Applicator for hazardous materials

Abstract

A pen-type hazardous material applicator for applying metal pretreatment material to complex geometries including blind holes, through holes, rivets, slots, chamfers, counterbores, counterbores and other hard to access surfaces.

Description

Applicator for hazardous materials

[0001] This application is a divisional application of Chinese invention patent application No. 202080049643.9 (PCT / US2020 / 032206), filed on May 8, 2020, entitled "Applicator for Hazardous Materials". Technical Field

[0002] The invention described herein relates to the field of applicators for hazardous materials, and in particular to applicators for dispensing discrete and finely controlled volumes of such materials. Background Technology

[0003] Many chemical applicators and application methods are known. These devices and techniques include, for example, spraying systems, pumping systems, immersion baths, etc. Different types of applicators include fiber markers, felt-tip pens, capillary pens, etc.

[0004] In the past, efforts have been made to improve the usability and safety of chemical coating systems and methods when flowing materials are hazardous, toxic, or otherwise aggressive. Particularly in the field of metal coating and treatment, this effort has involved developing systems in which the user physically detaches from the article to be treated or coated using equipment such as spray chambers and immersion baths. A major drawback of such systems is that small defects in the coating or treatment are difficult to repair and require the entire article to be completely re-immersed or recoated. This process can be particularly time-consuming and expensive, as a small defect in the coating will require sufficient chemicals or flowing materials to reprocess the entire article.

[0005] Typically, aluminum or other metal parts manufactured for commercial and military systems undergo a chemical treatment of their surfaces using conventional batch processing techniques to prevent corrosion. This chemical treatment process is crucial, for example, in applications requiring electrical and thermal insulation or conductivity. However, many parts are scratched during subsequent processing or machining steps after chemical treatment, which may remove a portion of the chemically treated corrosion protection layer from the part's surface. Therefore, it may be necessary to treat the scratched areas to restore the surface to its fully chemically treated corrosion-protected state.

[0006] The traditional method for repairing scratched surfaces is to obtain a bottle of coating solution and then apply it to the scratched area using a cotton ball, a small tip, a cloth, or a sponge, rubbing or otherwise applying the solution until the scratch is completely covered. In many cases, the shape of the part creates numerous problems when applying the coating solution to the surface.

[0007] Coating solutions can be, and often are, corrosive and hazardous materials because they may contain high levels of, for example, chromic acid, heavy metals, fluorides, ferrocyanides, and ferrocyanides. Conventional methods often apply excessive amounts of coating solution, frequently resulting in spills and creating hazardous conditions in the treated area. Conventional processes are messy, and large quantities of coating solution are wasted. Cotton balls, Q-tip pens, rags, or sponges used for applying or cleaning up coating solutions become hazardous waste due to their use, posing disposal problems.

[0008] Generally, coating solutions or flow materials fall into two categories: those that require rinsing to remove excess coating material and those that do not require rinsing. The former may require rinsing because they tend to form crystals, which create undesirable surface roughness and pose a hazard, as these crystals, along with any residual coating, are typically highly reactive, i.e., pH 1.5–4.5. Rinsing is necessary, but the resulting rinse water is corrosive because it is acidic and may be harmful or toxic to the environment, creating disposal problems. No-rinse (NR) coating materials do not form crystals, can be formulated to be self-leveling, and require no rinsing.

[0009] Early coating systems attempted to address the inefficiency of small defects in coatings, a problem partially solved by handheld pen applicators previously developed by the applicant for applying corrosive, hazardous, or other chemical coating solutions to scratched surfaces. Specifically, U.S. Patents 5,702,759 and 6,217,935 (in their entirety incorporated herein by reference) disclose applicators and methods for dispensing various chemicals using them. Devices using this technology have been found to be most useful for repairing scratches on planar conversion coated aluminum surfaces. The advent of these marker or pen applicators has increased the efficiency and speed of treating minor defects on coated metal surfaces and provides enhanced user and environmental safety by helping to isolate the user from reactive chemicals.

[0010] While the pen-type applicators mentioned above have improved industry, the inventors have found that problems still exist with coated surfaces having geometries more complex than flat surfaces. Therefore, the inventors have determined that there remains a need in the art for improved techniques for pen-type hazardous material applicators that can be used to improve coating on non-planar or complex geometries, particularly for applications with blind holes, through holes, rivets, gaps, chamfers, countersunk holes, and other hard-to-access surfaces.

[0011] The background description is provided to aid in understanding the following explanation of exemplary embodiments, and not to acknowledge that any or all of the background information is necessarily prior art. Summary of the Invention

[0012] The various embodiments described herein are intended to address or improve upon one or more deficiencies of existing pen-type applicator systems and may include features such as: means for supporting and / or increasing the rigidity of the applicator core, means for regulating the flow from the applicator chamber containing flowable material to the core, and / or means for positioning the core relative to at least a portion of the applicator housing at a non-zero angle. Various embodiments of the applicant's applicator can be used to apply material to complex geometries, particularly for applications having, by way of non-limiting example, blind holes, through holes, rivets, slits, chamfers, countersunk holes, and other hard-to-access surfaces.

[0013] According to one aspect of the invention (“Aspect 1”), an applicator for hazardous materials is provided, comprising: a housing (302, 402, 502, 602, 702, 802, 902, 1002, 1102, 1902) having chambers (308, 408, 508, 608, 708, 808, 1008, 1108), an outlet (310, 410, 510, 610, 710, 810, 1010, 1110), and a valve (314, 414, 514, 614, 714, 814, 1014, 1114) movable between a closed position where the outlet is not in fluid communication with the chamber and an open position where the outlet is in fluid communication with the chamber, configured to... A valve spring (318, 418, 518, 618, 718, 818, 1018, 1118) for a closed-position bias valve; and a core (312, 412, 512, 612, 712, 812, 912, 1012, 1112, 1912), the core being movably connected to a housing and configured to transmit an axial load to the valve to move the valve from a closed position to an open position, the core comprising a material suitable for receiving fluid from a discharge port and transmitting the fluid to a location outside the housing; wherein the applicator is characterized by means (322, 422, 522, 622, 722, 824, 922, 1021, 1124, 1922, 1930) for supporting and / or increasing the stiffness of the core.

[0014] Further illustrative aspects of the present invention can be summarized as follows:

[0015] Aspect 2. The applicator of any of the above aspects, wherein the means for supporting and / or increasing the stiffness of the core includes a tube (322, 522, 622, 824, 922, 1922) surrounding at least a portion of the core.

[0016] Aspect 3. The applicator of any of the above aspects, wherein the tube surrounding the core includes one or more transverse openings (324, 530, 626, 924) extending through the tube wall.

[0017] Aspect 4. The applicator of any of the above aspects, wherein the one or more lateral openings are located outside the housing.

[0018] Aspect 5. The applicator of any of the above aspects, wherein the one or more lateral openings are located inside the housing.

[0019] Aspect 6. The applicator of any of the above aspects, wherein the core is mounted on the tube to move between an extended position and a retracted position, and a core spring (526) is operably positioned between the core and the tube and configured to bias the core to the extended position.

[0020] Aspect 7. The applicator of any of the above aspects, wherein the core spring has a lower spring constant than the valve spring.

[0021] Aspect 8. The applicator of any of the above aspects, wherein the tube includes a trigger (624) located outside the housing, the trigger being configured to be operated to move the valve from a closed position to an open position.

[0022] Aspect 9. The applicator of any of the above aspects, wherein the housing further includes a gripping surface (628) spaced apart from the trigger, and the gripping surface is configured to be held to retain the housing against forces applied to the trigger.

[0023] Aspect 10. The applicator of any of the preceding aspects, wherein the core comprises one selected from different cores (812', 812', 812", 812", 812", 812"), the different cores being interchangeably connected to the tube.

[0024] Aspect 11. The applicator of any of the above aspects, wherein the means for supporting and / or increasing the stiffness of the core includes an internal support member (422, 1124) that is at least partially surrounded by the core.

[0025] Aspect 12. The applicator of any of the preceding aspects, wherein the core and preferably the internal support are bent or folded at a non-zero angle relative to the outlet.

[0026] Aspect 13. The applicator as described in any of the preceding aspects, wherein the housing comprises a tip portion (1004) and a handle portion (1006), and the tip portion is movable relative to the handle portion.

[0027] Aspect 14. The applicator of any of the above aspects, wherein the tip portion is connected to the handle portion by a rotating connector (1022).

[0028] Aspect 15. The applicator of any of the foregoing aspects, wherein the means for supporting and / or increasing core stiffness comprises an inner fiber bundle forming a first portion of the core, the first portion having greater stiffness than a second portion of the core, the second portion comprising an outer layer, preferably, the outer layer comprising a cover or coating of material or fibers chemically and / or mechanically treated to reduce its stiffness.

[0029] According to another aspect of the invention (“Aspect 16”), an applicator for hazardous materials is provided, comprising: a housing (1302, 1402, 1502, 1602, 1702, 1802, 2002, 2102, 2202, 2402) having chambers (1308, 1408, 1508, 1608, 1708, 1808, 2008, 2108, 2208, 2308, 2408); an outlet (1310, 1410, 1510, 1610, 1710, 1810, 2010, 2110, 2210, 2310, 2410); and a core (1312, 1410) connected to said outlet. 12, 1512, 1612, 1712, 1812, 2012, 2112, 2212, 2312, 2412); and valves (1314, 1414, 1514, 1630, 1730, 1830, 2014, 2114, 2214, 2330, 2428, 2430), fluidly connected to the chamber and movable between a closed position and an open position, wherein in the closed position the valve fluidly disconnects the outlet from the chamber, and in the open position the valve fluidly connects the outlet to the chamber; wherein the applicator is characterized by: means for regulating the flow rate from the chamber to the core.

[0030] Aspect 17. The applicator of any of the above aspects, wherein the means for regulating the flow rate includes a flexible wall (1322, 1422) of a chamber, said flexible wall being configured to be compressed to increase the flow rate.

[0031] Aspect 18. The applicator of any of the foregoing aspects, wherein the housing comprises a flexible bottle forming the flexible wall, or a portion of the housing comprises a flexible membrane forming the flexible wall.

[0032] Aspect 19. The applicator of any of the foregoing aspects, wherein the means for regulating the flow rate includes a piston (1622, 1722, 1822, 2326) that is slidable within and sealed on a cylinder (1624, 1708, 1808, 2328) to form a variable-size chamber (1634) in fluid communication with the core, the piston being movable to reduce the volume of the variable-size chamber thereby displacing fluid from the variable-size chamber to the core.

[0033] Aspect 20. The applicator of any of the above aspects, wherein the piston and cylinder are located in the housing.

[0034] Aspect 21. The applicator of any of the above aspects, wherein the piston and cylinder are connected to the housing via a flexible tube (2322).

[0035] Aspect 22. The applicator of any of the above aspects further includes a spring (1618) configured to bias the piston to reduce the volume of the variable-size chamber, and wherein the piston is connected to the core such that a force applied to the core acts on the spring to move the piston to increase the volume of the variable-size chamber.

[0036] Aspect 23. The applicator of any of the above aspects further includes a spring (1718, 1818, 2318) configured to bias the piston to increase the volume of the variable-size chamber, and wherein the applicator includes a button (1738, 1838, 2336) configured to be operated by a user to move the piston to decrease the volume of the variable-size chamber.

[0037] Aspect 24. The applicator of any of the above aspects, wherein the valve comprises:

[0038] • A first check valve (1630, 1730, 1834, 2330), located in a first passage extending through the piston, is configured to open when the piston moves to increase the volume of the variable-size chamber, and to close when the piston moves to decrease the volume of the variable-size chamber; and

[0039] • A second check valve (1630, 1730, 1834, 2330) is located in a second passage extending through the piston and is configured to open when the piston moves to decrease the volume of the variable-size chamber and to close when the piston moves to increase the volume of the variable-size chamber.

[0040] Aspect 25. The applicator of any of the above aspects also includes means for adjusting the stroke distance of the piston.

[0041] Aspect 26. The applicator of any of the above aspects, wherein the means for regulating the flow from the chamber to the core includes a trigger (624, 1738, 1838, 2004, 2124, 2224, 2324, 2424) configured as an operating valve, the trigger being separate from the core.

[0042] Aspect 27. The applicator of any of the foregoing aspects, wherein the trigger includes a proximal portion (2004) of the housing that is movable relative to a distal portion (2006) of the housing, thereby moving the valve to the open position.

[0043] Aspect 28. The applicator of any of the above aspects, wherein the trigger includes a cam driver (2128, 2228) operable to move a cam (2126, 2226) connected to a valve.

[0044] Aspect 29. The applicator of any of the above aspects, wherein the valve, cam actuator and cam are located on the housing.

[0045] Aspect 30. The applicator of any of the above aspects, wherein the valve, cam driver and cam are located on the flexible tube (2222) that connects the housing to the core.

[0046] Aspect 31. The applicator of any of the above aspects, wherein the trigger includes a flexible chamber (2426), and the valve includes a first one-way valve (2428) located between the flexible chamber and the core and a second one-way valve (2430) located between the flexible chamber and the core, wherein the first one-way valve is configured to close when the flexible chamber is compressed and open when the flexible chamber is expanded, and the second one-way valve is configured to open when the flexible chamber is compressed and close when the flexible chamber is expanded.

[0047] According to another aspect of the invention (“Aspect 32”), an applicator for hazardous materials is provided, comprising: a housing (1002, 1202, 2002, 2102, 2202, 2408) extending in a longitudinal “L” direction and having chambers (1008, 1208, 2008, 2108, 2208, 2308, 2408, 2508); an outlet (1010, 1210, 2010, 2110, 2210, 2310, 2410, 2510); and a core (1012, 1212, 2012, 2112, 2212, 2312, 2410) connected to said outlet. 2, 2512); and valves (1014, 1214, 2014, 2114, 2214, 2330, 2428, 2430, 2514), said valves being fluidly connected to said chamber and movable between a closed position and an open position, said valves fluidly disconnecting said outlet from said chamber in said closed position and said valves fluidly connecting said outlet to said chamber in said open position; wherein said applicator is characterized by: means for positioning said core relative to at least a portion of said housing at a non-zero angle, preferably said non-zero angle relative to said housing longitudinal direction “L” greater than or equal to 1 degree.

[0048] Aspect 33. The applicator of any of the foregoing aspects, wherein the means for positioning the core relative to at least a portion of the housing includes a proximal portion (1004, 2504) of the housing, which is movable relative to a distal portion (1006, 2506) of the housing.

[0049] Aspect 34. The applicator of any of the above aspects, wherein the proximal portion of the housing is connected to the distal portion of the housing by a swivel connector (1022) or a flexible section (2522).

[0050] Aspect 35. The applicator of any of the foregoing aspects, wherein the means for positioning the core relative to at least a portion of the housing at a non-zero angle includes a proximal portion (1204) of the housing fixed at a non-zero angle relative to a distal portion (1206) of the housing, the outlet 1210 and the core 1212 oriented along an axis A angled relative to the longitudinal direction L, preferably, the valve 1214 and the spring 1218 also oriented along axis A.

[0051] Aspect 36. The applicator of any of the foregoing aspects, wherein the means for positioning the core at a non-zero angle relative to at least a portion of the housing comprises a flexible tube (2022, 2122, 2222, 2322, 2422).

[0052] Aspect 37. The applicator of any of the foregoing aspects further includes means for regulating flow rate, the means including flexible walls of chambers (1008, 1208, 2008, 2108, 2208, 2308, 2408, 2508) configured to be compressed to increase flow rate.

[0053] Aspect 38. The applicator of any of the above aspects, wherein the housing (1002, 1202, 2002, 2102, 2202, 2302, 2402, 2502) comprises a flexible bottle forming a flexible wall, or a portion of the housing comprises a flexible membrane forming a flexible wall.

[0054] Aspect 39. The applicator of any of the foregoing aspects further includes means for regulating flow rate, the means including a piston (1624, 1722, 1822, 2326) which is slidable within and sealed on a cylinder (1624, 1708, 1808, 2328) to form a variable-sized cavity (1634) in fluid communication with the core, the piston being movable to reduce the volume of the variable-sized cavity, thereby displacing fluid from the variable-sized cavity to the core.

[0055] Aspect 40. The applicator of any of the above aspects, wherein the piston and cylinder are located in the housing.

[0056] Aspect 41. The applicator of any of the above aspects, wherein the piston and cylinder are connected to the housing by a flexible tube.

[0057] The applicant's pen applicator can be used to dispense hazardous materials, such as metal pretreatment products, including but not limited to conversion coating materials, including but not limited to Cr(VI), Cr(III), non-Cr conversion coating materials, and cleaning agents, adhesion promoters and other compositions for metal pretreatment, which are generally reactive and / or hazardous acidic or alkaline pH, such as, by way of non-limiting example, pH 1-5 or pH 9-14, said metal pretreatment products including but not limited to conversion coating materials. Attached Figure Description

[0058] Embodiments of the invention will now be described strictly by way of example with reference to the accompanying drawings, wherein:

[0059] Figure 1 is a schematic cross-sectional view of a prior art pen applicator.

[0060] Figure 2 is a schematic cross-sectional view of another pen-type applicator in the prior art.

[0061] Figure 3 is a schematic cross-sectional view of an embodiment of the pen-type applicator of the present invention.

[0062] Figure 4 is a schematic cross-sectional view of another embodiment of the pen-type applicator of the present invention.

[0063] Figure 5 is a schematic cross-sectional view of another embodiment of the pen-type applicator of the present invention.

[0064] Figure 6 is a schematic cross-sectional view of another embodiment of the pen-type applicator of the present invention.

[0065] Figure 7 is a schematic cross-sectional view of another embodiment of the pen-type applicator of the present invention.

[0066] Figure 8 is a schematic cross-sectional view of another embodiment of the pen-type applicator system of the present invention.

[0067] Figure 9 is a perspective view of another embodiment of the pen-type applicator of the present invention.

[0068] Figures 10A and 10B are schematic cross-sectional views of another embodiment of the pen-type applicator of the present invention.

[0069] Figure 11 is a schematic cross-sectional view of another embodiment of the pen-type applicator of the present invention.

[0070] Figure 12 is a schematic cross-sectional view of another embodiment of the pen-type applicator of the present invention.

[0071] Figure 13 is a schematic cross-sectional view of another embodiment of the pen-type applicator of the present invention.

[0072] Figure 14 is a schematic cross-sectional view of another embodiment of the pen-type applicator of the present invention.

[0073] Figure 15 is a schematic cross-sectional view of another embodiment of the pen-type applicator of the present invention.

[0074] Figure 16 is a schematic cross-sectional view of another embodiment of the pen-type applicator of the present invention.

[0075] Figure 17 is a schematic cross-sectional view of another embodiment of the pen-type applicator of the present invention.

[0076] Figures 18A and 18B are schematic cross-sectional views of another embodiment of the pen-type applicator of the present invention.

[0077] Figure 19 is a perspective view of another embodiment of the pen-type applicator of the present invention.

[0078] Figure 20 is a schematic cross-sectional view of another embodiment of the pen-type applicator of the present invention.

[0079] Figures 21A and 21B are schematic cross-sectional views of another embodiment of the pen-type applicator of the present invention.

[0080] Figures 22A and 22B are schematic cross-sectional views of another embodiment of the pen-type applicator of the present invention.

[0081] Figure 23 is a schematic cross-sectional view of another embodiment of the pen-type applicator of the present invention.

[0082] Figure 24 is a schematic cross-sectional view of another embodiment of the pen-type applicator of the present invention.

[0083] Figure 25 is a schematic cross-sectional view of another embodiment of the pen-type applicator of the present invention. Detailed Implementation

[0084] Pen applicators for dispensing hazardous chemicals are used in operating environments that are often unique to the specific industry associated with the chemical treatment being performed. For example, in the case of repair work on aircraft parts, pen applicators are frequently used by technicians who must perform the dispensing operation safely, completely, and accurately, while avoiding physical contact with the chemicals and misapplying material to surfaces or locations other than the target treatment area. Technicians also frequently use dispensers in hazardous environments, such as on scaffolding or ladders at a height sufficient to handle aircraft parts. The surface to be treated can be located in virtually any position and orientation relative to the technician, so the technician must be able to reach it from any direction (including straight upwards) to apply the chemicals.

[0085] Figure 1 illustrates a conventional pen-type applicator 100. The applicator 100 has a housing 102 extending longitudinally L from a proximal end 104 to a distal end 106. The housing forms a chamber 108 for receiving a flowable material. The proximal end 104 has an outlet 110 providing a fluid passage from the chamber 108 to the external environment. A core 112 is located in and protrudes from the outlet 110. The core 112 preferably comprises a porous material, such as polyester or polyethylene, which guides the flowable material from the chamber 108 to the surface being treated. The housing 102 includes a collar 114 extending radially from the housing 102 to form a disc-shaped protrusion. The collar 114 is sized to prevent the applicator 100 from being placed in a typical pocket of a technician's clothing.

[0086] The core 112 is movably supported within the outlet 110, for example by forming a component with a cooperative sliding shape or surface. A valve 116 is attached to the distal end of the core 112, and a spring 118 is disposed within the housing 102 to bias the valve 116 and the core 112 in a proximal direction. The spring 118 allows the core 112 and the valve 116 to move between, for example, a closed position as shown on the left side of FIG. 1 and an open position as shown on the right side of FIG. 1. In the closed position, the valve 116 contacts the corresponding wall of the chamber 108 to form a seal, preventing flowable material from being transferred from the chamber 108 to the core 112. In the open position, the valve 116 does not seal against the wall, and flowable material is freely transferred to the core 112 by gravity and then to the surface being processed.

[0087] Figures 1 and 2 illustrate two different arrangements of chamber 108 and spring 118. In Figure 1, spring 118 is positioned between a distal support wall 120 and valve 116, with support wall 120 located between the proximal and distal ends of chamber 108. The support wall 120 of Figure 1 includes one or more openings 122 to allow flowable material to move through chamber 108. This configuration of Figure 1 allows the distal end of chamber 108 (e.g., via nut 124) to be openable to replace flowable material without interfering with or removing spring 118. In Figure 2, the distal support wall 120 is formed at the distal end of chamber 108, which is more suitable for a permanently sealed housing 102.

[0088] It has been found that conventional pen-type dispensers, such as those shown in Figures 1 and 2, may have certain drawbacks. For example, the dispensing tip may be too large to fit into certain holes or fully extend into certain openings. Elongated pen configurations also cannot fit into relatively narrow spaces or reach corners. Furthermore, a safety collar extending radially from the pen body to prevent the device from being placed in a clothing pocket can obstruct access to certain surfaces. Another disadvantage is that the core cannot fit into corners and other small or narrow spaces, resulting in insufficient chemical coverage on the treated surface. These drawbacks necessitate the use of supplementary devices, such as cotton swabs, to fully treat surface portions inaccessible to the pen-type applicator core.

[0089] One potential modification to existing devices is to reduce the diameter or cross-section of the core to allow access to corners and narrower spaces. However, it has been found that reducing the core size leads to problems with the operating spring opening the valve. In typical use of existing devices, the operator simply presses the core against a surface to dispense material. This operation is simple, convenient, and can be performed with one hand, making it safer and easier when operating where the other hand can provide support. Reducing the core diameter decreases its rigidity and makes it less suitable for pressing the valve shut without bending or breaking; the same problem arises when lengthening the core.

[0090] In one embodiment, the resistance or stiffness of the valve and spring is reduced to allow for a smaller core with reduced strength. This addresses some application challenges, but a weaker spring could lead to the leakage of hazardous materials, and the pen body still obstructs access to smaller application areas.

[0091] In another embodiment, a stiffer core material can be used, but this may have the disadvantage of obstructing the flow of fluid materials and potentially clogging the core.

[0092] Referring now to Figures 3 to 5, the inventors have identified various other embodiments of the method that allow for smaller core diameters and / or larger core lengths without impairing the user’s ability to use the core to compress the spring.

[0093] Figure 3 illustrates an example of an applicator 300 having a housing 302 extending from a proximal end 304 to a distal end 306, with a chamber 308 for receiving flowable material. A collar (not shown) or other features may also be provided on the housing 302. A drain outlet 310 connects the chamber 308 to the external environment. A core 312 is located in and protrudes from the drain outlet 310. A valve 314 is operably connected directly or via an intermediate component to the distal end of the core 312 for movement with the core 312. The core 312 can slide longitudinally L within the drain outlet 310 between an extended position (left side of Figure 3) and a retracted position (right side of Figure 3). When the core 312 is in the extended position, the valve 314 abuts against and seals a corresponding first wall 316 (e.g., the wall of the chamber 308 or the surface of a valve assembly mounted in the applicator 300) to prevent flowable material from the chamber 308 to the core 312. When the core 312 is in the retracted position, the valve 314 disengages from the first wall 316 and allows flowable material to be transferred from the chamber 308 to the core 312. A spring 318 is located between the valve 314 and the second wall 320 (e.g., the wall of the chamber 308 or the surface of a valve assembly mounted in the applicator 300). The spring 318 is compressed to generate a resilient bias force that presses against the valve 314 to deflect the core 312 to the extended position. An opposing force is applied along the core 312 to overcome the spring bias and move the core 312 to the retracted position.

[0094] The embodiment of FIG3 preferably has a core 312 that is too small in size compared to the magnitude of the force required to repeatedly move the core 312 from the extended position to the retracted position. This means that the material and / or size of the core 312 is chosen such that the core 312 will tend to bend under the retraction force applied distally along the longitudinal direction L during use, without the additional specifications discussed herein, rather than moving to the retracted position with the valve open. The small core may not fail on the first start-up, but after some use before the contents of the applicator are exhausted, it will result in material waste and possible overflow of the remaining contents of the applicator 300. The selection of the size and material of the core 312 to present it as too small compared to the biasing force of the spring 318 is a conventional mechanical problem and can be determined mathematically or empirically without much experimentation, and does not need to be described in detail here. The durability of the core 312 in transmitting the retraction force is compensated by adding an external support tube 322 that defines a lumen 326 around the core 312, supporting and increasing the stiffness of the core and extending the length 312 of the core at least partially along the longitudinal direction.

[0095] The external support tube 322 may extend distally to contact valve 314 and may be integrally formed with valve 314, and may extend proximally when core 312 is in the retracted position to extend from or be flush with outlet 310, but other configurations are also possible. The support tube 322 and core 312 together possess sufficient strength to transmit the retraction force from core 312 to spring 318. Therefore, applying a distally oriented retraction force along longitudinal direction L to core 312 will cause core 312, tube 322, and valve 314 to retract, thereby allowing flowable material to be transferred from chamber 308 to core 312. Tube 322 may comprise any suitable rigid material, such as thermoplastics, polymers, rubber, etc., resistant to flowable material intrusion, and is preferably interference-fitted with core 312. However, it is not strictly required that tube 322 be more rigid than core 312, as long as the overall rigidity of the components is sufficient to transmit the retraction force to spring 318. Furthermore, the core 312 and tube 322 can be slightly flexible in the assembled state to allow the core 312 to twist / deform to handle narrow spaces and corners. The tube 322 can be mounted on the core 312, for example, by molding it into the appropriate position on the core 312, wrapping it around the core 312 and sealing it itself (e.g., by ultrasonic or thermal welding or adhesive bonding), shrinking it onto the core 312 (e.g., using a heat-sensitive thermoplastic that shrinks when heat is applied, pulling or press-fitting the core 312 into the tube 322, or extending the support tube 322 to attach it to the tubular mandrel and removing the tubular mandrel when the tube 322 surrounds the core 312), etc.

[0096] The proximal end of the core 312 protrudes from the support tube 322 by a distance sufficient to provide the desired configuration characteristics for the flowable material. For example, if the applicator 300 is intended primarily to guide material to the bottom of the recessed opening, the tube 322 may extend very close to the proximal end of the core 312. Conversely, if the applicator 300 is intended to coat the bottom and sides of the recess with material, a longer core extension may be possible between the proximal end of the core 312 and the proximal end of the tube 322. The tube 322 may also include a lateral opening 324 communicating with the lumen 326 to provide an additional outlet for the flowable material to move perpendicular to the longitudinal direction L (i.e., laterally), which is expected to provide a greater degree of stiffness to the core 312 while still allowing lateral flow to aid in the application of material to the sides of the recess. Lateral distribution can also be enhanced by forming the core 312 to extend outward from the lumen 326 of the tube 322 through the lateral opening 324. For example, the core 312 may include a soft material or a soft outer layer material (e.g., a layer of woven or nonwoven felt material) that is sufficiently compliant to protrude through the lateral opening 324 when the core 312 is arranged in the lumen 326 of the tube 322.

[0097] Figure 4 illustrates another example of an applicator 400 having a housing 402 extending from a proximal end 404 to a distal end 406, the housing having a chamber 408 for receiving flowable material. A collar (not shown) or other features may also be provided on the housing 402. A drain port 410 connects the chamber 408 to the external environment. A core 412 is located in and protrudes from the drain port 410. A valve 414 is operatively attached directly or via an intermediate component to the distal end of the core 412 for movement with the core 412. The core 412 can slide along the longitudinal direction L within the drain port 410 between an extended position (left side of Figure 4) and a retracted position (right side of Figure 4). When the core 412 is in the extended position, the valve 414 abuts against and seals a corresponding first wall 416 (e.g., the wall of the chamber 408 or the surface of a valve assembly mounted in the applicator 400) to prevent flowable material from the chamber 408 to the core 412. When the core 412 is in the retracted position, the valve 414 disengages from the first wall 416 and allows flowable material to be transferred from the cavity 408 to the core 412. A spring 418 is located between the valve 414 and the second wall 420 (e.g., the wall of the cavity 408 or the surface of a valve assembly mounted in the applicator 400). The spring 418 is compressed to generate a resilient biasing force that presses against the valve 414 to bias the core 412 to the extended position. An opposing force is applied along the core 412 to overcome the spring biasing and move the core 412 to the retracted position.

[0098] The embodiment of FIG4 preferably has a core 412 that is too small in size compared to the force required to move the core 412 from the extended position to the retracted position. The inability of the core 412 to transmit the retraction force during the service life of the applicator 400 is remedied by reinforcing the core with an internal support 422, which is surrounded or partially surrounded by the core 412 and extends at least partially along the length of the core 412 in the longitudinal direction. The internal support 422 may extend in the distal direction to contact the valve 414 and may be integrally formed with the valve 414, and may extend in the proximal direction when the core 412 is in the retracted position to extend from or be flush with the outlet 410, but other configurations are also possible. The internal support 422 and the core 412 together have sufficient strength to transmit the retraction force from the core 412 to the spring 418. Therefore, applying a retracting force pointing distally to the core 412 along the longitudinal direction L will cause the core 412, the internal support 422 and the valve 414 to retract, thereby allowing flowable material to be transferred from the chamber 408 to the core 412.

[0099] The internal support 422 may comprise any suitable rigid material, such as metal, thermoplastic, polymer, rubber, etc. It is not strictly required that the internal support 422 be more rigid than the core 412, as long as the overall rigidity of the components is sufficient to transmit the retraction force to the spring 418. Furthermore, the core 412 and the internal support 422 may be to some extent flexible in the assembled state to allow the core 412 to deform to handle narrow spaces and corners. For this purpose, the internal support 422 may extend to terminate near or at the proximal end of the core 412 to help push the core material into corners. The internal support 422 may be installed in the core 412, for example, by molding it into a cavity within the core 412, pressing in the core material, etc.

[0100] The internal support 422 can have any shape that helps resist buckling or inelastic deformation loads on the core 412. For example, the internal support 422 may include one or more cylindrical protrusions from the valve 414. The internal support 422 can also be hollow, with an open space or core material located therein. A hollow internal support 422 without core material can be particularly helpful in conveying flowable material at higher flow rates to the proximal end of the core 412. Similarly, the internal support 422, and especially the hollow internal support 422, can have lateral openings, such as the lateral opening 324 described with respect to the embodiment in Figure 3, to provide additional lateral flow paths for the flowable material. In view of this disclosure, other alternatives and variations will be apparent to those skilled in the art.

[0101] Figure 5 illustrates another example of an applicator 500 having a housing 502 extending from a proximal end 504 to a distal end 506, the housing having a chamber 508 for containing flowable material. A collar (not shown) or other features may also be provided on the housing 502. A drain port 510 connects the chamber 508 to the external environment. A core 512 is located in and protrudes from the drain port 510. A valve 514 is operatively attached directly or via an intermediate component to the distal end of the core 512 to move with the aspirating core 512 in a two-stage motion as described below. The core 512 can slide along the longitudinal direction L within the drain port 510 between an extended position (left side of Figure 5) and a retracted position (right side of Figure 5). When the core 512 is in the extended position, the valve 514 abuts against and seals a corresponding first wall 516 (e.g., the wall of the chamber 508 or the surface of a valve assembly mounted in the applicator 500) to prevent flowable material from the chamber 508 to the core 512. When the core 512 is in the retracted position, the valve 514 disengages from the first wall 516 and allows flowable material to be transferred from the chamber 508 to the core 512. A first spring 518 is located between the valve 514 and the second wall 520 (e.g., the wall of the chamber 508 or the surface of a valve assembly mounted in the applicator 500). The first spring 518 is compressed to generate an elastic biasing force that presses against the valve 514 to bias the core 512 to the extended position. An opposing force is applied along the core 512 to overcome the spring biasing and move the core 512 to the retracted position.

[0102] In this configuration, the core 512 is slidably held within the support 522, and the support 522 is slidably held within the outlet 510. The support 522 may be cylindrical or have other shapes to accommodate the cross-sectional profiles of the core 512 and the outlet 510 (e.g., rectangular, square, elliptical, etc.). The support 522 includes a support cavity 524 in which the core 512 can slide along a longitudinal direction L. A second spring 526 is located in the support cavity 524 between the distal end of the core 512 and the facing inner wall 528 of the support 522.

[0103] The embodiment of FIG5 preferably has a core 512 that is too small compared to the force required to move the first spring 518 to disengage the valve 514. However, the core 512 is not small enough to compress the second spring 526 compared to the required force. Therefore, the second spring 526 has a lower spring constant than the first spring 518.

[0104] This embodiment provides a two-stage retraction operation. A force applied along the longitudinal direction L to the distal end of the proximal end of the core 512 first compresses the second spring 526 until the core 512 retracts into the support cavity 524, then compresses the support 522 and the core 512 to the retracted position to disengage the valve 514. This embodiment effectively increases the stiffness of the core by retracting the core 512 into the rigid (or relatively rigid) support 522, overcoming the problem of a core 512 that is too small to transmit the valve opening force. The support 522 provides sufficient lateral support to transmit the retraction force and open the valve 514. When the core 512 is fully retracted in the support 522 (as shown in FIG. 5), the core 512 may protrude from the support 522, or it may be pressed flush with the proximal end of the support 522. The support 522 also includes an opening sufficient to allow flowable material to pass through the support to the core 512. For example, the support 522 may include a lateral opening 530 exposed to the chamber 508 when the valve 514 disengages. If necessary, a seal such as an O-ring 532 may be provided between the support 522 and the outlet 510 to prevent flowable material from leaking out.

[0105] Referring now to FIG. 6, other embodiments may include features that allow for the use of excessively small core sizes, but do not require support or reinforcement of the core to transmit the necessary force to disengage the valve. In FIG. 6, the applicator 600 has a housing 602 extending from a proximal end 604 to a distal end 606, the housing 602 having a chamber 608 for receiving flowable material. A collar (not shown) or other features may also be provided on the housing 602. A drain port 610 connects the chamber 608 to the external environment. A core 612 is located in and protrudes from the drain port 610. A valve 614 is operatively connected directly or via an intermediate portion to the distal end of the core 612 for movement with the core 612. The core 612 can slide along the longitudinal direction L within the drain port 610 between an extended position (left side of FIG. 6) and a retracted position (right side of FIG. 6). When the core 612 is in the extended position, the valve 614 abuts against and seals the corresponding first wall 616 (e.g., the wall of chamber 608 or the surface of a valve assembly mounted in the applicator 600) to prevent flowable material from chamber 608 to the core 612. When the core 612 is in the retracted position, the valve 614 disengages from the first wall 616 and allows flowable material to pass from chamber 608 to the core 612. A spring 618 is located between the valve 614 and the second wall 620 (e.g., the wall of chamber 608 or the surface of a valve assembly mounted in the applicator 600). The spring 618 is compressed to generate an elastic biasing force that presses against the valve 614 to bias the core 612 to the extended position.

[0106] The embodiment of FIG. 6 preferably has a small core 612 compared to the force required to move the first spring 618 to disengage the valve 614. However, the core 612 is immovable within the support 622, and the support 622 is slidably held in the outlet 610. The support 622 may be cylindrical or have other shapes to accommodate the cross-sectional profiles of the core 612 and the outlet 610 (e.g., rectangular, square, elliptical, etc.). The support 622 is operatively connected to the valve 614 such that a retraction force can be applied to the support 622 (in addition to or in place of the core 612) to disengage the valve 614. For this purpose, the support 622 may include a trigger 624 located outside the housing 602 to assist the operator in applying the retraction force. The support 622 may also include one or more openings 626 to allow flowable material to pass from the chamber 608 to the core 612 when the valve 614 disengages.

[0107] The shape and size of trigger 624 can be selected based on the operator's expected needs. For example, trigger 624 may include an annular plate surrounding core 612 (as shown), or other shapes that allow the operator to press the trigger using their fingers or by pushing the entire assembly against a fixed surface (e.g., placing trigger 624 against a rigid portion of the surface being treated and pushing the applicator 600 forward). Trigger 624 may also be provided with opposing gripping surfaces 628 (e.g., a ring adapted to receive the operator's thumb or a plate for receiving the palm) to allow the operator to squeeze trigger 624 against gripping surfaces 628 to actuate the single-handed opening of valve 614. Alternatively, additional seals such as O-rings 630 or gland seals may be provided between support 622 and outlet 610 to reduce the possibility of leakage through them.

[0108] The embodiment of Figure 6 allows for the use of a smaller core while still providing convenient and safe valve operation at the user's discretion. A variation of the embodiment of Figure 6 involves slidingly mounting the core 612 within a chamber of the support, with a second spring having a low spring constant biasing the core 612 to the extended position. This modification can provide the additional functionality of the embodiment of Figure 5. Other embodiments may combine the trigger features of Figure 6 with the core support features of Figures 3 and 4. Other alternatives and variations will be apparent to those skilled in the art in light of this disclosure.

[0109] Another problem with existing pen-type applicators is their inability to fit into narrow spaces and corners. This is particularly problematic in recessed holes, unusually shaped holes, and areas where the original coating has been damaged by deep scratches. This issue has also been observed when applying coatings around rivets and other fasteners, where there are small openings and narrow gaps at the connection between these fasteners and the underlying surface. Figures 7 and 8 illustrate embodiments suitable for addressing this situation.

[0110] Figure 7 illustrates an applicator 700 having a housing 702 extending from a proximal end 704 to a distal end 706, the housing 702 having a chamber 708 for receiving flowable material. A collar (not shown) or other features may also be provided on the housing 702. A drain port 710 connects the chamber 708 to the external environment. A core 712 is located in and protrudes from the drain port 710. A valve 714 is operably connected directly or via an intermediate portion to the distal end of the core 712 for movement with the core 712. The core 712 can slide along the longitudinal direction L within the drain port 710 between an extended position (left side of Figure 7) and a retracted position (right side of Figure 7). When the core 712 is in the extended position, the valve 714 abuts against and seals a corresponding first wall 716 (e.g., the wall of the chamber 708 or the surface of a valve assembly mounted in the applicator 700) to prevent flowable material from the chamber 708 to the core 712. When the core 712 is in the retracted position, the valve 714 disengages from the first wall 716 and allows flowable material to pass from the chamber 708 to the core 712. A spring 718 is located between the valve 714 and the second wall 720 (e.g., the wall of chamber 708 or the surface of a valve assembly mounted in the applicator 700). The spring 718 is compressed to generate a resilient biasing force that presses against the valve 714 to bias the core 712 into the extended position.

[0111] The size of the core 712 can be either too small or too large compared to the force required to press the spring 718 to move the valve 714 to the retracted position. If the core 712 is too small, other features such as those discussed above can be incorporated to accommodate or assist the operation of the valve 714.

[0112] The core 712 includes a central support portion 722 extending into the outlet 710, and a flexible outer layer 724 surrounding or attached to the central portion 722. The outer layer 724 is more flexible than the central support portion 722, which may be made of natural or synthetic fibers, preferably polyester, polyurethane, acrylic, nylon, or combinations thereof. For example, the central portion 722 may include relatively rigid bundles of polyester fibers joined to form a column shape, and the outer layer 724 may include a separate cap or coating formed of soft, porous and / or fibrous materials of synthetic and / or natural origin (e.g., felt, sponge, wool, cotton, etc.). Such a cap may be removable or permanently attached to the remainder of the core 712. As another example, the core 712 may include rigid fiber bundles, wherein inner fibers are collected into the rigid central support portion 722, and outer fibers are chemically or mechanically treated (e.g., roughened or shredded) to allow them to enter the softer outer layer 724. Alternatively, a tube or hollow internal support member, as disclosed herein, may replace the central support portion 722 to support and reinforce the core 712. In this case, an opening at the proximal end of the tube and / or a transverse opening along the length of the tube or support member may supply flowable material to the soft outer layer 724 of the core 712.

[0113] The relatively soft outer layer 724 can conform to surface irregularities, improving the applicator's ability to handle cracks and corners by providing extended reach. The softer outer layer 724 also helps distribute flowable material in the lateral direction, which aids in coating the inner walls of narrow orifices. This lateral coating is enhanced by making the diameter D1 of the softer outer layer 724 larger than the diameter D2 of the adjacent portion of the central support portion 722 and larger than the diameter D3 of the adjacent portion of the housing 702. This allows the proximal end of the core 712 to extend into the narrow orifice while the flexible outer layer 724 applies flowable material to the side surfaces of the orifice.

[0114] Figure 8 illustrates another embodiment of an applicator 800 suitable for applying flowable material to small or oddly shaped areas. In this case, the applicator 800 has a housing 802 extending from a proximal end 804 to a distal end 806, the housing 802 having a chamber 808 for receiving the flowable material. A collar (not shown) or other features may also be provided on the housing 802. A drain port 810 connects the chamber 808 to the external environment. One of a plurality of cores 812 may be attached to protrude from the drain port 810. A valve 814 is operably connected directly or via an intermediate portion to the distal end of the mounted core 812 for movement with the core 812. The mounted core 812 may slide within the drain port 810 along a longitudinal direction L between an extended position and a retracted position. When the installed core 812 is in the extended position, valve 814 abuts against and seals the corresponding first wall 816 (e.g., the wall of chamber 808 or the surface of a valve assembly mounted in the applicator 800) to prevent flowable material from chamber 808 to the installed core 812. When the installed core 812 is in the retracted position, valve 814 disengages from the first wall 816 and allows flowable material from chamber 808 to the core 812. Spring 818 is located between valve 814 and second wall 820 (e.g., the wall of chamber 808 or the surface of a valve assembly mounted in the applicator 800). Spring 818 is compressed to generate a resilient bias force that presses against valve 814 to bias the installed core 812 to the extended position.

[0115] The size of the core 812 can be either too large or too small compared to the force required to press the spring 818 to move the valve 814 to the retracted position. If the core 812 is too small, other features such as those discussed above can be combined to accommodate the permissible operation of the valve 814.

[0116] In the embodiment of FIG8, a collection of different wicks 812 is available for selective installation in the outlet 810. Each wick 812 may have a unique shape designed to process a particular surface. For example, the wick 812 may include a chisel-tipped wick 812' with a tapered proximal end, a wick 812" with a spherical proximal end, a wick 812"' with an inverse tapered proximal end, a wick 812"" with an enlarged cylindrical end, and a wick 812"" with a bevel or chisel tip. Other alternatives and variations will be apparent to those skilled in the art in light of this disclosure, and it will also be understood that these alternative wick shapes can be used in other embodiments.

[0117] The core 812 has a corresponding shaft 822 configured to be releasably secured in a support carrier 824 slidably mounted in a drain port 810. A seal, such as an O-ring (not shown), may be provided between the carrier 824 and the drain port 810. The carrier 824 is slidable relative to the housing 802 along a longitudinal direction L and is operatively connected to the valve 814. The core 812 and the carrier 824 may be held together by friction engagement or by a mechanism such as a stop or bayonet fitting. The carrier 824 includes one or more openings, such as those described with respect to the embodiment of FIG. 5, to allow flowable material to pass from the chamber 802 to the core 812 when the valve 814 is disengaged.

[0118] In use, the user selects the desired core 812, inserts it into the carrier 824 arranged in the outlet 810, and uses the applicator 800 as usual, but with the ability to customize the application to reach surfaces that are difficult to reach using the core 812 reinforced by the support carrier 824, which distributes the force applied to the tip of the actuation valve 814.

[0119] It will be understood that the foregoing embodiments may be used in conjunction with other embodiments described herein. As a non-limiting example, embodiments having a flexible outer layer 724 or a replaceable core 812 may be used with features such as the metering valve system shown in Figures 16 and 17.

[0120] Another persistent problem with conventional pen-type applicators is that while their size allows for operation by users wearing protective gear and holds a sufficient amount of flowable material, they are therefore not oriented to fit into confined spaces. Specifically, pen-type applicators may be too long to fit into narrow gaps, and the collar 114 may be too large to allow the applicator to tilt at a low angle to reach under protrusions or the like. Figures 9 through 12 show a variety of alternative applicators designed to provide greater maneuverability for working on surfaces in confined spaces.

[0121] Figure 9 illustrates an applicator 900 having a housing 902 extending from a proximal end 904 to a distal end 906 and a core 912 extending from the proximal end 904. The applicator 900 also includes other features such as a chamber for receiving flowable material, valves, etc. In one embodiment, the core 912 is disposed within the cavity of a support tube 922 perforated by a laterally extending hole 924, as described above with respect to the embodiment of Figure 3. However, other cores, including those described herein as non-limiting examples, may be used in other embodiments.

[0122] The housing 902 has an elongated and generally cylindrical shape and includes features such as ribs and knurling to allow a user with gloved hands to operate the applicator 900. The described housing features may be included in other embodiments disclosed herein. Specifically, the housing 902 includes a plurality of longitudinal ribs 926 and a plurality of circumferential ribs 928. The longitudinal ribs 926 project from adjacent outer surfaces of the housing 902 and extend along a longitudinal direction L (i.e., along the direction from the proximal end 904 of the housing to the distal end 906 of the housing). The longitudinal ribs 926 provide enhanced gripping and control for rotating the housing 902 about the longitudinal direction L. The circumferential ribs 928 extend radially from the longitudinal axis to surround the circumferential perimeter of the housing 902. The circumferential ribs 928 provide gripping and control for moving the housing 902 along the longitudinal direction L. Some or all of the circumferential ribs 928 may also have proximal faces that are inclined outward in the distal direction to provide a “serrated” arrangement to aid in enhanced gripping when pushed in the proximal direction. In general, the longitudinal ribs 926 and circumferential ribs 928 are intended to provide enhanced gripping and control of the applicator 900, particularly if the applicator 900 is made smaller than existing conventional devices and / or manipulated to ensure adequate contact between the surface and the core 912 in awkward positions. Although the embodiment of FIG9 has longitudinal ribs 926 and circumferential ribs 928, other embodiments may have only one type of rib, or neither.

[0123] Figure 9 also illustrates an alternative configuration of the collar 930. Specifically, the collar 930 is positioned on a cap 932, which is selectively attached to the housing 902 to cover and protect the core 912. The cap 932 may also have ribs (e.g., longitudinal ribs 934) to assist a gloved user in installing and removing the cap 932. The cap and collar features described above in Figure 9 may be included in other embodiments disclosed herein.

[0124] Figures 10A and 10B illustrate another embodiment of an applicator 1000 configured for use in a confined space. In this case, the applicator 1000 has a housing 1002 having a tip portion 1004 defining a proximal end and a handle portion 1006 defining a distal end. One or both portions 1004, 1006 have a chamber 1008 for holding flowable material. A collar (not shown) or other features may also be provided on the housing 1002. A drain port 1010 connects the chamber 1008 to the external environment. Similar to the embodiment of Figure 6, a core 1012 is located within a support 1021, and the support 1021 is slidably held in and protrudes from the drain port 1010. A valve 1014 is operably connected directly or via an intermediate portion to the distal end of the support 1021 for movement with the core 1012. The support 1021 holding the core 1012 is slidable along the longitudinal direction L within the outlet 1010 between an extended position and a retracted position. When the core 1012 is in the extended position, the valve 1014 abuts against and seals a corresponding first wall 1016 (e.g., the wall of chamber 1008 or the surface of a valve assembly mounted in the applicator 1000) to prevent flowable material from chamber 1008 to the core 1012. When the core 1012 is in the retracted position, the valve 1014 disengages from the first wall 1016 and allows flowable material to flow from chamber 1008 to the core 1012. A spring 1018 is located between the valve 1014 and a second wall 1020 (e.g., the wall of chamber 1008 or the surface of a valve assembly mounted in the applicator 1000). The spring 1018 is compressed to generate an elastic biasing force that presses against the valve 1014 to bias the core 1012 to the extended position.

[0125] The housing 1002 is movable between a first configuration as shown in FIG. 10a and a second configuration as shown in FIG. 10B. Specifically, the tip portion 1004 is connected to the handle portion 1006 via a hinged joint such as a swivel connector 1022. The swivel connector 1022 can include any movable joint, such as a pivot joint or a rotary joint. In the example shown, the swivel connector 1022 includes a swivel joint formed by a cylindrical boss 1024 extending from the tip portion 1004 and a cylindrical housing 1026 in the handle portion 1006. The boss 1024 mates into the housing 1026 and provides relative rotation between the tip portion 1004 and the handle portion 1006. The boss 1024 includes a lip 1028 or fastener (e.g., a spring clip, D-ring, etc.) that holds the components together. In this example, a chamber 1008 is formed in both the tip portion 1004 and the handle portion 1006, and the rotary connector 1022 has an opening 1030 that also provides fluid communication between the tip portion 1004 and the handle portion 1006. One or more rotary seals (not shown) may be provided to prevent leakage through the rotary connector 1022.

[0126] During use, the operator can rotate the tip portion 1004 relative to the handle portion 1006 to position the core 1012 at different angles. This helps to reach confined spaces and also provides different hand positions for using the applicator 1000 in general use. To simplify the structure, the spring 1018 and the valve 1014 are preferably located in the tip portion 1004, but this is not a strict requirement.

[0127] Figure 11 illustrates another embodiment of an applicator 1100 configured for use in a confined space. The applicator 1100 has a housing 1102 extending from a proximal end 1104 to a distal end 1106, and a chamber 1108 for holding flowable material. A collar (not shown) or other features may also be provided on the housing 1102. A drain port 1110 connects the chamber 1108 to the external environment. A core 1112 is located in and protrudes from the drain port 1110. A valve 1114 is operably connected directly or via an intermediate portion to the distal end of the core 1112 for movement with the core 1112. The core 1112 can slide along the longitudinal direction L within the drain port 1110 between an extended position and a retracted position. When the core 1112 is in the extended position, the valve 1114 abuts against and seals the corresponding first wall 1116 (e.g., the wall of chamber 1108 or the surface of a valve assembly mounted in the applicator 1100) to prevent flowable material from chamber 1108 to the core 1112. When the core 1112 is in the retracted position, the valve 1114 disengages from the first wall 1116 and allows flowable material from chamber 1108 to the core 1112. A spring 1118 is located between the valve 1114 and the second wall 1120 (e.g., the wall of chamber 1108 or the surface of a valve assembly mounted in the applicator 1100). The spring 1118 is compressed to generate an elastic biasing force that presses against the valve 1114 to bias the core 1112 to the extended position.

[0128] In this embodiment, core 1112 is configured to have a bent shape to laterally reach confined spaces, below suspensions, and corners. For example, core 1112 may include a bundle of porous fibers that is heated and bent to have permanently laterally extending L-shaped feet 1122. Feet 1122 may be supported by internal (or external) supports 1124, such as plastic rods extending along core 1112. The supports help maintain the shape of the feet 1122 portion of core 1112 and can be used to drive the feet 1122 laterally deeper into narrow spaces and press the bottom of the feet 1122 downward to address the bottom of holes. While L-shaped feet are desired in this embodiment, other embodiments may use cores with other shapes. For example, the proximal end of core 1112 may be configured as a J-hook (which may be particularly useful for reaching under flanges or rolled metal edges, such as open flanges) or have other shapes. Furthermore, in other embodiments, support 1124 may be omitted.

[0129] Figure 12 illustrates another embodiment of an applicator 1200 configured for use in a confined space. The applicator 1200 has a housing 1202 extending from a proximal end 1204 to a distal end 1206 and a chamber 1208 for holding flowable material. A collar (not shown) or other features may also be provided on the housing 1202. A drain outlet 1210 connects the chamber 1208 to the external environment. A core 1212 is located in and protrudes from the drain outlet 1210. A valve 1214 is operably connected directly or via an intermediate portion to the distal end of the core 1212 for movement with the core 1212. The core 1212 is slidable within the drain outlet 1210 between an extended position and a retracted position. When the core 1212 is in the extended position, the valve 1214 abuts against and seals the corresponding first wall 1216 (e.g., the wall of chamber 1208 or the surface of a valve assembly mounted in the applicator 1200) to prevent flowable material from chamber 1208 to the core 1212. When the core 1212 is in the retracted position, the valve 1214 disengages from the first wall 1216 and allows flowable material from chamber 1208 to the core 1212. A spring 1218 is located between the valve 1214 and a second wall 1220 (e.g., the wall of chamber 1208 or the surface of a valve assembly mounted in the applicator 1200). The spring 1218 is compressed to generate an elastic biasing force that presses against the valve 1214 to bias the core 1212 to the extended position.

[0130] In this example, the outlet 1210 and the core 1212 are oriented along axis A at an angle relative to the longitudinal direction L. For simplicity, valve 1214 and spring 1218 are also oriented along axis A, but this is not necessary in all embodiments. Axis A can be oriented at any desired angle relative to the longitudinal axis L, with 45° being a generally convenient angle for most applications. In other cases, the angle may be less than or greater than 45°. When used to treat the back of an article, an angle equal to or greater than 90° may be required, and it is conceivable that core 1212 can be oriented at an angle as large as 180° relative to the rest of the applicator 1200. Other alternatives and variations will be apparent to those skilled in the art in consideration of this disclosure.

[0131] Another drawback of conventional pen applicators is the difficulty in controlling the flow of the flowable material from the chamber to the core. Conventional systems, as shown in Figures 1 and 2, allow the operator to open and close the valve, but lack a mechanism to force the flowable medium into the core except through gravity, such as tilting or shaking the applicator. This is particularly problematic when the surface to be coated is above the core. Another issue related to flow control is that conventional applicators cannot accurately measure the amount of flowable medium, and the medium can continue to flow even after the core is saturated when the valve is open, potentially leading to dripping, pooling, and waste. Figures 13 through 17 illustrate embodiments of applicators that address one or more of these drawbacks.

[0132] Figure 13 illustrates one embodiment of an applicator 1300, configured to allow an operator to force a fluid medium from a chamber toward a core when a valve is open. The applicator 1300 has a housing 1302 extending from a proximal end 1304 to a distal end 1306 and a chamber 1308 for holding the flowable material. A collar (not shown) or other features may also be provided on the housing 1302. A discharge port 1310 connects the chamber 1308 to the external environment. A core 1312 is located in and protrudes from the discharge port 1310. A valve 1314 is operably connected directly or via an intermediate portion to the distal end of the core 1312 for movement with the core 1312. The core 1312 is slidable within the discharge port 1310 between an extended and retracted position. When the core 1312 is in the extended position, the valve 1314 abuts against and seals the corresponding first wall 1316 (e.g., the wall of chamber 1308 or the surface of a valve assembly mounted in the applicator 1300) to prevent flowable material from chamber 1308 to the core 1312. When the core 1312 is in the retracted position, the valve 1314 disengages from the first wall 1316 and allows flowable material from chamber 1308 to the core 1312. A spring 1318 is located between the valve 1314 and a second wall 1320 (e.g., the wall of chamber 1308 or the surface of a valve assembly mounted in the applicator 1300). The spring 1318 is compressed to generate an elastic biasing force that presses against the valve 1314 to bias the core 1312 to the extended position.

[0133] In this example, a portion of the housing 1302 and chamber 1308 includes a flexible wall portion, shown in Figure 13 as formed by a flexible bottle 1322, but it can take other forms. Referring to Figure 13, the flexible bottle 1322 can be compressed to generate internal pressure to force flowable material toward the core 1312, which provides the benefit of faster core saturation when the valve 1314 is opened. For example, the flexible bottle 1322 can be made of a flexible plastic material. The flexible bottle 1322 can also be transparent to allow viewing of the contents of chamber 1308. The flexible bottle 1322 can be permanently or removably attached to the remainder of the housing 1302. In this example, the proximal end of the bottle 1322 is threaded into a collar 1324 located on a rigid portion of the housing 1302 and can be removed to refill the bottle 1322. In other embodiments, the flexible bottle 1322 can be permanently attached to the remainder of the housing 1302.

[0134] The flexible bottle 1322 and the remainder of the housing 1302 are aligned along the longitudinal direction L, but this is not strictly required. In other examples, the flexible bottle 1322 may be threaded in or otherwise attached to protrude laterally from the remainder of the housing 1302 or at an angle relative to the remainder of the housing 1302. The flexible bottle 1322 may also be partially enclosed by the housing 1302, with a portion of the bottle 1322 exposed to allow a user to bend the bottle wall to force the flowable material toward the core. The flexible bottle 1322 may also be completely enclosed in the housing 1302 and compressed by a force applied by a plunger, such as a plunger located at a side end of the housing 1302. Although shown as having a cylindrical shape, the flexible bottle 1322 may have alternative shapes.

[0135] The flexible bottle 1322 shown is designed to return to its original shape after a torsional force is applied in order to serve as a handle that can be gripped by a user. However, in another alternative, the flexible bottle 1322 may include a bag-like structure (e.g., a pouch) that collapses during use. Other alternatives and variations will be apparent to those skilled in the art in light of this disclosure.

[0136] Figure 14 illustrates an embodiment of an applicator 1400 configured to allow an operator to force fluid media from a chamber to a core. The applicator 1400 has a housing 1402 extending from a proximal end 1404 to a distal end 1406 and a chamber 1408 for holding the flowable material. A collar (not shown) or other features may also be provided on the housing 1402. A drain port 1410 connects the chamber 1408 to the external environment. A core 1412 is located in and protrudes from the drain port 1410. A valve 1414 is operably connected directly or via an intermediate portion to the distal end of the core 1412 for movement with the core 1412. The core 1412 is slidable within the drain port 1410 between an extended position and a retracted position. When the core 1412 is in the extended position, the valve 1414 abuts against and seals the corresponding first wall 1416 (e.g., the wall of chamber 1408 or the surface of a valve assembly mounted in the applicator 1400) to prevent flowable material from chamber 1408 to the core 1412. When the core 1412 is in the retracted position, the valve 1414 disengages from the first wall 1416 and allows flowable material from chamber 1408 to the core 1412. A spring 1418 is located between the valve 1414 and the second wall 1420 (e.g., the wall of chamber 1408 or the surface of a valve assembly mounted in the applicator 1400). The spring 1418 is compressed to generate an elastic biasing force that presses against the valve 1414 to bias the core 1412 to the extended position.

[0137] In this example, a portion of chamber 1408 is formed as a user-accessible flexible membrane 1422. When valve 1414 is open, the user can press down on the flexible membrane 1422 to generate internal pressure within chamber 1408, forcing flowable material toward core 1412. Alternatively, core-operated valve 1414 can be omitted and replaced with a valve, such as the one described in FIG. 24, which automatically opens when sufficient pressure is applied to the flexible membrane 1422 to move flowable material from chamber 1402 to core 1412.

[0138] The flexible membrane 1422 may comprise any suitable flexible material, and it may be transparent to allow observation within the chamber 1408. The flexible membrane 1422 may also be located under a removable cover to prevent accidental operation. The flexible membrane 1422 may also be located within the housing 1402 and operated by an intermediate device (e.g., a button or plunger via the wall of the housing 1402). Other alternatives and variations will be apparent to those skilled in the art in light of this disclosure.

[0139] Figure 15 illustrates one embodiment of an applicator 1500 configured to prevent excessive deposition of flowable material when the core is moved to a fully retracted position. The applicator 1500 has a housing 1502 extending from a proximal end 1504 to a distal end 1506 and a chamber 1508 for retaining the flowable material. A collar (not shown) or other features may also be provided on the housing 1502. A drain outlet 1510 connects the chamber 1508 to the external environment. A core 1512 is located in and protrudes from the drain outlet 1510. A valve 1514 is operably connected directly or via an intermediate portion to the distal end of the core 1512 to move with the core 1512. The core 1512 is slidable within the drain outlet 1510 between an extended position and a retracted position. When the core 1512 is in the extended position, the valve 1514 abuts against and seals the corresponding first wall 1516 (e.g., the wall of chamber 1508 or the surface of a valve assembly mounted in the applicator 1500) to prevent flowable material from chamber 1508 to the core 1512. When the core 1512 is in the retracted position, the valve 1514 disengages from the first wall 1516 and allows flowable material to pass from chamber 1508 to the core 1512. A spring 1518 is located between the valve 1514 and the second wall 1520 (e.g., the wall of chamber 1508 or the surface of a valve assembly mounted in the applicator 1500). The spring 1518 is compressed to generate an elastic biasing force that presses against the valve 1514 to bias the core 1512 to the extended position.

[0140] In this example, valve 1514 is located in sub-chamber 1522, which lies between the main volume of chamber 1508 and core 1512. Sub-chamber 1522 is fluidly connected to the main volume of chamber 1508 via passage 1524, and spring 1518 may be located within sub-chamber 1522, as shown, or it may extend through opening 1524. Valve 1514 has a secondary seal 1526 that abuts and closes passage 1524 when core 1512 and valve 1514 are moved to the fully retracted position. Any type of sealing surface can be used (e.g., end face seal, conical seal (as shown), metering needle, etc.). This configuration prevents flowable material from continuing through the core when it is fully retracted and provides some measures to prevent over-dispensing of material.

[0141] Figure 16 illustrates an example of an applicator 1600 that prevents over-dispensing of flowable material when the core is retracted and provides precise metering of a fixed volume of flowable material when the core returns from the retracted position to the extended position. The applicator 1600 has a housing 1602 extending from a proximal end 1604 to a distal end 1606 and a chamber 1608 for retaining the flowable material. A collar (not shown) or other features may also be provided on the housing 1602. A drain port 1610 connects the chamber 1608 to the external environment. A core 1612 is located in and protrudes from the drain port 1610. A valve 1614 is operably connected directly or via an intermediate portion to the distal end of the core 1612 for movement with the core 1612. The core 1612 can slide within the drain port 1610 between the extended and retracted positions. When the core 1612 is in the extended position (shown on the left side of FIG. 16), the valve 1614 abuts against and seals the corresponding first wall 1616 (e.g., the wall of chamber 1608 or the surface of a valve assembly mounted in the applicator 1600) to prevent flowable material from chamber 1608 to the core 1612. When the core 1612 is in the retracted position (shown on the right side of FIG. 16), the valve 1614 disengages from the first wall 1616 and allows flowable material to flow from chamber 1608 to the core 1612. A spring 1618 is located between the valve 1614 and the second wall 1620 (e.g., the wall of chamber 1608 or the surface of a valve assembly mounted in the applicator 1600). The spring 1618 is compressed to generate an elastic biasing force that presses against the valve 1614 to bias the core 1612 to the extended position.

[0142] In this example, valve 1614 includes an assembly with a piston 1622 connected to move with core 1612 and sliding within cylinder 1624. The outer periphery of piston 1622 has one or more seals 1626 (e.g., O-rings or wiper seals) that contact cylinder 1624 to prevent flow of flowable material at the sliding intersection. Valve 1614 or first wall 1616 may also have face seals 1628 (e.g., O-rings or packing) to seal core 1612 when it is in the extended position. Piston 1622 includes one or more one-way valves 1630 configured to open when core 1612 and piston 1622 move from the extended position to the retracted position to allow flowable material through piston 1622, and to close when core 1612 and piston 1622 move from the retracted position to the extended position to prevent flow of flowable material through piston 1622.

[0143] The one-way valve 1630 may include any suitable mechanism that allows flow in one direction but prevents flow in other directions. The valve 1630 shown is a lift valve, but other examples include ball valves, baffle valves, and reed valves. Such devices typically include a separate or integral spring to hold the valve in the closed position, and the shape of the valve and seat is such that excess hydraulic pressure on one side of the valve forces the valve into the seat to maintain a seal, while excess hydraulic pressure on the other side causes the valve to move away from the seat against the bias of the spring to open the seal. Such devices are conventional and do not require further description here.

[0144] A perimeter seal 1626 and a one-way valve 1630 cooperate to form a variable-sized chamber 1634 between the piston 1622 and the core 1612. When the core 1612 moves to the retracted position, the chamber 1634 expands and fills with flowable material, and when the core 1612 moves to the extended position, the chamber 1634 contracts. During this extension, the seal 1626 and the one-way valve 1636 apply pressure to the flowable material to force it into the core 1612. The magnitude of the force depends on the spring constant of the spring 1618. The size of the chamber 1634 can be selected to provide the desired volume of flowable material during each stroke toward the extended position. If desired, the chamber 1634 may also include a mechanism (e.g., a movable wall) for changing its volume to allow the operator to adjust the dispensing volume. The applicator 1600 may also include a scale to indicate how much volume was dispensed as the operator retracts the core 1612 a certain distance. In light of this disclosure, other alternatives and variations will be readily apparent to those skilled in the art.

[0145] In this embodiment, the cylinder 1624 is optionally separated from the remainder of the chamber 1608 by an intermediate wall such as a second wall 1620, and a one-way valve 1632 may be disposed in the passage connecting the chamber 1608 to the piston. When the core 1612 moves to the retracted position, the one-way valve 1632 prevents flowable material from leaving the cylinder 1624. This helps ensure that flowable material is forced through the one-way valve 1630 in the piston 1622 to fill the variable-sized chamber 1636.

[0146] Figure 17 shows another example of an applicator 1700 that prevents over-dispensing of flowable material and provides precise metering of a fixed volume of flowable material. The applicator 1700 has a housing 1702 extending from a proximal end 1704 to a distal end 1706 and a chamber 1708 for holding the flowable material. A collar (not shown) or other features may also be provided on the housing 1702. A drain outlet 1710 connects the chamber 1708 to the external environment. A core 1712 is located in and protrudes from the drain outlet 1710. In this case, the core 1712 can be rigidly fixed in the drain outlet 1710, and the valve is replaced by a movable piston 1722 that slides within the chamber 1708. The piston 1722 functions as a valve. Similar to the embodiment of Figure 16, piston 1722 has a peripheral seal 1726 that seals against the chamber wall, and one or more one-way valves 1730 that prevent flowable material from passing through piston 1722 when piston moves toward core 1712, but allow flowable material to pass through piston 1722 when piston retracts from core 1712. In this case, one-way valve 1730 is shown as a baffle or reed valve (i.e., a flexible cantilever baffle covering the orifice). Spring 1718 is located between piston 1722 and core 1712 and is configured to bias piston 1722 away from core 1712.

[0147] Piston 1722 is manually operated by the user to move against the bias of spring 1718. Any suitable mechanism can be used to provide this control. For example, piston 1722 can be connected to rod 1732, which extends through opening 1734 at the distal end 1706 of housing 1702. Seal 1736 (e.g., a sliding seal or a gland seal) prevents flowable material from leaving at the sliding intersection. Rod 1723 can terminate at its distal end with an enlarged button 1738. Flexible diaphragm 1740 can also be provided to seal the end of rod 1723 and provide additional protection against flowable material leaving housing 1702 at that position. In use, the operator presses button 1738, moving the piston from the retracted position (shown on the right in Figure 17) to the extended position (shown on the left in Figure 17). During this movement, one-way valve 1730 closes, and flowable medium between piston 1722 and core 1712 is forced into core 1712. If necessary, an additional flow passage and check valve may be provided between button 1738 and piston 1722 to force flowable material through one-way valve 1730 in piston 1722 when piston moves to the retracted position, as described in the embodiment with respect to FIG. 16. Other alternatives and variations will be apparent to those skilled in the art in consideration of this disclosure.

[0148] Another problem with current pen-type applicators is that it is impossible to reverse the movement of the flowable material from the core and back into the chamber, except by flipping the applicator and pressing down the core. Even so, the core tends to retain the flowable material through capillary action, and the atmospheric pressure on the exposed side of the core is insufficient to overcome this capillary action. The embodiments of Figures 18a and 18b at least partially solve this problem.

[0149] The applicator 1800 has a housing 1802 extending from a proximal end 1804 to a distal end 1806 and a chamber 1808 for holding flowable material. A collar (not shown) or other features may also be provided on the housing 1802. A drain port 1810 connects the chamber 1808 to the external environment. A core 1812 is located in and protrudes from the drain port 1810. In this configuration, the core 1812 may be rigidly fixed in the drain port 1810, and the valve is replaced by a movable piston 1822 that slides within the chamber 1808. Similar to the embodiment of FIG. 16, the piston 1822 has a peripheral seal 1826 that seals against the chamber wall, and one or more first one-way valves 1830 that prevent flowable material from passing through the piston 1822 as the piston moves toward the core 1812, but allow flowable material to pass through the piston 1822 when the piston retracts from the core 1812. Piston 1822 is movable by control rod 1832, and spring 1818 is configured to bias piston 1822 away from core 1812. Thus, similar to the embodiment of FIG. 17, piston 1822 moves by pressing against control rod 1832 against the bias of spring 1818.

[0150] Piston 1822 also has one or more second check valves 1834 constructed in the opposite manner to the first check valve 1830; that is, when piston 1822 moves toward core 1812, the second check valve 1834 allows flowable material to pass through piston 1822, but prevents flowable material from passing through piston 1822 when piston 1822 moves away from core 1812. Valve controller 1836 is configured to selectively activate either the first check valve 1830 or the second check valve 1834. In this case, valve controller 1836 includes a cap pivotally attached to piston control rod 1832 and connected via a tube 1840 surrounding piston control rod 1832 to a knob 1838 located outside housing 1802. The position of piston 1822 is controlled by pushing down or pulling up on knob 1838, and valve controller 1836 is operated by rotating knob 1838. When valve controller 1836 is oriented to cover the first check valve 1830, as shown in FIG18A, the first check valve 1830 is disabled and the second check valve 1834 is enabled. When valve controller 1836 is oriented to cover the second check valve 1834, as shown in FIG18B, the first check valve 1830 is enabled and the second check valve 1834 is disabled. (FIG. 18B shows the first check valve 1830 in the open position without spring 1818.) In use, the operator can push and pull knob 1838 to move the piston toward or away from core 1812, and can rotate knob 1838 to operate valve controller 1836.

[0151] As with other embodiments, various seals and caps can be provided to prevent leakage of flowable material around knob 1838. A fixed stroke stop (not shown) can be provided within chamber 1802 to prevent piston 1822 from retracting further than desired. One or more adjustable stroke stops, such as screws 1842 and 1844, can also be provided to selectively control the stroke range of the piston. In this case, first screw 1842 can be adjusted to control the distance piston 1822 can retract from core 1812 (e.g., by abutting piston 1822), and second screw 1844 can be adjusted to control the distance piston 1822 can move toward core 1812 (e.g., by abutting knob 1838). Other alternatives and variations will be apparent to those skilled in the art in consideration of this disclosure.

[0152] The embodiments of Figures 18a and 18B offer a unique advantage by allowing the operator to manipulate the valve controller 1836 to control whether the piston 1822 pumps flowable material toward or away from the core 1812. Thus, when the core 1812 becomes oversaturated, or when preparation for operation is complete, the operator can pull the flowable material away from the core 1812. It will be understood that other embodiments may use alternative flow control mechanisms. For example, the rotary plate flow controller 1836 can be replaced by any suitable alternative mechanism, such as a cam-operated pin that extends to lock one or more check valves.

[0153] Another problem with conventional pen-type applicators is that they cannot be used to access narrow and deep openings. Even when the applicator is made relatively small, it still cannot reach certain corners or around other obstacles to apply material to certain areas. These problems can be at least partially solved by the embodiments shown in Figures 19-23.

[0154] Figure 19 illustrates an applicator 1900 having a housing 1902 extending from a proximal end 1904 to a distal end 1906 and an extension rod 1922 extending from the proximal end 1904. A core 1912 extends from the proximal end of the extension rod 1922. The applicator 1900 also includes other features such as a chamber for receiving flowable material, a valve, etc. The extension rod 1922 comprises a physical extension of the housing 1902 and may be rigid or have some flexibility to allow the user to precisely guide the core 1912 into confined spaces. The housing 1902 may include one or more types of ribs, such as those described with respect to Figure 9, to enhance user control over the applicator 1900. Any suitable triggering mechanism can be provided to actuate the internal valve to dispense flowable material. For example, the core 1912 may extend the full length of the extension rod 1922 and be movable to activate a valve located within the housing 1902. As another example, the core 1912 may be slidably held just at the end of the extension rod 1922 and is provided with a push rod to activate a valve located in the housing 1902. As yet another example, the valve may be located near the proximal end of the extension housing, adjacent to the core 1912, to allow for more localized operation of the core 1912. Alternatively, the extension rod 1922 may be a hollow tube, with the core 1912 fixed within the tube's cavity, and the valve may be located in the housing or near the end of the tube, actuated by a trigger on the housing or tube. As in other embodiments, a cap 1924 may be provided to cover the core 1912 when the device is not in use.

[0155] The embodiment of Figure 19 offers advantages when working surfaces in deep grooves. This functionality is enhanced by making the extension rod 1922 relatively narrow compared to the housing 1902 and not significantly larger than the core 1912 (and preferably approximately the same diameter as the core 1912). In this example, the diameter of the extension rod 1922 is no more than about 20% larger than the maximum diameter of the core 1912, more preferably no more than 10%. Alternatively, the core 1912 can be similar to the core of Figure 7, extending beyond the diameter of the rod by 1-50% or more, preferably no more than 10%.

[0156] Figure 19 also illustrates an alternative embodiment of core 1912, wherein core 1912 has a stepped shape. The proximal end 1926 of core 1912 is relatively small and flexible enough to bend and fit into narrow spaces and corners, while the distal end 1928 of core 1912 is relatively large and sufficiently rigid to be pressed against a surface with some force to activate the valve and deposit flowable material. Optionally, the transition portion 1930 of core 1912 between the proximal end 1926 and the distal end 1928 can be shaped to address specific features that may be encountered during the use of applicator 1900. For example, the transition portion 1930 can be tapered to facilitate the application of flowable material to a chamfered opening that receives a corresponding tapered fastener head for a flush seat of the fastener head. Other embodiments may use more than one proximal tip 1926. For example, core 1912 may have multiple flexible “finger” extensions extending from it in one or more directions. Other alternatives and variations will be apparent to those skilled in the art in light of this disclosure. Such a core can be used in any of the other embodiments described herein.

[0157] Figure 20 illustrates another embodiment of the applicator 2000 for treating surfaces that are distant or relatively difficult to reach. Here, the applicator 2000 has a housing 2002 extending from a proximal end 2004 to a distal end 2006, with a chamber 2008 for receiving a flowable material. A collar (not shown) or other features may also be provided on the housing 2002. An outlet 2010 connects the chamber 2008 to the external environment. A flexible hollow tube 2022 extends from the outlet 2010, and a core 2012 is located within and protrudes from the cavity of the flexible hollow tube. A valve 2014 is operatively connected to the proximal end 2004 of the housing 2002, and the proximal end 2004 of the housing 2002 is movable relative to the distal end 2006 of the housing 2002. For example, the proximal end 2004 may include a piston-like structure fitted into a cylindrical structure formed in the distal end 2006. A seal 2024 can be provided to prevent leakage at the sliding joint. When the distal end 2002 is in the extended position, the valve 2014 abuts against and seals the corresponding first wall 2016 (e.g., the wall of chamber 2008 or the surface of a valve assembly mounted in the applicator 2000) to prevent flowable material from chamber 2008 to core 2012. When the proximal end 2004 is in the retracted position, the valve 2014 disengages from the first wall 2016 and allows flowable material to flow from chamber 2008 to core 2012. A spring 2018 is located between the valve 2014 and the second wall 2020 (e.g., the wall of chamber 2008 or the surface of a valve assembly mounted in the applicator 2000). The spring 2018 is compressed to generate an elastic biasing force that presses against the valve 2014 to bias the proximal end 2004 to the extended position.

[0158] In use, the operator can squeeze the housing 2002 with one hand to move the proximal end 2004 towards the distal end 2006. This movement counteracts the bias of the spring 2018, disengaging the valve 2014 and allowing flowable material to flow from the chamber 2008 through the core 2012, thereby wetting the core 2012. When the user releases the pressure, the spring 2018 separates the proximal end 2004 and the distal end 2006 to reseat the valve and seal the applicator 2000. The user can then guide the core 2012 into contact with the surface to be coated by moving the entire applicator 2000 or by gripping and manipulating the tube near the core 2012.

[0159] This embodiment provides a relatively simple structure for the applicator 2000 with a flexibly mountable core 2012. The lumen 2022 can comprise any suitable material, such as a flexible polymer or rubber. The lumen 2022 can also be filled with the core material or with capillary filling to prevent free flow of flowable material from the core 2012 when the device is not in use. As in other embodiments, a flexible cap 2026 can be provided on the core 2012 and can help handle narrow cracks or holes, or other confined spaces with uneven surfaces (where the core 2012 may not be maneuverable), or can be flexible enough to conform to surface irregularities.

[0160] Figures 21A and 21B illustrate another embodiment of the applicator 2100, designed to treat surfaces that are distant or relatively difficult to reach. Here, the applicator 2100 has a housing 2102 extending from a proximal end 2104 to a distal end 2106, with a chamber 2108 for receiving flowable material. A collar (not shown) or other features may also be provided on the housing 2102. An outlet 2110 connects the chamber 2108 to the external environment. A flexible lumen 2122 extends from the outlet 2110, and a core 2112 is located within and protrudes from the flexible lumen 2122. A valve 2114 is provided in the housing 2102 to selectively prevent flow of flowable material from the chamber 2108 to the core 2112. In this case, the valve 2114 is operated by a trigger 2124 located on the side of the housing 2102. The valve 2114 is movable between a first position (Figure 21a) and a second position (Figure 21b). In the first position, valve 2114 abuts against and seals against the corresponding first wall 2116 (e.g., the wall of chamber 2108 or the surface of a valve assembly mounted in applicator 2100) to prevent flowable material from chamber 2108 to core 2112. In the second position, valve 2114 disengages from the first wall 2116 and allows flowable material to pass from chamber 2108 to core 2112. Spring 2118 is located between valve 2114 and second wall 2120 (e.g., the wall of chamber 2108 or the surface of a valve assembly mounted in applicator 2100). Spring 2118 is compressed to generate an elastic biasing force that presses against valve 2114 to bias valve 2114 to the first position.

[0161] Trigger 2124 may include any suitable mechanism. For example, in the illustrated embodiment, trigger 2124 includes a cam 2126 connected to valve 2114 and a cam driver 2128 movably mounted to housing 2102. Cam driver 2128 is configured to abut against cam 2126. Cam driver 2128 is movable between a first position (FIG. 21a) and a second position (FIG. 21b), in which cam driver 2128 allows valve 2114 to move to a first (i.e., closed) position, and in the second position, cam driver 2128 pushes against cam 2126 to hold valve 2114 in the second (i.e., closed) position. Cam driver 2128 may be pivotally, slidably, rotatably, or otherwise movably mounted to housing 2102. In this case, cam driver 2128 is pivotally mounted to housing, and a return spring 2130 may be provided to bias cam driver 2128 to the first position. Any suitable seal may be used to prevent leakage of flow material around the trigger components. In this configuration, a seal is provided by a flexible cap 2132 covering the cam drive 2128. During use, the operator presses the cam drive 2128 to open the valve 2114 and dispense flowable material into the core 2112.

[0162] Figures 22A and 22B illustrate another embodiment of the applicator 2200, designed to treat surfaces that are distant or relatively difficult to reach. Here, the applicator 2200 has a housing 2202 extending from a proximal end 2204 to a distal end 2206, with a chamber 2208 for receiving flowable material. A collar (not shown) or other features may also be provided on the housing 2202. An outlet 2210 connects the chamber 2208 to the external environment. A flexible tube 2222 extends from the outlet 2210 to a valve assembly 2224. A core 2212 protrudes from the valve assembly 2224. The valve assembly 2224 is configured to selectively prevent flowable material from the tube 2222 to the core 2212. In this case, the valve assembly 2224 includes a valve 2214 movable between a first position (Figure 22a) and a second position (Figure 22B). In the first position, valve 2214 abuts against and seals the corresponding first wall 2216 to prevent flowable material from reaching the core 2212. In the second position, valve 2214 disengages from the first wall 2216 and allows flowable material to reach the core 2212. Spring 2218 is located between valve 2214 and the second wall 2220. Spring 2218 is compressed to generate an elastic biasing force that presses against valve 2214 to bias valve 2214 to the first position.

[0163] Valve assembly 2224 includes any mechanism suitable for operating valve 2214. For example, in the illustrated embodiment, valve assembly 2224 includes a cam 2226 connected to valve 2214 and a cam driver 2228 movably mounted to trigger assembly 2224. Cam driver 2228 is configured to abut against cam 2226. Cam driver 2228 is movable between a first position (FIG. 22a) and a second position (FIG. 22B), in which cam driver 2228 allows valve 2214 to move to a first (i.e., closed) position, and in the second position, cam driver 2228 pushes against cam 2226 to hold valve 2214 in a second (i.e., closed) position. Cam driver 2228 may be pivotally, slidably, rotatably, or otherwise movably mounted to valve assembly 2224. In this case, cam driver 2228 is pivotally mounted to valve assembly 2224. A return spring (not shown) can be provided to bias the cam driver 2228 to a first position, or this return motion can be provided by the biasing force of the spring 2218 acting on the cam 2226. Any suitable seal can be used to prevent leakage of flowing material around the trigger assembly components.

[0164] The applicator 2200 of Figures 22A and 22B is intended to be particularly useful for providing one-handed operation of the applicator 2200. For example, the trigger assembly 2224 can be configured as a small rigid housing that the operator can actuate to wet the core 2212 with the flowable material, then manipulate the tube 2222 to guide the core 2212 to the desired treatment location, and then actuate the valve 2214 to dispense more flowable material as needed. The housing 2202 can then be attached to a nearby structure (e.g., scaffolding or ladder), or to a carrier or the operator's body (e.g., via a wristband), preferably to facilitate gravity feeding of the flowable material. If desired, a second valve can be provided on the housing 2202 to provide a flow cutoff at the housing 2202.

[0165] It will also be understood that the side-operated trigger shown in Figures 22A and 22B can be replaced by other trigger mechanisms to operate valve 2214. For example, valve assembly 2224 may be configured with a pistol grip and trigger. Other alternatives and variations will be apparent to those skilled in the art in light of this disclosure.

[0166] Figure 23 illustrates another embodiment of the applicator 2300, designed to treat surfaces that are distant or relatively difficult to reach. Here, the applicator 2300 has a housing 2302 extending from a proximal end 2304 to a distal end 2306, with a chamber 2308 for receiving flowable material. A collar (not shown) or other features may also be provided on the housing 2302. An outlet 2310 connects the chamber 2308 to the external environment. A flexible cavity 2322 extends from the outlet 2310 to a valve assembly 2324. A core 2312 protrudes from the valve assembly 2324. The valve assembly 2324 is configured to selectively prevent flowable material from the cavity 2322 to the core 2312. In this case, the valve assembly 2324 includes a piston 2326 that slides within a cylinder 2328. Piston 2326 is sealed against cylinder 2328 by a perimeter seal (not shown) and has one or more one-way valves 2330 that allow flowable material to flow from cavity 2322 to core 2312 but prevent flowable material from flowing in the opposite direction. Spring 2318 is located in cylinder 2328 and configured to bias piston 2326 away from core 2312. Check valve 2332 connects cavity 2322 to cylinder 2328 and is configured to allow flowable material to pass from cavity 2322 to cylinder 2328 but prevent flow in the opposite direction.

[0167] The trigger assembly 2324 also includes a push rod 2334 extending from the piston 2326 to the plunger 2336, which is located in an operator-accessible position. One or more triggers 2338 may be located on the trigger assembly 2324 adjacent to the plunger 2336. The piston 2326 is operated by holding the plunger 2336 and triggers 2338 in one hand and squeezing them together to overcome the bias of the spring 2318. This moves the piston 2326 toward the core 2312 while the one-way valve 2330 remains closed, thereby forcing flowable material toward the core 2312. When the plunger 2336 and triggers 2338 are released, the spring 2318 moves the piston 2326 away from the core 2312, and the one-way valve 2330 opens to allow flowable material to pass through it. During the return stroke, the check valve 2332 closes to prevent flowable material from flowing out of the cylinder 2328 and into the lumen 2322.

[0168] Using such a trigger 2324 at the end of the lumen 2322 can provide the advantage of controlling the flow of flowable material while minimizing the amount of flowable material retained between the valve and the core 2312. This reduces the amount of flowable material that may potentially escape from the applicator 2300 when the applicator is not in use.

[0169] If needed, trigger assembly 2324 may include or be shaped as extension rod 2340, which provides remote operation and control of core 2312. For example, in the embodiment of FIG. 23, an operator may hold plunger 2336 and trigger 2338 and use them to manipulate core 2312 into narrow spaces and under overhanging features.

[0170] Figure 24 illustrates another embodiment of the applicator 2400, designed to treat surfaces that are distant or relatively difficult to reach. Here, the applicator 2400 has a housing 2402 extending from a proximal end 2404 to a distal end 2406, with a chamber 2408 for containing flowable material. A collar (not shown) or other features may also be provided on the housing 2402. An outlet 2410 connects the chamber 2408 to the external environment. A flexible lumen 2422 extends from the outlet 2410 to a valve assembly 2424. A core 2412 protrudes from the valve assembly 2424. The valve assembly 2424 is configured to selectively prevent flowable material from the chamber 2422 to the core 2412. In this case, the valve assembly 2424 includes a flexible chamber 2426 located between an upstream check valve 2428 and a downstream check valve 2430. An operator can squeeze the chamber to force its contents through the downstream check valve 2430 and to the core 2412. During the extrusion process, the upstream check valve 2428 prevents flowable material from returning to the flexible lumen 2422. When the chamber 2426 is released, it returns to its original shape and is refilled by pulling flowable material through the upstream check valve 2428. Check valves 2428 and 2430 may include any suitable one-way valve. The downstream check valve 2430 preferably includes a one-way valve that is normally biased to a closed position by a spring 2432, etc., to prevent fluid leakage when no extrusion pressure is applied to the chamber 2426. The illustrated chamber 2426 comprises a bulb-shaped chamber that is flexible around its entire perimeter. An alternative chamber 2426 may be only partially flexible, such as the chamber described herein in conjunction with Figure 14.

[0171] For example, as shown in Figures 22a-24, using a valve at the end of the flexible lumen is expected to provide the benefit of controlling the flow of flowable material while minimizing the amount of flowable material retained between the valve and the core. This reduces the amount of flowable material that may escape from the applicator when not in use. However, in each case, the applicator can be modified to include a valve in the housing, for example, as shown in Figures 20-21B, to provide redundant flow control mechanisms. It will also be understood that the valve mechanisms shown in Figures 22A-24 can be used in embodiments without a flexible lumen. For example, the bulb-shaped cavity 2426 of Figure 24 and the associated valve can be mounted directly to the proximal end of the housing without an intermediate flexible lumen.

[0172] Figure 25 illustrates another embodiment of an applicator 2500 configured for use in a confined space. The applicator 2500 has a housing 2502 extending from a proximal end 2504 to a distal end 2506, and a chamber 2508 for holding flowable material. A collar (not shown) or other features may also be provided on the housing 2502. A drain port 2510 connects the chamber 2508 to the external environment. A core 2512 is located in and protrudes from the drain port 2510. A valve 2514 is operably connected directly or via an intermediate portion to the distal end of the core 2512 for movement with the core 2512. The core 2512 is slidable within the drain port 2510 between an extended position and a retracted position. When the core 2512 is in the extended position, the valve 2514 abuts against and seals the corresponding first wall 2516 (e.g., the wall of chamber 2508 or the surface of a valve assembly mounted in the applicator 2500) to prevent flowable material from chamber 2508 to the core 2512. When the core 2512 is in the retracted position, the valve 2514 disengages from the first wall 2516 and allows flowable material to pass from chamber 2508 to the core 2512. A spring 2518 is located between the valve 2514 and the second wall 2520 (e.g., the wall of chamber 2508 or the surface of a valve assembly mounted in the applicator 2500). The spring 2518 is compressed to generate an elastic biasing force that presses against the valve 2514 to bias the core 2512 to the extended position.

[0173] In this example, the discharge housing 2502 includes a flexible segment 2522 located between the distal end 2506 and the proximal end 2504 of the housing 2502. The flexible segment 2522 includes a region in which the housing 2502 is sufficiently flexible to allow the proximal end 2504, and therefore the core 2512, to be reoriented relative to the distal end 2506. The flexible segment 2522 may include, for example, a bellows-shaped cylindrical portion of the housing 2502 located between the valve 2514 and the distal end 2506. In this case, the core 2512 and the valve 2514 can be reoriented by bending the bellows. The bellows may comprise a portion integrally formed of the housing 2502, and may have a reduced wall thickness to facilitate bending. Alternatively, the bellows or other flexible segment 2522 may comprise a separate portion, such as a flexible guide, attached to the remainder of the housing. Other alternatives and variations will be apparent to those skilled in the art in light of this disclosure.

[0174] It should be understood that all or none of the above embodiments may be used for smaller cores, and this feature is not particularly required in any embodiment.

[0175] It will also be understood that the features described herein are shown in exemplary schematic configurations, and embodiments may include more sophisticated mechanisms or mechanisms with different shapes and sizes. For example, the valve mechanisms shown herein are generally illustrated in schematic form, but they may be replaced by any suitable corresponding mechanism or component having any number of operating parts. Non-limiting examples of alternative valve mechanisms are described in U.S. Patents 5,702,759; 4,848,947; 4,685,820 and 4,792,252, which are incorporated herein by reference. As another example, various fasteners or connecting components may be provided to connect these components to each other. For example, retaining clips, pins, adhesives or the like may be provided to hold the valve on the core when uniform movement of the components is required, and the core or other moving components may have other features to prevent extension or contraction beyond the desired travel limit. As another example, the springs discussed in the various embodiments may include any suitable spring, exemplary choices being: non-conical and conical helical springs, Bevel washer-type springs, cantilever leaf springs, elastic blocks, etc. Springs may also be mounted to act in compression or tension. In light of this disclosure, other alternatives and variations will be readily apparent to those skilled in the art.

[0176] This disclosure describes numerous inventive features and / or combinations thereof that can be used alone, in combination with each other, or in conjunction with other technologies. The embodiments described herein are exemplary and are not intended to limit the scope of the claims. It will also be understood that the invention described herein can be modified and adapted in various ways, and all such modifications and adaptations are intended to be included within the scope of this disclosure.

Claims

1. An applicator, comprising: A housing (302, 402, 502, 602, 702, 802, 902, 1002, 1102, 1902) having chambers (308, 408, 508, 608, 708, 808, 1008, 1108), an outlet (310, 410, 510, 610, 710, 810, 1010, 1110), and in a closed position where the outlet is not in fluid communication with the chamber, and in a position where the outlet is in fluid communication with the chamber. The valve (314, 414, 514, 614, 714, 814, 1014, 1114) movable between open and closed positions, and valve spring (318, 418, 518, 618, 718, 818, 1018, 1118) configured to bias the valve to the closed position; and core (312, 412, 512, 612, 712, 812, 912, 1012, 1112, 1912), the core being... The applicator is movably connected to the housing and configured to transfer axial loads to the valve to move the valve from a closed position to an open position. The core comprises a material adapted to receive fluid from a discharge port and transfer the fluid to a location outside the housing. The applicator is characterized by: means (322, 422, 522, 622, 722, 824, 922, 1021, 1124, 1922, 1930) for supporting and / or increasing the stiffness of the core; wherein the means (322, 522, 622, 824, 922, 1922) for supporting and / or increasing the stiffness of the core includes a tube surrounding at least a portion of the core; wherein the core is mounted to the tube to be movable between an extended position and a retracted position, and a core spring (526) is operably positioned between the core and the tube and configured to bias the core to the extended position; and wherein the core spring has a lower spring constant than the valve spring.

2. The applicator according to claim 1, wherein, The tube surrounding the core includes one or more lateral openings (324, 530, 626, 924) extending through the wall of the tube.

3. The applicator according to claim 2, wherein, The one or more lateral openings are located outside the housing.

4. The applicator according to claim 2, wherein, The one or more lateral openings are located within the housing.

5. The applicator according to claim 1, wherein, The tube includes a trigger (624) located outside the housing, and the trigger is configured to be operated to move the valve from a closed position to an open position.

6. The applicator according to claim 5, wherein, The housing also includes a gripping surface (628) spaced apart from the trigger, and the gripping surface is configured to be held in place against forces applied to the trigger.

7. The applicator according to claim 1, wherein, The core includes one selected from a chisel tip core (812') having a tapered proximal end, a core (812'') having a spherical proximal end, a core (812''') having an inverted tapered proximal end, a core (812'''') having an enlarged cylindrical end, and a core (812''''') having a bevel or chisel tip, which are interchangeably connected to the tube.

8. The applicator according to claim 1, wherein, The housing includes a tip portion (1004) and a handle portion (1006), and the tip portion is movable relative to the handle portion.

9. The applicator according to claim 8, wherein, The tip portion is connected to the handle portion via a rotating connector (1022).

10. The applicator according to claim 1, wherein, The device for supporting and / or increasing the stiffness of the core includes a rigid fiber bundle forming a first portion of the core, which has greater stiffness than a second portion of the core including the outer layer.

11. The applicator according to claim 1, wherein, The applicator is characterized by a means for positioning the core relative to at least a portion of the housing at a non-zero angle.

12. The applicator according to claim 11, wherein, The proximal portion of the housing is connected to the distal portion of the housing via a swivel connector (1022) or a flexible section (2522).

13. The applicator according to claim 11, wherein, The device for positioning a core relative to at least a portion of a housing at a non-zero angle includes a proximal portion of the housing positioned at a non-zero angle relative to a distal portion of the housing, and an outlet (1210) and a core (1212) oriented along an axis (A) at an angle relative to the longitudinal direction (L).

14. The applicator of claim 11 further includes means for adjusting the volume of the flow, said means for adjusting the volume of the flow including flexible walls of chambers (1008, 1208, 2008, 2108, 2208, 2308, 2408, 2508) configured to be compressed to increase the volume of the flow.

15. The applicator according to claim 14, wherein, The housing (1002, 1202, 2002, 2102, 2202, 2302, 2402, 2502) includes a flexible bottle forming a flexible wall, or a portion of the housing includes a flexible membrane forming the flexible wall.

16. The applicator according to claim 11, wherein, The non-zero angle is greater than or equal to 1 degree relative to the longitudinal direction (L) of the housing, and the means for positioning the core relative to at least a portion of the housing includes a proximal portion of the housing that is movable relative to a distal portion of the housing.

17. The applicator according to claim 13, wherein, The valve (1214) and valve spring are also oriented along axis (A).

18. A method for applying a metal pretreatment material to a complex geometry on a metal surface, the method comprising the step of contacting the complex geometry of the metal surface with the core of the applicator according to claim 1, wherein, The core receives metal pretreatment fluid from the outlet and allows the metal pretreatment fluid to pass to the metal surface being contacted.

19. The method according to claim 18, wherein, The applicator also includes one or more of the following: means for regulating the volume of the flow from the chamber to the core; means for positioning the core relative to at least a portion of the housing at a non-zero angle.

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