Spray applicator with fixed mixing chamber

Abstract

A fast curing multi-component spray applicator (10) includes a stationary mixing chamber (48) to eliminate a dynamic, metal-to-metal, high pressure fluid seal. A stationary mixing chamber (48) mixes the multiple components prior to dispensing the mixed components from the spray applicator (10). The spray applicator includes a fluid needle (76, 78) configured to engage and disengage the seal to perform fluid valving. Needles (76, 78) control the flow of fluid and air to a fixed mixing chamber (48).

Description

[0001] This application is a divisional application of the Chinese invention patent application with application number CN 202080073933.7 (date of entry into the Chinese national phase: April 21, 2022; invention name: Spray applicator with a fixed mixing chamber).

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims priority to U.S. Provisional Application No. 62 / 926,064, filed on October 25, 2019 by CJ Pellin, for “Jet Applicator With Fixed Mixing Chamber.” Technical Field

[0004] The present disclosure relates generally to spray applicators. More particularly, the present disclosure relates to a mixing chamber in a spray applicator. Background Art

[0005] Spray applicators can be used for a variety of purposes, but two common uses are spray foam insulation and elastomeric coatings. Spray foam insulation is applied to a substrate to provide thermal insulation from the environment. Elastomeric coatings can be applied to a substrate to protect a surface, an example being a spray-type cabin liner. In either application, two or more components are mixed within a spray applicator, causing a chemical reaction to occur. The ratio of the mixture is strictly controlled, and the end result is a mixture of components with the desired physical properties, depending on the specific application. Fast-curing, multi-component, air-purged applicators typically use dynamic, metal-to-metal high-pressure seals to control the flow of the multi-components within the spray applicator. Dynamic, metal-to-metal high-pressure seals require hardened steel and multi-process precision machining operations to achieve suitable sealing surfaces and material properties. Summary of the invention

[0006] According to one aspect of the present disclosure, a jet applicator includes a fixed mixing chamber, a valve assembly and a fluid housing. The fixed mixing chamber includes a jet orifice configured to distribute fluid. The valve assembly is at least partially arranged in the fluid housing, and the valve assembly is configured to control the flow of fluid and air to the fixed mixing chamber. The valve assembly includes a first fluid needle and a second fluid needle, and the first fluid needle and the second fluid needle are operably connected to be actuated simultaneously. The first fluid needle is configured to translate between a first fluid open position and a first fluid closed position. When in the first fluid open position, the first fluid needle disengages from the first valve seal, and when in the first fluid closed position, the first fluid needle engages the first valve seal. The second fluid needle is configured to translate between a second fluid open position and a second fluid closed position. When in the second fluid open position, the second fluid needle disengages from the second valve seal, and when in the second fluid closed position, the second fluid needle engages the second valve seal.

[0007] According to another aspect of the present disclosure, a method includes translating a first fluid needle between a first fluid open position and a first fluid closed position by a pneumatic piston. The first fluid needle disengages from a first valve seal in the first fluid open position and engages with the first valve seal in the first fluid closed position. A second fluid needle is translated between a second fluid open position and a second fluid closed position by the pneumatic piston. The second fluid needle disengages from a second valve seal in the second fluid open position and engages with a second valve seal in the second fluid closed position. The method also includes flowing the first fluid and the second fluid to a fixed mixing chamber when the first fluid needle is in the first fluid open position and the second fluid needle is in the second fluid open position. The method also includes dispensing a multi-component fluid mixture from the fixed mixing chamber through a jet orifice of the fixed mixing chamber. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is a schematic block diagram of the injection system.

[0009] Figure 2A is a perspective view of a spray applicator.

[0010] Figure 2B is an exploded perspective view of a spray applicator.

[0011] Figure 3A is a cross-sectional view of the spray applicator in a fluid-enclosed state.

[0012] Figure 3B is a cross-sectional view of the spray applicator in an intermediate state.

[0013] Figure 3C is a cross-sectional view of the spray applicator in a fluidly open state.

[0014] Figure 4A is a perspective view of a second embodiment of a spray applicator.

[0015] Figure 4B is an exploded perspective view of a second embodiment of a spray applicator.

[0016] Figure 4C is a cross-sectional view of a second embodiment of a spray applicator in a fluidly open state.

[0017] Figure 4D is a perspective view of a seal used in a second embodiment of a spray applicator. Specific embodiments

[0018] Figure 1 is a schematic block diagram of spray system 10. Spray system 10 includes spray applicator 12, fluid supplies 14a and 14b, pumps 16a and 16b, and air supply 18. Spray applicator 12 includes trigger 22, spray valve 24, control valve 26, and spray orifice 28.

[0019] The spray system 10 is a system configured to generate and apply a fluid spray to a substrate. In some examples, the spray system 10 is configured to combine two or more fluids to generate a multi-component fluid spray for application to a substrate. In some examples, the spray system 10 is configured to generate and apply a coating of spray foam insulation or an elastomer to a substrate. Although the spray system 10 is described as applying a multi-component fluid, it should be understood that the spray system 10 can be configured to spray a single fluid.

[0020] Fluid supply source 14a, 14b stores fluid before spraying.Multi-component fluid can be formed by combining to produce the multiple fluids of spray foam or elastomer.For example, fluid supply source 14a can store the first fluid, such as resin, and fluid supply source 14b can store the second fluid, such as catalyst.The first and second fluids combine at the spray applicator 12 place and spray from the spray applicator 12 as the spray of multi-component fluid.Therefore, the spray applicator 12 can be referred to as mixer, mixing manifold, distributor and / or spray gun alternatively.Spray applicator 12 generates the spray of multi-component fluid and applies the multi-component fluid to the substrate.

[0021] The pump 16a is configured to draw a first fluid from the fluid supply source 14a and deliver the first fluid downstream to the jet applicator 12. The pump 16b is configured to draw a second fluid from the fluid supply source 14b and deliver the second fluid downstream to the jet applicator 12. The pumps 16a, 16b can be controlled by a system controller. Similarly, the air supply source 18 is connected to the jet applicator 12 and is configured to provide a flow of compressed air to the jet applicator 12. The air supply source 18 can be any suitable configuration for providing compressed air to the jet applicator 12. For example, the air supply source 18 can be a compressor, a pressurized tank, or any other suitable configuration.

[0022] The spray applicator 12 is configured to receive a fluid and generate a spray of the fluid. The trigger 22 is attached to the spray applicator 12 and is configured to control the spraying of the spray applicator 12. The user activates the trigger 22 to switch the spray valve 24 to the fluid open position, thereby opening a fluid flow path through the spray applicator 12 to the spray orifice 28. It is understood that the trigger 22 can be any configuration suitable for activating and deactivating the spray applicator 12. The user releases the trigger 22 to switch the spray valve 24 to the fluid closed position, thereby closing the fluid flow path through the spray orifice 28.

[0023] The trigger 22 actuates the control valve 26 so that the control valve 26 switches the jet valve 24 between the fluid open position and the fluid closed position. In some examples, the control valve 26 directs compressed air from the air supply source 18 to the jet valve 24 to drive the jet valve 24 between the fluid open position and the fluid closed position. In some examples, the control valve 26 switches between a first position and a second position to direct air and drive the jet valve 24. For example, when the control valve 26 is in one of the first position and the second position, the control valve 26 can direct air through a first internal path within the jet applicator 12 to drive the jet valve 24 from the fluid closed position to the fluid open position. Then, the control valve 26 can switch to the other of the first position and the second position to direct air through a second internal path within the jet applicator 12 and drive the jet valve 24 from the fluid open position to the fluid closed position.

[0024] In operation, a user actuates trigger 22 to cause control valve 26 to switch and direct air to jet valve 24 to switch jet valve 24 to a fluid open position. Jet valve 24 is held in the fluid open position until the user releases trigger 22. When trigger 22 is released, control valve 26 switches back and directs air to jet valve 24 to switch jet valve 24 to a fluid closed position. In some examples, jet valve 24 is held in the fluid open position while trigger 22 is actuated, and jet valve 24 returns to the fluid closed position when trigger 22 is released.

[0025] Figure 2A is a perspective view of the spray applicator 12 . Figure 2B is an exploded perspective view of the spray applicator 12 . Figure 2A and Figure 2B The spray applicator 12 includes a trigger 22, a spray valve 24 ( Figure 2B ), injection orifice 28, body 30, grip 32, retaining cap 34, air cap 36, first fluid manifold 38, second fluid manifold 40, air receiver 42, air exhaust 44, fluid housing 46 and fixed mixing chamber 48

[0026] The body 30 is the main protective housing that covers the internal components of the spray applicator 12. In addition, the body 30 provides connection points for other components of the spray applicator 12. The grip portion 32 is connected to the body 30 and provides a handle for the user to hold on it when using the spray applicator 12. The grip portion 32 also provides coverage and protection for the internal components of the spray applicator 12. The trigger 22 is connected to the body 30 and is configured to control the spraying of the spray applicator 12. The retaining cap 34 is connected to the body 30 and is configured to protect and secure the internal components within the spray applicator 12. The retaining cap 34 is removable from the body 30, thereby allowing the user to access the internal components of the spray applicator 12, such as the fluid housing 46 and the fixed mixing chamber 48. The air cap 36 is attached to the retaining cap 34 and is configured to secure the internal components within the spray applicator 12 and direct the purge air near the spray orifice 28. The air cap 36 is removable from the retaining cap 34, thereby allowing the user to access the internal components of the spray applicator 12, such as the fluid housing 46 and the fixed mixing chamber 48.

[0027] The first fluid manifold 38 and the second fluid manifold 40 are each adjacent to and connected to the body 30. The first fluid manifold 38 is configured to receive fluid from the fluid supply source 14a ( Figure 1 ) of the first fluid, wherein pump 16a ( Figure 1 ) delivers the first fluid from the fluid supply source 14a to the jet applicator 12. The second fluid manifold 40 is configured to receive the second fluid from the fluid supply source 14b, wherein the pump 16b delivers the second fluid from the fluid supply source 14b to the jet applicator 12. In the illustrated example, the first fluid manifold 38 and the second fluid manifold 40 are formed as a single manifold that is mounted to the jet applicator 12. In the illustrated embodiment, the first fluid and the second fluid can be received by the jet applicator 12, mixed within the jet applicator 12, and then dispensed from the jet orifice 28 onto the substrate. In another embodiment, the jet applicator 12 can receive fluids from a single fluid receiver and dispense the single fluid from the jet orifice 28 onto the substrate.

[0028] In the illustrated embodiment, the air receiver 42 is connected to the rear of the grip 32. In another embodiment, the air receiver 42 can be connected to the bottom of the grip 32. Thus, the spray applicator 12 may include multiple air receivers 42, only one of which is connected to the air supply source 18 ( Figure 1 ). The air receiver 42 is configured to receive air from the air supply source 18. In operation, a user connects the air supply source 18 to the air receiver 42 using a hose, tube, pipe, or other standard connection. An air exhaust device 44 is disposed at the bottom of the grip 32. The air exhaust device 44 is configured to exhaust air from the spray applicator 12 during translation of the spray valve 24.

[0029] In some cases, the spray applicator 12 may require disassembly and replacement of parts. More specifically, the paths within the fluid housing 46 and / or the fixed mixing chamber 48 may become clogged due to solidified fluid and / or degradation of internal components, and parts may need to be replaced. To disassemble the spray applicator 12, the user removes the air cap 36 from the retaining cap 34, thereby allowing access to the fixed mixing chamber 48. The fixed mixing chamber 48 can then be removed from the fluid housing 46, and more specifically from the contour cavity 72 of the fluid housing 46. When the fixed mixing chamber 48 is removed, the user can remove the retaining cap 34 from the body 30, exposing the fluid housing 46. The fluid housing 46 can then be slid over the injection valve 24 and removed from the body 30 of the spray applicator 12. When the fluid housing 46 is removed, the seal within the fluid housing 46 wipes the residue from the injection valve 24, thereby improving efficiency during the disassembly process. The spray applicator 12 can be assembled by reversing the process. The fluid housing 46 is inserted into the spray applicator 12 and receives the needle of the spray valve 24. The mixing chamber 48 is inserted into the contour cavity 72. The retaining cap 34 is secured to the spray applicator 12, thereby securing the fluid housing 46 to the spray applicator 12. The air cap 36 is connected to the retaining cap 34 and further presses the mixing chamber 48 into the contour cavity 72, thereby enhancing the seal therebetween.

[0030] The rapid assembly and disassembly of the spray applicator 12 reduces downtime and increases productivity in the event that the fluid housing 46 and / or the fixed mixing chamber 48 need to be removed for repair or removed and replaced. In addition, the fluid housing 46 contains a seal that engages the spray valve 24, and the inclusion of multiple components within the fluid housing 46 increases the efficiency of the assembly and disassembly process. In addition, any crossover of fluids is limited to the fluid housing 46 and the fixed mixing chamber 48, which can be easily replaced.

[0031] Figure 3A is a cross-sectional view of the spray applicator 12 showing the spray valve 24 in a fluidly closed position. Figure 3B is a cross-sectional view of the spray applicator 12 showing the spray valve 24 in an intermediate position. Figure 3C is a cross-sectional view of the spray applicator 12 showing the spray valve 24 in a fluidly open position. Figure 3A-3C The spray applicator 12 includes a body 30, a retaining cap 34, an air cap 36, a fluid housing 46, a fixed mixing chamber 48, and a valve assembly 50. The fixed mixing chamber 48 includes a spray orifice 28, a contoured end 52, a first sealing groove 54, a second sealing groove 56, a first port 58, a second port 60, and a mixing hole 62. The fluid housing 46 includes a first hole 64, a second hole 66, a first outlet 68, a second outlet 70, and a contoured cavity 72. The spray valve 24 includes a valve assembly 50 and a pneumatic piston 74 ( Figure 3C The valve assembly 50 includes a first fluid needle 76 , a second fluid needle 78 , a first valve seal 80 , a second valve seal 82 , a first air seal 84 , a second air seal 86 , a first fluid seal 88 , and a second fluid seal 90 .

[0032] It should be understood that the spray applicator 12 is a multi-component spray applicator that includes a mixing device. The mixing device includes all internal components within the spray applicator 12 that allow the spray applicator 12 to receive more than one fluid, mix the fluids, and dispense the fluids from the spray applicator 12. More specifically, the mixing device can include a fluid housing 46, a fixed mixing chamber 48, and a spray valve 24. The mixing device includes all features within the fluid housing 46 and the fixed mixing chamber 48. In addition, the mixing device includes all features and components within the spray valve 24 as defined above.

[0033] 2 , the retaining cap 34 is connected to the body 30 and the air cap 36 is connected to the retaining cap 34. The fluid housing 46 is positioned within a cavity in the body 30 and is secured in place by the retaining cap 34. The retaining cap 34 is adjacent to and presses against a surface of the fluid housing 46, fixedly retaining the fluid housing 46 in position within the spray applicator 12. The fluid housing 46 may be removed from the body 30 of the spray applicator 12 by first removing the retaining cap 34 that holds the fluid housing 46 in position, and then removing the fluid housing 46 from the cavity in the body 30. The fluid housing 46 may need to be removed from the body 30 of the spray applicator 12 for a variety of reasons, including but not limited to blockage of a path in the fluid housing 46 due to solidified fluid and / or degradation of internal components of the fluid housing 46.

[0034] In the illustrated embodiment, the fluid housing 46 includes a first bore 64, a second bore 66, a first outlet 68, a second outlet 70, and a molded cavity 72. The first bore 64 is a bore disposed within the fluid housing 46 that is configured to receive a first fluid from the fluid supply source 14a (FIG. 1) through the first fluid manifold 38 and deliver the first fluid to the first outlet 68. In addition, the first bore 64 accommodates components of the valve assembly 50. The second bore 66 is a bore disposed within the fluid housing 46 opposite the first bore 64 and is configured to receive a second fluid from the fluid supply source 14b through the second fluid manifold 40 and deliver the second fluid to the second outlet 70. In addition, the second bore 66 accommodates components of the valve assembly 50. The first outlet 68 is a bore within the fluid housing 46 that is configured to deliver the first fluid from the first bore 64 to the fixed mixing chamber 48 when the injection valve 24 is in the fluid open position. In addition, when the injection valve 24 is in the fluid closed position, the first outlet 68 is configured to deliver air from the air supply source 18 to the fixed mixing chamber 48. The second outlet 70 is a hole arranged in the fluid housing 46, which is arranged opposite the first outlet 68 and is configured to deliver a second fluid from the second hole 66 to the fixed mixing chamber 48 when the injection valve 24 is in the fluid open position. In addition, when the injection valve 24 is in the fluid closed position, the second outlet 70 is configured to deliver air from the air supply source 18 to the fixed mixing chamber 48. The contoured cavity 72 is a port in the fluid housing 46 that is configured to sealingly receive the contoured end 52 of the fixed mixing chamber 48 to prevent fluid and air leakage.

[0035] The fixed mixing chamber 48 includes an injection orifice 28, a contoured end 52, a first sealing groove 54, a second sealing groove 56, a first port 58, a second port 60, and a mixing hole 62. The fixed mixing chamber 48 is positioned in a cavity between the fluid housing 46 and the air cap 36. More specifically, the contoured end 52 of the fixed mixing chamber 48 is positioned in a contoured cavity 72 of the fluid housing 46, and an opposite end of the fixed mixing chamber 48 extends into the air cap 36. The air cap 36 is configured to press against a surface of the fixed mixing chamber 48 to secure the fixed mixing chamber 48 within the contoured cavity 72. In the illustrated embodiment, the contoured end 52 is a wedge-shaped end configured to be pressed into a wedge-shaped cavity 72 in the fluid housing 46. However, it is understood that the contoured end 52 may be any geometric shape, such as a cone or a frustoconical shape, which will facilitate sealing between the fixed mixing chamber 48 and the fluid housing 46. Furthermore, the shaped cavity 72 may be any corresponding shape to receive the shaped end 52 .

[0036] The spray orifice 28 is located at one end of the fixed mixing chamber 48 and is configured to distribute the fluid onto the substrate in a spray mode. The profiled end 52 is located at the opposite end of the fixed mixing chamber 48 away from the spray orifice 28. The profiled end 52 is configured to be pressed into the profiled cavity 72 of the fluid housing 46 to increase the fluid seal between the fluid housing 46 and the fixed mixing chamber 48. The profiled end 52 also includes a first sealing groove 54 and a second sealing groove 56. The first sealing groove 54 and the second sealing groove 56 are configured to receive a first seal and a second seal, respectively, to seal between the profiled end 52 and the profiled cavity 72 and prevent leakage of the fluid from the first outlet 68 and the second outlet 70 into the fluid housing 46. In the illustrated embodiment, the first sealing groove 54 is located on the first surface of the fixed mixing chamber 28 and is configured to surround the first port 50. In addition, the second sealing groove 56 is located on the second surface of the fixed mixing chamber 28 and is configured to surround the second port 60. In other embodiments, the first sealing groove 54 and the second sealing groove 56 can circumferentially surround the molded end 52, wherein the first sealing groove 54 is positioned above the first outlet 68 and the second outlet 70, so that the first sealing groove 54 is between the injection orifice 28 and the outlets 68, 70, and the second sealing groove 56 is positioned below the first outlet 68 and the second outlet 70, so that the outlets 68, 70 are between the second sealing groove 56 and the injection orifice 28.

[0037] The first port 58 is a hole in the fixed mixing chamber 48 that is fluidly connected to the first outlet 68 of the fluid housing 46. The first port 58 is configured to receive a first fluid from the first outlet 68 and deliver the first fluid to the mixing hole 62. The second port 60 is a hole in the fixed mixing chamber 48 opposite the first port 58 that is fluidly connected to the second outlet 70 of the fluid housing 46. The second port 60 is configured to receive a second fluid from the second outlet 70 and deliver the second fluid to the mixing hole 62. The mixing hole 62 is a hole that is fluidly connected to the first port 58 and the second port 60 and extends from the first port 58 and the second port 60 to the injection orifice 28. The mixing hole 62 is configured to receive a first fluid from the first port 58 and a second fluid from the second port 60 and mix the first fluid and the second fluid into a multi-component fluid mixture that will be dispensed from the injection orifice 28 of the fixed mixing chamber 48. In the illustrated embodiment, the fixed mixing chamber 48 is constructed of metal. In another embodiment, the fixed mixing chamber 48 can be constructed of a polymer.

[0038] The valve assembly 50 includes a first fluid needle 76, a second fluid needle 78, a first valve seal 80, a second valve seal 82, a first air seal 84, a second air seal 86, a first fluid seal 88, and a second fluid seal 90. The first fluid needle 76 includes a first needle head 92, a first needle neck 94, and a first needle shaft 96. The second fluid needle 78 includes a second needle head 98, a second needle neck 100, and a second needle shaft 102. The first fluid needle 76 and the second fluid needle 78 can be made of one of a metal or a polymer.

[0039] The valve assembly 50 is at least partially disposed within the first hole 64 and the second hole 66 of the fluid housing 46. The valve assembly 50 is configured to control the flow of fluid and air through the fluid housing 46 to the fixed mixing chamber 48. More specifically, the valve assembly 50 is configured to control the flow of the first fluid to the first port 58 of the fixed mixing chamber 48 and to control the flow of the second fluid to the second port 60 of the fixed mixing chamber 48. The pneumatic piston 74 is disposed within the body 30 of the jet applicator 12 and is configured to drive the first fluid needle 76 and the second fluid needle 78 in a linear manner using compressed air from the air supply source 18. More specifically, the pneumatic piston 74 is configured to cause the first fluid needle 76 and the second fluid needle 78 to axially translate in a linear manner relative to the axis A. In the illustrated embodiment, the pneumatic piston 74 is utilized to generate the desired linear motion of the first fluid needle 76 and the second fluid needle 78. In another embodiment, a hydraulic piston, an electric piston, or a mechanical piston may be used to generate the desired linear motion of the first fluid needle 76 and the second fluid needle 78.

[0040] The first fluid needle 76 is at least partially arranged in the first hole 64 of the fluid housing 46 and attached to the pneumatic piston 74, which is configured to control the translational movement of the first fluid needle 76. The first fluid needle 76 is configured to translate between the first fluid open position and the first fluid closed position. The second fluid needle 78 is at least partially arranged in the first hole 64 of the fluid housing 46 and attached to the pneumatic piston 74, which is configured to control the translational movement of the second fluid needle 78. The second fluid needle 78 is configured to translate between the second fluid open position and the second fluid closed position. The first fluid needle 76 and the second fluid needle 78 are operably connected to the pneumatic piston 74 for simultaneous actuation. When the jet applicator 12 is in the fluid open state, the first fluid needle 76 is in the first fluid open position and the second fluid needle 78 is in the second fluid open position. Similarly, when the jet applicator 12 is in the fluid closed state, the first fluid needle 76 is in the first fluid closed position and the second fluid needle 78 is in the second fluid closed position.

[0041] A first valve seal 80 is disposed within the first bore 64 of the fluid housing 46. The first valve seal 80 is configured to provide a liquid-tight and air-tight connection between the fluid housing 46 and the first needle 92 of the first fluid needle 76 when the jet applicator 12 is in a fluid-closed state. A second valve seal 82 is disposed within the second bore 66 of the fluid housing 46. The second valve seal 82 is configured to provide a liquid-tight and air-tight connection between the fluid housing 46 and the second needle 98 of the second fluid needle 78 when the jet applicator 12 is in a fluid-closed state. A first air seal 84 is at least partially disposed within the fluid housing 46 and is configured to provide a liquid-tight and air-tight connection between the fluid housing 46 and the first needle 92 when the jet applicator 12 is in a fluid-open state. A second air seal 86 is at least partially disposed within the fluid housing 46 and is configured to provide a liquid-tight and air-tight connection between the fluid housing 46 and the second needle 98 when the jet applicator 12 is in a fluid-open state.

[0042] A first fluid seal 88 is disposed within the first bore 64 of the fluid housing 46. The first fluid seal 88 is configured to provide a fluid-tight and air-tight connection between the fluid housing 46 and the first needle shaft 96 of the first fluid needle 76. A second fluid seal 90 is disposed within the second bore 66 of the fluid housing 46. The second fluid seal 90 is configured to provide a fluid-tight and air-tight connection between the fluid housing 46 and the second needle shaft 102 of the second fluid needle 78. Both the first fluid seal 88 and the second fluid seal 90 are configured to prevent fluid and air from escaping from the fluid housing 46 into the body 30 of the spray applicator 12. Each of the first valve seal 80, the first air seal 84, and the first fluid seal 88 is at least partially disposed within the fluid housing 46, and each is configured to sealingly engage a portion of the first fluid needle 76. Each of the second valve seal 82, the second air seal 86, and the second fluid seal 90 is at least partially disposed within the fluid housing 46, and each is configured to sealingly engage a portion of the second fluid needle 78.

[0043] In operation, a user squeezes the trigger 22 to actuate the pneumatic piston 74 from the fluid closed position to the fluid open position, thereby causing fluid to be dispensed from the spray applicator 12 . Figure 3AThe spray applicator 12 is illustrated in a fluid-closed state. When in the fluid-closed position, the first fluid needle 76 is sealingly engaged with the first valve seal 80 and disengaged from the first air seal 84, so that the first fluid needle 76 is in the first fluid-closed position. When in the fluid-closed position, the second fluid needle 78 is sealingly engaged with the second valve seal 82 and disengaged from the second air seal 86, so that the second fluid needle 78 is in the second fluid-closed position. When the first fluid needle 76 is in the first fluid-closed position, fluid is prevented from flowing out of the first hole 64 to the fixed mixing chamber 48 and air is allowed to travel through the first air seal 84, through the first outlet 68 and into the fixed mixing chamber 48 through the first port 58. Similarly, when the second fluid needle 78 is in the second fluid-closed position, fluid is prevented from flowing out of the second hole 66 to the fixed mixing chamber 48, and air is allowed to travel through the second air seal 86, through the second outlet 70 and into the fixed mixing chamber 48 through the second port 60. The air allowed to travel to the fixed mixing chamber 48 , referred to as purge air, is configured to be continuously exhausted from the injection orifice 28 to keep the first port 58 , the second port 60 , and the mixing holes 62 free of fluid or other debris.

[0044] Figure 3B The spray applicator 12 is illustrated in an intermediate state where both fluid and air flow are shut off. When a user squeezes the trigger 22, the spray applicator 12 begins to switch from the fluid closed state to the fluid open state. Figure 3B The diagram shows the moment when both fluid and air are blocked from entering the fixed mixing chamber 48. More specifically, Figure 3B The first valve seal 80 and the first air seal 84 are shown to be simultaneously engaged with the first needle 92 of the first fluid needle 76, which occurs at an intermediate position between the first fluid open position and the first fluid closed position. The first needle 92 is sized to simultaneously engage with the first valve seal 80 and the first air seal 84. Likewise, Figure 3B Also illustrated is the moment when the second valve seal 82 and the second air seal 86 simultaneously engage the second needle 98 of the second fluid needle 78, which occurs at an intermediate position between the second fluid open position and the second fluid closed position. The second needle 98 is sized to simultaneously engage the second valve seal 82 and the second air seal 86. To prevent fluid from inadvertently entering the air path and air from inadvertently entering the fluid path, the intermediate state stops the flow of fluid and air.

[0045] Figure 3CThe jet applicator 12 is illustrated in a fluidly open state. When in the fluidly open state, the first fluid needle 76 is disengaged from the first valve seal 80 and sealingly engaged with the first air seal 84. In addition, when in the fluidly open state, the second fluid needle 78 is disengaged from the second valve seal 82 and sealingly engaged with the second air seal 86. When in the first fluidly open state, air is prevented from flowing through the first air seal 84 to the fixed mixing chamber 48, and fluid is allowed to travel through the first needle neck 94, through the first outlet 68, and into the fixed mixing chamber 48 through the first port 58. More specifically, when the first fluid needle 76 extends through the first valve seal 80, the first fluid flows around the first needle neck 94. Likewise, when in the second fluidly open state, air is prevented from flowing through the second air seal 86 to the fixed mixing chamber 48, and fluid is allowed to travel through the second needle neck 100, through the second outlet 70, and into the fixed mixing chamber 48 through the second port 60. More specifically, when the second fluid needle 78 extends through the second valve seal 82, the second fluid flows around the second needle neck 100. The fluid flowing to travel to the fixed mixing chamber 48 is mixed within the mixing hole 62 and then dispensed from the injection orifice 28 as a multi-component fluid.

[0046] The fixed mixing chamber 48 and valve assembly 50 within the fluid housing 46 removes the need for dynamic, metal-to-metal, high pressure fluid seals typically used with manual spray applicators. Removing the metal-to-metal, high pressure fluid seals reduces the manufacturing costs associated with prior mixing chamber designs. In addition, the fixed mixing chamber 48 can be constructed of metal or polymer and can be easily removed from the spray applicator 12, which reduces downtime and increases productivity. The fixed mixing chamber 48 is a simplified and improved mixing chamber because the fixed mixing chamber 48 remains fixed while the valve assembly 50 translates during operation, resulting in fewer moving parts within the fixed mixing chamber 48.

[0047] Figure 4A is a perspective view of the second spray applicator 12'. Figure 4B is an exploded perspective view of the second spray applicator 12 ′. Figure 4C is a cross-sectional view of the second spray applicator 12' in a fluidly open state. Figure 4D is a perspective view of the seal within the second spray applicator 12'. Figure 4A-4D The second spray applicator 12 ′ and the spray applicator 12 ( Figure 1-Figure 3C ) are substantially similar, with some differences described below and in Figure 4A-4D The second spray applicator 12' includes a trigger 22', a spray valve 24' ( Figure 4B), injection orifice 28', body 30', grip 32', cap 34', retaining cap 36', first fluid manifold 38', second fluid manifold 40', air receiver 42', air exhaust 44', fluid housing 46' and fixed mixing chamber 48'.

[0048] The body 30' is the main protective housing that covers the internal components of the second jet applicator 12'. In addition, the body 30' provides a connection point for other components of the second jet applicator 12'. The grip 32' is connected to the body 30' and provides a handle for the user to hold on it when using the second jet applicator 12'. The grip 32' also provides coverage and protection for the internal components of the second jet applicator 12'. The trigger 22' is connected to the body 30' and is configured to control the spraying of the second jet applicator 12'. The cap 34' is connected to the body 30' and is configured to cover and protect the internal components within the second jet applicator 12'. The cap 34' can be removed from the body 30', thereby allowing the user to access the internal components of the second jet applicator 12', such as the fluid housing 46' and the fixed mixing chamber 48'. The retaining cap 36' is attached to the fluid housing 46', and the retaining cap 36' is configured to fix the internal components in the second jet applicator 12'. More specifically, the retaining cap 36' is threaded onto the mating threads of the fluid housing 46' to secure the retaining cap 36' to the fluid housing 46' and the second spray applicator 12'. The retaining cap 36' can be removed from the fluid housing 46', thereby allowing a user to access the internal components of the second spray applicator 12', such as the fluid housing 46' and the fixed mixing chamber 48'.

[0049] The first fluid manifold 38' and the second fluid manifold 40' are each adjacent to and connected to the body 30'. The first fluid manifold 38' is configured to receive fluid from the fluid supply source 14a ( Figure 1 ) a first fluid, wherein pump 16a ( Figure 1 ) delivers the first fluid from the fluid supply source 14a to the second jet applicator 12'. The second fluid manifold 40' is configured to receive a second fluid from the fluid source 14b, wherein the pump 16b delivers the second fluid from the fluid supply source 14b to the second jet applicator 12'. In the illustrated example, the first fluid manifold 38' and the second fluid manifold 40' are formed as a single manifold that is mounted to the second jet applicator 12'. In the illustrated embodiment, the first fluid and the second fluid can be received by the second jet applicator 12', mixed within the second jet applicator 12', and then dispensed from the jet orifice 28' onto the substrate. In another embodiment, the second jet applicator 12' can receive fluid from a single fluid receiver and dispense the single fluid from the jet orifice 28' onto the substrate.

[0050] In the illustrated embodiment, the air receiver 42' is connected to the rear of the grip 32'. In another embodiment, the air receiver 42' can be connected to the bottom of the grip 32'. Thus, the second spray applicator 12' can include multiple air receivers 42', only one of which is connected to the air supply source 18 ( Figure 1 ). The air receiver 42' is configured to receive air from the air supply source 18. In operation, a user connects the air supply source 18 to the air receiver 42' using a hose, tube, pipe or other standard connection. An air exhaust device 44' is disposed at the bottom of the grip 32'. The air exhaust device 44' is configured to exhaust air from the second spray applicator 12' during translation of the spray valve 24'.

[0051] In some cases, the second jet applicator 12' may require removal and replacement of parts. More specifically, pathways within the fluid housing 46' and / or the fixed mixing chamber 48' may become clogged due to solidified fluid and / or degradation of internal components, and parts may require replacement. To disassemble the second jet applicator 12', the user removes the retaining cap 36' from the fluid housing 46' and then removes the cap 34' from the fluid housing 46', thereby allowing access to the fixed mixing chamber 48'. The fixed mixing chamber 48' can then be removed from the fluid housing 46', and more specifically from the molded cavity 72' of the fluid housing 46'. When removing the fixed mixing chamber 48', the user can remove the fluid housing 46' from the body 30'. The fluid housing 46' can be removed from the body 30' by unscrewing the fluid housing 46' from the mating threads on the body 30'. The fluid housing 46' can then be slid over the injection valve 24' and removed from the body 30' of the second injection applicator 12'. When the fluid housing 46' is removed, the seal within the fluid housing 46' will wipe the residue from the injection valve 24', thereby improving efficiency during the disassembly process. The second injection applicator 12' can be assembled by reversing the process. The fluid housing 46' is slid over the injection valve 24' and screwed into the mating threads of the body 30'. The fixed mixing chamber 48' is inserted into the molded cavity 72'. The cap 34' is fixed to the second injection applicator 12', and the retaining cap 36' is screwed onto the mating threads of the fluid housing 46' to further press the mixing chamber 48' into the molded cavity 72', thereby enhancing the seal therebetween.

[0052] In the event that the fluid housing 46' and / or the fixed mixing chamber 48' need to be removed for maintenance or removed and replaced, the rapid assembly and disassembly of the second spray applicator 12' reduces downtime and increases productivity. In addition, the fluid housing 46' contains a seal that engages the spray valve 24', and the inclusion of multiple components within the fluid housing 46' increases the efficiency of the assembly and disassembly process. In addition, any crossover of fluids is limited to the housing 46' and the fixed mixing chamber 48', which can easily replace the fluids.

[0053] Figure 4C The second jet applicator 12' is shown in a fluid open state. The internal components of the second jet applicator 12' are substantially similar to the internal components of the jet applicator 12 ( Figure 1-Figure 3C ). In addition, the operation of the second jet applicator 12' is substantially similar to that of the jet applicator 12. Therefore, to avoid repeated description of the components and operation of the second jet applicator 12', only the differences between the second jet applicator 12' and the second jet applicator 12' will be discussed.

[0054] As discussed, the jet applicator 12 includes a first valve seal 80 and a first air seal 84, which are configured to sealingly engage with the first fluid needle 76. The second jet applicator 12' combines the first valve seal 80 and the first air seal 84 into a single first seal sleeve 80'. The first seal sleeve 80' is positioned within the fluid housing 46', and the first seal sleeve 80' is configured to sealingly engage with the first fluid needle 76' to provide the sealing function of the first valve seal 80 and the first air seal 84 of the jet applicator 12. When the second jet applicator 12' is in the fluid open state ( Figure 4C ), the first fluid needle 76' is disengaged from the upper portion of the first sealing sleeve 80' to allow fluid to flow to the fixed mixing chamber 48', and the first fluid needle 76' is sealingly engaged with the lower portion of the first sealing sleeve 80' to block the flow of purge air to the fixed mixing chamber 48'. The first fluid needle 76' remains engaged with the first sealing sleeve 80' in each of the fluid open state, the fluid closed state, and the intermediate state. When the first fluid needle 76' is converted between each state, the first fluid needle 76' remains engaged with the first sealing sleeve 80'. Therefore, the first sealing sleeve 80' of the second jet applicator 12' combines the first valve seal 80 and the first air seal 84 of the jet applicator 12 into a single component. In addition, the first sealing sleeve 80' of the second jet applicator 12' is configured to provide the same functions as the first valve seal 80 and the first air seal 84 of the jet applicator 12.

[0055] Likewise, the jet applicator 12 includes a second valve seal 82 and a second air seal 86, which are configured to sealingly engage with the second fluid needle 78. The second jet applicator 12' combines the second valve seal 82 and the second air seal 86 into a single second seal sleeve 82'. The second seal sleeve 82' is positioned within the fluid housing 46', and the second seal sleeve 82' is configured to sealingly engage with the second fluid needle 78' to provide the sealing function of the second valve seal 82 and the second air seal 86 of the jet applicator 12. When the second jet applicator 12' is in the fluid open state ( Figure 4C ), the second fluid needle 78' is disengaged from the upper portion of the second sealing sleeve 82' to allow fluid to flow to the fixed mixing chamber 48', and the second fluid needle 78' is sealingly engaged with the lower portion of the second sealing sleeve 82' to block the flow of purge air to the fixed mixing chamber 48'. The second fluid needle 78' remains engaged with the second sealing sleeve 82' in each of the fluid open state, the fluid closed state, and the intermediate state. When the second fluid needle 78' is converted between each state, the second fluid needle 78' remains engaged with the second sealing sleeve 82'. Therefore, the second sealing sleeve 82' of the second jet applicator 12' combines the second valve seal 82 and the second air seal 86 of the jet applicator 12 into a single component. In addition, the second sealing sleeve 82' of the second jet applicator 12' is configured to provide the same functions as the second valve seal 82 and the second air seal 86 of the jet applicator 12.

[0056] The first and second sealing sleeves 80', 82' are identical components that provide the same functions within the second spray applicator 12'. The only difference between the first and second sealing sleeves 80', 82' is the fluid needle that each is configured to engage. The following discussion describes the first sealing sleeve 80', but the details are equally applicable to the second sealing sleeve 80', and the details for each sealing sleeve will not be repeated to avoid duplication of description. Figure 4D As shown, the first sealing sleeve 80' is generally cylindrical in shape and includes a plurality of external grooves 80A', a plurality of internal grooves 80B' and a flat surface 104'. More specifically, the first sealing sleeve 80' includes a curved outer surface with a plurality of external grooves 80A' that completely surround the first sealing sleeve 80'. Each of the plurality of external grooves 80A' is configured to receive a sealing member, such as an O-ring seal. The sealing member positioned within each of the plurality of external grooves 80A' abuts the first sealing sleeve 80' and the fluid housing 46' to create a sealing interface between the components, thereby preventing fluid from flowing between the first sealing sleeve 80' and the fluid housing 46'. In addition, the first sealing sleeve 80' includes a plurality of internal grooves 80B' ( Figure 4C), each of the plurality of internal grooves 80B' is configured to receive a seal member, such as an O-ring seal. The seal member positioned within each of the plurality of internal grooves 80B' abuts against the first seal sleeve 80' and the first fluid needle 76' to create a sealing interface between the components, thereby preventing fluid from flowing between the first seal sleeve 80' and the first fluid needle 76'.

[0057] The flat surface 104' is positioned on the curved outer surface of the first sealing sleeve 80' and the flat surface 104' is configured to engage the flat surface of the fluid housing 46' to prevent the first sealing sleeve 80' from rotating within the fluid housing 46'. In addition, the flat surface 104' is configured to engage the flat surface of the fluid housing 46' to ensure proper alignment and sealing engagement of the first sealing sleeve 80' with the fluid housing 46'. More specifically, the flat surface 104' ensures proper sealing alignment of the first passage 106' of the first sealing sleeve 80' with the first outlet 68' of the fluid housing 46'. The first passage 106' extends from the interior of the first sealing sleeve 80' through the first sealing sleeve 80' to the outlet hole formed on the flat surface 104'. Compared with the spray applicator 12, the first sealing sleeve 80' of the second spray applicator 12' simplifies and reduces the number of components in the second spray applicator 12' by combining the two components into a single component. The above description of the first sealing sleeve 80' is applicable to the second sealing sleeve 82', which is the same as the first sealing sleeve 80'.

[0058] like Figure 4C As shown, the second jet applicator 12' includes a puck 110' positioned adjacent to the end of the fluid housing 46'. The puck 110' includes two air passages, one adjacent to the end of the first fluid needle 76', and the other adjacent to the end of the second fluid needle 78'. The air passages within the puck 110' are configured to direct air received through the air receiver 42' to the fixed mixing chamber 48' when the second jet applicator 12' is de-activated to purge any remaining fluid from the fixed mixing chamber 48'. The puck 110' can be constructed of metal, polymer, or composite material. The puck 110' is a removable component that can be removed from the fluid housing 46' to access the internal components within the fluid housing 46'. In addition, in the event that the puck 110' is damaged due to clogging of the second jet applicator 12', the puck 110' can be easily removed from the fluid housing 46' and replaced.

[0059] The fixed mixing chamber 48' and valve assembly 50' within the fluid housing 46' removes the need for dynamic, metal-to-metal, high pressure fluid seals typically used with manual spray applicators. Removing the metal-to-metal, high pressure fluid seals reduces the manufacturing costs associated with prior mixing chamber designs. In addition, the fixed mixing chamber 48' can be constructed of metal or polymer and can be easily removed from the second spray applicator 12', which reduces downtime and increases productivity. The fixed mixing chamber 48' is a simplified and improved mixing chamber because the fixed mixing chamber 48' remains fixed while the valve assembly 50' translates during operation, resulting in fewer moving parts within the fixed mixing chamber 48'.

[0060] Although the present invention has been described with reference to (one or more) exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for its elements without departing from the scope of the present invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present invention without departing from the basic scope of the present invention. Therefore, it is intended that the present invention is not limited to the specific (one or more) embodiments disclosed, but that the present invention will include all embodiments falling within the scope of the appended claims.

Claims

1. A mixing device for a multi-component jet applicator, the mixing device being configured to receive a first fluid and a second fluid and mix the first fluid and the second fluid to generate a multi-component fluid jetted from the multi-component jet applicator, the mixing device comprising: A fluid housing, the fluid housing being mountable to and removable from the body of the spray applicator, the fluid housing comprising: a shaped cavity extending into the first end of the fluid housing, the shaped cavity being configured to receive a fixed mixing chamber to support the fixed mixing chamber, the fluid housing being configured to provide a first component fluid and a second component fluid to the mixing chamber within the shaped cavity; a first aperture opening through the second end of the fluid housing, the first aperture being configured to receive a first component fluid; and a second aperture, the first aperture opening through a second end of the fluid housing, the second aperture configured to receive a second component fluid; a first valve seal disposed within the first bore, the first valve seal being configured to engage with the first needle when the first valve is in a first fluid-closed state to prevent the first component fluid from flowing to the molding cavity, and the first valve seal being spaced apart from the first needle when the first valve is in a first fluid-open state to allow the first component fluid to flow to the molding cavity; and and a second valve seal disposed within the fluid housing, the second valve seal being configured to engage with the second needle when the second valve is in a second fluid closed state to prevent the second component fluid from flowing into the molding cavity, and the second valve seal being spaced apart from the second needle when the second valve is in a second fluid open state to allow the second component fluid to flow into the molding cavity.

2. The mixing device according to claim 1, wherein The first needle and the second needle are operably connected to be actuated simultaneously.

3. The mixing device according to claim 1, wherein During installation of the fluid housing onto the body of the jet applicator, the first needle and the second needle are installed into the first hole and the second hole, respectively, and wherein, during removal of the fluid housing from the body of the jet applicator, the first needle and the second needle are withdrawn from the first hole and the second hole, respectively.

4. The mixing device according to any one of claims 1 to 3, further comprising: and a first air seal disposed within the first hole, the first air seal being configured to engage with the first needle when the first valve is in a first air closed state to prevent compressed gas from flowing to the molding cavity, and the first air seal being spaced apart from the first needle when the first valve is in a first air open state to allow compressed gas to flow from the first hole to the molding cavity.

5. The mixing device according to claim 4, further comprising: and a second air seal disposed within the second hole, the second air seal being configured to engage with the second needle when the second valve is in a second air-closed state to prevent compressed gas from flowing to the molding cavity, and the second air seal being spaced apart from the second needle when the second valve is in a second air-open state to allow compressed gas to flow from the second hole to the molding cavity.

6. The mixing device according to claim 4, wherein: The first air seal is disposed closer to the first end than the first valve seal.

7. The mixing device according to claim 4, wherein: The first air seal is coaxially arranged with the first valve seal on a first axis.

8. The mixing device according to claim 4, wherein The first needle is actuatable to an intermediate state in which the first needle engages the first valve seal to prevent the first component fluid from flowing to the molding cavity and engages the first air seal to prevent compressed gas from flowing to the molding cavity.

9. The mixing device according to claim 8, wherein The first needle is actuatable along a first valve axis between the first fluid sealing state and the intermediate state and between the intermediate state and the first air sealing state.

10. The mixing device according to claim 4, wherein: The first air seal, the first valve seal, and the first fluid needle are coaxially arranged on a first valve axis.

11. The mixing device according to claim 1, wherein The first needle includes a first needle head and a first needle neck extending from the first needle head, and wherein a diameter of the first needle neck is smaller than a diameter of the first needle head.

12. The mixing device according to claim 11, wherein The first needle head engages the first valve seal when the first valve is in the first fluid closed state, and wherein the first needle neck is radially disposed inwardly of and overlaps the first valve seal when the first valve is in the first fluid open state.

13. The mixing device according to claim 11, wherein The first needle neck is exposed to the first component fluid when the first valve is in the first fluid open state and the first fluid closed state.

14. The mixing device according to claim 11, further comprising: a first port formed in the fluid housing and fluidly connecting the first hole and the mold cavity; wherein the first needle is actuatable along a first valve axis between the first fluid open state and the first fluid closed state; and The first needle is arranged at a first axial side of the first port when the first valve is in the first fluid open state, and the first needle is arranged at a second axial side of the first port when the first valve is in the first fluid closed state.

15. The mixing device according to any one of claims 1 to 3 and 11 to 14, wherein The first valve is arranged on the first valve axis and the second valve is arranged on the second valve axis, the first valve axis being spaced apart from the second valve axis.

16. The mixing device according to claim 15, wherein The molding cavity is arranged on a central axis, and the central axis is arranged between the first axis and the second axis.

17. The mixing device of claim 1, further comprising: A first port is formed in the fluid housing and fluidly connects the first hole and the mold cavity.

18. The mixing device according to claim 17, further comprising: A second port is formed in the fluid housing and fluidly connects the second hole and the mold cavity.

19. The mixing device of claim 1, further comprising: a first air seal disposed within the first bore, the first air seal configured to interface with the first fluid needle when the first valve is in a first air-closed state to prevent compressed gas from flowing to the molding cavity, and the first air seal to be spaced apart from the first needle when the first valve is in a first air-open state to allow compressed gas to flow from the first bore to the molding cavity; and A first port is formed in the fluid housing and fluidly connects the first bore and the molded cavity, the first port intersecting the first bore at a location axially between the first valve seal and the first air seal.

20. The mixing device of claim 1, further comprising: An air cap is mountable to the first end of the fluid housing, the air cap being configured to engage the stationary mixing chamber to retain the stationary mixing chamber within the molded cavity.

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