Note: Descriptions are shown in the official language in which they were submitted.
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FLUNG HEAD INJECTOR FOR AEROSOL CAN
BACKGROUND OF THE INVENTION
[0002] The present invention relates to the art of filling pressurized
containers. It
finds particular application in conjunction with manually injecting activators
into
aerosol cans which have been previously charged with liquefied propellants and
filled with paints, adhesives, resins or coatings and will be described with
particular
reference thereto. It is to be appreciated, however,. that the present
invention may
also find application in conjunction with injecting other coating systems,
including,
but not limited to lubricants, fiberglass resins, SMC resins, adhesives,
epoxy,
urethane adhesives, and any other products which can be catalyzed or activated
and dispensed from aerosol cans.
[0003] There are two common methods for filling an aerosol container with
propellant, namely, the "under the cup" method which lifts the valve mounting
cup
and the 'pressure filling" method.
[0004] More and more,
the aerosol industry is resorting to 'pressure filling' of the
container with propellant rather than 'under the cup" or out of the valve cup
filling.
The reasons are to diminish the loss of costly propellants and to minimize
emissions
of propellant into the atmosphere. In under the cup filling, a filling head
actually lifts
the valve cup partially out of the aerosol container and the propellant is
driven under
pressure through the opening between the bead (opening) of the container and
the
channel or circular skirt of the valve cup. In pressure filling, after product
is placed in
the aer0S01 can, the valve is crimped onto a one-inch diameter opening of the
can.
Then, propellant is charged into the can through the valve,
[00051 Pneumatically operated and hand operated machines have been available
for some time for injecting paint and other coatings into precharged aerosol
cans,
For example, as illustrated in U.S. Patent No. 3,797,534, such devices
commonly
included a manual lever for lifting an aerosol can to be charged into contact
with a
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relatively small reservoir, e.g., one quart. A pneumatically operated piston
drives the
paint from a cylinder at the bottom of the reservoir through the aerosol valve
into the
can. Another example of an aerosol filling machine is the Omni-Fille Pump
owned
by Sherwin-Williams.
[0006] Another example of an aerosol can filling machine is the Z-1000 Filling
Machine of Seymour of Sycamore, Illinois. The machine can include a manual
lever
and a bottle containing activator. The Z-1000 fills tints, pigments, gel coats
and
base coats into Seymour's pre-charged cans. The Z-100 is a manually operated
pump which adds reducers, catalysts, and hardeners to an aerosol can already
filled
with paint or coating, propellant and solvent. The filling machine adds
activator into
a bottle, which then pumps the activate:ninth the aerosol can. A problem with
this
system is that the pump used does not generate enough pressure= to easily pump
the activator through the valve of the can. The pumping system also can have
leaks.
10007] A disadvantage of using filling machines such as those described is the
machines are not typically portable and the filling process must occur at the
machine
location rather than in the field. Another disadvantage is that the filling
machines are
expensive.
[0008] Still another disadvantage of a filling pump is that it is difficult
to provide
sufficient pressure to inject the activator into the valve of the aerosol can.
The
present invention provides a new and improved portable aerosol can filling gun
which overcomes the above-referenced deficiencies of the prior systems while
providing more advantageous overall results.
SUMMARY OF THE INVENTION
[0009] The present invention provides a filling gun which is used to add an
activator to the aerosol can. The present invention relates to a filling gun
assembly,
similar in configuration to a caulking gun, which is used to manually inject
an
activator into an aerosol can without installing the can onto a pneumatic or
manually
operated aerosol can filling machine. The gun is inexpensive, portable,
lightweight,
easy to use, and can be easily transported to and used in machine shops,
plants,
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body shops, etc. In contrast, a filling machine is typically not portable and
is
expensive.
[00101 A filling head gun having a housing; a handle assembly connected to the
housing; stilling head attached to the housing; wherein a plunger extends
through
an opening of the housing and an opening of an activator reservoir attached to
the
plunger, the reservoir is moved into position via the plunger to feed
activator through
the filling head to an aerosol can.
[0011] A filling head and aerosol can assembly comprising: an aerosol can
having a valve and dip tube, propellant, a coating, and a body; a filling head
assembly comprising: a housing; a handle connected to said housing; a filling
head
attached to said housing via a piston rod; a tube containing activator which
is=
connected to said piston rod wherein said handle is depressed to move said
piston
rod to feed activator through said tube into said filling head; and wherein
said filling
head is mounted onto said mounting cup, and a stem of said filling head seals
on
said valve mounting cup of said aerosol can..
[0012] A method of filling pressurized aerosol can, includes removing a
spray
head from the Can; mounting a filling head of a filling head gun to a valve
assembly
of the can; sealing a valve mounting cup of the can with a stem of the filling
head;
pushing on the valve assembly of the can; Pushing a pressurized reservoir of
activator into contact with the filling head, releasing activator into the
aerosol can
through the stem of the fill head into the valve assembly of the can.
[0013] One aspect of the filling gun is that it is portable and can be
readily used in
the field. Another aspect of the filling gun is that it is inexpensive. Yet
another
advantage of the filling gun is that it allows the mixing of a coating and
activator at
the time of use, this preventing curing of the coating in the can. .
[0014] Another aspect of the filling gun is that it provides sufficient
thrust pressure
to inject activator into the valve of the can.
[0015] Still another aspect of the filling gun is that it can be adapted to
be used
with female or male valves or any valve system.
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[0015a] In accordance with another aspect of the present invention, there
is
provided a filling head gun comprising: a housing; a reservoir containing a
pressurized activator; a handle assembly connected to said housing; a filling
head
attached to said housing; and a plunger, wherein said plunger extends through
an
opening of said housing and said reservoir attached to said plunger, wherein
said
reservoir is moved into position to contact said filling head via said plunger
to feed
said pressurized activator through said filling head to an associated aerosol
can, and
further wherein said filling head comprises a stem to seal an associated valve
mountable cap of said aerosol can.
[0015b] In accordance with a further aspect of the present invention, there
is
provided a filling head and aerosol can assembly comprising: an aerosol can
having
a body having a valve and dip tube, propellant, a coating, and a valve
mounting cup;
a filling head assembly comprising: a housing; a reservoir for containing
pressurized
activator; a handle connected to said housing; a filling head attached to said
housing
via a piston rod; a tube connected to said piston rod wherein said handle is
depressed to move said piston rod to feed said pressurized activator through
said
tube into said filling head; and wherein said filling head is mounted onto
said
mounting cup, and a stem of said filling head seals on said valve mounting cup
of
said aerosol can.
[0015b] In accordance with a further aspect of the present invention, there
is
provided a method of filling a pressurized aerosol can, comprising: removing a
spray
head from the can; mounting a filling head of a filling head gun to a valve
assembly of
the can; sealing a valve mounting cup of the can with a stem of the filling
head;
pushing on the valve assembly of the can with the filling head; pushing a
reservoir of
pressurized activator into contact with the filling head, releasing the
pressurized
activator into the aerosol can through the stem of the filling head into the
valve
assembly of the can.
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[0016] Still further aspects of the present invention will become apparent
upon
reading and understanding the following detailed description of the preferred
embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The invention may take form in various parts and arrangements of parts.
The drawings are only for purposes of illustrating a preferred embodiment and
are
not to be Construed as limiting the invention.
[0018] FIG. 1 is a side elevational view of an existing aerosol can filling
pump;
[0019] FIG. 2 is side elevational view illustrating an aerosol can;
[0020] FIG. 3 is an exploded view of a female aerosol valve assembly;
[0021] FIG. 4 is an exploded view of a male aerosol valve assembly;
[0022] FIG. 5 is a perspective view of an aerosol can filling gun in
accordance
with the present invention;
[0023] FIG. 6 is an exploded perspective view of the filling gun of FIG. 5;
[0024] FIG. 6A is a view of the filling head showing a spring and ball
mechanism
within the filling head;
[0025] FIG. 7 illustrates the filling gun in a used or depressed
configuration; and
[0026] FIG 8 illustrates the filling gun in a used or depressed
configuration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] Referring to Figure 1, the use of an existing manual spray pump A in an
aerosol can includes the following steps: First, the sprayhead is removed from
the
aerosol can. Then, a washer 10 is removed from the side of the pump and
inserted.
into the bottle flange 12. A collar lock 14 is turned counter-Crockwise to
expose
prongs 16, which are snapped onto the top of the aerosol can. While the pump
assembly is held in one hand, the lock collar is turned clockwise with the
other hand
to lower the pump onto the can. The collar is tightened snugly. The bottle 18
is .
filled with a reducer, catalyst or hardener and screwed into the bottle
flange. A dip
tube 20 has a length which is adjusted so that it is touching the bottom of
the bottle.
The can is placed on a hard surface. The plunger 22 is firmly pressed down to
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pump the material from the bottle into the aerosol can. The material in the
bottle is
sucked into the dip tube on the upward stroke and is pushed into the aerosol
can on
the downward stroke. The appropriate amount of catalyst is pumped into the can
plus
one extra pump, which allows for the catalyst in the dip tube that never gets
mixed in
with the paint. Each bottle holds about 1.5 or 2 fluid ounces and each stroke
is about
a quarter of an ounce. The catalyzed paint must be used within 20 hours of
pumping
the catalyst into the can.
[0028] Referring now to Figure 2, an aerosol can B typically has seven main
components: a sprayhead (actuator) 30; a cap 32; a valve and dip tube 34;
propellant
36; product or coating 38 such as paint, a gel, an adhesive or an epoxy; a can
body
40 and a mixing ball 42 (which rattles when shaken). The propellant drives the
product or coating out through the valve at the top of the can at a pressure
of about
50 to 60 lbs. Aerosol cans are typically supplied in 4-ounce, 6-ounce, 8-
ounce, 12-
ounce, 16-ounce, 20-ounce, 24-ounce and 32-ounce sizes.
[0029] Referring to Figure 3, a female valve assembly C is the valve often
used
with paints, adhesives and resins. This type of valve is used because the
sprayhead
can be easily removed and cleaned. The stem 44 on the female valve is located
on
the sprayhead or actuator 46 and the metering slot 48 on the stem determines
the
amount of product that is sprayed. To clean the sprayhead, a pin or knife is
used on
the slot at the base of the sprayhead. Once the blockage is cleared, the
sprayhead
can be placed back into the valve and used again. The sprayhead is placed into
position with a twist and push action.
[0030] In the usual aerosol can or container, product and propellant are
placed in
a valved container. Referring to Figure 3, a valve body 47, a spring 49, a
spring cup
50, a gasket 52, and a mounting cup 54 and dip tube 56 together form the valve
assembly and are ail crimped onto the top opening of an aerosol can. The
opening is
typically one inch in diameter. The valve stem 44 emerges through the pedestal
portion of the container closure or mounting cup 54. The actuator 46 is
frictionally
fitted to the valve stem; the actuator being the component that receives
manual
pressure from the user of the aerosol container to actuate or open the valve
and,
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thereby, to cause egress of the container contents. The spring head or
activator is
depressed which in turn causes the container contents to exit the can.
[0031] Referring to Figure 4, a male valve assembly D is shown. The male
valve
also has a stem 60, valve body 62, a spring 64, a gasket 66, and a mounting
cup 68
and dip tube 70 which are all crimped onto a can. However, a metering slot 71
for a
male valve is located on the stem of the valve itself. That is, the male
sprayhead 72
does not have a stem. To clean the male valve, a thin knife is used to clear
the
blockage. The sprayhead is cleaned and reattached.
[0032] With reference now to Figure 5, the filling gun E for charging
pressurized
aerosol cans in accordance with a preferred embodiment is shown.
[0033] The present invention relates to a filling gun assembly E, similar
in
configuration to a caulking gun, which is used to inject an activator into an
aerosol
can B shown in Figure 2 without installing the can onto a pneumatic or
manually
operated aerosol can filling machine. The gun is inexpensive, portable,
lightweight,
easy to use, and can be easily transported to and used in machine shops,
plants,
body shops, etc. The gun is configured similar to a caulking gun, as described
for
example in U.S. Patent No. 7,073,691.
[0034] The gun is preferably used with a two-component system, wherein the
can contains two components; i.e., a clear liquid or coating or paint, as well
as a
solvent and propellant, The coating can be a clear or color paint, base coat,
clear or
gel coat, or an adhesive, resin or epoxy. The gun is used as part of a two-
part
process, where activator is filled into or added to an aerosol can by the gun
which is
filled with a paint, adhesive coating, aerosol spray, epoxy, etc. in a mixing
ratio such
as 4:1, 1:1 or 2:1. For example, a 4-ounce product may require 1 ounce of
activator;
thus, the mixing ratio is 4;1. For 8 ounces of product, 4 ounces of activator
may be
required, or a 2:1 mixing ratio. Any ratio in the range of 1:1 to 10:1 is
contemplated
by the invention.
[0035] The filling gun 75 has an activator, a catalyst, a hardener, or a
reducer
within a tube or container or reservoir 79 which is injected into the can
through a
filling head 80. The tube or reservoir is pressurized with activator, much as
an
aerosol can is pressurized. Existing filling systems have solvents and
propellants in
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the can, and the paint or coating is injected into the can through a filling
head. The
can then sprays the paint which air dries after application. In contrast, the
present
invention is used with a can which is already filled with paint, adhesive,
resin or
solvent and propenant at the aerosol manufacturer.
[0036] The gun has a tube housing 82 and a handgrip portion or trigger
housing
84. The tube housing 82 is cut away along the side walls 77, 78 to provide
easy
access for inserting a tube 79 into the tube housing.
[0037] Filler head 80 is supported by a groove or semi-circular cutout 86
formed
in U-shaped wall 88, which is at an end of side walls 77, 78 of housing 82.
[0038] Passing through the housings is a piston rod 94. Although the piston
rod
94 is shown as installed in the trigger housing 84, it can be withdrawn out
the
rearward end of the housing 84 for complete removal. With the piston rod
removed,
the portions of the gun can be easily disassembled. When the gun is completely
assembled, the piston rod 94 passes through central holes 96, 98 in the tube
housing
wall 89 and the handgrip housing, respectively.
[0039] The handle trigger 85 is ergonomically shaped to dismantle in users
hand
and is shaped to fit the users fingers. This configuration provides for a very
comfortable, natural gripping tool which, by virtue of its shape, enables the
user to
hold the handgrip portions 97, 99 in his hand, with less likelihood that the
handgrip
will slip from its natural position.
[0040] The U-shaped opening 88 in the forward wall of the housing 82 is
provided to permit the filling head to extend forward from the housing.
[0041] The system uses a filling head which has a stem 100 much like the
stem
of an aerosol can as shown in Figure 3. The stem does not have a metering
slot,
however.
[0042] The spray head of the aerosol can B is removed to attach the filling
head
80 onto the top of the can. The stem 100 of the filling head seals on the
valve
mounting cup 54, and the filling head pushes down on the valve assembly
thereby
charging the can through the dip tube 56 to the bottom of the can.
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[0043] The filling head 80 is described as being used with a female valve,
but
the filling head can also be used with a male valve as well, and also with any
other
valve system for an aerosol can without departing from the scope of the
present
invention.
[0044] When the activator is pressure filled into the can, the activator or
catalyst
causes a chemical reaction with the product. The shelf life of the product
begins
once the product is activated. The shelf life can range from two hours to
several
days or more, Therefore, the activator should not be added until the time of
filling
and use of the product, since the product becomes cured quickly and is ready
to
use. For example, the catalyst should not be added to a paint spray can until
the
user is ready to spray the automobile or whatever will be sprayed. At the time
of
application, the hardened or catalyzed paint, adhesive, or resin has a
chemical
reaction on the application surface and dries on the surface.
[0045] For example, a gallon of clear or colored paint would have added to
it a
quart of activator, resulting in a catalyzed product. A catalyzed product is
preferable
to use than a non-catalyzed product, since the catalyzed product has better
performance characteristics. The paint alone would never dry or cure until the
catalyst is added. The same applies to an adhesive, such as a structural
urethane
adhesive used to glue metal to metal or plastic to metal on cars or trucks.
Another
application would be SMC resins which would be catalyzed to be used for boat
repairs.
[0046] Referring again to Figure 5, the filling head 80 can be of different
sizes to
accommodate different volumes of material. The filling head is attached to
liquid
reservoir or tube 79 which holds about 2-1/4 ounces of catalyst or activator.
However, other size reservoirs, such as a 4-ounce reservoir 79 could also be
used
when the filling head is used with different valve systems. The reservoir 79
has an
opening 102 to accommodate the piston rod or plunger 94, which is attached to
handle 84. The plunger and reservoir are housed within the housing 82.
[0047] Referring now more particularly to Figures 5-9, the gun 75 has
filler head
80 which has stem 100 mounted to either a female valve or a male valve on the
aerosol can which are shown in Figures 3 and 4. Slight movement of the filler
head
by squeezing the gun handle 84 will depress the valve stem 100 sufficiently to
open
the
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associated can valve C or D and thus establish communication between the
interior
of the can and the passage of the filling head. It is essential that a seal be
established before the valve of the filler head is open to permit the feed of
activator
under pressure through the passage.
[0048] Referring to Figures 6 and 6A, trigger 85 of the handle 84 is
depressed,
thus moving the plunger or piston rod 94 connected to an end of the activator
reservoir 79. The reservoir has an 0-ring 73 which comes in contact with a
surface of
the filling head 80 as the reservoir enters an opening of the filling head.
The filling
head 80 has a spring 81 and ball 83 assembly which are pushed toward end 101
of
the filling head as activator is released into the filling head toward stem
100. The
stem then depresses a valve assembly C or D on the aerosol can.
[0049] As soon as the valve of the can is open, activator under pressure
will be
fed into the chamber of the can. At the same time, the plunger or piston 94 is
pushed
by the handle 84 to feed activator from the reservoir 79 into the chamber of
the can
through the filling head. The pressure of the filling head and reservoir
exceeds that of
the pressurized aerosol can, thus preventing activator from traveling from the
can
back into the filling head.
[0050] The activator is then fed into the aerosol can, thus creating a
mixture
within the can such as colored paint, coating, adhesives, fiberglass resins,
epoxy,
etc. The can is immediately available for spraying a customized paint,
adhesive, resin
or coating by the user while in the field.
[0051] The handle is depressed to move the plunger or piston to push the
plunger into the reservoir, thus forcing liquid activator into the filling
head. The
activator then travels through the stem and into the valve assembly of the
aerosol
can. The reservoir moves from the position shown In Figure 7 to the in-use
position
of Figure 8. The stem is pushed down on the mounting cup 54 or 68 of the can.
The activator is then pushed through the dip tube 56 or 70 to the bottom of
the can.
In the present invention, the activator supply is poured into bottle, or tube
or
reservoir 79, such as a one- or two-ounce bottle, which is mounted into the
gun.
The gun has about a 26 to 1 thrust pressure, which aids in filling the can
with
activator through the valve. The plunger preferably has a thrust ratio of
about 26:1,
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,
but the thrust ratio can be 50:1 or other ratios as well, without departing
from the
scope of the invention.
[0052] Typically, the aerosol can is placed vertically on a support
surface and
the filling head is manually pressed downwardly onto the valve assembly which
seals the stem 100 onto the valve. However, the filling head can also be used
in a
horizontal orientation wherein the can is horizontally secured or held and the
filling
head is laterally pressed into the valve.
[0053] Since the gun is transportable, the gun can be easily used
in the field,
such as body shops, factories, oil rigs, etc. The gun is inexpensive (around
$150) in
comparison to a pneumatic filling machine (around $3,500). A manual filling
machine
costs around $500.
[0054] Thus, the user can activate the coating in the field at the
time of use. For
example, the gun can be given to the user with an activator which is injected
into the
can and results in a specific paint, adhesive, resin or coating within the can
for
immediate use.
[0055] The problem with a previously activated product, such as is
made with a
filling machine, is that the activator can set up and cure in the can if not
used within
several hours. Thus, it is preferable to inject the activator just prior to
use. Once
activated, the coating cures due to the chemical reaction between the
activator and
paint. After use, the can should be discarded.
[0056] Advantages of the filling gun are it low cost, portability,
ease in using in
the field, such as in body shops, oil rigs, factories, plants, etc.; and
ability to be used
with an aerosol can having a female or male valve, or any valve system. The
filling
gun can be used with any product that needs to be catalyzed or activated, such
as
paints, adhesives, resins, fiberglass or SMC resins, epoxy, etc.
[0057] The exemplary embodiment has been described with reference
to the
preferred embodiments. Obviously, modifications and alterations will occur to
others
upon reading and understanding the preceding detailed description. It is
intended
that the exemplary embodiment be construed as including all such modifications
and
alterations insofar as they come within the scope thereof.
