Portable battery powered liquid sprayer

Abstract

A portable battery powered liquid sprayer includes a supply canister assembly, a body assembly, a battery, and a wand. The supply tank assembly contains a liquid to be sprayed. The body assembly is selectively coupled to and supported by the supply canister assembly. The body assembly receives the motor and the pump. A battery is removably coupled to the body assembly and is operable to power the motor. The wand is movable relative to the body assembly and is in fluid communication with the supply canister assembly. The wand includes a nozzle, and the wand is operable to activate a motor that drives a pump to pump liquid from the supply canister assembly to eject liquid from the nozzle.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 270,834, filed on October 22, 2021, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates generally to liquid sprayers, and more particularly to portable battery-powered liquid sprayers. Background Art

[0004] Handheld chemical sprayers are used to spray or otherwise discharge a liquid formulation onto an object. The sprayer typically transfers the liquid formulation from a reservoir to an object using a pump, vacuum, or any other device capable of creating a pressure differential between the reservoir and an area outside the reservoir, thereby pushing the liquid formulation to the area outside the reservoir. The liquid formulation can be any number of liquid formulations, including pesticides, fertilizers, insecticides, termiticides, fungicides, or other chemical formulations. Utility Model Content

[0005] In an independent aspect, the present disclosure provides a portable battery-powered liquid sprayer, the liquid sprayer comprising: a supply tank assembly for containing a liquid to be sprayed; a body assembly selectively coupled to and supported by the supply tank assembly, the body assembly receiving a motor and a pump; a battery removably coupled to the body assembly and operable to power the motor; and a wand movable relative to the body assembly and in fluid communication with the supply tank assembly. The wand includes a nozzle, and the wand is operable to activate a motor that drives the pump to pump liquid from the supply tank assembly to spray the liquid from the nozzle.

[0006] In another independent aspect, the present disclosure provides a portable battery-powered liquid sprayer, the sprayer comprising: a supply tank assembly for containing a liquid to be sprayed; a body assembly coupled to the supply tank assembly, the body assembly comprising a motor and a pump; a battery removably coupled to the body assembly and operable to power the motor to drive the pump; and a wand in fluid communication with the supply tank assembly. The wand comprises a nozzle, a mechanical valve assembly, a handle, a micro switch disposed in the handle, and a trigger movably coupled to the handle. The trigger is movable to actuate both the mechanical valve assembly and the micro switch, and actuation of the micro switch energizes the motor.

[0007] In another independent aspect, the present disclosure provides a method of storing a portable battery-powered liquid sprayer in a five-gallon bucket. The method includes: maintaining a connection between a body assembly and a supply tank assembly; removing a battery from the body assembly; and placing a wand in a first docking station extending between the body assembly and the supply tank assembly such that the wand is held in a substantially vertical position relative to a ground surface. The method further includes positioning the sprayer in the five-gallon bucket such that the body assembly and the supply tank assembly are fully contained within the bucket, with at least a portion of the wand extending beyond the confines of the bucket.

[0008] Other features and aspects of the present disclosure will become apparent by consideration of the following detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 A side view of a nebulizer according to an embodiment of the present disclosure is shown, showing the wand in a first storage position.

[0010] Figure 2 yes Figure 1 A perspective view of a sprayer of , showing the wand in a second storage position.

[0011] Figure 3A yes Figure 1 Exploded view of a portion of the tank assembly of a sprayer.

[0012] Figure 3B is an exploded cross-sectional view of the sprayer showing the check valve assembly of the tank assembly.

[0013] Figure 4 yes Figure 1 A bottom perspective view of the body assembly of a sprayer with the tank assembly removed, showing the motor, pump and controller.

[0014] Figure 5 yes Figure 1 A perspective view of a nebulizer with the wand removed.

[0015] Figure 6 yes Figure 1 Side view of a user interface module of a nebulizer.

[0016] Figure 7 yes Figure 1 A perspective view of a wand of a nebulizer.

[0017] Figure 8 yes Figure 7 An enlarged perspective view of a rod with a portion of the rod removed.

[0018] Fig. 9 yes Figure 8 Cross-sectional view of a rod.

[0019] Fig.10 yes Figure 1 A perspective view of a sprayer positioned in a standard five gallon bucket.

[0020] Fig.11 yes Figure 1 A side view of a nebulizer showing the external dimensions of the nebulizer.

[0021] Fig.12 yes Figure 1 Front view of a nebulizer showing the external dimensions of the nebulizer.

[0022] Fig.13 Depicted carrying by hand Figure 1 A nebulizer showing the nebulizer's center of gravity.

[0023] Before explaining any embodiment of the present disclosure in detail, it should be understood that the application of the present invention is not limited to the construction details and component arrangements set forth in the following description or shown in the following drawings. The present invention can have other embodiments and can be practiced or executed in a variety of different ways. In addition, it should be understood that the words and terms used herein are for descriptive purposes and should not be considered as limiting. DETAILED DESCRIPTION

[0024] Figure 1 A portable battery-powered sprayer 10 (hereinafter referred to as a "sprayer") is shown. In the illustrated embodiment, the sprayer 10 is operable to dispense a liquid solution (e.g., water, pesticides, fertilizers, insecticides, termites, fungicides, or a mixture of water and some chemical formulation) onto a surface or object (such as vegetation).

[0025] refer to Figure 1 and Figure 2 , the illustrated sprayer 10 includes a body assembly 14, a supply tank assembly 18 for storing a liquid solution, and a wand 22 in fluid communication with the supply tank assembly 18 and removably coupled to the body assembly 14. Generally speaking, the body assembly 14 includes a handle 30 having a gripping area 34 for a user to grasp when manipulating the sprayer 10, a user interface module 38, and a battery receptacle 42 for receiving a battery 46 that provides power to the sprayer 10.

[0026] The supply tank assembly 18 is removably coupled to the body assembly 14 via a quick release mechanism 26. The quick release mechanism 26 of the illustrated embodiment includes an over-center buckle-type latch. In other embodiments, the quick release mechanism 26 may alternatively include one or more cam-type levers, knobs, or other quick release devices that permit the supply tank assembly 18 to be attached to and detached from the body assembly 14 without tools.

[0027] 3, the supply tank assembly 18 includes an integral container having a cylindrical filling passage 50 extending upward from a top surface 54 of the tank assembly 18 for adding a liquid solution to the tank assembly 18. The filling passage 50 includes an inlet opening 58 that allows liquid to enter the tank assembly 18, a filter 62 that blocks debris or other large particles from entering the tank assembly 18 through the inlet opening 58, and a measuring cup 66 that is threadedly coupled to the filling passage 50. Specifically, the measuring cup 66 includes threads 70 on the inner periphery of the measuring cup 66 that engage with corresponding threads 74 on the outer periphery of the filling passage 50 adjacent to the inlet opening 58. The measuring cup 66 is movable between a first state in which the measuring cup 66 is coupled to the filling passage 50 to seal the inlet opening 58 and a second state in which the measuring cup 66 is disconnected from the filling passage 50 so that a user can measure the amount of a chemical, etc. before placing the chemical into the tank assembly 18 (e.g., to ensure a proper ratio of chemical to water when preparing a liquid solution).

[0028] Continue to refer Figure 3A and Figure 3B , the supply tank assembly 18 further includes an outlet opening 78 disposed at the top surface 54 of the tank assembly 18. The outlet opening 78 receives a pick-up line 82 and extends between the outlet opening 78 and a bottom surface 86 of the tank assembly 18 such that the pick-up line 82 can draw liquid solution from the bottom surface 86 of the tank assembly 18. A check valve assembly 94 is coupled to the pick-up line 82 to enable fluid to selectively flow through the pick-up line 82. Moreover, a cap 98 is threadably coupled to the outlet opening 78, thereby enabling a user to remove the cap 98, the pick-up line 82, and the check valve assembly 94 (e.g., for maintenance and cleaning purposes). Figure 3B As shown, the check valve assembly 94 is disposed within a cap 98 and includes a valve 96 and a spring 97 that biases the valve 96 upward toward a closed position. The check valve assembly 94 may be in the closed position ( Figure 3B ) and an open position. In the closed position, valve 96 seals cap 98 to prevent inadvertent escape of liquid solution in supply tank assembly 18. In the open position, valve 96 no longer seals cap 98, thereby permitting liquid solution to flow out of fluid supply tank 18, as explained in further detail below.

[0029] refer to Figure 4, the body assembly 14 houses an electric motor 102 (e.g., a brushed or brushless DC motor) that receives power from the battery 46, a pump 106 driven by the motor 102, and a printed circuit board or "PCB" 110 for controlling various aspects of the sprayer 10. The pump 106 (e.g., an impeller pump, a centrifugal pump, a positive displacement pump, etc.) is driven by the motor 102 and includes an inlet port 114 that draws a liquid solution into the pump 106 and an outlet port 118 that directs the pressurized liquid solution out of the pump 106. Specifically, the inlet port 114 is selectively received within the cap 98 of the supply tank assembly 18 so that the inlet port 114 is in fluid communication with the pick-up line 82 for drawing the liquid solution from the supply tank assembly 18. The inlet port 114 includes a stamping 116 ( Figure 3B ), when the supply tank assembly 18 is coupled to the body assembly 14, the ram engages the valve 96 and overcomes the bias of the spring 97 to displace the valve downward from the closed position toward the open position. At this point, the check valve assembly 94 is in the open position, and the liquid solution is then permitted to travel from the tank assembly 18 and the pick-up line 82, through the open check valve assembly 94, and to the pump 106 and the outlet port 118, which directs the liquid solution to the wand port 90 ( Figure 5 ).

[0030] In the illustrated embodiment, the body assembly 14 further includes a belt mount 120 ( Figure 1 ), which extends away from the body assembly 14 and is capable of receiving a shoulder strap (not shown) so that the user can carry the sprayer 10 hands-free. The body assembly 14 also includes a semicircular cutout 146 ( Figure 4 Specifically, when body assembly 14 is coupled to supply tank assembly 18, semicircular cutout 146 in body assembly 14 allows fill passage 50 and measuring cup 66 to extend beyond a portion of body assembly 14. In this way, a user can access fill passage 50 and measuring cup 66 without removing body assembly 14 from supply tank assembly 18.

[0031] refer to Figure 5, the sprayer 10 further includes a first docking station 122 and a second docking station 126, both of which are capable of receiving and retaining at least a portion of the wand 22. The first docking station 122 is disposed adjacent to the front surface 134 of the sprayer 10. Specifically, the first docking station 122 includes a first retention portion 138 disposed at the distal end of the handle 30 and a second retention portion 142 extending adjacent to the bottom surface 86 of the canister assembly 18 and away from the front surface 134 of the sprayer 10. A portion of the wand 22 passes through the first retention portion 138 until the wand 22 engages the second retention portion 142. Thus, when the first docking station 122 receives the wand 22, the wand 22 is carried by the sprayer 10 through the first retention portion 138 and the second retention portion 142. The second docking station 126 is disposed on the handle 30 and includes a groove 130 extending along the length of the handle 30. The groove 130 is capable of receiving a portion of the wand 22 and retaining it on the body assembly 14.

[0032] In the illustrated embodiment, when in the disengaged state, the wand 22 can be manipulated relative to the body assembly 14. In contrast, the wand 22 can also be maintained in a first storage position in which the wand 22 is received in the first docking station 122 and in a second storage position in which the wand 22 is received in the second docking station 126. In the first storage position, the wand 22 simply remains upright in the first docking station 122 ( Figure 1 In the second storage position, the wand 22 remains substantially parallel to the ground surface and is coupled to the second docking station 126 (e.g., via a press fit) such that a portion of the groove 130 is temporarily deformed to lock the wand 22 in place when the wand 22 is received by the handle 30 ( Figure 2 ).

[0033] refer to Figure 6, a user interface module or "UI module" 38 is disposed on the body assembly 14, while in other embodiments, the UI module 38 may alternatively be disposed on the wand 22. The UI module 38 enables a user to change various settings and monitor the operation of the sprayer 10. Specifically, the UI module 38 includes a power button 150 operable to electrically connect the battery 46 to the PCB 110 and the motor 102, a control knob 154, and a power level indicator 158 for displaying the remaining life (i.e., charge) of the battery 46. The control knob 154 is operable to change the voltage and / or current supplied to the motor 102 so as to adjust the pressure and / or flow rate of the liquid solution sprayed from the wand 22 during operation of the sprayer 10. For example, in the illustrated embodiment, the power control knob 154 is adjustable between three different operating positions so that three different voltages (i.e., corresponding to three different motor speeds) can be supplied to the motor 102, the three different voltages varying between a first minimum voltage and a third maximum voltage, thereby providing three different pressures and / or flow rates for the sprayer. In other embodiments, the control knob 154 can be adjusted between fewer or more than three positions and corresponding voltages. In the illustrated embodiment, at least a portion of the UI module 38, particularly the power level indicator 158, is illuminated by a light emitting diode (LED) to provide visual feedback to the user.

[0034] refer to Figures 7 to 9 The wand 22 includes: a wand handle 162 for the user to grasp when holding and manipulating the wand 22; an actuator or trigger 166 disposed adjacent to the wand handle 162 and depressible to dispense the liquid solution from the wand 22; and a nozzle 170 extending away from the wand handle 162 and used to direct the liquid solution directly to the object. The nozzle 170 has an extended shaft and a tip, and is connected to the wand 22 via a threaded collar 172 ( Figure 8 ) is removably coupled to the wand handle 162. The wand 22 further includes a trigger lock 174 extending from the wand handle 162. When the trigger 166 is depressed, the trigger lock 174 can be moved from an unlocked position to a locked position to keep the trigger 166 depressed, so that the user does not need to continue to depress the trigger 166 when dispensing the liquid solution. The wand 22 further includes a flexible hose 178 disposed between the wand handle 162 of the wand 22 and the wand port 90 of the body assembly 14. That is, the wand 22 is in fluid communication with the pump 106 via the hose 178, the pickup line 82, and the supply tank assembly 18.

[0035] When the rod 22 is in the first storage position ( Figure 1 ), the nozzle 170 is received in the first retention portion 138 and the second retention portion 142 of the first docking station 122, and when the wand 22 is in the second storage position ( Figure 2 ), the rod handle 162 is received in the groove 130 of the second docking station 126.

[0036] refer to Figures 7 to 9 The activation and deactivation of the motor 102 is controlled by the trigger 166 of the rod 22. The micro switch 182 ( Figure 8 ) is located within the wand handle 162 and includes a lever 186 to mechanically amplify the distance the trigger 166 travels when the micro switch 182 is actuated. An electrical wire 188 extends through or along the hose 178 and electrically connects the micro switch 182 to the PCB 110. Fig. 9 As shown, the rod 22 also includes a mechanical valve assembly 190 ( Fig. 9 ), the mechanical valve assembly having a valve hole 194, a stopper 198, a plunger 202 extending within the valve hole 194 between the trigger 166 and the stopper 198, and a spring 206 biasing the plunger 202 toward the trigger 166.

[0037] refer to Figures 10 to 12 The sprayer 10 is advantageously shaped and sized to fit within a standard five-gallon bucket 210. A typical standard five-gallon bucket 210 has a bottom diameter D1 of about 260 mm, a top diameter D2 of about 300 mm, and a height H of about 360 mm. Fig.11 and Fig.12 As shown, the sprayer 10 has an overall height 214 measured from the bottom surface 86 to the handle 30, an overall length 218 measured from the first retention portion 138 to the battery receptacle 42, and an overall width 222 measured from the opposite side surface of the supply tank assembly 18. The overall height 214 is about 300 mm to about 310 mm, and more specifically 306 mm. The overall length 218 is about 240 mm to about 250 mm, and more specifically 242 mm. The overall width 222 is about 190 mm to about 200 mm, and more specifically 195 mm.

[0038] refer to Fig.13 , the sprayer 10 can be held by the user's hand. Specifically, the user can grasp the gripping area 34 to carry and manipulate the sprayer 10. The sprayer 10 includes a center of gravity 226 that remains within the vertical footprint of the gripping area 34 when the sprayer 10 is carried. As such, when the user carries the sprayer 10, the center of gravity 226 also generally remains aligned with the user's hand to avoid torque and strain on the user's wrist.

[0039] In operation, when trigger 166 is depressed, trigger 166 first actuates plunger 202 to open mechanical valve assembly 190 and fluidly connect hose 178 with nozzle 170. As trigger 166 continues to pivot toward wand handle 162, trigger 166 subsequently engages lever 186 and actuates microswitch 182 to enable motor 102 and begin pumping liquid from supply tank assembly 18 out of nozzle 170. Mechanical valve assembly 190 opens before microswitch 182 enables motor 102, which prevents pump 106 from building pressure in hose 178 and, therefore, prevents any undesirable liquid bursting or overspray during operation of sprayer 10.

[0040] Similarly, when the trigger 166 is released, the trigger 166 first disengages from the lever 186 to open the microswitch 182, and then disengages from the plunger 202 to close the mechanical valve assembly 190. This ensures that the motor 102 is deactivated and the pump 106 stops pumping liquid before the valve assembly 190 is closed, thereby preventing pressure from building up in the hose 178.

[0041] Various features of the invention are set forth in the appended claims.

Claims

1. A portable battery-powered liquid sprayer, the sprayer comprising: A supply tank assembly for containing a liquid to be sprayed; a body assembly selectively coupled to and supported by the supply tank assembly, the body assembly receiving a motor and a pump; a battery removably coupled to the body assembly and operable to power the motor; as well as a wand movable relative to the body assembly and in fluid communication with the supply tank assembly, the wand including a nozzle; Therein, the wand includes an actuator operable to activate a motor that drives the pump to pump the liquid from the supply tank assembly and spray the liquid from the nozzle.

2. The sprayer of claim 1, further comprising a filling passage extending upward from the supply tank assembly so that the supply tank assembly can be filled with the liquid through the filling passage.

3. The sprayer of claim 2, further comprising a measuring cup threadably coupled to the filling passage, wherein: The measuring cup is movable between a first state in which the measuring cup is coupled to the fill channel to seal an inlet opening of the fill channel and a second state in which the measuring cup is disconnected from the fill channel and wherein the measuring cup can be filled to measure an amount of liquid to be added to the supply tank.

4. The sprayer according to claim 3, wherein: The fill passage extends over at least a portion of the body assembly to enable access to the measuring cup when the supply tank assembly and the body assembly are coupled to one another.

5. The sprayer of claim 1 , further comprising an outlet opening disposed on the supply tank assembly, a pick-up line extending between the outlet opening and a bottom surface of the supply tank assembly, and a cap threadably secured to the outlet opening, wherein: The pick-up line is in fluid communication with the pump.

6. The sprayer of claim 1, further comprising first and second docking stations each capable of receiving and retaining the wand.

7. The sprayer according to claim 6, wherein: The nozzle of the wand is positioned within the first docking station to secure the wand in a first storage position in which the wand is substantially vertical relative to a ground surface.

8. The sprayer according to claim 7, wherein: The first docking station includes a first retention portion and a second retention portion that cooperate to retain the nozzle of the wand in the first storage position.

9. The sprayer according to claim 6, wherein: The handle of the wand is positioned within the second docking station to secure the wand in a second storage position in which the wand is substantially horizontal relative to a ground surface.

10. The sprayer of claim 9, wherein: The second docking station includes a recess that is resiliently deformable to selectively secure the handle of the wand in the second storage position.

11. The sprayer of claim 1 , further comprising a user interface module having a power button operable to electrically connect the battery with the controller and the motor, a power control knob for adjusting the pressure of the liquid sprayed through the nozzle, and a power level indicator for displaying the remaining charge capacity of the battery.

12. The sprayer of claim 1, wherein: The body assembly and the supply tank assembly combine to define an overall height of about 300 millimeters to about 310 millimeters measured from a bottom surface of the supply tank assembly to a handle of the body assembly.

13. The sprayer of claim 12, wherein: The body assembly and the supply tank assembly combine to define an overall length of about 240 millimeters to about 250 millimeters measured from the first docking station to the battery receptacle.

14. The sprayer of claim 13, wherein: The body assembly and the supply tank assembly combine to define an overall width of about 190 millimeters to about 200 millimeters measured from opposing upstanding side surfaces of the supply tank assembly.

15. The sprayer of claim 14, wherein: The body assembly and the supply tank assembly together are configured to be received within a standard sized five gallon bucket.

16. A portable battery-powered liquid sprayer, the sprayer comprising: A supply tank assembly for containing a liquid to be sprayed; a body assembly coupled to the supply tank assembly, the body assembly including a motor and a pump; a battery removably coupled to the body assembly and operable to power the motor to drive the pump; as well as a rod in fluid communication with the supply tank assembly, the rod comprising nozzle, Mechanical valve components, handle, a micro switch disposed in the handle, and a trigger movably coupled to the handle, wherein the trigger is movable to actuate both the mechanical valve assembly and the micro switch, and The actuation of the micro switch energizes the motor.

17. The sprayer of claim 12, wherein: Movement of the trigger to the actuated position first actuates the mechanical valve assembly and subsequently actuates the microswitch.

18. The sprayer of claim 13, wherein: The mechanical valve assembly opens when the trigger is actuated to place the nozzle in fluid communication with the pump and supply tank assembly.

19. The sprayer of claim 16, further comprising a user interface module having a power button operable to electrically connect the battery with the controller and the motor, a power control knob for adjusting the pressure of the liquid sprayed through the nozzle, and a power level indicator for displaying the remaining charge capacity of the battery.

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