Sector air operating lever for a spray gun

Abstract

A fan air control assembly for a spray gun (10) controls the flow of a fan air portion of compressed air to a spray end of the spray gun (10) to control the resulting spray pattern. A fan air lever (28) is accessible from the exterior of the spray gun (10) and can be manipulated by the hand of a user holding the sprayer and manipulating a trigger while spraying. The fan air control assembly (20) is rotatable about a valve axis (B) to control the flow of the fan air portion.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 079,027, filed September 16, 2020, entitled “FAN AIR LEVER FOR A SPRAY GUN”, the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0003] This disclosure generally relates to sprayers. More specifically, this disclosure relates to fan-shaped air control for sprayers. Background Technology

[0004] A spray gun can be used to spray fluids onto a surface. For example, a spray gun can be used to apply paint, varnish, finishes, and other coatings to furniture, cabinets, appliances, equipment, manufactured parts, etc. While various fluids can be sprayed using the embodiments cited herein, paint will be used as an example. Typically, paint is pressurized by a piston, diaphragm, or other volumetric pump. This pump can apply the paint at pressures ranging from 500 to 5000 pounds per square inch (psi), although higher or lower pressures are possible. The pump delivers the paint under pressure through a flexible hose. The spray gun is used to dispense the paint and is attached to the end of the hose opposite the pump. In this way, the spray gun does not include a pump; instead, the paint pumped to the spray gun is released through the hose. The spray gun atomizes the paint into a fan-shaped spray under pressure and then applies it to the surface.

[0005] Some spray guns emit a stream of compressed air to help atomize and / or shape the fluid spray. This fan-shaped airflow can control the spray pattern and / or aid in the atomization of the sprayed liquid. Such spray guns emit fluid through a spray nozzle and generate an airflow near the fluid spray. Summary of the Invention

[0006] According to one aspect of the present disclosure, a fan air control assembly for a spray gun is configured to control the flow of a fan air portion of compressed air to a spray end of the spray gun, the fan air portion configured to form a spray pattern emitted by the spray gun. The fan air control assembly includes a fan lever and a valve assembly operably connected to the fan lever. The valve assembly includes a valve seat having a shaft bore extending axially therethrough along a valve axis, a seat body, a positioning body extending from the seat body in a first axial direction, and a flow control body extending from the seat body in a second axial direction, wherein at least one flow opening extends through the flow control body. A valve member is disposed at least partially within the shaft bore and is secured to the fan lever. The valve member includes a shaft body having a flow controller disposed within the flow control body of the valve seat, the flow controller including at least one flow resistor and at least one flow passage extending at least partially about the valve axis. The valve member is rotatable about the valve axis to actuate the valve assembly between a maximum flow state and a minimum flow state.

[0007] According to another additional or alternative aspect of the present disclosure, a method of controlling fan air flow during spraying with a fluid spray applicator includes grasping a handle of the fluid spray applicator with a first hand, actuating a trigger of the fluid spray applicator with the first hand to cause the fluid spray applicator to emit a liquid spray, pressing a fan lever projecting from a lateral side of a gun body of the fluid spray applicator with the first hand from a first position associated with a base state to a second position associated with an actuated state, the fan lever connected to a valve member to rotate the valve member about a valve axis to change a fan air flow to a spray end of the fluid spray applicator, and releasing the fan lever with the first hand.

[0008] According to another additional or alternative aspect of the present disclosure, a method of forming a fan air controller for a spray gun includes passing an axially elongated valve member through a shaft bore extending through a valve seat, inserting a rotation limiter into a stem opening in the valve member, the rotation limiter disposed in a rotation notch formed in the valve seat, wherein the rotation notch limits travel of the rotation limiter in a first circumferential direction and a second circumferential direction, connecting the valve seat to the spray gun with an interface thread, placing a spring on the valve seat such that a first spring arm of the spring is disposed in a valve groove formed on the valve seat, placing a fan lever on a portion of the valve member projecting from the valve seat and such that a second spring arm of the spring is disposed in a lever groove formed on the fan lever, rotating the fan lever in the first circumferential direction to a first position associated with an actuated state, securing the fan lever to the valve member with the fan lever in the first position, and rotating the fan lever and the valve member from the first position to a second position associated with a base state with the spring. BRIEF DESCRIPTION OF DRAWINGS

[0009] Figure 1is an isometric view of the air cap.

[0010] Figure 2A is a first isometric exploded view of the fan air control assembly.

[0011] Figure 2B is Figure 2A is a second isometric exploded view of the fan air control assembly shown in

[0012] Figure 3 is a cross-sectional view of the fan air control assembly mounted to the air cap taken along line 3-3 in Figure 1

[0013] Figure 4 is an isometric view of the valve assembly of the fan air control assembly mounted to the air cap.

[0014] Figure 5A is an elevational view showing the fan lever in a first position.

[0015] Figure 5B is an elevational view showing the fan lever in a second actuated state.

[0016] Figure 5C is an elevational view showing the fan lever in a third base state. DETAILED DESCRIPTION

[0017] The present disclosure relates generally to fan air control for an air cap. The fan air lever of the present disclosure provides simple, quick, responsive control of fan air used during spraying. The fan portion of compressed air is configured to form a spray pattern emitted by the spray gun. The spray liquid is expelled through a spray tip, and the fan portion of compressed air can be expelled through an air cap surrounding the spray tip. The fan air lever of the present disclosure can be manipulated by a user’s single hand that is also manipulating the spray gun during spraying. In some examples, the fan air lever allows the fan air to feather between a minimum flow and a maximum flow, and can hold the fan air flow at a desired flow. The fan air lever is easily operable by depressing the fan air lever and releasing the fan air lever to cause the lever to spring back to a fan air open position while the spray gun is spraying and held in the user’s hand. The fan air lever is capable of automatically restoring the fan air flow to a desired flow upon release.

[0018] Figure 1 is an isometric view of the air cap 10. The air cap 10 includes a gun body 12, a handle 14, an air cap 16, a trigger 18, a fan air control assembly 20, an air inlet 22, a fluid inlet 24, and a fluid tube 26. A fan lever 28 of the fan air control assembly 20 is shown. The fan lever 28 includes a lever cap 30 and an adapter 32. ​

[0019] Sprayer 10 is configured to receive a spray liquid and compressed air and emit a fluid spray. For example, sprayer 10 can be used to spray paint, varnish, finishes, and other coatings on furniture, cabinets, appliances, equipment, manufactured parts, and the like. While various fluids can be sprayed by the embodiments referenced herein, paint will be used as an example. While sprayer 10 is shown in the figures as an electrostatic sprayer, it should be understood that sprayer 10 can be any desired configuration for generating and applying a liquid spray. Figure 1 Sprayer 10 is configured to receive a spray liquid and compressed air and emit a fluid spray. For example, sprayer 10 can be used to spray paint, varnish, finishes, and other coatings on furniture, cabinets, appliances, equipment, manufactured parts, and the like. While various fluids can be sprayed by the embodiments referenced herein, paint will be used as an example. While sprayer 10 is shown in the figures as an electrostatic sprayer, it should be understood that sprayer 10 can be any desired configuration for generating and applying a liquid spray.

[0020] Gun body 12 supports various components of sprayer 10. Gun body 12 can be formed from a single component or multiple components that are connected together. Air cap 16 is disposed at a spray end of gun body 12 and is configured to emit compressed air near a spray nozzle that atomizes a fluid spray. The compressed air can provide a fan of air of compressed air that interacts with the liquid spray to form a spray pattern. In some examples, the entire volume of compressed air provided to sprayer 10 is used as the fan of air. The fan of air controls the width of the spray fan emitted by the spray gun. For example, controlling the fan of air to a minimum flow (which can be no flow in some examples) reduces the width of the spray pattern, resulting in a more circular spray pattern, while increasing the fan of air flow increases the width of the spray pattern, resulting in a flatter, wider pattern. For example, a minimum fan of air flow can result in a circular spray pattern, while a maximum fan of air flow can result in an elongated elliptical pattern. Sprayer 10 is configured to emit the spray liquid along a spray axis A. For example, the circular or elongated spray pattern can be centered on the spray axis A.

[0021] Handle 14 extends from gun body 12. In the example shown, handle 14 is integrally formed as part of gun body 12. However, it should be understood that handle 14 can be formed separately from gun body 12 and removably or permanently connected to gun body 12. Handle 14 can be considered to form part of gun body 12. Handle 14 can be grasped by a user’s hand to allow the user to manipulate and orient sprayer 10. Trigger 18 extends from gun body 12. Trigger 18 is configured to actuate one or more valves (not shown) disposed within gun body 12 to control the flow of spray liquid to and through a spray orifice. As such, trigger 18 controls the spraying of sprayer 10. Trigger 18 is disposed to be manipulated by the user’s hand that also grasps handle 14.

[0022] In the example shown, the sprayer 10 is configured to receive spraying liquid and compressed air at the lower distal end of the handle 14. The fluid inlet 24 is an accessory configured to connect to a tube extending from a fluid source (e.g., a pump, such as a piston pump). A fluid tube 26 extends between the fluid inlet 24 and the front end of the gun body 12 through which it emits a spray of liquid. It should be understood that in other examples, the sprayer 10 may include and / or support a fluid source. For example, a reservoir (e.g., a bag, cup, etc.) may store the spraying liquid and be mounted to the gun body 12.

[0023] Air inlet 22 is an accessory located at the lower distal end of handle 14. Air inlet 22 is configured to connect to a pipe extending from an air source (e.g., an air compressor, compressed air canister, etc.). Compressed air flows through handle 14 and gun body 12 and reaches air cap 16.

[0024] A fan-shaped air control assembly 20 is mounted to the gun body 12 and configured to control the flow of a fan-shaped air portion toward the spraying end of the sprayer 10. The fan-shaped air control assembly 20 is actuable to control the fan-shaped air output through the sprayer 10. In some examples, the fan-shaped air control assembly 20 may be configured to actuate the fan-shaped airflow between a minimum flow state and a maximum flow state. The fan-shaped air control assembly 20 extends from a lateral cantilever of the gun body 12. In the example shown, the fan-shaped air control assembly 20 is configured to rotate about the valve axis B between a minimum flow position associated with the minimum fan-shaped air flow and a maximum flow position associated with the maximum fan-shaped air flow.

[0025] The fan-shaped operating lever 28 is disposed outside the sprayer 10 and extends laterally away from the lateral side of the gun body 12. In the example shown, the fan-shaped operating lever 28 includes an adapter 32, which is connected to the valve member 74 (in... Figures 2A to 3 (Best visible in B), valve member 74 extends into gun body 12 and the fan-shaped air path through gun body 12 to control the flow of fan-shaped air. Operating lever cap 30 is connected to adapter 32. Operating lever cap 30 includes an operating lever arm 36 extending from operating lever body 34 of operating lever cap 30. Operating lever arm 36 extends away from valve axis B. Operating lever body 34 engages with adapter 32. Operating lever cap 30 and adapter 32 are fixed together such that rotating operating lever cap 30 about valve axis B causes adapter 32 to rotate about valve axis B, which in turn causes fan-shaped air control valve member 74 to rotate about axis B to change the flow rate of the fan-shaped air section. Operating lever cap 30 and adapter 32 can be formed as a single component or as multiple components fixed together. In some examples, operating lever cap 30 and adapter 32 are detachably connected such that these components can be disconnected without compromising the operability of the fan-shaped operating lever 28.

[0026] Sprayer 10 can be operated by a single hand of a user. Sector air control assembly 20 is positioned such that sector air control assembly 20 can be actuated by the same hand of the user that is grasping handle 14. Lever arm 36 protrudes radially from lever body 34 relative to axis B and provides a protrusion for the user to engage to rotate lever cap 30 about axis B. Lever arm 36 spaces the point at which the user exerts a rotational force on sector lever 28 from axis B. Thus, lever arm 36 can facilitate the user exerting less force on sector lever 28 to drive rotation about valve axis B, thereby facilitating operation with a single finger, such as the user's thumb.

[0027] A user can grasp handle 14, actuate trigger 18 to control spraying, and simultaneously manipulate sector air control assembly 20 with the same hand to control sector air output. For example, a user can grasp handle 14 and wrap one or more fingers of the user around trigger 18. The user can pull trigger 18 with the fingers that interface with trigger 18 to cause spraying of spray fluid. With the same hand that manipulates trigger 18, the user can rotate sector lever 28 about axis B by interfacing with lever arm 36, while the thumb of the hand also manipulates trigger 18 and grasps handle 14. For example, the user can press on the top of lever arm 36 to cause rotation about axis B. While sprayer 10 is shown in a right-hand configuration, with sector lever 28 positioned on the left side of gun body 12 such that the user's right thumb is positioned to interface with sector lever 28 during right-hand spraying, it should be understood that sprayer can additionally or alternatively have a left-hand configuration, with sector lever 28 positioned on the right lateral side of gun body 12 such that the user's left thumb is positioned to interface with sector lever 28 during left-hand spraying.

[0028] Sector air control assembly 20 provides significant advantages. A user can actively manipulate sector air flow while actively discharging a liquid spray with sprayer 10. Other sector air controls include needles and other valves that require the user to stop spraying and actively change sector air before resuming spraying. Sector air control assembly 20 allows a user to actively feather sector air during spraying, thereby providing direct visual feedback about the pattern being output, thereby increasing the user's confidence and reducing material waste due to testing pattern shapes after adjustments. A user can place and maintain sector air flow at a desired flow rate, including a maximum flow rate, a minimum flow rate, and any intermediate flow rate between the maximum and minimum flow rates. Sector air control assembly 20 reduces downtime and increases spraying operation efficiency because sector air can be actively controlled during spraying by a human-controlled, easy-to-use assembly for adjusting sector air flow.

[0029] Figure 2A is a first isometric view of sector air control assembly 20.Figure 2B This is a second isometric exploded view of the sector-shaped air control assembly 20. We will discuss this together. Figure 2A and 2B The sector-shaped air control assembly 20 includes a sector-shaped operating lever 28, a spring 38, and a valve assembly 40. The sector-shaped operating lever 28 includes an operating lever cap 30 and an adapter 32. The operating lever cap 30 includes an operating lever body 34, an operating lever arm 36, a fixing device opening 42, a receiving chamber 44, and a chamber flat portion 46. The operating lever arm 36 includes a knob 48. The adapter 32 includes an adapter body 50, an adapter protrusion 52, an operating lever wall 54, an operating lever groove 56, a valve chamber 58, an outer chamber 60, an inner chamber 62, an adapter opening 64, an adapter flat portion 66, and a fixing device opening 68. The spring 38 includes a spring leg 70. The valve assembly 40 includes a valve seat 72, a valve component 74, and a valve seal 76. The valve seat 72 includes a flow control body 78, a seat body 80, a positioning body 82, a shaft hole 84, a flow opening 86, a valve groove 88, and a rotating notch 90. The shaft hole 84 includes a first axial end 92 and a second axial end 94. Valve component 74 includes connector 96, flow controller 98, shaft 100, head 102, mounting groove 104, stem opening 106, sealing groove 108, flow passage 110, flow restrictor 112, and rotation limiter 114.

[0030] The fan-shaped air control assembly 20 is configured to control the flow of a fan-shaped portion of compressed air to the spraying end of the sprayer 10 (e.g., to the air cap 16). A fan-shaped operating lever 28 engages with a valve assembly 40 to actuate a valve member 74, thereby changing the flow rate of the fan-shaped air portion. The fan-shaped operating lever 28 is configured to actuate the valve member 74 relative to a valve seat 72 to control the state of the valve assembly 40, thereby controlling the state of the fan-shaped air control assembly 20. In the example shown, the fan-shaped operating lever 28 is configured to rotate the valve member about axis B.

[0031] The fan-shaped air control assembly 20 can be in a first position associated with the minimum flow state of the fan-shaped air section (e.g., no flow). Figure 5B ) and the second position associated with the maximum flow state of the fan-shaped air section ( Figure 5C Actuation occurs between the first and second positions. In some examples, the fan-shaped air control assembly 20 can be positioned at any desired location between the first and second positions to provide an intermediate flow rate between the maximum and minimum flow rates. Thus, the fan-shaped air control assembly 20 can feather the flow of the fan-shaped air portion through the sprayer.

[0032] The sector-shaped handle 28 is engaged with the valve assembly 40 to control the valve assembly 40 between a fully closed state and a fully open state. The handle cap 30 is connected to the adapter 32 to form the sector-shaped handle 28. The handle cap 30 and the adapter 32 are configured to be fixed together to rotate simultaneously about the valve axis B. The handle arm 36 protrudes from the handle body 34. In the example shown, the handle arm 36 extends radially outward relative to the handle body 34. The handle arm 36 is a protrusion that facilitates user engagement with the sector-shaped handle 28 and the application of torque on the sector-shaped handle 28 to rotate the sector-shaped handle 28 about the axis B. The knob 48 is formed at the distal end of the handle arm 36 opposite the handle body 34. The knob 48 is an axial protrusion (relative to the axis B) on the handle arm 36 that provides an enlarged surface area at the distal end of the handle arm 36. The larger surface area of the knob 48 makes it easier for a user to engage with the handle sector-shaped handle 28.

[0033] The receiving chamber 44 is formed in the handle body 34. In the example shown, the receiving chamber 44 extends partially, but not completely, through the handle body 34 along the axis B. The receiving chamber 44 is disposed on the axis B such that the axis B extends through the receiving chamber 44. In the example shown, a chamber flat 46 is formed on a wall of the handle body 34 that defines the receiving chamber 44. The chamber flat 46 is a variation in the smooth profile surface that defines the receiving chamber 44. The chamber flat 46 can be considered to form a profile wall portion of the receiving chamber 44. The chamber flat 46 is configured to engage with a portion of the adapter 32 (e.g., with the adapter protrusion 52) to rotationally lock the handle cap 30 and the adapter 32 together. More specifically, the chamber flat 46 is configured to engage with an adapter flat 66 formed on the adapter 32 to form a rotational lock. The chamber flat 46 forms the rotational lock engagement within the receiving chamber 44.

[0034] The fixture opening 42 extends through the handle cap 30 between an outer radial edge (relative to the valve axis B) and an interior of the receiving chamber 44. The fixture opening 42 is configured to receive a fastener, such as a handle set screw 118, that is configured to pass through the fixture opening 42 and engage with the adapter 32 to secure the adapter 32 to the handle cap 30. In some examples, the fixture opening 42 can be a threaded opening that is configured to receive the handle set screw 118.

[0035] A recess 116 is formed on an inner axial side of the lever arm 36 that is oriented toward the sprayer 10 (relative to the axis B). The recess 116 provides a passageway for a fastener (e.g., an additional valve screw 120) to be applied through the lever body 34. For example, the second securing device opening 42 can be formed to pass through the lever body 34 from within the recess 116, such as in examples where the lever cap 30 and the adapter 32 are integrally formed and directly connected to the valve member 74. In these examples, the fastener applied through the recess 116 can directly engage with the valve member 74.

[0036] The adapter 32 is configured to engage with the lever cap 30 for actuation about the valve axis B by the lever cap 30. The adapter 32 is also configured to engage with the valve member 74 for actuation of the valve member 74 to control the flow of the sector air. An adapter body 50 forms a first portion of the adapter 32, and an adapter protrusion 52 forms a second portion of the adapter 32. The adapter body 50 and the adapter protrusion 52 can be coaxially disposed about the valve axis B.

[0037] The adapter protrusion 52 has a smaller width than the adapter body 50. The adapter protrusion 52 extends from the adapter body 50 in a first axial direction AD1 (which is toward the lever cap 30) and away from the gun body 12 in the case where the sector air control assembly 20 is installed to the sprayer 10. The adapter protrusion 52 extends into and is received by the receiving chamber 44 of the lever cap 30. An adapter flat 66 is formed on an exterior of the adapter protrusion 52. The adapter flat 66 is configured to engage with the chamber flat 46 to form a rotational lock between the lever cap 30 and the adapter 32. This rotational lock prevents relative rotation about the lever axis B. A lever set screw 118 is configured to engage with the exterior of the adapter protrusion 52 to axially secure the adapter 32 to the lever cap 30 relative to the valve axis B. In the illustrated example, the lever set screw 118 extends through the chamber flat 46 and engages with the adapter flat 66 formed on the adapter protrusion 52.

[0038] In the illustrated example, the adapter body 50 includes a cylindrical wall that axially projects away from the adapter protrusion 52 and toward the gun body 12 in the second axial direction AD2 and away from the operating lever cap 30. The adapter body 50 is disposed outside of the receiving chamber 44. The operating lever wall 54 is disposed at a junction between the adapter protrusion 52 and the adapter body 50. An outer surface of the operating lever wall 54 (oriented along the first axial direction AD1) extends radially relative to the axis B between an outer edge of the adapter protrusion 52 and an outer edge of the adapter body 50. In the case where the adapter 32 is installed to the operating lever cap 30, the outer surface of the operating lever wall 54 is axially opposite an axially oriented edge of the operating lever body 34 (oriented along the second axial direction AD2). The outer surface of the operating lever wall 54 extends completely around the adapter protrusion 52.

[0039] The adapter 32 defines a valve chamber 58. The valve chamber 58 is formed inside of the adapter 32. During operation, portions of the valve assembly 40 are disposed within the valve chamber 58. In the illustrated example, the valve chamber 58 includes an outer chamber 60 that extends into the adapter protrusion 52 and an inner chamber 62 that is at least partially defined by the adapter body 50. The outer chamber 60 has a smaller diameter than the inner chamber 62. The outer chamber 60 and the inner chamber 62 are coaxially disposed about the valve axis B. In the illustrated example, the receiving chamber 44, the outer chamber 60, and the inner chamber 62 are coaxially disposed about the valve axis B.

[0040] An inner side of the operating lever wall 54 is oriented into the valve chamber 58. In the illustrated example, the operating lever wall 54 is axially oriented into the inner chamber 62 and is disposed at an axial end of the inner chamber 62 opposite the adapter opening 64 disposed at an open axial end of the valve chamber 58. Portions of the valve assembly 40 extend into the valve chamber 58 through the adapter opening 64. The adapter 32 is formed such that the outer chamber 60 extends from the operating lever wall 54 along the valve axis B in the first axial direction AD1 and the inner chamber 62 extends from the operating lever wall 54 along the second axial direction AD2 relative to the valve axis B. The first axial direction AD1 is an opposite direction to the second axial direction AD2.

[0041] An operating lever recess 56 is formed within the adapter 32. The operating lever recess 56 is formed at a distal end of the inner chamber 62 opposite the adapter opening 64. In the example shown, the operating lever recess 56 is formed on the operating lever wall 54 and disposed within the valve chamber 58. More specifically, the operating lever recess 56 is formed on an inner side of the operating lever wall 54. The sector-shaped operating lever 28 includes a plurality of operating lever recesses 56 disposed about the valve axis B. The array of operating lever recesses 56 is formed circumferentially about the valve axis B. The operating lever recesses 56 can be formed tangent to one or more circles centered on the valve axis B. In the example shown, each operating lever recess 56 is formed tangent to the same common circle centered on the valve axis B. The operating lever recesses 56 are formed as depressions in the operating lever wall 54. It will be appreciated that the operating lever recesses 56 can be integrally formed during manufacture of the sector-shaped operating lever 28 (e.g., by casting, molding, additive manufacturing, etc.), or formed after manufacture of the sector-shaped operating lever 26, for example, by removing material (e.g., machining). While the sector-shaped operating lever 28 is shown as including a set of four operating lever recesses 56, it will be appreciated that the sector-shaped operating lever 28 can include any desired number of operating lever recesses 56, including more or fewer than the four operating lever recesses 56 shown. The operating lever recesses 56 facilitate mounting of the sector-shaped operating lever 28 to the spring 38 in a plurality of orientations to position the sector-shaped operating lever 28 in a desired orientation during operation.

[0042] A securing device opening 68 extends through the adapter protrusion 52 to the outer chamber 60. The securing device opening 68 is configured to receive a fastener through the securing device opening 68 and into engagement with the valve member 74 to secure the valve member 74 and the adapter 32 together for simultaneous rotation. In some examples, the securing device opening 68 can be a threaded opening configured to receive a valve set screw 120. While the adapter 32 is shown as including a plurality of securing device openings 68 (two in the example shown) such that the sector-shaped operating lever 28 is secured to the valve member 74 by a plurality of valve set screws 120, it will be appreciated that the adapter 32 can include a single securing device opening 68 or more than two securing device openings 68. In the example shown, the securing device openings 68 are disposed within the receiving chamber 44 with the operating lever cap 30 mounted to the adapter 32. Disposing the securing device openings 68 within the receiving chamber 44 prevents the valve set screws 120 from backing out during operation and protects the screw interface from environmental contamination.

[0043] The valve assembly 40 is removably mounted to the sprayer 10. The valve assembly 40 extends at least partially into the sprayer 10 and axially outward from the sprayer 10 along the valve axis B to engage the operating lever 28. The valve assembly 40 controls the sector-shaped air flow through the gun body 12. A portion of the valve assembly 40 extends into the sector-shaped air path to be in direct contact with the sector-shaped air flowing within the sprayer 10.

[0044] Valve seat 72 is configured to engage with and connect to gun body 12 to mount valve assembly 40 to sprayer 10. Valve seat 72 can alternatively be referred to as a valve nut. Shaft bore 84 extends axially through valve seat 72. In the example shown, shaft bore 84 is disposed coaxially with receiving chamber 44, outer chamber 60, and inner chamber 62. Shaft bore 84 is open at both axial ends of shaft bore 84. First axial end 92 of shaft bore 84 is oriented in first axial direction AD1 and away from sector lever 28, and second axial end 94 of shaft bore 84 is oriented in second axial direction AD2 and toward sector lever 28.

[0045] Seat body 80 is configured to engage with a portion of gun body 12 to secure valve assembly 40 to sprayer 10. For example, seat body 80 can include external threads formed thereon that engage with internal threads formed in a mounting bore in gun body 12. Engagement between seat body 80 and gun body 12 (e.g., by interface threads) secures valve assembly 40, and thus sector air control assembly 20, to sprayer 10.

[0046] Flow control body 78 extends from seat body 80 in second axial direction AD2. Flow control body 78 is configured to be disposed within gun body 12. In the example shown, flow control body 78 is cylindrical and extends from seat body 80 in second axial direction AD2. In some examples, a distal end of flow control body 78 can engage with a portion of gun body 12 to form a seal within gun body 12, as discussed in more detail below with respect to FIG. 3. Shaft bore 84 extends through flow control body 78 between an exterior of flow control body 78 and an interior of flow control body 78. Flow control body 78 is configured to be disposed within gun body 12. In the example shown, flow control body 78 is cylindrical and extends from seat body 80 in second axial direction AD2. In some examples, a distal end of flow control body 78 can engage with a portion of gun body 12 to form a seal within gun body 12, as discussed in more detail below with respect to FIG. 3. Figure 3 Flow opening 86 extends through flow control body 78 between an exterior of flow control body 78 and shaft bore 84. Flow opening 86 provides a passageway for compressed air to flow between a first chamber exterior to flow control body 78 and a second chamber interior to flow control body 78. Second axial end 94 of shaft bore 84 provides a second opening through which sector air can flow. For example, second axial end 94 can be one of an inlet and an outlet of a valve of sector air control assembly 20, and flow opening 86 can be the other of the inlet and the outlet of the valve of sector air control assembly 20. In the example shown, second axial end 94 forms the inlet and flow opening 86 forms the outlet.

[0047] A positioning body 82 is disposed on an axial side of the seat body 80 opposite the flow control body 78. In the example shown, the positioning body 82 extends from the seat body 80 in the first axial direction AD1. In the example shown, the protruding positioning body 82 is an arcuate body that extends partially around the valve axis B. The positioning body 82 extends between circumferential end portions 122. A rotational recess 90 is disposed circumferentially between and defined by the circumferential end portions 122. In the example shown, the rotational recess 90 is a depression formed by a break in the annular region of the positioning body 82, such that the positioning body 82 is arcuate and does not extend completely around the axis B. In some examples, the rotational recess 90 extends over an angular range of less than or equal to 90 degrees (e.g., circumferentially around the valve axis B). In some examples, the rotational recess 90 extends over an angular range of less than or equal to 60 degrees. The valve member 74 can be rotated a quarter turn or less between the fully closed state and the fully open state. In some examples, the valve member 74 can be rotated a fifth of a turn or less between the fully closed state and the fully open state. The small angular turn between fully open and fully closed provides easy actuation for the user and allows for precise control while simultaneously manipulating the sprayer 10 and spraying with the sprayer 10.

[0048] A valve recess 88 is formed on the valve seat 72. In the example shown, the valve recess 88 is formed on an axial end of the valve seat 72. More specifically, the valve recess 88 is formed on an axial end of the positioning body 82 that is oriented in the first axial direction AD1. The valve recess 88 is formed on the axial end of the positioning body 82. The valve recess 88 is formed on an exterior of the valve seat 72. The valve recess 88 is disposed at a distal end of the valve seat 72 in the first axial direction AD1. The valve seat 72 includes a plurality of valve recesses 88 disposed about the valve axis B. The array of valve recesses 88 is formed at least partially about the valve axis B. In the example shown, the valve recesses 88 form an arcuate array of recesses about the valve axis B. The valve recesses 88 can be formed tangentially to one or more circles centered on the valve axis B. In the example shown, each valve recess 88 is formed tangentially to a common circle centered on the valve axis B. The valve recesses 88 are formed as depressions in the axial end face of the positioning body 82. It will be appreciated that the valve recesses 88 can be formed integrally during manufacture of the valve seat 72 (e.g., by casting, molding, additive manufacturing, etc.), or formed after manufacture of the valve seat 72, such as by removing material (e.g., machining). While the valve seat 72 is shown as including a set of five valve recesses 88, it will be appreciated that the valve seat can include any desired number of valve recesses 88 (including more or fewer than the five valve recesses 88 shown). The number of valve recesses 88 can be the same as or different (more or fewer) than the number of lever recesses 56.

[0049] As shown, the valve seat 72 includes a tool interface surface 124 formed on the exterior of the positioning body 82. The tool interface surface 124 facilitates installation of the valve member 74 to the sprayer 10. For example, the seat body 80 can include threads, and a user can twist the valve seat 72 by a wrench (or other tool) that interfaces with the tool interface surface 124. As shown, some valve recesses 88 can have a different length than other valve recesses 88.

[0050] The valve member 74 is elongated along a valve axis B. The valve member 74 is configured to rotate about the valve axis B between an open state and a closed state. With the components of the sector air control assembly 20 assembled together, portions of the valve member 74 are disposed within the outer chamber 60, the inner chamber 62, and the shaft bore 84. The shaft body 100 extends axially relative to the valve axis B between a connector 96 disposed at a first axial end of the valve member 74 and a flow controller 98 disposed at a second axial end of the valve member 74.

[0051] The connector 96 of the valve member 74 extends into the outer chamber 60. A head 102 is disposed at a distal portion of the first axial end of the valve member 74. A mounting recess 104 is formed on the valve member 74. The mounting recess 104 is a radial indentation that extends into the valve member 74 relative to the valve axis B. In this way, the diameter of the valve member 74 at the mounting recess 104 is smaller than the diameter at the head 102 or other portions of the shaft body 100. The mounting recess 104 can extend annularly around the valve member 74. The mounting recess 104 is configured to be radially aligned with the fixture opening 68 with the connector 96 disposed in the outer chamber 60. The radial alignment facilitates the valve set screw 120 extending into the mounting recess 104 to secure the valve member 74 and the sector lever 28 together. The head 102 has a larger diameter than the portion of the valve member 74 that defines the radially inner side of the mounting recess 104, which facilitates the head 102 axially engaging the lever set screw 118 to prevent the sector lever 28 from being pulled axially away from the valve member 74 along the valve axis B.

[0052] The stem opening 106 extends into the shaft body 100. The stem opening 106 is configured to receive a rotation limiter 114. The rotation limiter 114 protrudes radially from the valve member 74 relative to the valve axis B. The rotation limiter 114 is a protrusion that is disposed in the rotation notch 90 during operation. The circumferential end 122 interfaces with the rotation limiter 114 to limit rotational movement of the valve member 74 about the valve axis B. The rotation limiter 114 can have any desired configuration for engaging the valve seat 72 and limiting rotation of the valve member 74. For example, the rotation limiter 114 can be a dowel pin, a rod, a shaft, a stem, a screw, a bolt, or other type of protrusion. The rotation limiter 114 can be detachably connected to the valve member 74 to facilitate assembly and disassembly of the sector air control assembly 20. In some examples, the rotation limiter 114 can be configured to be threaded onto the valve member 74 through an interface on the rotation limiter 114 and in the stem opening 106. It will be appreciated that in some examples, the rotation limiter 114 can be integrally formed as part of the valve member 74.

[0053] The valve member 74 is rotationally limited about the valve axis B such that the valve member 74 does not fully rotate 360 degrees about the valve axis B. For example, the valve member 74 can be limited to rotating up to 90 degrees, up to 60 degrees, or less during operation. The interface 77 limits rotation of the valve member 74 about the valve axis B. In the illustrated example, the interface 77 is formed between the valve member 74 and the valve seat 72. More specifically, the interface 77 is formed by the rotation limiter 114 disposed within the rotation notch 90 such that the rotation notch 90 defines a rotational travel limit for the rotation limiter 114, and thus a rotational travel limit for the valve member 74.

[0054] The rotation notch 90 is sized such that the valve assembly 40 is in a maximum flow state when the rotation limiter 114 interfaces with a first circumferential end 122 defining the rotation notch 90, and such that the valve assembly 40 is in a minimum flow state when the rotation limiter 114 interfaces with another second circumferential end 122 of the rotation notch 90. In the illustrated example, the rotation notch 90 is sized such that the valve assembly 40 is fully open when the rotation limiter 114 is at one circumferential end 122 defining the rotation notch 90, and such that the valve assembly is fully closed when the rotation limiter 114 is at the other circumferential end 122 defining the rotation notch 90.

[0055] A seal groove 108 is formed axially on the valve member 74 between the flow controller 98 and the connector 96. A valve seal 76 is mounted on the valve member 74 and is received by the seal groove 108. The valve seal 76 is disposed within the shaft bore 84 and engages a surface of the valve seat 72 within the shaft bore 84. In the illustrated example, the valve seal 76 is disposed within a portion of the shaft bore 84 defined by the seat body 80. The valve seal 76 can engage and seal against the portion of the seat body 80 that defines the shaft bore 84. The interface between the valve seal 76 and the valve seat 72 forms an air-tight seal to prevent the leakage of sector air from the sector air control assembly 20. The valve seal 76 can be an elastomeric seal. The valve seal 76 can be an O-ring or the like.

[0056] The flow controller 98 of the valve member 74 forms an actuatable flow control component of the valve assembly 40. In the illustrated example, the flow controller 98 is a barrel having an opening that is radially through it relative to the valve axis B. With the valve member 74 mounted to the valve seat 72, the flow controller 98 is disposed within the shaft bore 84. More specifically, the flow controller 98 is disposed within the portion of the shaft bore 84 defined by the flow control body 78. The flow controller 98 interacts with the flow control body 78 to control the flow of sector air through the valve assembly 40. In the illustrated example, the flow controller 98 directly engages the flow control body 78 to form a sealed interface therebetween. When the valve assembly 40 is closed, the interface between the outer surface of the flow controller 98 and the inner surface of the flow control body 78 seals the flow path through the valve assembly 40. The axial end of the flow controller 98 that is oriented in the second axial direction AD2 is open to allow sector air to flow into the interior of the flow controller 98 through the second axial end 94 of the shaft bore 84. In the illustrated example, the flow controller 98 forms a barrel valve member.

[0057] The flow controller 98 of the valve member 74 forms an actuatable flow control component of the valve assembly 40. In the illustrated example, the flow controller 98 is a barrel having an opening that is radially through it relative to the valve axis B. With the valve member 74 mounted to the valve seat 72, the flow controller 98 is disposed within the shaft bore 84. More specifically, the flow controller 98 is disposed within the portion of the shaft bore 84 defined by the flow control body 78. The flow controller 98 interacts with the flow control body 78 to control the flow of sector air through the valve assembly 40. In the illustrated example, the flow controller 98 directly engages the flow control body 78 to form a sealed interface therebetween. When the valve assembly 40 is closed, the interface between the outer surface of the flow controller 98 and the inner surface of the flow control body 78 seals the flow path through the valve assembly 40. The axial end of the flow controller 98 that is oriented in the second axial direction AD2 is open to allow sector air to flow into the interior of the flow controller 98 through the second axial end 94 of the shaft bore 84. In the illustrated example, the flow controller 98 forms a barrel valve member.

[0058] The valve assembly 40 is opened such that fan air can flow through the valve assembly 40 when the flow passage 110 is radially aligned with the flow opening 86 (e.g., such that a radial line from the valve axis B extends through both the flow passage 110 and the flow opening 86). The valve assembly 40 is closed such that fan air cannot flow through the valve assembly 40 when the flow blocker 112 is radially aligned with the flow opening 86. In some examples, the flow passage 110 is wider (circumferentially about the valve axis B) than the flow opening 86. As such, the valve member 74 can be positioned such that no portion of the flow blocker 112 is radially aligned with the flow opening 86 with the valve assembly 40 in the open state. In this open state, the fan air control valve can be considered fully open. The valve member 74 can be positioned at an intermediate flow position relative to the valve seat 72. With the valve member 74 in the intermediate position, the flow opening 86 is partially aligned with the flow passage 110 and partially aligned with the flow blocker 112. As such, in the intermediate flow position, the flow passage 110 and the flow blocker 112 can each be partially radially misaligned and partially radially aligned with the flow opening 86.

[0059] In some examples, the valve member 74 is configured to maintain any desired flow position relative to the valve seat 72 when the user releases the fan lever 28. For example, the interface between the valve seal 76 and the valve seat 72 can prevent the valve member 74 from rotating about the valve axis B unless the user applies sufficient force. The interface can resist rotation due to gravity acting on the lever arm 36 and due to forces generated by the user moving the sprayer 10 during operation. As such, the user can feather the fan air to a desired flow during spraying and can release the fan lever 28 to maintain the fan air at the desired flow. The sprayer 10 is thereby easily and quickly configured to produce and maintain a desired spray pattern.

[0060] In the illustrated example, the spring 38 is axially disposed between the fan lever 28 and a portion of the valve assembly 40. The spring 38, the shaft hole 84, and the valve chamber 58 are coaxially disposed. In the illustrated example, the spring 38 is a torsion spring configured to exert a torque on the fan lever 28 to drive rotation about the valve axis B. The spring 38 is configured to engage with the fan lever 28 and to engage with the valve assembly 40 to automatically return the valve assembly 40 to a base state (associated with one of the minimum flow position and the maximum flow position) when the fan lever 28 is released. In the illustrated example, the base state is associated with the maximum fan air state such that the fan lever 28 is actuated from the base state to reduce fan air flow through the gun body 12. When the fan lever 28 is released, the spring 38 returns the valve assembly 40 to the base state.

[0061] The spring 38 is engaged with the sector lever 28 at the lever recess 56 and with the valve assembly 40 at the valve recess 88. A first spring leg 70 of the spring 38 is housed within the lever recess 56. A second spring leg 70 is housed within the valve recess 88. The recesses forming the lever recess 56 and the valve recess 88 house the spring legs 70. The valve seat 72 is fixed to the gun body 12 to prevent rotation of the valve seat 72 about the valve axis B. The spring 38 is supported on the valve seat 72 and exerts a circumferential force on the sector lever 28 to bias the sector lever 28 in a rotational direction about the valve axis B. The plurality of lever recesses 56 and the plurality of valve recesses 88 facilitate positioning of the sector lever 28 in any desired orientation about the valve axis B when mounted to the valve assembly 40. The plurality of valve recesses 88 facilitate mounting of the spring 38 to the valve seat 72 in a plurality of orientations to facilitate mounting of the sector lever 28 in a desired orientation independent of the final orientation of the valve seat 72, which can change due to the threaded interface connecting the valve member 74 to the gun body 12. The plurality of lever recesses 56 facilitate mounting of the sector lever 28 to the spring 38 in a desired orientation to facilitate comfortable and ergonomic actuation by a user. For example, a user can vary the orientation in which the lever arm 36 extends away from the valve axis B by seating the spring legs 70 in different ones of the lever recesses 56 and / or different ones of the valve recesses 88. In the illustrated example, the sector lever is pre-tensioned by the spring 38 to keep the valve open. The plurality of lever recesses 56 and valve recesses 88 facilitate a user setting the spring 38 at a desired tension for operation. For example, a larger rotation between a starting position Figure 5A ) and an actuated position Figure 5B ) provides a larger tension, while a smaller rotation between the starting position and the actuated state provides a smaller tension.

[0062] The sector valve assembly 40 controls the flow of sector air during operation of the sprayer. During assembly, the valve member 74 is passed through the shaft bore 84 in the first axial direction AD1. In some examples, a portion of the valve member 74 (e.g., adjacent the seal recess 108) can have a larger diameter than a portion of the shaft bore 84 to limit movement of the valve member 74 in the first axial direction AD1. The valve member 74 can be rotated about the valve axis B until the rod opening 106 is aligned within the rotational notch 90. The rotation limiter 114 is inserted into the rod opening 106 and fixed to the valve member 74. Thereby, the valve member 74 is axially fixed relative to the valve seat 72 by the rotation limiter 114 axially extending over a portion of the valve seat 72 to prevent movement in the second axial direction AD2, and by the varying diameter portion of the valve member 74 and the valve seat 72 within the shaft bore 84 to prevent movement in the first axial direction AD1.

[0063] The spring 38 is inserted over the valve member 74 and positioned on the valve seat 72 such that the spring leg 70 is disposed within the valve recess 88. In some examples, the spring 38 is positioned such that the free spring leg 70 (the spring leg 70 that is not within the valve recess 88) is oriented generally vertically or generally horizontally. Such positioning facilitates ergonomic positioning of the user of the fan-shaped air lever 28 during operation.

[0064] The fan-shaped air lever 28 is moved axially in the second axial direction AD2 and onto the valve assembly 40. More specifically, the fan-shaped air lever 28 is moved onto the valve assembly 40 such that the connector 96 of the valve member 74 is disposed within the outer chamber 60. The fan-shaped air lever 28 is positioned on the valve assembly 40 such that the free spring leg 70 is disposed within one of the lever recesses 56. The adapter 32 is connected to the valve member 74 by the valve set screw 120 extending through the fixture opening 68 and into the mounting recess 104. The lever cap 30 is mounted to the adapter 32 by the lever set screw 118 extending through the fixture opening 42 and interfacing with the adapter protrusion 52.

[0065] The fan-shaped air control assembly 20 provides significant advantages. The fan-shaped air control assembly 20 facilitates active fan-shaped air control during spraying. By actuating the fan-shaped air control assembly 20, different spray patterns can be created during a single spray process. The user can actively feather the air flow and change the spray pattern during spraying, resulting in tighter spraying at the edges and a more uniform pattern. The fan-shaped air control assembly 20 thus reduces job time, reduces material usage and waste, and improves spray operation efficiency. The fan-shaped air control assembly 20 allows for individual adjustment of the lever by a single user. The valve recess 88 and the lever recess 56 counteract the effects of thread connection seating variations of the valve seat 72.

[0066] Figure 3 is a cross-sectional view taken along line 3-3 in Figure 1 FIG. 4, showing the fan-shaped air control assembly 20 mounted to the sprayer 10. The fan-shaped air control assembly 20 is mounted to the sprayer 10 at the mounting hole 138. The mounting hole 138 is formed within the gun body 12 and intersects the fan-shaped air flow path through the gun body 12.

[0067] Valve assembly 40 is directly mounted to gun body 12 by valve seat 72 engaging gun body 12 within mounting bore 138. In the example shown, valve seat 72 is threadably connected to gun body 12. A distal end of flow control body 78 engages gun body 12 within mounting bore 138. In the example shown, annular face 126 of flow control body 78 directly engages gun body 12 to form a sealed interface. The sealed interface prevents undesired flow of scallop air between inlet 128 and outlet 130. Annular face 126 is a bevel configured to engage a bevel within mounting bore 138. Annular face 126 and a portion of mounting bore 138 are inclined radially inward in the second axial direction AD2 and toward valve axis B.

[0068] An annular chamber 132 is formed around the exterior of flow controller 98. Annular chamber 132 is defined between flow controller 98 and the portion of gun body 12 that defines mounting bore 138. Annular chamber 132 is the portion of the mounting bore that has a diameter greater than the outer diameter of flow controller 98. Annular chamber 132 counteracts the effects of threaded connection seating variations of valve seat 72 because flow opening 86 will be positioned in fluid connection with annular chamber 132 regardless of the rotational position of valve seat 72 about valve axis B.

[0069] With valve member 74 in the open state such that flow passage 110 is at least partially aligned with flow opening 86, scallop air can flow from inlet 128, through second axial end 94, through flow passage 110 and flow opening 86, and downstream to outlet 130. With valve member 74 in the closed state such that flow passage 110 is not aligned with flow opening 86, scallop air can flow into valve assembly 40, but is prevented from flowing to outlet 130 by flow blocker 112 that is aligned with flow opening 86 to completely cover flow opening 86.

[0070] A shoulder 134 is formed on a portion of valve member 74 axially disposed between seal groove 108 and head 102. In the example shown, shoulder 134 is axially formed between seal groove 108 and stem opening 106 such that shoulder 134 is axially disposed between seal groove 108 and rotation limiter 114. A brace 136 is formed by the portion of valve seat 72 that defines shaft bore 84. In the example shown, brace 136 is an annular narrowing of shaft bore 84. More specifically, shaft bore 84 has a first diameter portion between first axial end 92 and brace 136, and shaft bore 84 has a second, larger diameter portion between brace 136 and second axial end 94. The interface between shoulder 134 and brace 136 limits axial movement of valve member 74 relative to valve seat 72 in the first axial direction AD1.

[0071] The adapter body 50 extends over and at least partially surrounds the portion of the valve seat 72 disposed outside the gun body 12. In the illustrated example, the adapter body 50 houses the positioning body 82 within the outer chamber 60. The adapter body 50 receiving the positioning body 82 prevents contaminants from migrating into the valve assembly 40. The adapter body 50 extending over the positioning body 82 creates an elongated labyrinth path between the environment surrounding the fan air control assembly 20 and the flow controller of the valve assembly 40 (e.g., formed by the flow control body 78 and the flow controller 98). Any contaminants would need to flow between the adapter body 50 and the positioning body 82 and turn 180 degrees to flow between the positioning body 82 and the shaft body 100 before reaching the valve seal 76.

[0072] The adapter 32 receiving and extending over the positioning body 82 provides a robust fan air control assembly 20. The adapter 32 extending over the positioning body 82 prevents unwanted eccentric forces from being applied to the valve member 74 because the overlap between the adapter 32 and the positioning body 82 can maintain concentricity about the axis B. This overlap maintains concentricity between the fan lever 28 and the valve stem 74, and thus between the valve member 74 and the valve seat 72, preventing unwanted side loads that can cause undesired wear and premature failure of components.

[0073] The fan air control assembly 20 can be retrofitted onto existing sprayers 10. Sprayers with fan air include valves for controlling flow and, thus, the resulting spray pattern. These valves are often needle valves that are threaded into or out of engagement with a valve seat to vary the flow of the fan air portion. The fan air control assembly 20 is configured to be installed to the same threads (e.g., within the mounting hole 138) as previous fan valves. No other modifications to the sprayer 10 are needed to change the configuration to the quick control provided by the fan air control assembly 20.

[0074] Figure 4 FIG. 17 is an isometric view showing the valve assembly 40 installed to the sprayer 10. Figure 5A FIG. 18 is a front view showing the fan lever 28 in a first position. Figure 5B FIG. 19 is a front view showing the fan lever 28 in a second position associated with an actuated state of the fan air control assembly 20. Figure 5C FIG. 20 is a front view showing the fan lever E in a third position associated with a base state of the fan air control assembly 20.

[0075] The valve assembly 40 is mounted to the gun body 12 in the assembled state. The valve member 40 passes through the shaft hole 84, and the shoulder 134 engages with the support portion 136. The rod opening 106 is aligned with the rotation recess 90, and the rotation limiter 114 is connected to the valve member 74. The rotation limiter 114 is thus disposed in the rotation recess 90. The valve member 74 extends through the shaft hole 84, with the rotation limiter 114 disposed in the rotation recess 90. The valve member 74 is thus axially fixed to the valve seat 72 and rotatably limited by the interface 77 between the rotation limiter 114 and the rotation recess 90.

[0076] The seat 80 is inserted into the valve mounting hole 138 of the sprayer 10 and engages with a portion of the gun body 12 to secure the valve assembly to the sprayer 10 (e.g., by engagement threads). The seat 80 can rotate about the valve axis B to connect to and disconnect from the gun body 12, for example, via interface threads.

[0077] Spring 38 is mounted to valve assembly 40. Spring 38 is axially movable along valve axis B such that valve member 74 extends through the coil of spring 38. First spring arm 70 of spring 38 is placed in valve recess 88. As described above, the plurality of valve recesses 88 facilitate mounting spring 38 to seat 80 in a desired orientation (e.g., such that spring leg 70 extends in a desired direction), regardless of the final orientation of valve seat 72 about valve axis B, which may vary (e.g., due to threaded mounting interface).

[0078] Valve member 74 rotates to a desired starting position associated with one of the maximum and minimum sector airflow states. Rotation limiter 114 is at the limit of rotational movement and, when in the starting position, engages with one of the circumferential ends 122 defining the rotational notch 90. In the example discussed, valve member 74 is placed in the minimum flow position during installation, such as... Figure 4 As shown. More specifically, valve member 74 is positioned such that valve assembly 40 is fully closed when valve member 74 is in the initial position.

[0079] The sector-shaped operating lever 28 engages with the mounted valve assembly 40. The initial engagement of the sector-shaped operating lever 28 with the valve assembly 40 results in the sector-shaped operating lever 28 being in a different orientation than the maximum flow direction (e.g., Figure 5C The third position shown) and minimum flow orientation (e.g., Figure 5B The installation orientation of one or both of the second positions shown in the diagram. Figure 5A The position and orientation of the sector-shaped operating lever 28 associated with the actuation state and the base state about the valve axis B are independent of the orientation of the valve seat 72 when it is mounted to the sprayer 10. For example, the rotating notch 90 can be oriented in any radial direction relative to the valve axis B, and the position associated with the actuation state and the base state can still be […].Figure 5B and 5C The position shown is indicated. The independent orientation of the sector-shaped operating lever 28 is due to the multiple valve recesses 88 and the operating lever recess 56 facilitating installation in various orientations, and because the spring 38 facilitates any desired relative rotational positioning between the sector-shaped operating lever 28 and the valve seat 72.

[0080] A sector-shaped operating lever 28 is positioned on the portion of the valve member 74 that protrudes from the valve seat 72. The sector-shaped operating lever 28 engages with a spring 38, and thus engages with the valve seat 72 via the spring 38. A second spring leg 70 is disposed in the operating lever recess 56 of the sector-shaped operating lever 28. Figure 2A and 2B Ideally, the operating lever recess 56 can be wider than the valve recess 88 for ease of installation, as the interface between the operating lever recess 56 and the second spring arm 70 is not visible during installation. The narrower valve recess 88 reduces play during rotation of the sector operating lever 28, thus providing the user with quick response and stretch feedback.

[0081] When the sector-shaped operating lever 28 is initially positioned on the valve assembly 40, a portion of the valve member 74 is disposed within the outer chamber 60, and the valve member 74 is rotatably disengaged from the sector-shaped operating lever 28. The sector-shaped operating lever 28 is connected to the valve assembly 40 via a spring 38, but is not directly connected to any component of the valve assembly 40. Rotating the sector-shaped operating lever 28 about the valve axis B does not simultaneously rotate the valve member 74, because the sector-shaped operating lever 28 and the valve member 74 are disengaged.

[0082] The sector-shaped operating lever 28 is along the first circumferential direction CD1 (in Figures 5A to 5C In the view, the rotation is clockwise from the mounting orientation to the desired orientation associated with the actuation state. Figure 5B In the example shown, the desired orientation is that the fan-shaped operating lever 28 is set... Figure 5B At the second position shown, the sector-shaped operating lever 28 rotates from the mounting orientation to the desired orientation in the same direction as the initial rotation direction of the valve member 74. The sector-shaped operating lever 28 thus rotates in the first rotational direction (e.g., the circumferential direction CD1), while the valve member 74 is already at its rotational limit in the first rotational direction (e.g., due to the interface between the rotation limiter 114 and the rotation recess 90). In the example shown, the rotation limiter 114 is positioned along the circumferential direction CD1 at the first circumferential end of the rotation recess 90, so the sector-shaped operating lever 28 also rotates clockwise along the circumferential direction CD1 from the mounting orientation to the desired orientation. Once the valve member 74 is rotated and locked to the sector-shaped operating lever 28, the common rotational direction helps the spring 38 return the valve member 74 to its base state.

[0083] Spring 38 resists the rotation of the sector-shaped operating lever 28 along the first circumferential direction CD1 and along the second circumferential direction CD2, which is opposite to the first circumferential direction CD1. Figures 5A to 5C (In the view, this is in a counter-clockwise direction) biased sector-shaped operating lever 28. The sector-shaped operating lever 28 rotates about valve axis B to the desired position associated with the actuation state. Figure 5B This position is the location of the sector lever 28 when actuated by the user during operation. In the example shown, the actuation state is associated with the minimum flow state. It should be understood that in some examples, the actuation state may be associated with the maximum flow state. The position associated with the actuation state can be any desired position that is comfortable for the user.

[0084] The sector-shaped operating lever 28 is secured to the valve member 74 when in the desired position associated with the actuation state. In the example shown, the operating lever cap 30 can be pulled away from the adapter 32 along the first axial direction AD1 while retaining the adapter 32, to prevent the spring 38 from rotating the adapter 32 away from the desired orientation associated with the actuation state. When the adapter 32 is held in the position associated with the actuation state, the adapter 32 is rotatably secured to the valve member 74. For example, the valve set screw 120 can be inserted through the fixing opening 68 to engage with the valve member 74 at the mounting recess 104. Thus, the adapter 32 and the valve member 74 are rotatably secured together for simultaneous rotation.

[0085] Adapter 32 can be released, and spring 38 causes adapter 32 to rotate in the second circumferential direction CD2 back to the orientation associated with the base state. Figure 5C The base state is the position of the sector lever 28 during operation when it is not actuated by the user. In the example shown, the base state is associated with the maximum flow state. It should be understood that in some examples, the base state may be associated with the minimum flow state. Interface 77 restricts rotation along the second circumferential direction CD2 to hold the valve assembly 40 in the base state.

[0086] Rotation limiter 114 and rotation notch 90 limit the rotation of valve member 74 and thus sector-shaped operating lever 28 in two circumferential directions CD1, CD2. In the example shown, rotation limiter 114 limits the rotation of valve member 74 and thus sector-shaped operating lever 28 relative to the actuated state in the second circumferential direction CD2. Rotation limiter 114 engages one of the circumferential ends 122 of rotation notch 90 to limit the return rotation along the second circumferential direction CD2. Spring 38 thereby moves valve member 74 relative to valve seat 72 from the position associated with the actuated state ( Figure 5B Driven to the location associated with the base state ( Figure 5C). The lever cap 30 is placed on the adapter 32 and secured to the adapter 32, for example, by lever screws 118. It will be appreciated that, in some examples, the lever cap 30 and the adapter 32 are formed as a single assembly, such that the lever cap 30 is connected to the valve assembly 40 at the same time as the adapter 32 before the spring 38 rotates the valve member 74 to place the valve assembly 40 in the base state.

[0087] During operation, the fan air control assembly 20 controls the flow of fan air portion to the air cap 16. During spraying, the fan air control assembly 20 is typically in the base state Figure 5C ). The base state is associated with the maximum flow state in the illustrated example, such that the maximum volume of fan air can normally flow through the valve assembly 40 (e.g., from the inlet 128 through the second axial end 94, the flow passage 110, and the flow opening 86 to the outlet 130) to interact with and shape the spray liquid expelled by the sprayer 10. A user can actuate the fan air control assembly 20 from the base state to an actuated state, and to any intermediate state therebetween, by pressing on the fan lever 28 to rotate the fan lever 28, and thus the valve member 74, about the valve axis B. In the illustrated example, the user presses the fan lever 28 to cause rotation in the first circumferential direction CD1 when actuating from the base state.

[0088] The rotating valve member 74 at least partially aligns the flow restrictor 112 with the flow passage 110, thereby limiting the flow of the fan air portion through the valve assembly 40. In the illustrated example, the user can rotate the fan lever 28, and thus the valve member 74, to the actuated state Figure 5B ), to completely shut off the flow of fan air. With the fan air control assembly 20 in the actuated state, the flow restrictor 112 completely covers the flow opening 86, thereby preventing fan air from flowing through the valve assembly 40. In the illustrated example, removal of the actuation force from the fan lever 28 (e.g., the user removing their thumb from the lever arm 36) causes the fan air control assembly 20 to automatically return to the base state. The spring 38 exerts a rotational force on the fan lever 28, and thus on the valve member 74 by the fan lever 28, such that the fan lever 28 and the valve member 74 rotate back to the base state when the actuation force is removed. The user can feather the spray pattern during operation by pushing the fan lever 28 between various positions associated with the actuated state and the base state.

[0089] While the sector air control assembly 20 is described as automatically returning to the base state, it should be appreciated that examples of the sector air control assembly 20 can be configured to remain in a position other than the position associated with the base state. For example, some examples of the sector air control assembly 20 do not include the spring 38. In such examples, a user can place the sector valve assembly 40 in a position associated with a desired sector air flow and remove the actuation force from the sector lever 28 without the sector valve assembly 40 returning to the base state.

[0090] While the application has been described with reference to the example embodiments thereof, it is to be understood that the application is not limited to the described embodiments or constructions. To the contrary, it is contemplated to cover and embrace all modifications, changes, and alterations that fall within the scope of the application. Accordingly, other have been provided the full scope of the application set forth by the claims. Further, while the foregoing has been described in some detail for purposes of clarity and the specific embodiments have been set forth above, numerous modifications, changes and substitutions can be made which fall within the scope of the applications. It is therefore desired to be protected not only by the described embodiments, but also by all equivalents.

Claims

1. A fan-shaped air control assembly for a spray gun, configured to control the flow of a fan-shaped air portion of compressed air to the spraying end of the spray gun, the fan-shaped air portion being configured to form a spray pattern emitted by the spray gun, wherein the fan-shaped air control assembly comprises: Fan-shaped operating lever; A valve assembly operatively connected to the sector-shaped operating lever, the valve assembly comprising: A valve seat having a shaft hole extending axially through the valve seat along the valve axis, the valve seat comprising: seat body; A positioning body extending from the seat in a first axial direction; and A flow control body extending from the seat in a second axial direction opposite to the first axial direction, wherein at least one flow opening extends through the flow control body; A valve component, which is at least partially disposed within the shaft bore and fixed to the sector-shaped operating rod, wherein the valve component comprises: A shaft having a flow controller disposed within a flow control body of the valve seat, the flow controller including at least one flow passage and at least one flow restrictor extending at least partially around the valve axis; The valve component is rotatable about the valve axis to actuate the valve assembly between a maximum flow state and a minimum flow state.

2. The fan-shaped air control assembly according to claim 1, wherein, The valve component further includes: A connector is disposed at the axial end of the valve component opposite to the flow controller, the connector being disposed within the sector-shaped operating lever and fixed to the sector-shaped operating lever.

3. The fan-shaped air control assembly according to claim 2, wherein, The connector includes a head having a first diameter and a mounting groove spaced apart from the head in the second axial direction, wherein the valve member is secured to the sector-shaped operating rod by a first fastener extending through the sector-shaped operating rod and into the mounting groove.

4. The fan-shaped air control assembly according to claim 3, wherein, The first fastener includes a plurality of set screws.

5. The fan-shaped air control assembly according to claim 3, wherein, The at least one flow restrictor includes an arc-shaped axial protrusion.

6. The fan-shaped air control assembly according to claim 5, wherein, The at least one flow restrictor includes a plurality of flow restrictors, and the at least one flow channel includes a plurality of flow channels.

7. The fan-shaped air control assembly according to claims 1-6, wherein, External threads are formed on the seat body.

8. The fan-shaped air control assembly according to claims 1-6, wherein, At least one tool interface surface is formed on the radial exterior of the positioning body.

9. The fan-shaped air control assembly according to claims 1-6, wherein, The valve component includes a sealing groove formed on the outside of the shaft of the valve component, wherein a valve seal is disposed in the sealing groove, and wherein the valve seal engages with a portion of the valve seat forming the shaft bore.

10. The fan-shaped air control assembly according to claims 1-6, wherein, The valve member includes a shoulder formed on the shaft, the valve seat includes a support formed in the shaft bore, and the support engages with the shoulder to restrict movement of the valve member in the first axial direction.

11. The fan-shaped air control assembly according to claims 3-6, wherein, The sector-shaped operating lever includes: Adapter, wherein the first fastener extends through the adapter to engage with the valve member; and An operating lever cap that receives a portion of the adapter and is connected to the adapter, the operating lever cap including an operating lever arm extending away from the valve axis.

12. The fan-shaped air control assembly according to claim 11, wherein, The control lever includes a knob located at the distal end of the control lever.

13. The fan-shaped air control assembly according to claim 11, wherein: The operating lever cap defines the receiving chamber; The adapter includes a protrusion extending in the first axial direction and a cylindrical body extending in the second axial direction; The protrusion extends into the receiving chamber; and The adapter is secured to the operating lever cap by a second fastener that extends through the operating lever cap and engages with the protrusion.

14. The fan-shaped air control assembly according to claim 13, wherein, The protrusion includes a first flat portion, and the operating lever cap includes a second flat portion that at least partially defines the receiving chamber, wherein the first flat portion engages with the second flat portion to prevent the operating lever cap from rotating relative to the adapter.

15. The fan-shaped air control assembly according to claims 1-6, further comprising: A rotating notch is formed between the first circumferential end of the positioning body and the second circumferential end of the positioning body; and A rotation limiter extends from the shaft of the valve member and is disposed within the rotation recess; The rotating notch restricts the rotation limiter's movement about the valve axis in a first circumferential direction and its movement about the valve axis in a second circumferential direction.

16. The fan-shaped air control assembly according to claim 15, further comprising: A spring, which engages with the sector-shaped operating lever and the valve seat, is configured to bias the sector-shaped operating lever in the second circumferential direction.

17. The fan-shaped air control assembly according to claim 16, wherein, The spring is a torsion spring.

18. The fan-shaped air control assembly according to claim 16, wherein: The valve component includes at least one valve recess oriented along a first axial direction; The sector-shaped operating lever includes at least one operating lever groove oriented along the second axial direction; The first spring arm of the spring is disposed in the first valve groove of the at least one valve groove, and the second spring arm of the spring is disposed in the first operating rod groove of the at least one operating rod groove.

19. The fan-shaped air control assembly according to claim 18, wherein, The at least one valve recess includes a plurality of valve recesses formed on the end face of the positioning body.

20. The fan-shaped air control assembly according to claim 18, wherein, The at least one operating lever groove includes a plurality of operating lever grooves formed on the sector-shaped operating lever.

21. The fan-shaped air control assembly according to claim 3, wherein: The valve component includes a plurality of valve grooves oriented along the first axial direction; The sector-shaped operating lever includes: An adapter, wherein the first fastener extends through the adapter to engage with the valve member, the adapter defining a valve chamber, the valve member being disposed at least partially within the valve chamber; Multiple operating lever grooves are formed on the adapter and disposed in the valve chamber, and the multiple operating lever grooves are oriented along the second axial direction; An operating lever cap that receives a portion of the adapter and is connected to the adapter, the operating lever cap including an operating lever arm extending away from the valve axis; The spring is disposed between the valve seat and the sector-shaped operating lever; and The first spring arm of the spring is disposed in the first valve groove among the plurality of valve grooves, and the second spring arm of the spring is disposed in the first operating rod groove among the plurality of operating rod grooves.

22. The fan-shaped air control assembly according to claims 1-6, wherein, The at least one flow restrictor is aligned with the flow opening to prevent any fan-shaped airflow through the flow opening when the valve assembly is in the minimum flow state.

23. A fluid sprayer, comprising: A gun body having a handle extending from the gun body; A trigger, extending from the gun body, is configured to be actuated to control the spraying performed by the fluid sprayer; The fan-shaped air control assembly according to any of the preceding claims, wherein the fan-shaped air control assembly is mounted to the gun body and extends into the fan-shaped airflow path through the gun body to control the flow rate of the fan-shaped air through the gun body.

24. A method for controlling a fan-shaped airflow during spraying with a fluid sprayer, the method comprising: Grasp the handle of the fluid sprayer with your first hand; The first hand is used to activate the trigger of the fluid sprayer to cause the fluid sprayer to emit a liquid spray; Using the first hand, press the fan-shaped operating lever protruding from the lateral side of the fluid sprayer's gun body from a first position associated with the base state to a second position associated with the actuation state. The fan-shaped operating lever is connected to a valve member to rotate the valve member about a valve axis, thereby changing the flow rate of the fan-shaped air flowing to the spraying end of the fluid sprayer. Release the sector-shaped control lever with the first hand; and When the sector-shaped operating lever is released, a torsion spring engaged with the sector-shaped operating lever causes the sector-shaped operating lever to return from the second position to the first position.

25. A method for forming a fan-shaped air controller for a sprayer, the method comprising: The valve member that extends axially passes through the shaft hole that extends through the valve seat; A rotation limiter is inserted into a rod opening in the valve member, the rotation limiter being disposed in a rotation recess formed in the valve seat, wherein the rotation recess restricts the movement of the rotation limiter in a first circumferential direction and in a second circumferential direction; The valve seat is connected to the spray gun via an interface thread; The spring is placed on the valve seat such that the first spring arm of the spring is disposed in the valve groove formed on the valve seat; The sector-shaped operating lever is placed on the portion of the valve component that protrudes from the valve seat, such that the second spring arm of the spring is disposed in the operating lever groove formed on the sector-shaped operating lever; Rotate the sector-shaped operating lever along the first circumferential direction to a first position associated with the actuation state; When the sector-shaped operating lever is in the first position, the sector-shaped operating lever is fixed to the valve component; and The spring rotates the sector-shaped operating lever and valve component from the first position to a second position associated with the base state.

26. The method of claim 25, further comprising: The valve member is oriented such that the rotation limiter is positioned at the first circumferential end of the rotation notch before the sector-shaped operating lever is placed on the portion of the valve member; The first circumferential end is spaced apart from the second circumferential end of the rotating notch in the first circumferential direction.

Images