert gases such as air and
nitrogen for the purpose of cleaning. For example, a number of
products on the market allow computer and electronics equipment to
be cleaned using a stream of inert gas contained in assemblies such
as the propellant assembly 764. The propellant assembly 764 is
operated by depressing the actuator button 774, which opens an
internal valve (not shown) and allows the pressurized inert fluid
to flow from the propellant container 770 to the propellant nozzle
772.
[0300] The hopper container 766 comprises a hopper portion 776 and
an outlet portion 778. The hopper portion defines a hopper chamber
780. The outlet portion 778 defines an outlet chamber 782, a
portion of which is identified by reference characters 784 as a
mixing area. The mixing area is immediately adjacent to an outlet
opening 786 formed in the outlet portion 778.
[0301] In use, the propellant nozzle 772 extends from the
propellant container 770. The outlet portion 778 of the propellant
container 770 contains a substantial portion of the propellant
nozzle 772. The propellant nozzle 772 defines a nozzle passageway
788 that terminates in a nozzle opening 790. When assembled, the
nozzle opening 790 is located adjacent to the outlet opening 786,
with the mixing area 784 arranged between the nozzle opening 790
and the outlet opening 786. The hopper seal 768 seals the hopper
portion 778 of the hopper container 776 against the outer surface
of the propellant nozzle 772.
[0302] The hopper container 776 contains the acoustic texture
material 756 and the ambient air 758. The propellant assembly 764
contains the propellant material 760.
[0303] In use, the hopper assembly 762 is arranged such that the
hopper portion 760 is above the outlet portion 778. This allows
gravity to feed the texture material 756 into the outlet chamber
782. Texture material in the outlet chamber 782 flows into the
mixing area. When the actuator button 774 is depressed, a stream of
pressurized propellant material flows through the nozzle passageway
788 and out of the nozzle openings 790 where it mixes with the
texture material in the mixing area 784 and subsequently carries a
portion of the texture material out of the outlet opening 786.
[0304] The propellant assembly 764 further comprises an outlet cap
792 from which the propellant nozzle 772 extends. It would be
possible to incorporate the functions of the propellant nozzle 772
and the outlet portion 778 of the hopper container 766 into the
outlet cap 792.
XVII. Fourteenth Embodiment
[0305] Referring now to FIGS. 40-42, depicted therein at 800 is a
fourteenth embodiment of the dispensing system constructed in
accordance with, and embodying, the principles of the present
invention. The dispensing system 800 comprises a mechanical portion
802 and a fluid portion as discussed above.
[0306] The mechanical portion 802 comprises a container assembly
804, a valve assembly 806, an outlet assembly 808, and a metering
assembly 810.
[0307] The container assembly 804 comprises a container 812 on
which is sealingly mounted a cap 814.
[0308] The valve assembly 806 comprises a valve housing 816, a
valve stem 818, a valve spring 820, and a valve seal 822. As in the
ninth through twelfth embodiments discussed above, the valve
housing 816 is mounted within the container 812 and pressurized
acoustic texture material is located within the valve housing 816.
The valve seal 822 is mounted onto the cap 814 and in turn mounts
the valve stem 818 to the cap 814 in a manner that allows the stem
818 to move up and down relative to the container 812. The valve
spring 820 resists downward movement of the valve stem 818.
[0309] The valve assembly 806 is shown in its closed configuration
in FIG. 40, and pressurized texture material is not allowed to flow
out of the mechanical portion 802.
[0310] The outlet assembly 808 comprises an outlet member fixedly
attached to the valve stem 818, and a valve cap 826.
[0311] The metering assembly 808 comprises a torsion member 828 and
a base member 830. The torsion member comprises a torsion bar
portion 832, actuator fingers 834, and trigger projections 836. The
base member 830 comprises a mounting flange 838 and bar supports
840.
[0312] The base member 830 is assembled on to the cap 814 using the
mounting flange 838. The base member 830 is thus secured relative
to the container 812. The bar supports 840 extend upwardly and
support both ends of the torsion bar portion 832 of the torsion
member 828.
[0313] The base member 830 further defines a trigger surface 842
and first and second release surfaces 844 (FIG. 42). In addition,
trigger ledges 846 are formed on either side of the outlet member
824 as perhaps best shown in FIG. 41. In addition, release edges
848 are formed on the trigger projections 836. A trigger surface
849 (FIG. 40) is formed on the actuator fingers 834.
[0314] When the mechanical portion 802 is in its predispensing
state as shown in FIG. 40, the actuator fingers 834 are canted
upwardly and the trigger projections 836 rest on the release ledges
846 and trigger surface 842. Pushing downward on the actuator
fingers 834 as shown by the arrow in FIG. 40 displaces the actuator
fingers 834 downward. Because the trigger projections 836 are
supported by the trigger surface 842, the trigger projections 836
initially cannot move. This creates torsion in the torsion bar
portion 832 of the torsion member 828. As the actuator fingers 834
move down further, the trigger surfaces 849 act on the base member
830 and displace the trigger surface away from the torsion bar
portion 832 until at some point the trigger surface 842 no longer
supports the trigger projections 836. At this point, the torsion
built up in the torsion bar portion 832 causes the trigger
projections 836 to snap downwardly. Because these trigger
projections 836 rest on the trigger ledges 846, the downward
movement of the trigger projections 836 is transferred to the
outlet member 824 and thus the valve stem 818. As the valve stem
818 moves downward, it disengages from the valve seal 822 and
allows texture material to flow out of the mechanical portion
802.
[0315] As the trigger projections descend, the release edges 848
thereon engage the release surfaces 844 formed on the base member
830. These release surfaces 844 are slanted in a manner that causes
the trigger projections to separate from each other as they move
down after contacting the release surfaces 844.
[0316] As the trigger projections separate from each other, they
disengage from the trigger ledges 846 formed on the outlet member
824 such that the trigger projections no longer hold the valve stem
818 down against the valve spring 820. The valve spring 820 is thus
free to return the valve stem 818 back to its original position in
which the valve assembly 806 is closed. The user then simply
releases the actuator fingers 834, and the torsion bar portion 832
of the torsion member 824 snaps the actuator fingers 834 and
trigger projections 836 back up to the original position as shown
in FIG. 40.
[0317] The dispensing system 800 thus allows the user to determine
when a portion of acoustic texture material is released from the
mechanical portion 802, but the metering assembly 810 opens and
closes the valve assembly 806 in a predetermined sequence that
determines the amount of texture material that is released. Again,
the exact amount of texture material that is released depends on a
number of factors that may be adjusted given the circumstances.
XVIII. Fifteenth Embodiment
[0318] Referring now to FIGS. 43-45, depicted therein at 850 is a
fifteenth embodiment of a dispensing system constructed in
accordance with, and embodying, the principles of the present
invention. The dispensing system 850 comprises a fluid portion as
generally described above with reference to FIG. 1 and a mechanical
portion 852. The mechanical portion 852 comprises a container
assembly 854, a valve assembly 856, an outlet assembly 858, and a
metering assembly 860.
[0319] The valve assembly 856 comprises a valve stem 862, a valve
seal 864, and a valve spring 856. The valve assembly 856 works in
the same basic manner as the valve assemblies as a number of other
embodiments disclosed herein and will not be described in
detail.
[0320] The outlet assembly 858 comprises an outlet member 868 and
is also constructed and operates in the same manner as various
outlet assemblies described above.
[0321] The metering assembly 860 comprises a base member 870, a
gear member 872, and a yoke member 874.
[0322] The base member 870 comprises a mounting flange 878 that
allows the base member to be adapted onto the container assembly
854. The base member 870 further comprises gear supports 880 and
actuator supports 882. The gear members 872 comprise gear portions
884, a yoke housing 886, and an axle portion 888. The axle portion
888 engages the gear supports 880 such that the gear members 872
are mounted on either side of the outlet member 868 with the yoke
housing 886 facing in and the gear portions 884 facing out.
[0323] The actuator member 876 comprises a pair of actuator racks
890 and a pair of finger projections 892. The actuator member is
mounted on the actuator supports 882 such that the actuator racks
890 are aligned with the gear portions 884. The finger projections
892 extend on either side of the outlet member 868 on the opposite
side of the actuator supports 882.
[0324] During use, the user presses downward on the finger
projections 892 such that teeth 890a on the actuator rack 890
engage teeth 884a on the gear portion 884. Accordingly, pushing
down on the finger projections 892 causes the teeth 890a and 884a
to engage each other such that the gear portions 884 rotate about a
trigger axis 896.
[0325] As the gear portions 884 rotate, the housing portions 886
also rotate. These yoke housings define yoke channels 894 that
receive either end of the yoke member 874. Yoke member 874 is in
turn connected to the outlet member 868 such that downward movement
of the yoke member 874 is transmitted to the outlet member 868. The
outlet member 868 is in turn rigidly connected to the valve stem
862. Accordingly, pushing down on the finger projections 892 places
the valve assembly 856 in its open position and allows texture
material to be dispensed through the outlet member 868.
[0326] The gear member 872 is operatively connected to a spring
(not shown) which, when the teeth 890a on the actuator rack 890
rotate the gear member 884 90 degrees, rotates the gear member 884
an additional 90 degrees such that a second set of teeth 884b on
the gear portion 884 engage the teeth 890a on the rack 890. The
spring then resets itself to be ready for the next cycle.
[0327] As the yoke housing 886 rotates through the initial 90
degrees, it drives the yoke member 874 such that the yoke member
opens the valve assembly 856. As the yoke housing 886 moves from 90
degrees to 180 degrees, it allows the valve spring 866 to force the
valve stem 862 back up, thereby closing the valve assembly 856.
[0328] The metering assembly 860 thus opens and closes the valve
assembly 856 in response to pressing of the finger projections 892
to allow a predetermined, limited, amount of acoustic texture
material to be released from the system 850.
XIX. Sixteenth Embodiment
[0329] Referring now to FIGS. 46-48, depicted therein at 900 is a
sixteenth embodiment of a dispensing system constructed in
accordance with, and embodying, the principles of the present
invention. The dispensing system 900 comprises a fluid portion as
described above with reference to FIG. 1 and a mechanical portion
902.
[0330] The mechanical portion 902 comprises a container assembly
904, a valve assembly 906, an outlet assembly 908, and a metering
assembly 910. The valve assembly 906 comprises a valve stem 912 and
a valve spring 914 and operates in the same manner as the valve
assemblies of a number of other embodiments described above. The
outlet assembly 908 comprises an outlet member 916 that similarly
operates in the same basic fashion as the outlet assemblies
described above.
[0331] The metering assembly 910 comprises a base member 918, a
first gear member 920, a second gear member 922, a third gear
member 924, a fourth gear member 926, a first drive axle 928, a
second drive axle 930, a first drive projection 932 (FIG. 48), a
second drive projection 934 (FIG. 48), and an actuator member 936.
The actuator member 936 is similar to the actuator member of the
fifteenth embodiment described above and will not be discussed
below in further detail. The first gear member 920 comprises an
outer gear portion 938 and an inner gear portion 904. A pair of
drive tabs 942 (FIG. 48) extend from either side of the outlet
member 916.
[0332] The base member 918 comprises a mounting flange 940 that
allows the base member to be securely mounted onto the container
assembly 904. Extending from the mounting flange are first, second,
and third gear posts 946, 948, and 950. In addition, drive posts
952 extend upwardly from the base member 918.
[0333] The first gear posts 946 support the first gear member 920.
The second gear posts support the second and third gear members 922
and 924. The third gear post 950 supports the fourth gear members
926. The drive posts 952 support the first and second drive axles
928 and 930.
[0334] Actuator racks 954 extending from the actuator member 936
are aligned with the outer gear portions 938 of the first gear
members 920. Accordingly, pivoting the actuator member 936 about an
actuator axis 954 causes rotation of the first gear member 920. The
inner gear portion 940 in turn rotates and engages the second and
fourth gear members 922 and 926 to cause these to rotate in the
same direction. The second gear member in turn engages the third
gear member 924 so that the third and fourth gear members rotate in
opposite directions.
[0335] As shown in FIG. 46, the first and second drive projections
932 and 934 are mounted on the drive axles 928 and 930 such that
rotation of the drive axles 928 and 930 causes the drive
projections 932 and 934 to act on the drive tabs 942 and thus place
the valve assembly in its open configuration. When the drive
projections 932 and 934 rotate slightly less than 90 degrees, they
disengage from the drive tabs 942 and allow the valve spring 914 to
raise the valve stem 912 and place the valve assembly 906 back into
its closed position. The drive projections 932 and 934 are then
rotated approximately 270 degrees until they again come into
contact with the drive tabs 942. The process may be repeated.
Again, the metering assembly 910 opens and closes the valve
assembly 906 in a manner that dispenses a limited, controlled
amount of texture material and does not allow the user to leave the
valve assembly 906 in its open configuration for an extended period
of time.
[0336] It is apparent that various modifications could be made the
present invention without departing from the basic teachings
thereof.
* * * * *