Spray and Foam Producing Nozzle Apparatus

1. Field of the Invention

This invention relates generally to nozzle apparatus, and more particularly to a nozzle apparatus for cleaning applications, which is rapidly convertible between spray and foam forming modes of operation.

2. Description of the Prior Art

Industrial cleaning apparatus has traditionally employed the principle of directing high pressure spray of relatively dilute detergent solutions against the article to be cleaned, thus relying upon the hydraulic cleansing action of the spray. In several applications, such as in conveyor type spray washers (e.g., dishwashers, hydro-bottle washers, etc.) the production of foam during the cleaning operation is generally undesirable and defoaming agents are typically used to minimize foam formation. In other applications such as in the cleaning of carpets and upholstery it has been found that foam cleansers used in combination with brushing/scrubbing action are effective to suspend the soil removed from the carpet or upholstery in the foam. When the foam is allowed to dry, the foam/soil residue can be simply vacuumed away. In such applications, the foaming agent is desirably of a type which will dry to a powder so that it can be completely removed when dry.

The use of foam in cleaning food handling equipment and other industrial hard surface applications, however, is relatively new in the art. It has now been found that in certain industrial cleaning applications particularily in those requiring the cleaning of large surfaces or hard to reach geometrical configurations, it is desirable to use a non-drying foam cleansing agent which will cling to the surface to be cleaned for extended periods of time, prolonging the contact between the soil and detergent within the foam for solvation, hydration or emulsification of the soil. In many applications, foam cleansing techniques can be significantly more efficient and less expensive to use than the prior art high pressure hydraulic cleansing techniques. With the use of hydraulic cleansing techniques, large volumes of relatively dilute detergent solutions are directed at high pressure against the object to be cleansed. With such techniques, the cleansing of stubborn soil requires the hydraulic spray to be directed at a specific area for extended periods of time, prolonging the cleansing operation. Further, with use of conventional high pressure cleaning operations, the high pressure spray nozzle must typically be held within a foot of the surface to be cleaned to provide effective hydraulic cleansing action.

The use of foam cleansing techniques for hard surfaces overcomes the aforementioned disadvantages of hydraulic cleansing techniques. When cleansing with foam, which is highly visible to the operator, the operator knows exactly what areas have been exposed to the cleaner thus insuring against missed areas. Likewise, the adequacy of rinsing is visually detectable, enabling an operator to completely rinse off any residues of cleansing solution from the object being cleaned. Since the foam clings to vertical and overhead surfaces, such surfaces are particularly adapted for cleansing by this technique. Further, since the cleansing action is minimally dependent on any hydraulic action, the "reach" of a foam producing nozzle can be extended from 10 to 20 feet making it possible to clean relatively remote areas without the need for the operator's physical presence directly adjacent the object to be cleaned. Foam cleaning enables significant time to be saved in the cleansing of larger articles since an operator can start with foam applications from one end of the article to be cleaned, work his way to the far end, and simply return to his starting point and begin rinsing operations. No wasted time for prolonged spraying efforts in any one area to remove stubborn soil is required. Also, since the same volume of detergent solution may clean a significantly greater area with the foam generating operations as compared to high-pressure spray producing applications, the detergent concentration level within the foam can be significantly increased to insure high cleansing action thereby, in a highly economical manner.

Prior art cleansing apparatus has conventionally been designed to accommodate a fixed type of nozzle designed either to eject high-pressure spray solutions for hydraulic cleansing action or to produce and to eject a foam-type cleanser. The foam producing nozzles have been provided with various tips which may be secured to the ejection port of the nozzle to vary the foam ejection pattern emitted therefrom. It is highly desirable for an operator to use the same nozzle for directing cleansing foam against the object to be cleaned and for directing a rinse solution for removing the foam from the object. However, the prior art is void of any such nozzle apparatus.

Foam producing nozzle configurations have also appeared for use in applications other than for cleansing. The largest use of such nozzles has been in the fire extinguishing art and in the distribution of herbicides and insecticides. As in the cleansing art, however, such nozzles have been designed for a single purpose use of producing either foam or pressurized sprays.

The present invention overcomes the above-mentioned shortcomings of the prior art nozzle structures for use with pressurized spray and/or foam producing cleansing apparatus. The present invention provides a highly versatile hand-held nozzle apparatus which is usable with a detergent solution source for enabling an operator to selectively direct against the target area either a pressurized spray for hydraulic cleansing or rinsing action, or a dry (stiff) foam for foam cleansing action. The nozzle apparatus of this invention is rapidly convertible between its pressurized spray and its foam producing modes, filling a long-felt need for such a device in the art.

In the present invention, a spray and foam producing nozzle apparatus is rapidly convertible, while the device is operatively ejecting cleansing solution therefrom, between a pressurized spray mode for hydraulic cleansing action and a foam-producing mode for foam cleansing action. The output nozzle apparatus is supplied with cleansing solution or rinsing solution directed under pressure from a supply source. The source can either be of a high-pressure output type or of a low-pressure output type, of the order of magnitude of water pressure from a water main, and can be either portable or stationary.

The convertible nozzle configuration resembles a conventional pressurized wand-type apparatus, having an elongated first conduit member connected to a pistol grip handle for enabling hand-carrying thereof and operative directional aiming of the elongated conduit portion. The pressurized solution enters the first elongate conduit by means of an inlet port and is projected therethrough to an outlet port at one end thereof. A spray-forming nozzle connected at the outlet port forms the pressurized solution into a spray and directs the spray longitudinally outward therefrom.

A second elongate tube assembly sized to overlie the first conduit shaft and attached nozzle, is slidably mounted in coaxial alignment to the first conduit portion. A clamping mechanism at one end of the outer tube enables the tube to be positioned in retracted and extended positions relative to the underlying first conduit shaft. In its retracted position, the outer tube freely exposes the spray-forming nozzle to permit uninterrupted spray-forming action thereby. In its extended position, the outer tube encompasses and extends beyond the nozzle. In the extended position, spray ejected from the nozzle is turbulently advanced through the outer tube. A plurality of holes through the outer tube permit air to be drawn into the internal chamber formed by the outer tube, which aspirates with the turbulent spray to produce a foam therefrom which is directionally projected from the outer tube toward a target area. Foam is produced in this mode of operation whenever the solution being sprayed by the nozzle contains a surfactant. The clamping mechanism enables an operator to rapidly extend or retract the outer tube to respectively convert between foam-producing and spray modes of operation.

While the invention will be disclosed with respect to a preferred embodiment thereof, employing specific material in its construction, it will be understood that other types of materials can be equally well employed within the spirit and intent of this invention. Further, while specific dimensions, pressures and geometrical configurations will be described with respect to various elements of the preferred embodiment, it will be understood that such dimensions, pressures and geometrical configurations are design parameters which can be varied and combined in numerous fashions to achieve the intent and purposes of this invention.

Referring to the drawing, wherein like numerals represent like parts throughout the several views:

FIG. 1 is a side elevational view of the spray and foam-producing nozzle apparatus of this invention.

FIG. 2 is an end view of the spray-forming nozzle portion of the apparatus disclosed in FIG. 1;

FIG. 3 is a cross-sectional view generally taken along the line 3--3 of the spray-forming nozzle of FIG. 2;

FIG. 4 is a cross-sectional view generally taken along the line 4--4 of the spray-forming nozzle of FIG. 2;

FIG. 5 is a cross-sectional view generally taken along the line 5--5 of the apparatus disclosed in FIG. 1, illustrating the outer foam-producing member in its extended position; and

FIG. 6 is a block diagram representation of the spray and foam-nozzle apparatus in combination with a typical high-pressure solution supply unit .

Referring to the figures, there is generally illustrated at 10 in FIG. 1 a preferred embodiment of a convertible spray and foam-producing nozzle apparatus constructed according to the principles of this invention. The spray and foam-producing apparatus is shaped in what is typically referred to as a wand configuration, having a first elongate cylindrical rigid conduit 12 defining an internal passageway 14 extending therethrough from an inlet port 15 to an outlet port 16 each located, in the preferred embodiment, at opposite ends of the first conduit member 12. The first conduit member 12 passes through a pistol grip handle 18 which enables an operator of the device to hand-carry the assembly and to accurately point or aim the outlet port 16 of the first conduit member 12 so as to direct the flow emanating therefrom as desired.

A spray-forming nozzle 20 is connected to the first conduit member 12 at its outlet port 16. The nozzle 20 is threaded to the first conduit shaft 12 at its outlet port 16 by means of a hexagonal head nut portion 20a. The spray-forming nozzle 20 may be of any construction which forms a spray of solution passing under pressure therethrough and which directs the formed spray longitudinally outward therefrom. In the preferred embodiment, the spray-forming nozzle 20 comprises what is known in the art as a V-jet nozzle having a central passageway therethrough leading from the larger diameter outlet port 16 of the first conduit shaft 12 to a significantly smaller nozzle opening 20b.

The ejection end of the nozzle 20 includes a pair of flow directing ramp surfaces 20c located directly adjacent the nozzle outlet opening 20b. Each of the flow directing ramp surfaces 20c is positioned in a plane inclined to the horizontal (as viewed in FIGS. 1, 2 and 3) so as to direct the spray of solution ejected from the nozzle outlet 20b at a predetermined angle with respect to the longitudinal axis of the nozzle. The nozzle 20 also includes a pair of side ramps 20d extending outwardly from the flow directing ramp surfaces 20c in planes respectively and symmetrically inclined relative to a vertical longitudinal plane (as viewed in FIGS. 1, 2 and 3) of the nozzle, 20. The flow directing and side ramps 20c and 20d respectively, in combination, produce and direct a spray from that solution passing through the nozzle opening 20b, which is directed longitudinally outwardly therefrom in a fan-shaped V pattern with respect to the longitudinal horizontal plane of the nozzle 20.

A support sleeve member 24 coaxially overlies the first conduit shaft 12 for free sliding engagement therealong. Forward sliding motion of the sleeve 24 relative to the underlying first conduit member 12 is restricted, as illustrated in FIG. 5, by its engagement with the hexagonal nut portion 20a of the nozzle 20. The rearward end of the sleeve 24 is bifurcated to form a plurality of collet finger members 24a which are radially movable with respect to the longitudinal axis of the sleeve 24. The outer surface of the collet sleeve 24 adjacent the collet finger members 24a is threaded to accept a collet nut 25. The outer surface of the collet nut 25 is knurled to enable an operator to easily grasp and thread the nut 25 relative to the sleeve member 24. The collet nut 25 has an internal truncated conical surface 25a symmetrically disposed about the longitudinal axis of the nut for engaging the collet finger members 24a.

The collet fingers 24a are radially movable with respect to the longitudinal axis of the sleeve 24 such that when the collet nut 25 is threaded onto the sleeve 24 the collet finger members 24a are depressed in latching engagement against the outer surface of the first cylindrical shaft member 12 so as to frictionally secure the sleeve 24 to the underlying shaft 12. As the collet nut 25 is threaded in the direction so as to remove the conical surface 25a from engagement with the collet finger members 24a, the collet finger members 24a act under their internal bias tension to release their frictional hold upon the underlying shaft 12 to enable free sliding movement of the sleeve 24 relative to the underlying shaft 12.

An end cap 28 is threaded to the support sleeve member 24 and is securely affixed thereto by means of a lock nut 29, also threaded to the sleeve 24, and by a set screw 30 within the end cap 28. The end cap 28 has a forwardly disposed cylindrical portion 28a.

An elongate second cylindrical tube member 32 is secured to the inner surface of the cylindrical extended portion 28a of the end cap 28. The inner periphery of the elongate outer tube 32 defines an internal chamber 34 closed at one end by the end cap 28 and open at the opposite extremity forming an outlet port 32a of the outer tube 32. The second cylindrical member 32 may be made of semi-rigid or rigid material and has an inner diameter sized to freely pass over the hexagonal nut portion 20a of the nozzle 20, see FIGS. 2 through 5. The length of the cylindrical outer tube 32 is sized such that when the sleeve and collet assembly 24 and 25 respectively are retracted in their rearmost position as illustrated in FIG. 1, the outlet port of the outer cylindrical tube 32 is spaced back from the ejection end of the nozzle 20 so as to permit normal spray-forming action by the nozzle 20. A pair of holes 36 radially extend through the cylindrical walls of the elongate outer tube member 32 at diametrically opposite positions thereof and are longitudinally spaced from the end cap 28 such that they open into the inner chamber 34 of the tube 32 just rearward of the hexagonal nut 20a of the nozzle 20 when the sleeve and collet assembly 24 and 25 respectively are positioned in their maximally extended position as illustrated in FIG. 5.

A block diagram of a typical source for supplying a detergent or rinse solution under pressure to the convertible spray and foam producing apparatus 10 is illustrated at 40 in FIG. 6. Referring thereto, the solution supply source illustrated at 40 is of the type which could typically be employed for use with a portable washing apparatus which uses a relatively small one or two gallon reservoir of concentrated detergent solution. An example of such an apparatus is the Porta-Washer, Modle P manufactured by Economics Laboratory, Inc. However, as will become apparent upon a more detailed description herein, the invention is equally well applicable to its use with stationary solution supply systems as well as with low-pressure supply systems operating directly off of normal water inlet supply pressures.

Referring to FIG. 6, the solution supply source 40 includes a pump 42 having a first intake port 42a, a second intake port 42b and an outlet port 42c. The intake port 42a of the pump 42 is connected by means of a conduit 43 to an appropriate fresh water source such as a standard water line or the like having a typical water line pressure of 30 to 40 p.s.i. In the preferred embodiment, the pump 42 is of a type having a capability of developing and maintaining an output pressure of approximately 700 p.s.i. The outlet port 42c of the pump 42 is connected by means of a conduit 44 to the inlet port 45a of an unloader valve 45. The unloader valve 45 also has a main outlet port 45b, a secondary outlet port 45c and a pressure adjustment means (not illustrated). The secondary outlet port 45c of the underloader valve 45 is connected by means of a bypass or return path conduit 46 to the second intake port 42b of the pump 42. The unloader valve may be of any type standard in the industry which functions to normally provide flow from its inlet port 45a to its main outlet port 45b whenever the back-pressure at its outlet port is below a predetermined adjustable level, and operates to provide bypass flow its inlet port 45a to its secondary outlet port 45c to provide a closed loop for fluid flow between the unloader valve 45 and the pump 42 whenever the back-pressure at its main outlet port 45b exceeds a predetermined value.

The main outlet port 45b of the unloader valve 45 is connected to a conduit 47 which is bifurcated into first and second branches 47a and 47b respectively. The first branch 47a of the conduit 47 is directly connected to a first inlet port 48a of an aspirator unit 48. The aspirator 48 further has a second inlet port 48b and an outlet port 48c. The aspirator 48 is of a type well-known in the art which functions in response to sufficient fluid flow between its first inlet port 48a and its outlet port 48c to draw solution at a predetermined rate into its second inlet port 48b for mixing or aspirating the draw-in solution with the main fluid flowing out of the outlet port 40c.

The second inlet port 48b of the aspirator 48 is connected by means of a conduit 49 terminating at a strainer 50 in a reservoir 52 for concentrated detergent solution generally designated at 53.

The second branch 47b of the conduit 47 is connected by means of a "selection" valve 55 to a first branch 57a of a conduit 57. The selection valve 55 is in the preferred embodiment, a simple ball-valve which opens or closes the fluid flow path between the conduits 47b and 57a. The conduit 57 further has a second branch 57b connected to the outlet port 48c of the aspirator 48. The first and second branches 57a and 57b of the conduit 57 at an output coupling 58 of the solution supply source 40.

The coupling 58 is connected, in the preferred embodiment, by means of a high-pressure hose 60 to a "shut-off" valve 62 to the inlet port 15 of the first conduit shaft 12 of the convertible spray and foam producing apparatus 10. The shut-off valve 62 is in the preferred embodiment, a ball-valve which operates simply to open and close the fluid flow path between the hose 60 and the inlet port 15 of the conduit 12.

As previously discussed, the convertible spray and foam-producing nozzle apparatus 10 of this invention can be employed with any pressurized source of detergent solution to direct that solution in either a pressurized spray or foam condition at the object to be cleaned. The apparatus is preferably usable for combined use with a high pressure solution supply source (e.g., on the order of 300 to 700 p.s.i.), but can also be employed for use with fairly low pressure solution supplies as would be derived from direct use with a 40-60 p.s.i. source such as taken directly from a water main. With reference to its preferred use with a high-pressure supply system as illustrated in FIG. 6, the pump 42 drives water from its intake port 42a through the unloader valve 45 to the conduit 47. When the selection valve 55 is closed, indicating a "Wash" selection, the high-pressure water flow from the conduit 47 is directed through the aspirator 48, to the output coupling of the supply unit 40. As the high-pressure water flow is forced through the aspirator 48, a predetermined amount of the concentrated detergent solution 53 within the detergent reservoir 52 is pulled through the strainer 50 and connecting conduit 49 into the aspirator 48 and is mixed with the water passing therethrough.

When the selection valve 55 is positioned in an open position, designating a "Rinse" cycle, the high-pressure water passing through the conduit 47 is primarily bypassed around the aspirator 48 and through the selection valve 55 to the output coupling 58. While a small amount of fluid flow is present through the aspirator 48, the rate of flow is insufficient to cause detergent solution from being drawn into its inlet port 48b. Therefore, for all practical purposes, the aspirator is essentially inoperative in this position.

When the shut-off valve 62 is closed, blocking fluid flow into the inlet port 15 of the conduit 12, the back-pressure at the main outlet port 45b of the unloader valve 45 causes the unloader valve to divert fluid flow from its inlet port 45a through the bypass conduit 46 to the second intake port 42b of the pump 42. The pump can be operated in this mode of operation for short periods of time in which it merely recycles water between its outlet port 42c and its second intake port 42b. When the shut-off valve 62 is opened, the solution provided from the supply source 40 is allowed to enter the inlet port 15 of the first conduit 12 and to proceed through the internal passageway 14 thereof to the spray-forming nozzle 20.

When the sleeve and collet assembly 24 and 25 are positioned in their fully retracted position, the outer cylindrical tube 32 overlies the first cylindrical shaft 12 along its length such that the nozzle 20 is exposed beyond the output end 32a of the outer tube 32. This is the "Spray" cleansing mode of operation for the device, and the solution passing through the inner tube 12 is ejected from the nozzle opening 20b of the nozzle 20 in a V-shaped fan-out spray pattern as directed by the flow directing ramp surfaces 20c of the nozzle 20. In this mode of operation, the spray and foam producing apparatus 10 acts as a conventional hard-spray cleaning wand for directing a pressurized spray for washing or rinsing via hydraulic action.

The convertible spray and foam producing apparatus 10 can be rapidly converted to its "Foam" producing cleansing mode by partially unscrewing the collet nut 25 so as to release the gripping pressure of the collet finger members 24a from the underlying cylindrical shaft 12 and by sliding the entire collet 25, sleeve 24, end cap 28 and outer cylindrical tube 32 in the longitudinal direction of spray (i.e., from right to left in FIG. 1) such that the outer tube 32 encompasses the nozzle 20, with the outlet port 32a of the outer tube 32 longitudinally extending beyond the nozzle 20. The collet nut 25 may be tightened anywhere along the longitudinal length of the first conduit 12, as restrained by the length of the sleeve 24, to position the outlet port 32a of the outer tube 32 at an infinite number of positions longitudinally spaced from the nozzle 20 in the direction of solution spray. However, it has been experimentally determined that a foam having dryer (i.e., lower weight) characteristics is produced when the outer tube 32 is positioned in its maximally extended position as illustrated in FIG. 5. When the outer tube 32 is positioned in its extended position, the spray from the nozzle 20 is violently directed against the inner chamber walls 34 of the outer tube 32, creating severe turbulence therein. Air is drawn into the chamber 34 through the holes 36 within the tube 32 and is aspirated with the detergent or surfactant bearing solution emanating from the nozzle 20 to produce foam.

The foam thus produced is directed outwardly from the outlet port 32a of the outer tube 32 and is projected under force against a remotely located target area. The apparatus 10 can be rapidly converted from its spray mode to its foam producing mode while the shut-off valve 62 is open. Thus an operator can initially cleanse or rinse an object under the spray mode of operation, can convert immediately to the foam producing mode of operation to apply a layer of concentrated cleansing foam to the object, and can thereafter, without interruption, reconvert back to a spray mode of operation to rinse the foam from the target area.

While the invention has been described with respect to its use with a particular type of portable supply apparatus 40, it will be noted that other supply apparatus could equally well be used. For example, a stationary-type of supply apparatus could be used, wherein the detergent solution is drawn out of a large (55 gallon) drum; in such case, an aspirator 48 would not be required. Without the use of an aspirator, the output working pressure of the apparatus can be maintained at the high pressure output level from the pump (e.g., at 700 lbs. in the preferred embodiment) when operating in either the spray or foam producing modes.

It will be apparent that a number of design parameters can be changed without departing from the spirit and intent of this invention. For example, the length of the outer tube 24 can be varied to effect the quality of foam produced and to determine the reach (i.e., the distance over which the foam can be projected) of the foam producing apparatus. A longer outer tube 32 will provide a longer reach. Similarly, as the length of the outer tube 32 is decreased, the quality of the foam produced thereby proportionately changes from a dry foam to a wet foam as a result of the incomplete aspiration between the air and liquid solution within the chamber 34. Further, different combinations of spray-forming nozzles 20 and outer tube 32 dimensions can be employed to produce various foam qualities. In the preferred embodiment, the V-jet nozzle used develops a 25% angle (with respect to the longitudinal nozzle axis) spray with an output of 0.6 gallons per minute at 40 p.s.i. pressure. Also, the size and location of the air intake holes 36 through the outer tube 32 can be varied to effect various aspiration effects within the inner chamber 34 of the tube 32.

While we have disclosed a specific embodiment of our invention, it is to be understood that this disclosure is for the purposes of illustration only. Other modifications of the invention will be apparent to those skilled in the art in light of the foregoing description. This description is intended to provide a concrete example of one embodiment which clearly discloses the present invention. Accordingly, the invention, is not limited to any one particular embodiment, but is limited only by the broad scope of the appended claims.