Sprayer with Modular Components and Pop-up Deflectors

Abstract

A sprayer includes a pop-up deflector plate that can engage with a braking assembly in an extended position. The braking module is fixed to the sprayer body and includes a rotatable connector coupled to the braking assembly. The pop-up deflector plate is disposed near the nozzle and engages with the rotatable connector in the extended position.

Description

Technical Field

[0001] The present invention relates to a modular industrial sprinkler including a pop-up deflector, and more particularly, to a selectively configurable sprinkler assembly having a pop-up deflector that can operate as a spinner or a spin body. Background Art

[0002] Industrial sprinklers with exposed nozzles can become easily clogged due to debris accumulating inside or around the nozzles. Clogged nozzles can have an adverse effect on the spray pattern and require time-consuming cleaning and maintenance. Debris can similarly accumulate around the spinning deflector plate, which can slow down or clog the deflector plate. Summary of the Invention

[0003] Accordingly, it is desirable to provide a sprinkler assembly including a pop-up deflector that protects the nozzle during non-use. It is also desirable to incorporate the pop-up deflector into a spinner assembly including a brake, etc., for better control of the spray pattern during use. Further, it is desirable to construct the sprinkler assembly using modular components that can be selectively configured to obtain different characteristics for the sprinkler assembly.

[0004] In an exemplary embodiment, the sprinkler includes a pop-up deflector plate that can engage with a brake assembly in an extended position. The brake module is fixed to the sprinkler body and the brake module includes a rotatable connector coupled to the brake assembly. The nozzle module is mateable with the sprinkler body and the nozzle module includes a nozzle, and the deflector plate is mateable with the nozzle module and is disposed adjacent to the nozzle. The deflector plate can move between a retracted position and an extended position within the nozzle module. The deflector plate includes a fluid flow deflection surface and a torque shaft, wherein the torque shaft engages with the rotatable connector in the extended position.

[0005] The torque shaft can engage with the rotatable connector in the retracted position. The rotatable connector can include a channel having a cross-sectional shape, and the torque shaft can be shaped to correspond to the cross-sectional shape to engage the channel and transmit torque between the deflector plate and the rotatable connector. In some embodiments, the cross-sectional shape can be square, and the torque shaft can be shaped to fit within the square shape. The cross-sectional shape can include ridges, wherein the torque shaft can be provided with splines that can engage with the ridges.

[0006] The nozzle module can include an upper nozzle coupled to a nozzle base, wherein the deflector plate can move between a retracted position and an extended position within the upper nozzle. The nozzle module can be connected to the sprinkler body in a slip-fit manner. The rotatable connector can be positioned to serve as a stop limit for the deflector plate in the extended position.

[0007] In some embodiments, the torque shaft can be conical so that the torque shaft disengages from the rotatable connector in the retracted position.

[0008] The sprinkler can further include a base unit to which the nozzle module can be fixed. The base unit has a connection structure that can be connected to a water source under pressure.

[0009] In a suspended spinner embodiment, the sprinkler can be provided with a spring acting between the rotatable connector and the deflector plate, and the spring biases the deflector plate towards the retracted position.

[0010] The deflector plate can include separable diffuser tabs.

[0011] The brake module, the nozzle module, and the deflector plate can be modular components. Herein, the sprinkler can include a plurality of brake modules with varying braking characteristics, a plurality of nozzle modules with varying flow characteristics, and a plurality of deflector plates with varying liquid flow distribution characteristics, wherein these plurality of brake modules, nozzle modules, and deflector plates can be selectively and independently attached to the sprinkler body.

[0012] In another exemplary embodiment, the sprinkler assembly includes a plurality of interchangeable modular components. The sprinkler assembly includes a sprinkler body that includes a coupler for securing the interchangeable modular components. The plurality of interchangeable components include a plurality of brake modules respectively fixed to the sprinkler body, a plurality of nozzle modules that can be respectively fixed to the sprinkler body, and a plurality of deflector plates that can be respectively mated with the plurality of nozzle modules and are disposed adjacent to the nozzles. The plurality of deflector plates respectively have different braking characteristics from no braking to maximum braking, wherein each brake module includes a rotatable connector. Each of the plurality of nozzle modules includes a nozzle with a large nozzle size, wherein the corresponding nozzle sizes of the plurality of nozzle modules reflect different flow characteristics. Each deflector plate can move between a retracted position and an extended position within the corresponding nozzle module, and each deflector plate includes a liquid flow deflection surface and a torque shaft. The torque shaft engages the rotatable connector in the extended position.

[0013] In some embodiments, the sprinkler assembly includes a jewel cup bearing and a ball bearing. The jewel cup bearing is installed in the rotatable connector, and the ball bearing is disposed at the end of the torque shaft and engages the jewel cup bearing when the deflector plate is in the extended position.

[0014] In yet another exemplary embodiment, the sprinkler includes a sprinkler body; a brake module fixed to the sprinkler body and including a rotatable connector coupled to a brake assembly; a nozzle; and a pop-up deflector plate disposed adjacent to the nozzle and engaging the rotatable connector in the extended position. Description of the Drawings

[0015] These and other aspects and advantages will be described in detail with reference to the accompanying drawings, in which:

[0016] Figure 1 and Figure 2 is a cross-sectional view of a sprinkler assembly according to one embodiment;

[0017] Figure 3 and Figure 4 show the sprinkler assemblies in FIGS. Figure 1 and Figure 2 with the deflector plates in the extended position and the retracted position, respectively;

[0018] Figures 5 to 8 shows a sprinkler assembly that includes variations available due to the modular construction of the sprinkler assembly;

[0019] Figures 9 to 12 shows a spinner variation of the sprinkler assembly;

[0020] Figures 13 to 16 shows a suspended spinner type of the sprinkler assembly; and

[0021] Figure 17 and Figure 18 shows a sprinkler assembly that incorporates separable tabs of short radius for limiting the throw / distribution range of the sprinkler. DETAILED DESCRIPTION

[0022] The sprinkler of the described embodiment is a lower-cost pop-up sprinkler that can be configured as a spinner (i.e., incorporating a brake to control the rotation speed) or a spinner (i.e., free rotation). The sprinkler includes modular components such that nozzle, deflector, and brake parameters can be varied according to user specifications. In the spinner configuration, the pop-up deflector plate can engage the braking assembly in the extended position. The braking module is fixed to the sprinkler body and the braking module includes a rotatable connector coupled to the braking assembly. The pop-up deflector plate is disposed adjacent the nozzle and engages the rotatable connector in the extended position. Due to the modular construction, the braking assembly can be interchanged with the spinner assembly. Additionally, the nozzle module can be provided with or without a flow control structure, and the nozzle module can similarly be interchanged with alternative nozzle modules. Further, the deflector plate can be interchanged with alternative deflector plates to reflect the desired spray pattern.

[0023] Figures 1 to 4An exemplary construction is shown. The sprayer includes a sprayer body 10, which serves as a connection structure for modular components of the assembled sprayer. The sprayer body 10 includes a first compartment 12 for fixing the brake module 14 and a second compartment 16 for fixing the nozzle module 18. The nozzle module 18 can be connected to the sprayer body 10 in a slip-fit manner. The sprayer body arm 20 extends between the first compartment 12 and the second compartment 16.

[0024] The nozzle module 18 includes a nozzle upper part 22 that engages with a nozzle base 24. In some embodiments, the nozzle upper part 22 is coupled to the nozzle base 24 in a slip-fit manner. The nozzle base 24 can include an integrated nozzle 26 through which water flows out. A flow washer 28 can be included to provide flow control from the nozzle 26.

[0025] The deflector plate 30 cooperates with the nozzle module 18 and is disposed adjacent to the nozzle 26. The water flow passing through the nozzle 26 is directed onto the deflector plate 30, and the deflector plate 30 is provided with a liquid flow deflection surface 32 for deflecting and distributing the water flow. The shape of the liquid flow deflection surface 32 is designed such that the deflector plate 30 rotates when impacted by the water flow from the nozzle 26. The deflector plate 30 can be in a retracted position ( Figure 2 and Figure 4 as shown) and an extended position ( Figure 1 and Figure 3 as shown) within the nozzle module 18. The deflector plate 30 further includes a torque shaft 34 that extends from a side of the deflector plate 30 opposite to the side facing the nozzle 26.

[0026] The brake module 14 is fixed within the first compartment 12 and includes a shaft 36 that is coupled to a rotatable connector 38. The brake module can be of any type suitable for the intended purpose. In some embodiments, the brake module is a viscous brake assembly that includes a rotor attached to the shaft 36 and disposed in a viscous fluid pool 42. The rotor 40 and the viscous fluid 42 are used to prevent the rotation of the shaft 36. The viscous brake assembly can further include a bearing 44 and seals 46 and retainers 48 to enclose and fix the assembly, and the shaft 36 is rotatable within the bearing 44. Other types of brake assemblies can be incorporated into the brake module 14.

[0027] Continuing to refer to Figure 1 and Figure 3, the torque shaft 34 engages with the rotatable connector 38 in the extended position. This engagement between the torque shaft 34 and the rotatable connector 38 enables the mutual conversion of torque between the torque shaft 34 and the rotatable connector 38. That is to say, the rotatable connector 38 may include a channel having a cross-sectional shape, in which the torque shaft 34 is shaped to correspond to the cross-sectional shape to engage in the channel and transfer torque between the deflector plate 30 and the rotatable connector 38. In Figure 1 and Figure 2 In the illustrated embodiment, the cross-sectional shape includes ridges, wherein the torque shaft 34 includes splines that can engage with the ridges. In Figure 3 and Figure 4 , the cross-sectional shape is square, and the torque shaft 34 is shaped to fit within the square shape. Any combination of cross-sectional shapes and torque shaft shapes can be used, and the present invention is not necessarily limited to the illustrated variations. Other shapes and / or connection methods can be used to achieve the desired function.

[0028] In some embodiments, the torque shaft 34 engages with the rotatable connector 38 in both the extended position and the retracted position. Through this engagement, the deflector plate 30 and the rotatable connector 38 are coupled before the water flows out through the nozzle 26. In an alternative embodiment, the torque shaft 34 disengages from the connector 38 in the retracted position (see the discussion below with reference to Figures 5 - 8 ). Thus, the deflector plate 30 begins to rotate freely at startup until the torque shaft 34 engages with the rotatable connector 38. This configuration can be desirable when a strong brake is used for a particular application. The rotating deflector plate can provide some potential and kinetic energy to overcome a potentially difficult startup before engaging with the rotatable connector 38.

[0029] Continuing to refer to Figure 1 and Figure 2 , the deflector plate 30 is movable within the upper nozzle 22 between a retracted position and an extended position. As shown, the rotatable connector 38 is positioned to serve as a stop limit for the deflector plate 30 in the extended position. That is to say, the ejection range of the deflector plate 30 is defined by the seat on the upper nozzle 22 and the depth of the rotatable connector 38, and the deflector plate 30 engages on the seat of the upper nozzle 22 in the retracted position (see Figure 2 ), and the torque shaft 34 is disposed within the rotatable connector 38 in the extended position (see Figure 1 ). The deflector plate 30 can thus be simply placed within the upper nozzle 22 during the assembly process without the need for a movable connection.

[0030] To assemble the sprayer, the nozzle module 18 can be slid into the second compartment 16 of the sprayer body 10, and the deflector plate 30 can be disposed in the nozzle upper part 22. The brake module 14 can be secured in the first compartment 12 using any suitable connector (such as a right-angle swivel lock). This known type of lock is useful for joining plastic parts and uses tabs and ridges to secure the parts with a right-angle swivel lock or twist lock. The brake module 14 is mounted such that the rotatable connector 38 engages or aligns with the torque shaft 34.

[0031] The assembly can be secured to the base unit 50 using a similar right-angle swivel lock or the like. The base unit 50 includes a connection structure that can be connected to a water source under pressure. In some embodiments, the base unit 50 includes a stake adapter that can be connected by a right-angle swivel lock. Alternatively, the base unit 50 can be threadedly connected using a threaded Acme connector, or the base unit 50 can be press-fitted and glued.

[0032] In use, before the water flow passes through the nozzle 26, the deflector plate 30 is disposed in its retracted position under the action of gravity as Figure 2 and Figure 4 shown. When the water flow passes through the nozzle 26, the water flow impinges on the liquid flow deflection surface 32 and moves the deflector plate 30 from the retracted position to the extended position as Figure 1 and Figure 3 shown. The ejected liquid flow also causes the deflector plate 30 to rotate due to the shape of the liquid flow deflection surface 32. In the extended position, the free rotation of the deflector plate 30 is prevented by the engagement between the torque shaft 34 and the rotatable connector 38, and the rotatable connector 38 in turn is coupled to the brake module 14. The amount of braking can be controlled by swapping one brake module for another according to the intended application. Alternative brake modules can include a fluid with a lower viscosity or no brake at all (forming a spinneret configuration).

[0033] Figures 5 to 8 A variant of the sprayer assembly is shown. In the variant shown, the torque shaft 34 is tapered so that the torque shaft 34 disengages from the rotatable connector 38 in the retracted position. Figures 5 to 8 The variant shown in Figure 1 also includes an alternative nozzle base 24 and a standard nozzle 26 without the flow control washer 28 shown in

[0034] Figures 9 to 12 A variant using a spinneret module 114 instead of the brake module 14 is shown. In this variant, the deflector plate 30 can rotate freely. As Figure 10As shown, the spinner module 114 may include a jewel cup bearing 52 and / or a ball bearing 54. The jewel cup bearing 52 is mounted in a rotatable connector 38, and the ball bearing 54 is disposed at the end of the torque shaft 34 and engages the jewel cup bearing 52 when the deflector plate is in the extended position. The bearings 52 and 54 may be used together or separately. In the spinner configuration, the bearings 52 and 54 can reduce wear and extend the service life of the sprinkler. Figures 9 to 12 The variant shown in includes a threaded Acme connector as the base unit 50.

[0035] Figures 13 to 16 A variant suitable for use as a suspended spinner is shown. In this variant, the base unit 50 is mounted above ground as shown. The nozzle module is shown to have a flow control nozzle 26 and a flow control washer 28. A spring 56 is disposed above the torque shaft 34 and acts between the rotatable connector 38 and the deflector plate 30. The spring 56 biases the deflector plate 30 towards the retracted position as Figure 14 and Figure 16 shown. The spring constant is selected such that the water flow exiting the nozzle 26 acts on the deflector plate 30 and overcomes the force of the spring 56 to extend the deflector plate 30 from the retracted position to the extended position. When the water flow is shut off, the spring 56 pulls the deflector plate 30 back to the retracted position. In this embodiment, it may be desirable to use a brake module with reduced braking force (e.g., by using a fluid with reduced viscosity) such that the deflector plate 30 rotates faster during use. Faster rotation may be required in the suspended variant so that the sprinkler can maintain its center.

[0036] In some embodiments, it may be desirable to incorporate detachable diffuser tabs on the deflector plate 30 as Figure 17 and Figure 18 shown. The diffuser tabs 58 are used to make the water closer to the sprinkler distribution for smaller vegetation, etc. As the vegetation grows, the detachable diffuser tabs 58 can be easily removed from the deflector plate 30. Alternatively, due to the modular construction of the sprinkler, the deflector plate 30 can be easily interchanged with different deflector plates.

[0037] The modular construction of the described sprinkler helps to assemble the sprinkler in many of the described variants to be suitable for different intended functions. Thus, the assembly may include multiple brake modules with different braking characteristics, multiple nozzle modules with different flow characteristics, and multiple deflector plates with different liquid flow distribution characteristics. These multiple brake modules, nozzle modules, and / or deflector plates can be selectively and independently attached to the sprinkler body. Different braking characteristics range from no braking to maximum braking as described. The nozzle module may include nozzles of different sizes to reflect different flow characteristics.

[0038] The sprayer according to the described embodiments incorporates a pop-up deflector plate in the spinner assembly. Additionally, the modular construction enables the use of multiple variants depending on the desired efficacy.

[0039] Although the invention has been described in connection with the presently considered most practical and preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Claims

1. A sprayer, comprising: A sprayer body; A braking module fixed to the sprayer body and including a rotatable connector coupled to a braking assembly, the rotatable connector being selectively detachable from and reattachable to the sprayer body; A nozzle module capable of cooperating with the sprayer body, wherein the nozzle module includes an upper nozzle portion coupled to a nozzle base, the upper nozzle portion having a deflector plate receiving channel therein, and the nozzle base including a nozzle; and A deflector plate capable of cooperating with the nozzle module and disposed facing the nozzle, the deflector plate being movable between a retracted position and an extended position within the nozzle module, the deflector plate including a liquid flow deflector surface and a torque shaft, and the deflector plate being independent of the braking module and selectively placeable within and removable from the nozzle module, wherein the torque shaft engages the rotatable connector in the extended position; the ejection range of the deflector plate is defined by a seat portion on the upper nozzle portion and the depth of the rotatable connector; The braking module, the nozzle module, and the deflector plate are all interchangeable modular components.

2. The sprayer according to claim 1, wherein, The torque shaft engages the rotatable connector in the retracted position.

3. The sprayer according to claim 1, wherein, The rotatable connector includes a channel having a cross-sectional shape, and wherein the torque shaft is shaped to correspond to the cross-sectional shape so as to engage the channel and transmit torque between the deflector plate and the rotatable connector.

4. The sprayer according to claim 3, wherein, The cross-sectional shape is square, and wherein the torque shaft is shaped to fit within the square shape.

5. The sprayer according to claim 3, wherein, The cross-sectional shape includes ridges, and wherein the torque shaft includes splines capable of engaging the ridges.

6. The sprayer according to claim 1, wherein, The nozzle module is connected to the sprayer body in a slip-fit manner.

7. The sprayer according to claim 1, further comprising a base unit, the nozzle module being fixed to the base unit, the base unit having a connection structure capable of connecting to a water source under pressure.

8. The sprayer according to claim 1, further comprising a spring acting between the rotatable connector and the deflector plate, the spring biasing the deflector plate toward the retracted position.

9. The sprayer according to claim 1, wherein, The deflector plate includes detachable diffuser tabs.

10. The sprayer according to claim 1, comprising: A plurality of braking modules having different braking characteristics, a plurality of nozzle modules having different flow characteristics, and a plurality of deflector plates having different liquid flow distribution characteristics, wherein the plurality of braking modules, the plurality of nozzle modules, and the plurality of deflector plates are selectively and independently attachable to the sprayer body.

11. A sprayer, comprising: A sprayer body; A braking module fixed to the sprayer body and including a rotatable connector coupled to a braking assembly, A nozzle module capable of cooperating with the sprayer body and including a nozzle, the nozzle module including an upper nozzle portion coupled to a nozzle base, the upper nozzle portion having a deflector plate receiving channel therein, and the nozzle base including a nozzle; and A deflector plate, which is capable of cooperating with the nozzle module and is disposed facing the nozzle, the deflector plate being movable between a retracted position and an extended position in the nozzle module, the deflector plate including a liquid flow deflection surface and a torque shaft, wherein the torque shaft engages with the rotatable connector in the extended position; Wherein, the torque shaft is conical so that the torque shaft disengages from the rotatable connector in the retracted position; The brake module, the nozzle module, and the deflector plate are all interchangeable modular components.

12. A sprayer assembly, which includes a plurality of interchangeable modular components, the sprayer assembly including: A sprayer body, which includes a compartment for fixing the interchangeable modular components; The plurality of interchangeable components include: A plurality of brake modules, each of the plurality of brake modules being selectively fixable to and detachable from the sprayer body, the plurality of brake modules respectively having different braking characteristics from no braking to maximum braking, each of the brake modules including a rotatable connector; A plurality of nozzle modules, each of the plurality of nozzle modules being selectively fixable to and detachable from the sprayer body, each of the plurality of nozzle modules including a nozzle having a nozzle size, wherein the corresponding nozzle sizes of the plurality of nozzle modules reflect different flow characteristics, wherein each nozzle module includes a nozzle upper part coupled to a nozzle base, and each of the nozzle upper parts internally includes a deflector plate receiving channel; and A plurality of deflector plates, each of the plurality of deflector plates being selectively capable of cooperating with the plurality of nozzle modules and being disposed facing the nozzle, each of the deflector plates being independent of the plurality of brake modules and separable from the plurality of brake modules, each of the deflector plates being movable between a retracted position and an extended position in a corresponding nozzle module, each of the deflector plates including a liquid flow deflection surface and a torque shaft, wherein the torque shaft engages with the rotatable connector in the extended position.

13. The sprayer assembly according to claim 12, wherein, At least one of the brake modules includes a brake assembly, and the rotatable connector is coupled to the brake assembly.

14. The sprayer assembly according to claim 12, further including a jewel cup bearing and a ball bearing, the jewel cup bearing being installed in the rotatable connector, and the ball bearing being disposed at the end of the torque shaft and engaging with the jewel cup bearing when the deflector plate is in the extended position.

15. The sprayer assembly according to claim 12, wherein, Each of the rotatable connectors includes a channel having a cross-sectional shape, and wherein the shape of each of the torque shafts is designed to correspond to the cross-sectional shape so as to engage with the channel and transmit torque between the deflector plate and the rotatable connector.

16. A sprayer, including: A sprayer body; A brake module, which is fixed to the sprayer body and includes a rotatable connector coupled to a brake assembly; A nozzle module, comprising an upper nozzle part coupled to a nozzle base, the upper nozzle part internally including a deflector plate receiving channel, the nozzle base including a nozzle; and A pop-up deflector plate, which is arranged in the path of the liquid flow ejected from the nozzle, and the pop-up deflector plate engages with the rotatable connector at the extended position and disengages from the rotatable connector at the retracted position.

17. The sprinkler according to claim 16, further comprising a nozzle module, the nozzle module being fixed to the sprinkler body and including a nozzle base and an upper nozzle part, the nozzle base accommodating the nozzle, and the pop-up deflector plate being movable in the upper nozzle part to the extended position and being movable from the extended position.

18. The sprayer according to claim 17, wherein, The rotatable connector is positioned to serve as a stop limit for the deflector plate in the extended position.

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