Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
MIX ON DEMAND SPRAYER WITH EXTERNAL BY-PASS CIRCUIT
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of pending United
States patent
application Ser. No. 15/725,937 filed October 5, 2017, and entitled "MIX ON
DEMAND
SPRAYER," the contents of which are fully incorporated herein.
FIELD OF THE INVENTION
[0002] The present invention generally relates to fluid delivery systems,
and more
particularly to a pump-driven fluid delivery system, and still more
particularly to a pump-driven
fluid delivery system having an external bypass circuit for alleviating pump
stresses when
dispensing fluids at different pressures and/or volumes.
BACKGROUND OF THE INVENTION
[0003] Sprayers, such as broadcast sprayers are used across an array of
applications,
including farms, golf courses and residential properties, to apply water or
other liquids, such as
pesticides including herbicides, insecticides and the like. As such, these
sprayers may need to
cover a large area and, therefore, generally include large tanks strapped to a
vehicle, such as an
all-terrain vehicle (ATV) or golf cart, or may be mounted onto a tow-behind
trailer. Typically in
use, these tanks are filled with a selected fluid composition that is to be
applied. By way of
example, pesticide solutions may be anywhere from about 1% to about 10% active
chemical in
water. In one scenario, a user may spray a diluted herbicide solution, such as
to target thistle.
However, to apply a second pesticide solution, such as a diluted insecticide
to fruit trees, the user
will first have to completely empty the tank of the herbicide solution before
rinsing the tank of
any residual chemicals and finally refilling the tank with the desired
insecticide solution. As
may be readily apparent from the above, there are numerous drawbacks to such
systems. For
example and without limitation, such drawbacks may include waste of chemicals,
the need for
controlled disposal of unused chemicals, the time consuming need to thoroughly
clean the tank
between applications and the potential for cross-contamination and application
of unwanted
chemicals after incomplete or unsuccessful cleaning of the tank.
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[0004] To alleviate some of the above-referenced drawbacks of broadcast
sprayers,
systems have been developed which segregate the chemical portion from the
water/diluent
portion of the system. In such systems, the chemical is stored in a smaller,
separate tank than the
large water tank. Metering devices may then add chemical to a flow of water
prior to emission
from a wand or boom sprayer. In this manner, the chemical remains isolated
from the water
tank, thereby minimizing or avoiding possible contamination of the water
source. However,
heretofore systems require complex plumbing regimes and interconnectivities of
the various
components making such systems difficult to use and burdensome to operate and
clean.
[0005] Broadcast sprayers have also been configured as variable pressure
sprayers which
may selectively spray fluid from either a spray wand or through a boom-and-
nozzle arrangement
where multiple nozzles may be supported on a boom. Due to the multiple nozzles
within the
boom-and-nozzle arrangement, fluid must be delivered at high pressure so as to
enable proper
spraying at each of the individual nozzles. However, a spray wand uses a
single nozzle and may
become damaged if it receives high pressure fluid. To that end, current
systems typically use
pumps with a high pressure cut out switch. These systems are configured with a
recirculation
manifold whereby excess flow from the pump is diverted back to the supply
tank. A valve and
pressure gauge is provided on the manifold so the user can tune the percentage
of flow going
back to the tank while maintaining adequate pressure for the lower flow
application (spray
wand). Without providing for this recirculation pressure bleed off in the low
flow application,
pressure would build quickly and rapidly cycle the pressure cut off switch. A
situation that is
detrimental to both the switch and the pump. However, such a system should not
be used in two-
tank systems as the mixed fluid exiting the pump would be recycled to the
water tank, thereby
contaminating the water tank and changing the concentration of the chemical
that is being
sprayed.
[0006] Thus, there remains a need for a sprayer that segregates the
chemical tank from
the water tank but is also more easily plumbed, operated and cleaned. There
remains a further
need for a variable pressure sprayer wherein the mixed fluid is not recycled
to the diluent tank
when operating at reduced spraying pressure. The present invention satisfies
this as well as other
needs.
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SUMMARY OF THE INVENTION
[0007] In view of the above and in accordance with an aspect of the
present invention,
the present invention is generally directed to a sprayer system comprising a
first tank configured
to hold a diluent; a mounting bracket mounted to the first tank; and a second
tank removably
mounted to the first tank and configured to hold a liquid concentrate. A
mixing manifold is
mounted to the mounting bracket and has a first inlet fitting configured to
receive a fixed amount
of diluent from the first tank and a second inlet configured to receive a
selectively adjustable
amount of liquid concentrate from the second tank. The fixed amount of diluent
and selectively
adjustable amount of concentrate are combined to form a mixed solution. The
mixing manifold
includes a mixed solution outlet and a positive displacement pump is mounted
to the mounting
bracket and has a suction port fluidly coupled to the mixed solution outlet. A
pressure port is
configured to fluidly couple with a spray device. The second tank may be
separable from the
first tank without requiring removal of the mixing manifold or positive
displacement pump.
[0008] In a further aspect of the present invention, the positive
displacement pump is a
diaphragm pump and the first inlet fitting further includes a check valve
configured to prevent
backflow of the mixed solution toward the first tank.
[0009] In still another aspect of the present invention, the mixing
manifold further
includes a disc defining a first annular series of spaced-apart flow-metering
holes. Successive
respective flow-metering holes have an increasing hole diameter and the disc
is adapted to rotate
to align a selected flow-metering hole in fluid communication with the second
inlet to thereby
define the selectively adjustable amount of concentrate in the mixed solution.
The disc may
further define a second annular series of spaced-apart stop holes. Each
respective stop hole
within the second annular series radially aligns with a respective flow-
metering hole of the first
annular series. A single respective stop hole receives a stop member when the
selected flow-
metering hole is aligned with the second inlet. The stop member may be a ball
bearing biased to
engage the disc wherein a diameter of the ball bearing is slightly larger than
a diameter of each
of the stop holes.
[0010] In another aspect of the present invention, the first inlet
fitting may further include
a check valve configured to prevent backflow of the mixed solution toward the
first tank and the
second tank may be removably mounted to the mounting bracket on the first
tank.
[0011] In still a further aspect of the present invention, the second
tank may include a
quick disconnect coupling configured to releasably couple a concentrate tube
to a tank fitment
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defined on the second tank. The concentrate tube may then deliver the liquid
concentrate to the
mixing manifold. The quick disconnect coupling may comprise a fitment housing
having a first
end, a second end and a stepped bore region therebetween, wherein the first
end is coupled to the
tank fitment defined on the second tank. A tubing nut may be removably coupled
to the second
end of the fitment housing and a tubing coupling may be configured to be
received within the
tubing nut and abut against a mouth opening defined by the second end of the
fitment housing.
A plug member may have a plug end, a flanged end and a body portion
therebetween. The plug
end may be received in the first end of the fitment housing while the flanged
end may be
received within the second end of the fitment housing and the body portion may
extend through
the stepped bore region of the fitment housing. A biasing member may also be
received within
the stepped bore region, wherein the biasing member urges the plug end of the
tubing coupling to
seal the first end of the fitment housing when the tubing nut is removed from
the second end of
the fitment housing. A biasing force is stored within the biasing member by
the flanged end
when the tubing nut is coupled to the second end of the fitting housing,
whereby fluid
concentrate within the second tank can flow through the quick disconnect
coupling to the mixing
manifold. The body portion of the plug member may comprise a plurality of
spaced apart
spindles with open slots defined therebetween to permit flow of fluid
concentrate therethrough.
[0012] In yet another aspect of the present invention, the sprayer system
may further
include a pressure by-pass circuit fluidly coupling the pressure port to the
suction port. The
pressure by-pass circuit may be configured to selectively regulate a fluid
pressure of the mixed
solution being delivered to the spray device. The pressure by-pass circuit may
be either internal
to the positive displacement pump or an external pathway around the positive
displacement
pump.
[0013] In accordance with another aspect of the present invention, the
present invention
is generally directed to a sprayer system comprising a first tank configured
to hold a diluent; a
mounting bracket mounted to the first tank; and a second tank removably
mounted to the first
tank and configured to hold a liquid concentrate. A mixing manifold is mounted
to the mounting
bracket and has a first inlet fitting configured to receive a fixed amount of
diluent from the first
tank and a second inlet configured to receive a selectively adjustable amount
of liquid
concentrate from the second tank. The fixed amount of diluent and selectively
adjustable
amount of concentrate are combined to form a mixed solution. The mixing
manifold includes a
mixed solution outlet and a positive displacement pump is mounted to the
mounting bracket and
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has a suction port fluidly coupled to the mixed solution outlet. A pressure
port may be fluidly
coupled to at least one spray device. The second tank may be separable from
the first tank
without requiring removal of the mixing manifold or positive displacement
pump. The at least
one spray device may be a low pressure spray nozzle or a high pressure boom
carrying two or
more boom nozzles. Alternatively, the at least one spray device is a low
pressure spray nozzle
and a high pressure boom carrying two or more boom nozzles whereby the mixed
fluid is
selectively received by either the low pressure spray nozzle or the high
pressure boom. The
sprayer system may further include a pressure by-pass circuit fluidly coupling
the pressure port
to the suction port. The pressure by-pass circuit may be configured to
selectively regulate a fluid
pressure of the mixed solution being received by the low pressure spray
nozzle. The pressure
by-pass circuit may be either internal to the positive displacement pump or an
external pathway
around the positive displacement pump.
[0014] In accordance with yet another aspect of the present invention, an
external by-
pass circuit for a positive displacement pump includes a flow diverter valve
coupled to the
pressure port of the pump. The flow diverter has an end coupled with a high
flow output and
another end coupled with a low flow output. The low flow end includes a by-
pass arm coupled
to and input flow fitting. The flow diverter valve further includes a ball
valve to direct fluid to
either the high flow or low flow output. The input flow fitting is coupled to
the suction port of
the pump at the one end and couples with a fluid source at the other end. The
input flow fitting
includes a flow control arm which includes a needle valve to selectively
control flow within the
flow control arm. The flow control arm also includes a by-pass fitting fluidly
coupled with the
by-pass arm of the flow diverter valve.
[0015] Additional objects, advantages and novel aspects of the present
invention will be
set forth in part in the description which follows, and will in part become
apparent to those in the
practice of the invention, when considered with the attached figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a perspective view of a sprayer system in accordance
with an aspect of
the present invention;
[0017] FIG. 2 is an exploded view of the sprayer system shown in FIG. 1;
[0018] FIG. 3 is a front perspective view of the sprayer system shown in
FIG. 1 with the
diluent tank removed;
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[0019] FIG. 4 is a rear perspective view of the sprayer system shown in
FIG. 3;
[0020] FIG. 5 is an exploded view of a liquid concentrate tank used
within the sprayer
system shown in FIG. 1;
[0021] FIG. 6 is a cross section view of the liquid concentrate tank used
within the
sprayer system shown in FIG. 1;
[0022] FIG. 7 is a cross section view of a tubing fixture used with the
liquid concentrate
tank shown in FIG. 5;
[0023] FIG. 8 is an exploded cross section view of the tubing fixture
shown in FIG. 7;
[0024] FIG. 9 is a top perspective view of a mixing manifold used within
the sprayer
system shown in FIG. 1;
[0025] FIG. 10 is a bottom perspective view of the mixing manifold shown
in FIG. 9;
[0026] FIG. 11 is a top front exploded view of the mixing manifold shown
in FIGS. 9
and 10;
[0027] FIG. 12 is a bottom front exploded view of the mixing manifold
shown in FIGS. 9
and 10;
[0028] FIG. 13 is a cross section view of the mixing manifold, taken
generally along line
13-13 in FIG. 9;
[0029] FIG. 14 is an isolated view of a disc used within the mixing
manifold shown in
FIGS. 9 through 13;
[0030] FIG. 15 is a schematic view of a pressure by-pass system suitable
for use within a
variable pressure sprayer system in accordance with an aspect of the present
invention;
[0031] FIG. 16 is a perspective view of an external by-pass circuit
suitable for use within
a variable pressure sprayer system in accordance with an aspect of the present
invention;
[0032] FIG. 17 is a perspective view of a flow diverter valve suitable
for use within the
external by-pass circuit shown in FIG. 16;
[0033] FIG. 18 is a longitudinal cross section of the flow diverter valve
shown in FIG.
17, taken generally along line 18-18 within in FIG. 17;
[0034] FIG. 19 is a lateral cross section of the flow diverter valve
shown in FIG. 17,
taken generally along line 19-19 within in FIG. 17;
[0035] FIG. 20 is a perspective view of a input flow fitting suitable for
use within the
external by-pass circuit shown in FIG. 16; and
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[0036] FIG. 21 is a longitudinal cross section of the input flow fitting
shown in FIG. 20,
taken generally along line 21-21 within in FIG. 20.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
100371 Referring now to FIGS. 1 and 2, in accordance with an aspect of
the present
invention, sprayer system 10 may generally comprise a first tank 12, mounting
bracket 14,
second tank 16, mixing manifold 38 and positive displacement pump 42, such as
and without
limitation thereto, a diaphragm pump. Mounting bracket 14 may be mounted to
first tank 12,
such as via mechanical fasteners 18. To provide further support and to resist
lateral movement
of mounting bracket 14 in the x-z plane, first tank 12 may include a tang 20
configured to reside
within a notch 22 defined within mounting bracket 14. Second tank 16 may be
mounted to first
tank 12 and mounting bracket 14, such as via a strap (not shown). To that end,
second tank 16
may include a strap recess 24 configured to receive the strap and first tank
12 may further
include a strap tie down clamp 26 whereby movement of second tank 16 in the y-
axis is
prohibited. To minimize lateral displacement of second tank 16 (i.e., in the x-
z plane) mounting
bracket 14 may include one or more upwardly extending nodules 28 configured to
coincide with
matching indentations 30 defined on bottom wall 32 of second tank 16 (see FIG.
6). In this
manner, a user may unfasten the strap and lift second tank away from mounting
bracket 14 and
first tank 12, such as via handle 17, without requiring the use of tools.
Strap tie down clamp 26
may further include a wand receiving portion 34 defining a wand receiving
recess 36 whereby a
spray wand (not shown) may be releasably coupled to sprayer system 10 when the
spray wand is
not in use. With continued reference to FIGS. 1 and 2, and with additional
reference to FIGS. 3
and 4, a mixing manifold 38 may be mounted to mounting bracket 14, such as via
mechanical
fasteners 40, and positive displacement pump 42 may be mounted to mounting
bracket 14 such
as via mechanical fasteners 44. In this manner, each of the second tank 16,
mixing manifold 38
and positive displacement pump 42 may be individually and separately removed
from mounting
bracket 14 and first tank 12.
[0038] In operation, first tank 12 includes a diluent outlet 46 having a
diluent fitting 47
configured to receive one end of diluent tubing (not shown) in a substantially
fluid-tight seal.
The opposing end of the diluent tubing is mounted onto a first inlet fitting
48 of mixing manifold
38 (see also FIGS. 9-13). First inlet fitting 48 may include a tapered nipple
50 and ribbed
portion 52 so as to snuggly receive the diluent tubing thereon in a
substantially fluid-tight seal.
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An optional hose clamp (not shown) may also be used to more securely clamp the
diluent tubing
to ribbed portion 52. Mixing manifold 38 may further include a second inlet 54
configured to
receive concentrate tubing (not shown) from second tank 16. As shown most
clearly in FIGS. 4
and 10, mixing manifold 38 may include a notch 56 proportioned to permit
passage of
concentrate tubing through housing 58 of mixing manifold 38. Mounting bracket
14 may also
include a recess 60 to accommodate passage of the concentrate tubing (see
FIGS. 2 and 4).
Thus, a first end of the concentrate tubing may be mounted to fitment 62
housed within second
inlet 54. The concentrate tubing may then extend toward second tank 16 wherein
the opposing
end of the concentrate tubing is mounted to second tank 16 via concentrate
outlet fitting 64.
[0039] With reference to FIGS. 5 and 6, second tank 16 may be filled with
a selected
fluid concentrate through tank opening 19 defined by a threaded mouth portion
21. A cap 23
may be removably threaded onto mouth portion 21 so as to seal second tank 16.
An optional 0-
ring 25 may also facilitate a fluid-tight seal between second tank 16 and cap
23. To prevent
clogging of downstream plumbing components, mouth portion 21 may further
receive filter
element 27 therein. When filling second tank 16 with fluid concentrate, the
fluid will pass
through filter element 27 whereby particulate matter larger than the pore size
of the filter element
will be strained out of the fluid. Accordingly, the pore size of filter
element 27 should be
selected so as to be smaller than the internal diameter of the smallest
diameter downstream
component, such as disc 168 which will be discussed in greater detail below.
[0040] With reference to FIGS. 7 and 8, to facilitate tool-less removal
of second tank 16
from mounting bracket 16 and mixing manifold 38, concentrate outlet fitting 64
may be a quick
disconnect coupling generally comprised of a fitment housing 66 having a first
end 68
configured to be threadably coupled to a corresponding tank fitment 70 defined
on second tank
16 (see FIG. 5). First end 68 of fitment housing 66 may also be configured to
receive a tank
tubing coupling 72 whereby tank tubing coupling 72 includes a flanged end 74
proportioned to
abut against mouth opening 76 of tank fitment 70 such that tank tubing
coupling 72 is entrapped
between mouth opening 76 and stepped wall 78 of fitment housing 66 when
fitment housing 66
is threaded onto tank fitment 70. To promote a fluid-tight seal between tank
fitment 70 and
fitment housing 66, one or more seals, such as 0-rings 80, 82 may be included.
The opposing
end of tank tubing coupling 72 may include one or more barbs 84 dimensioned to
snuggly
receive a concentrate pick-up tube (not shown) which may extend from tank
tubing coupling 72
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to proximate bottom wall 32 of second tank 16. In this manner, liquid
concentrate may be drawn
from second tank 16 as will be described in greater detail below.
[0041] With continued reference to FIGS. 7 and 8, second end 86 of
fitment housing 66
may include male threads 88 configured to threadably engage female threads 90
defined within a
first end 92 of tubing nut 94. Second end 86 may further define a bore 96
dimensioned to
receive a first end 98 of a concentrate tubing coupling 100 therein upon
threaded engagement of
tubing nut 94 with fitment housing 66. The opposing end 102 of concentrate
tubing coupling
100 may include one or more barbs 104 dimensioned to snuggly receive the
opposing end of the
concentrate tubing as described above. Annular flange 106 on concentrate
tubing coupling may
engage seat portion 95 of tubing nut 94 such that tubing nut 94 may permit
mounting of
concentrate tubing coupling 100 to second tank 16 with minimal, if any,
twisting of the
concentrate tubing as tubing nut 94 is rotatably threaded onto male threads
88. To assist in
properly seating concentrate tubing coupling 100 within fitment housing 66,
annular flange 106
may also be dimensioned to abut against the mouth opening 110 of bore 96 when
tubing nut 94 is
fully tightened. An 0-ring seal 112 may also promote a fluid-tight seal
between concentrate
tubing coupling 100 and bore 96 of fitment housing 66.
[0042] In a further aspect of the invention, bore 96 may be further
include a series of
steps 114, 116, 118 thereby defining bore regions 96a, 114a, 116a, 118a.
Concentrate tubing
coupling 100 may reside within bore region 96a such that terminal end 120 of
first end 98 of
concentrate tubing coupling 100 may seat against step 114. The wall thickness
of terminal end
120 may be selected so that internal bore 122 of concentrate tubing coupling
100 is slightly
smaller than the diameter of bore region 114a. In this manner, terminal end
120 partially
occludes bore region 114a whereby flanged end 124 of plug member 126 may be
engaged by
concentrate tubing coupling 100 as tubing nut 94 is threaded onto fitment
housing 66. Bore
region 114a may be proportioned to receive flanged end 124 while step 116 has
a smaller
diameter than flanged end 124 whereby flanged end 124 is precluded from
entering bore region
116a. Plug member 126 may further include a body portion 128 dimensioned to
pass through
and extend within bore regions 116a, 118a before terminating at a second end
130. Second end
130 of plug member 126 may include an 0-ring seal 132 having an external
diameter greater that
the diameter of bore region 118a. In one aspect of the invention, body portion
128 may be
comprised of a plurality of spaced-apart spindles 134 configured to define
open slots 136
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therebetween so as to promote fluid travel through plug member 126, as will be
discussed in
greater detail below.
[0043] Plug member 126 may translate along longitudinal axis L of fitment
housing 66
so as to selectively plug or unplug bore region 118a and control outflow of
liquid concentrate
from second tank 16 to mixing matrix 38. To that end, as shown in FIG. 7,
tubing nut 94 may be
threadably coupled to fitment housing 66 to thereby secure concentrate tubing
coupling 100
therein. Terminal end 120 of concentrate tubing coupling 100 engages flanged
end 124 of plug
member 126 so as to direct second end 130 a spaced distance from bore region
118a. In this
position, fluid may flow from second tank 16 through tank tubing coupling 72,
fitment housing
66 and the concentrate tubing coupling before passing to mixing manifold 38.
[0044] Fitment housing 66 may further include a biasing member, such as
compression
spring 138, configured to engage flanged end 124 at a first end 140 and step
118 at second end
142. In this manner, threading of tubing nut 94 and concentrate tubing
coupling 100 may
compress spring 138 to thereby cause potential energy to be stored within
spring 138.
Unthreading of tubing nut 94 and removal of concentrate tubing coupling 100
from fitment
housing 66 enables spring 138 to release the stored potential energy so as to
cause plug member
126 to translate along longitudinal axis L generally in the direction
generally indicated by arrow
144. Plug member 126 will continue to translate until 0-ring 132 engages
surface 146 of fitment
housing 66 whereby 0-ring 132 and second end 130 of plug member 126 occlude
bore region
118a. In this manner, fluid concentrate may no longer flow into concentrate
tubing coupling
100. As a result, second tank 16 may be rendered substantially leak proof
Second tank 16 may
then be removed from mounting bracket 14 as described above and stored with
minimal to no
loss of liquid concentrate.
[0045] In accordance with an aspect of the invention, following removal
of second tank
16 as described above, a replacement second tank (not shown) may be mounted to
mounting
bracket 14. Tubing nut 94 and concentrate tubing coupling 100 may then be
threaded onto a
fitment housing (similar to fitment housing 66) on the replacement second tank
as described
above. As a result, the plug member within the fitment housing may be opened
so as to allow
transfer of the alternative liquid concentrate within the replacement second
tank to mixing
manifold 38 as described above. In a further aspect of the invention, a
replacement second tank
may be filled with water so as to enable flushing of the system between
chemicals that are to be
sprayed, thereby reducing cross-contamination or misapplication of the
chemicals. Thus, sprayer
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system 10 may be configured to selectively spray any number of various liquid
concentrates
requiring only the removal and replacement of selected second tanks and
remounting of tubing
nut 94 and concentrate tubing coupling 100. Respective second tanks may be
stored with little to
no threat of leakage of respective liquid concentrates contained therein,
thereby reducing waste
of the concentrates. Moreover, user exposure to a concentrate is minimized as
the second tank
does not need to be emptied, washed and refilled every time a new liquid
concentrate desired to
be sprayed.
[0046] Turning now to FIGS. 9-13, various views of mixing manifold 38 are
shown. As
can be seen, housing 58 of mixing manifold 38 may be generally comprised of
upper 148 and
lower 150 housing subunits. Manifold support member 152 may be interposed
between subunits
148, 150. To that end, the interior corners of lower housing subunit 150 may
include nodules
154 dimensioned such that respective feet 156 on manifold support member 152
seat upon
respective nodules 154. Upper housing subunit 148 may include respective lobes
158
dimensioned to receive a respective foot 156 therein. Each lobe 158 may also
include a notch
160 for permitting passage therethrough of a respective leg 162 on manifold
support member
152. In this manner, manifold support member 152 may be securely seated within
manifold
housing 58 and be constrained so as to prevent lateral and torsional movement
of manifold
support member 152. As described above, manifold support member 152 includes
second inlet
54 configured to receive fitment 62. Manifold support member 152 may further
include a spring
well 164 dimensioned to receive a stop spring 166, as will discussed in
greater detail below.
[0047] Mixing manifold 38 may further include disc 168 rotatably mounted
atop
manifold support member 152 whereby center hole 170 defined by disc 168
receives post 172
formed on manifold support member 152. Disc 168 may then be capped by upper
housing
subunit 148 wherein upper housing subunit 148 includes one or more openings
174 therethrough
such that a portion of the outer circumference of disc 168 may be engaged by a
user so as to
selectively rotate disc 168 about post 172. With additional reference to FIG.
14, disc 168 may
further define an outer annular series of spaced-apart through-holes, such as
flow metering holes
176a-176h. Each of flow metering holes 176a-176h may have a slightly larger
diameter than the
immediately preceding flow metering hole. In operation one of holes 176a-176h
is aligned with
internal bore 178 defined by fitment 62. Fitment spring 63 may urge fitment 62
against disc 168
so as to create and maintain a substantially fluid-tight seal between fitment
62 and disc 168. In
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this manner, a user may selectively control the volume of liquid concentrate
that may pass
through disc 168, as will be discussed in greater detail below.
[0048] Disc 168 may also further define an inner annular series of spaced
apart through-
holes, such as chamfered spring stop holes 180a-180h. Each respective spring
stop hole 180a-
180h is configured to align radially with its respective flow metering hole
176a-176h. In
operation, a selected one of holes 180a-180h is aligned with spring well 164
whereby a positive
stop member, such as ball bearing 182, seats within a portion of the selected
spring stop hole
180a-180h through urging of stop spring 166 resident within spring well 164.
In this manner, a
user may receive feedback indicating proper alignment of the selected flow
metering hole 176a-
176h upon seating of ball bearing 182. To change the amount of liquid
concentrate added to the
diluent stream, a user may rotate disc 168 whereby disc 168 may apply downward
force against
ball bearing 182 so as to compress stop spring 166 within spring well 164.
Disc 168 may then be
further rotated until the desired flow metering hole 176a-176h is aligned with
internal bore 178
of fitment 62 such that ball bearing 182 seats within the desired spring stop
hole 180a-180h. As
most clearly shown in FIG. 14, disc 168 may also include respective indicia
184a-184h
proximate a respective flow metering hole 176a-176h. Indicia 184a-184h may
correlate with the
respective diameter of respective flow metering holes 176a-176h so as to
provide visual
indication to the user as to which of the respective flow metering holes 176a-
176h is currently
aligned with internal bore 178 of fitment 62.
[0049] As seen most clearly in FIG. 13, mixing manifold 38 may include a
fluid channel
186 wherein a first end 188 of fluid channel 186 may define female threads 190
configured to
matingly receive corresponding male threads 192 defined by manifold terminus
194 of first inlet
fitting 48. The opposing second end 196 of fluid channel 186 may similarly
define female
threads 198 configured to matingly receive corresponding male threads 200 on
manifold
terminus 202 of manifold outlet fitting 204. A flow plug 206 may be interposed
within fluid
channel 186 adjacent the internal extent of female threads 190. Fluid channel
186 may further
define a step 208 so as to provide a positive stop to insertion of flow plug
206 in the direction
generally indicated by arrow 210. In this manner, bore 212 of first inlet
fitting 48 may align with
the longitudinal axis P of longitudinal bore 214 of flow plug 206 whereby a
constant volume of
diluent may be received from first tank 12 after flowing through first inlet
fitting 48 into flow
plug 206.
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[0050] As further seen in FIG. 13, flow plug 206 may further include a
radially extending
bore 216 which may be configured to fluidly align with one of flow metering
holes 176a-176h
and internal bore 178 of fitment 62. In this manner, a user selected volume of
liquid concentrate
may be received from second tank 16, wherein the selected volume of liquid
concentrate is then
mixed with, and diluted by, the constant volume of diluent being received
through first inlet 48
as described above. Flow plug 206 may also define an annular groove 218
configured to define a
fluid tight channel with internal wall surface 220 of mixing manifold 38.
Annular groove 218
coincides with radially extending bore 216 such that fluid concentrate may
still pass through
radially extending bore 216 into longitudinal bore 214 should radially
extending bore 216 be
misaligned with one of flow metering holes 176a-176h and internal bore 178.
Fluid channel 186
may further define a mixing chamber portion 222 which may further promote
mixing of the
diluent and fluid concentrate prior to outputting the mixed fluid through
manifold outlet fitting
204.
[0051] With reference to FIGS. 3 and 4, manifold outlet tubing (not
shown) may fluidly
couple manifold outlet fitting 204 with positive displacement pump suction
port 224. In this
manner, upon a suction stroke of positive displacement pump 42, mixed fluid is
drawn into pump
42 from mixing manifold 38. As described above, the mixed fluid is comprised
of a constant
volume of diluent into which is charged a user-selected volume of liquid
concentrate. Thus, on a
pressure stroke of pump 42, the mixed fluid is forced out of pressure port 226
of positive
displacement pump 42. Pressure port 226 may be fluidly coupled to a spray
device, such as a
spray wand or boom sprayer (not shown). To prevent backflow of mixed fluid
through first inlet
fitting 48 into first tank 12, first inlet fitting 48 may include a check
valve 228 (see FIG. 13). In
this manner, cyclical operation of positive displacement pump 42 will
alternately draw mixed
fluid from mixing manifold 38 and discharge this mixed fluid through an
attached sprayer
whereby the concentration of the fluid concentrate dilution is selected, and
easily modified by,
the user through setting of disc 168. In should be understood by those skilled
in the art that
positive displacement pump 42 may be powered by any suitable power source,
such as a
dedicated battery or through wiring pump 42 to the battery of the vehicle
(e.g., ATV or golf
cart).
[0052] Turning now to FIG. 15, a sprayer system 10' may be configured to
operate as a
variable pressure sprayer. Sprayer system 10' may include first tank 12 and
second tank 16 each
fluidly coupled to mixing manifold 38 as described above with regard to
sprayer system 10.
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Check valve 228 may be interposed between mixing manifold 38 and first tank 12
to prevent
backflow of mixed fluid into first tank 12, also as described above. Mixed
fluid may be drawn
from mixing manifold 38 through operation of positive displacement pump 42
whereby the
mixed fluid is output through pressure port 226. The mixed fluid may then be
selectively
delivered to a spray nozzle 230 (such as a handheld sprayer) or to a boom 232
upon which are
mounted a plurality of boom nozzles 234.
[0053] In accordance with one aspect of the invention, flow to spray
nozzle 230 or boom
232 may be selectively controlled by a selector valve 236. Flow control at
each boom nozzle
234 may also be further controlled by respective ball valve 238. Spray nozzle
230 may also
include a pressure reducing valve 240 which is metered to control the fluid
pressure of the mixed
fluid entering spray nozzle 230 so as to minimize or prevent damage to spray
nozzle 230.
[0054] Positive displacement pump 42 may include a pressure by-pass
circuit 242 fluidly
coupling pressure port 226 with suction port 224. Pressure by-pass circuit 242
may operate to
decrease the fluid pressure of the mixed fluid being delivered to spray nozzle
230 while also
maintaining segregation of the mixed fluid from either first tank 12 or second
tank 16. Pressure
by-pass circuit 242 may be either internal to positive displacement pump 42 of
may be en
external pressure by-pass loop around positive displacement pump 42.
[0055] Turning now to FIGS. 16 through 21 and with particular reference
to FIG. 16, an
exemplary embodiment of an external by-pass circuit 342 is shown mounted onto
positive
displacement pump 42. External by-pass circuit 342 generally comprises a input
flow fitting 344
including an adjustable needle valve assembly 346 (see also FIGS. 20 and 21),
a flow diverter
valve 336 (see also FIGS. 17 through 19), and a by-pass line 348 fluidly
coupling the flow
diverter valve to the input flow fitting 344. As will be discussed in greater
detail below, flow
diverter valve 336 may operate similarly to selector valve 236 described above
so as to direct
flow to either a high flow output, such as a boom sprayer 232, or a low flow
output, such as a
handheld wand 230 (see FIG. 15). As shown in FIG. 16, input flow fitting 344
is coupled to
suction (inlet) port 224 of positive displacement pump 42 while flow diverter
valve 336 is
coupled to pressure (output) port 226. It should be noted that, while shown as
being directly
coupled to their respective ports 224, 226, input flow fitting 344 and flow
diverter valve 336 may
be indirectly coupled to their respective ports 224, 226, such as through
intermediate hoses, tubes
or other plumbing hardware.
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[0056] Turning now to FIGS. 17 through 19, flow diverter valve 336 may
include a
generally T-shaped valve body 350 defining an inlet orifice 352, high flow
outlet orifice 354 and
low flow outlet orifice 356. Resident within the junction of the intersecting
arms of valve body
350 is a ball valve 358. A handle 360 may be used to selectively rotate ball
valve 358 so as to
control fluid flow from inlet orifice 352 to either high flow outlet orifice
354 or low flow outlet
orifice 356 as desired. Inlet orifice 352 may threadably receive quick-connect
fitting 362
whereby flow diverter valve 336 may be releasably coupled to pressure port 226
of pump 42.
High flow outlet orifice 354 may threadably receive a high pressure fitting
364 adapted to
receive a corresponding fitting (not shown) mounted onto the high flow output
(e.g., boom
sprayer 232). Low flow outlet orifice 356 may threadably receive a first arm
366 of generally T-
shaped by-pass fitting 368. A second end 370 of by-pass fitting 368 may be
adapted to receive
tubing or a corresponding fitting (not shown) mounted onto the low flow output
(e.g., handheld
wand 230) so as to deliver a spray portion of the fluid to the low flow
output. Additionally, by-
pass arm 372 of by-pass fitting 368 may be configured to receive a first end
374 of by-pass line
348 so as to deliver a by-pass portion of the fluid to input flow fitting 344.
It should be noted
that discussion of the seals and gaskets used to form water-tight connections
has been omitted.
[0057] With reference to FIGS. 20 and 21, input flow fitting 344 may
include a tubular
body 376 defining a fluid flow path 377 extending from a first end 378 to a
second send 380.
First end 378 may be adapted to couple input flow fitting 344 with suction
port 224 of pump 42
while second end 380 is adapted to fluidly couple input flow fitting 344 with
manifold outlet
fitting 204 (see FIGS. 3 and 4), such as through appropriate hosing or tubing
(not shown). Input
flow fitting 344 may further include a flow control arm 382 extending
outwardly from tubular
body 376. In one aspect of the present invention, flow control arm 382 is
arranged substantially
perpendicular to tubular body 376. Flow control arm 382 defines a flow control
channel 384
wherein distal end 385 receives a threaded retainer 387 of needle valve
assembly 346 therein.
Needle 386 is threadably received within threaded retainer 387 whereby needle
386 may regulate
fluid flow through flow control channel 384, as will be discussed in greater
detail below. A
retaining cap 389 secures threaded retainer 387 and needle 386 to flow control
arm 382. A knob
391 is coupled to needle 386 so as to enable controlled placement of needle
386 within flow
control channel 384 in relation to by-pass orifice 395 which fluidly joins
flow control channel
384 with fluid flow path 377. Knob 391 may include reference indicia 393 so as
to provide a
visual aid for a user to track the needle placement when adjusting the flow
control, as will
CA 3036038 2019-03-07
described below. Arranged along flow control arm 382 is a by-pass fitting 388
having a fitted
end 390 configured to receive second end 392 of by-pass line 348. As a result,
by-pass fitting
388 is in fluid communication, via by-pass line 348, with by-pass arm 372 of
flow diverter valve
336 whereby fluid may flow from flow diverter valve 336 to input flow fitting
344. Again,
discussion of the seals and gaskets used to form water-tight connections has
been omitted.
[0058] In operation, a low pressure fluid is drawn into positive
displacement pump 42
through second end 380 of input flow fitting 344 during the suction stroke of
the pump. In
accordance with an aspect of the present invention, this fluid is received
from mixing manifold
38 and may include a liquid concentrate, such as a chemical from second tank
16, mixed within a
diluent (water) from first tank 12. As described above, mixing of the fluids
within mixing
manifold 38 generates a discharge fluid having the liquid concentrate at a
user-selected,
consistent dilution. Upon further operation of positive displacement pump 42,
the fluid is
charged to a high pressure through the discharge stroke of the pump. This high
pressure fluid is
then discharged through flow diverter valve 336. Depending upon the
positioning of handle 360
and ball valve 358, the high pressure fluid may exit through either high
pressure fitting 364 or
by-pass fitting 368. If the fluid path within flow diverter valve 336 is
directed toward high
pressure fitting 364, all of the high pressure fluid will flow through high
pressure fitting 364 for
downstream delivery to a boom sprayer 232 or other high pressure output.
Alternatively, if the
fluid path within flow diverter valve 336 is directed toward by-pass fitting
368, a sprayer portion
of the fluid is delivered downstream through second end 370 to the low
pressure output, such as
a handheld wand 230, while the remainder of the fluid flow (the by-pass
portion) is recycled to
input flow fitting 344 through by-pass arm 372 and by-pass line 348.
[0059] In accordance with an aspect of the present invention, the amount
of fluid flow
received by input flow fitting 344 from flow diverter valve 336 may be
selectively controlled by
needle valve assembly 346. That is, needle 386 may be selectively positioned
within flow
control channel 384 (such as via knob 391) so as to constrict or expand to
open volume of by-
pass orifice 395. For instance, by advancing needle 386 toward fluid flow path
377, the open
volume of by-pass orifice 395 is decreased. As a result, less fluid may be
received by flow
control channel 384, thus decreasing the volume of the by-pass portion and
increasing the
volume (and pressure) of the sprayer portion. Conversely, by retreating needle
386 away from
fluid flow path 377, the open volume of by-pass orifice 395 is increased. As a
result, more fluid
may be received by flow control channel 384, thus increasing the volume of the
by-pass portion
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and decreasing the volume (and pressure) of the sprayer portion. Therefore,
the volume and
pressure of the sprayer portion may thus be selectively controlled by needle
386 and knob 391.
It should also be noted that the by-pass portion is recycled prior to positive
displacement pump
suction port 224 but after mixing manifold 38. Thus, the by-pass portion is
fed into already
mixed fluid and not either the first tank 12 or second tank 16 as is known in
the art. Therefore,
dilution of the liquid concentrate is not changed when alternating between
high flow and low
flow operations, the diluent tank 12 does not become contaminated by the
chemicals of the liquid
concentrate within the by-pass portion, and the liquid concentrate is not
diluted in its tank 16 by
the by-pass portion. As a result, the unwanted rapid cycling of the pump and
its cut off switch is
eliminated while also preserving the desired dilution of the liquid
concentrate within the sprayed
fluid without contamination of the supply tanks.
[0060]
The foregoing description of the preferred embodiment of the invention has
been
presented for the purpose of illustration and description. It is not intended
to be exhaustive nor is
it intended to limit the invention to the precise form disclosed. It will be
apparent to those skilled
in the art that the disclosed embodiments may be modified in light of the
above teachings. The
embodiments described are chosen to provide an illustration of principles of
the invention and its
practical application to enable thereby one of ordinary skill in the art to
utilize the invention in
various embodiments and with various modifications as are suited to the
particular use
contemplated. Therefore, the foregoing description is to be considered
exemplary, rather than
limiting, and the true scope of the invention is that described in the
following claims.
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