Alignment tool for spray gun

Abstract

The alignment tool is configured to be mounted to the spray gun to be supported by the spray gun. The alignment tool includes a path indicator protruding from the tool body and providing an indication of a gap distance between the spray gun and the target surface prior to spraying by the spray gun.

Description

[0001] Cross-reference to related application(s)

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 449,820, filed on March 3, 2023, and entitled “ALIGNMENT TOOL FOR A SPRAY GUN,” and claims the benefit of U.S. Application No. 18 / 202,070, filed on May 25, 2023, and entitled “ALIGNMENT TOOL FOR A SPRAY GUN,” which claims the benefit of U.S. Provisional Application No. 63 / 449,820, the disclosures of which are incorporated herein by reference in their entirety. Background Art

[0003] The present disclosure generally relates to spray guns for spraying paint and other coatings.

[0004] Each time the tip or retaining ring assembly is removed from the spray gun, for example, for cleaning, replacement, or other maintenance, the operator needs to realign the tip. Aligning the tip on an air-assisted, airless gun is a cumbersome process that requires multiple adjustments and rotations to facilitate proper alignment. Alignment may require multiple spraying iterations to test the alignment to ensure that the tip is correctly aligned. Precise orientation and alignment of the tip can be difficult for a variety of reasons. In particular, this is due to the fact that there is no reliable way to indicate where the tip is oriented without performing a spray test.

[0005] The spray gun can be configured as an automatic spray gun that sprays remotely or as a manual spray gun that is actuated by an operator to spray by pressing a trigger. During spraying, a desired distance should be maintained between the spray gun and the target surface to provide a high-quality finished surface. During spraying with an automatic gun, a desired distance should be maintained to prevent the spray gun from contacting and potentially damaging the object being sprayed. Summary of the Invention

[0006] According to one aspect of the present disclosure, an alignment tool for adjusting the orientation of a spray pattern emitted by an air-assisted airless spray gun includes a tool body, a first engagement surface, and a second engagement surface. The tool body extends between a first end and a second end. The first engagement surface is disposed at the first end, the first end at least partially defining a first opening configured to receive a first air horn portion of an air cap of the spray gun. The second engagement surface is disposed at the first end, the first end at least partially defining a second opening configured to receive a second air horn portion of the air cap. The first engagement surface is configured to engage with the first air horn portion, and the second engagement surface is configured to engage with the second air horn portion to apply a rotational force to the air cap about a spray axis passing through the air cap.

[0007] According to additional or alternative aspects of the present disclosure, an alignment system includes an air-assisted airless spray gun configured to produce a fluid spray and an alignment tool. The air-assisted airless spray gun includes a gun body and an air cap assembly mounted to the gun body, the air cap assembly configured to emit a fan of fluid spray from a spray orifice in a fan orientation. The air cap assembly includes an air cap and an air cap housing, the air cap having a first air horn portion extending axially from the air cap and radially spaced from the spray orifice, and a second air horn portion extending axially from the air cap and radially spaced from the spray orifice, the air cap housing being connected to the gun body to secure the air cap to the gun body. The alignment tool is configured to extend above the air cap and engage with the first and second air horn portions to apply a rotational force to the air cap through engagement between the alignment tool and the first and second air horn portions to change the angular position of the air cap and thereby change the fan orientation.

[0008] According to another additional or alternative aspect of the present disclosure, a method of adjusting the angular orientation of a spray pattern emitted by an air-assisted airless spray gun includes: connecting an air cap and a spray tip to an air-assisted airless spray gun by an air cap housing that extends over the air cap and engages a gun body of the air-assisted airless spray gun; engaging a first air horn portion of the air cap with an alignment tool; rotating the alignment tool about a spray axis to apply a rotational force to the air cap through engagement between the first air horn portion and the alignment tool; and aligning an indicator formed on one of the alignment tool and the spray gun with one of a series of markings formed on the other of the alignment tool and the spray gun, thereby orienting the spray tip to emit a fan of spray in a desired fan orientation.

[0009] According to yet another additional or alternative aspect of the present disclosure, an alignment tool for a spray gun includes a tool body, a second end, and a path indicator, wherein the tool body extends about an axis and between a first end and a second end, the second end being open to receive a leading end of the spray gun into a cavity defined by the tool body; the path indicator is supported by the tool body, the path indicator including a first protrusion extending outwardly away from the tool body.

[0010] According to yet another additional or alternative aspect of the present disclosure, an alignment tool for a spray gun includes a tool body, a second end, a tab, and a path indicator; the tool body extends about an axis and between a first end and a second end, the second end being open to receive a front end of the spray gun into a cavity defined by the tool body; the tab is supported to be connected to the tool body at an interface between the tab and the tool body, the tab supports an inner protrusion extending inwardly from an inner side of the tab, the inner protrusion being configured to engage the spray gun to mount the alignment tool on the spray gun; the path indicator is supported by the tool body, the path indicator including a first protrusion extending outwardly away from the tool body.

[0011] This summary is provided by way of example only and not limitation. Other aspects of the present disclosure will be appreciated in view of the entirety of this disclosure, including the entire text, claims, and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1A is a perspective view of a spray machine including multiple air-assisted airless spray guns.

[0013] Figure 1B Is from Figure 1A A perspective view of the air-assisted airless spray gun assembly.

[0014] Figure 2 is an isometric view of an air-assisted airless spray gun.

[0015] Figure 3A yes Figure 2 Front elevation view of the spray tip of an air-assisted airless spray gun.

[0016] Figure 3B yes Figure 2 Schematic depiction of a series of markings on the gun body of an air-assisted airless spray gun.

[0017] Figure 4A is a top view of the alignment tool.

[0018] Figure 4B yes Figure 4A Front elevation view of the alignment tool.

[0019] Figure 4CIt is along Figure 4A A cross-sectional view of the alignment tool taken along line CC in FIG.

[0020] Figure 5A is a top plan view showing an alignment tool mounted to an air-assisted airless spray gun with the air cap of the air-assisted airless spray gun oriented in a home position.

[0021] Figure 5B is a front elevation view showing the alignment tool mounted to an air-assisted airless spray gun with the air cap in Figure 5A starting position.

[0022] Figure 6A is shown to be installed to Figure 5A A top plan view of the alignment tool for an air-assisted airless spray gun with the air cap adjusted to the desired spraying position.

[0023] Figure 6B is a front elevation view showing an air-assisted airless spray gun with the alignment tool mounted to the gun and with the air cap in Figure 6A Desired spraying position.

[0024] Figure 7 is an isometric view of another embodiment of an air cap for an air-assisted airless spray gun.

[0025] Figure 8 is an isometric view of a manual spray gun.

[0026] Figure 9 is a schematic diagram of an alignment tool provided on a spray gun.

[0027] Figure 10A is an isometric view showing an alignment tool mounted on an automatic spray gun.

[0028] Figure 10B is a first isometric view of the alignment tool.

[0029] Figure 10C is a second isometric view of the alignment tool.

[0030] Figure 10D It is along Figure 10B A cross-sectional view taken along line DD in FIG.

[0031] Figure 11 is a cross-sectional view of a portion of a spray gun showing an alignment tool mounted on the spray gun.

[0032] Figure 12 It is along Figure 10B A cross-sectional view taken along line 12-12 in FIG. 1 shows a portion of a path indicator of the alignment tool.

[0033] Although the above-identified drawings illustrate one or more embodiments of the present disclosure, other embodiments are also contemplated (as noted in the discussion). In all cases, the present disclosure presents embodiments by way of representation and not limitation. It will be appreciated that those skilled in the art can devise numerous other modifications and embodiments that fall within the scope and spirit of the principles of the present disclosure. The drawings may not be drawn to scale, and applications and embodiments of the present disclosure may include features and components not specifically shown in the drawings. DETAILED DESCRIPTION

[0034] The disclosed alignment tool includes an indicator and a series of markings, and can interact with the air cap of a spray gun, such as an air-assisted, airless (AA) spray gun. The alignment tool can indicate the rotational position of the air cap horn, and the alignment tool can have features aligned with positional markings. For example, the alignment tool can engage the air cap of an AA spray gun to adjust the angle of the spray fan emitted by such a spray gun. The alignment tool, with these corresponding positional markings, can allow an operator to easily and accurately align the air cap to a desired orientation.

[0035] Figure 1A is a perspective view of a spray machine 10 including a plurality of spray guns 12 . Figure 1B is a perspective view of a spray gun 12 spraying a surface. Figure 1A and Figure 1B . Fluid spraying machines (such as in Figure 1A The sprayer 10 depicted in FIG may have multiple spray guns 12, and each spray gun 12 may have a variety of spray tip orientations to maximize uniformity of coverage and minimize product waste. Poor spray tip alignment may result in finished product surface defects (such as halos), which may require the sprayed surface to be passed through the sprayer 10 multiple times in order to achieve the desired coverage. The alignment tool 14 (discussed below and in FIG) may be used to align the spray tip with the spray gun 12. Figures 4A to 4B The cam (best seen in the center) facilitates quick and efficient alignment of each spray tip, providing users with confidence and reducing downtime by ensuring all spray tips are correctly aligned.

[0036] Figure 2 FIG2 is an isometric view of a spray gun 12. The spray gun 12 includes a gun body 16, an air cap assembly 18, and an indicia 28. The air cap assembly 18 includes a spray tip 20, an air cap 22, and an air cap housing 24. In the example shown, the air cap 22 includes an air bell 26. The air cap housing 24 secures the air cap 22 to the gun body 16.

[0037] In the example shown, the spray gun 12 is an automatic AA spray gun because the spray gun 12 can be automatically operated by a machine rather than directly operated by a user. It should be understood that in some examples, the spray gun 12 can be a manual AA spray gun configured to be operated by a user. For example, the spray gun 12 can include a handle configured to be grasped by a user and a trigger configured to be manipulated by the user to cause spraying through the spray gun 12.

[0038] The gun body 16 is configured to receive a flow of spray fluid and an air flow. The gun body 16 supports the other components of the spray gun 12. The gun body 16 includes a first side 17a and a second side 17b. In the example shown, the second side 17b is flat and can form the mounting side of the spray gun 12. For example, the second side 17b can be mounted to a support, such as a support of the sprayer 10. The first side 17a can be considered to be the top side, and the second side 17b can be considered to be the bottom side. In some examples, the second side 17b is mounted to a support (such as a spray arm of the sprayer 10) so that the second side 17b can be considered to be the supporting side of the gun body 16. For example, fasteners (such as bolts, screws, retaining rings or other suitable fasteners) can connect the gun body 16 to the support.

[0039] Spray gun 12 is configured to emit the atomized spray of spraying fluid, for being applied to substrate.Spraying fluid is emitted as atomized fluid spray by spray tip.Pressurized air is emitted by air cap 22 and is configured to interact with atomized fluid spray so that the pattern emitted from spray gun 12 is shaped, such as by making the fluid spray fan flatten or widen.Upstream fluid pressure can drive spraying fluid by spray gun 12 and spray tip 20 to cause atomization with enough pressure.Like this, atomized fluid spray can be generated without air, and the shaping air emitted by air cap 22 helps to shape the spray pattern of gained.

[0040] The air cap 22 is at least partially disposed within an air cap housing 24. The air cap housing 24 is connected to the gun body 16 (such as by interface threads or other options) and secures the air cap 22 to the gun body 16. The spray tip 20 is at least partially disposed within the air cap 22 and is configured to emit a fluid spray. The spray tip 20 may include a spray nozzle 30 (e.g., a nozzle 30) that atomizes the spray fluid. Figure 3A (as shown). The spray nozzle 30 can shape the fluid spray. The spray gun 12 is configured to emit the fluid spray along the spray axis AA. The fluid spray is emitted into a shaped pattern by the shaping air. For example, the spray pattern can be an elongated fan orthogonal to the spray axis AA. The air horn portion 26 extends generally axially from the main body of the air cap 22. The air horn portion 26 is disposed on opposite lateral sides of the spray tip 20.

[0041] Indicia 28 provides an indicator for the orientation of spray tip 20. Indicia 28 provides a visual indication of the orientation of spray tip 20 relative to the long axis of the spray fan generated by spray tip 20. In the example shown, an array of indicia is arranged about axis AA to form indicia 28. In some examples, indicia 28 may include additional indicators, such as letters or numbers, to provide additional orientation information to the user. In the example shown, gun body 16 includes indicia 28. However, it should be understood that indicia 28 may additionally or alternatively be located on any desired portion of spray gun 10 suitable for orienting spray tip 20 relative to, for example, air cap 24 (among other options).

[0042] Figure 3A is a front elevation view of the air cap assembly 18 . Figure 3B is a schematic depiction of the markings 28 that are arranged around the circumference of the spray gun 12. Figure 3A and 3B Indicia 28 is configured to indicate the angular position of air cap 22 relative to spray gun 12. Indicia 28 may be formed on gun body 16 and / or air cap housing 24 (or elsewhere on spray gun 12). In the example shown, indicia 28 includes a series of graduated markings arranged at least partially around the circumference of gun body 16. Indicia 28 includes an angular indicator to provide a user with a visual indication of the angular offset of air cap 22.

[0043] An air cap housing 24 is connected to the gun body 16 to secure the air cap 22 to the gun body 16. Air bells 26 extend axially relative to the air cap 22. Each air bell 26 is radially spaced from the spray tip 20. The air cap housing 24 can extend above the air cap 22 and be connected to the gun body 16, thereby securing the air cap 22 to the gun body 16. The air cap 22 is rotationally connected to the gun body 16 so that the air cap 22 can be rotated about the spray axis AA and relative to the gun body 16 while mounted to the gun body 16 to change the orientation of the spray nozzle 30. The orientation of the spray nozzle 30 controls the orientation of the longer portion of the spray fan. The air cap 22 and spray tip 20 may need to be removed from the spray gun 12 for cleaning, repair, replacement, or other maintenance. For example, the air cap housing 24 can be removed from the gun body 16, and then the air cap 22 and spray tip 20 can be removed. The air cap 22 and the spray tip 20 are repositioned on the spray gun 12 and secured to the gun body 16 by the air cap housing 24. However, after the spray gun 12 is reassembled, the spray nozzle 30 is often misoriented relative to the desired spray orientation. Thus, the orientation of the air cap 22, and therefore the spray tip 20 and the spray nozzle 30, needs to be adjusted to the desired spray orientation.

[0044] The spray tip 20 extends through the air cap 22 and is configured to atomize a spray fluid (such as paint, stain, or other options such as lacquer). A spray nozzle 30 is formed through the spray tip 20 and is configured to emit fluid. The spray tip 20 can spray with a fan-shaped spray pattern, which can produce a generally elliptical spray pattern on the surface being sprayed. For example, the spray nozzle 30 can be a cat's eye-shaped orifice or other shape that emits an elongated fan of spray. By rotating the air cap 22, a range of fan orientations are possible for the spray pattern. The air cap 22 emits shaping air, while the spray tip 20 emits the spray fluid.

[0045] Marker 28 is configured to indicate the fan orientation of the spray tip 20, wherein the fan orientation of the spray tip 20 is defined by an angular offset θ of the air cap 22 relative to a vertical plane VV. The vertical plane VV is oriented orthogonal to the spray axis AA, and the angular offset θ can be in a clockwise circumferential direction or a counterclockwise circumferential direction from the vertical plane VV. The vertical plane VV defines a neutral position of the air cap 22 such that when the air cap 22 is in the neutral position, the fan orientation of the spray tip 20 is oriented along the vertical plane VV. In the example shown, when the air cap 22 is in the neutral position, the angular offset θ is set to 0 degrees such that the spray plane SS and the vertical plane VV are coplanar. As discussed in more detail below, the alignment tool 14 (at Figures 4A to 4C The air cap 22 (best seen in FIG. 1 ) is used to rotate the air cap 22 (and therefore the spray tip 20) about the spray axis AA to orient the spray orifice 30 to a desired position. The starting position of the air cap 22 can be, for example, the position in which the air cap 22 is subsequently attached to the gun body 16. The air cap 22 is rotated from the starting position to the desired spray position by the alignment tool 14 such that an angular offset θ is formed between the neutral position and the desired spray position. With the air cap 22 in the spray position, the spray tip 20 is oriented to eject material along a spray plane SS.

[0046] It should be understood that Figure 3AThe spray plane SS in FIG. 2 is shown by way of example, and during operation, the desired spray plane SS can have any desired orientation about the spray axis AA, including alignment with the vertical plane VV or offset from the vertical plane VV by any desired angular value. The spray fan plane SS can be rotationally mirrored about the spray axis AA. In this example, rotating the air cap 22 (and therefore the spray tip 18) clockwise by a first angular offset relative to the vertical plane VV results in the same spray pattern as rotating the air cap 22 counterclockwise by a second angular offset relative to the vertical plane VV, where the sum of the first and second angular offsets is 180 degrees. For example, rotating the air cap 22 clockwise by 35 degrees results in the same spray fan as rotating the air cap 22 counterclockwise by 145 degrees. The indicia 28 can also be rotationally mirrored to facilitate rotation of the air cap 22 in either rotational direction to align the spray tip 20. Thus, the indicia 28 facilitates quick and easy alignment of the air cap 22 in less than a half turn in either rotational direction to align the spray tip 20 for spraying.

[0047] Figure 4A is an isometric view of the alignment tool 14 . Figure 4B is a top view of the alignment tool 14 . Figure 4C It is along Figure 4A A cross-sectional view of the alignment tool 14 taken along line CC in FIG. Figures 4A to 4C The alignment tool 14 includes a tool body 32 , an indicator 34 , and an end protrusion 36 . The tool body 32 includes a closed end 38 , a sidewall 39 , and an open end 40 .

[0048] The tool body 32 extends between a first end and a second end. In the example shown, the first end is a closed end 38, and the second end is an open end 40. However, it should be understood that the first end and the second end of the tool body 32 can be formed in any desired manner. In the example shown, the alignment tool 14 is a cylindrical component, and the tool body 32 includes a substantially circular, circumferential sidewall 39 between the closed end 38 and the open end 40. The sidewall 39 can narrow toward the closed end 38. The sidewall 39 can include relief and / or other features (such as knurling, grooves, or other contoured surfaces) to facilitate gripping of the alignment tool 14. The tool body 32 includes an annular edge 41 that defines the opening of the open end 40. In the example shown, the annular edge 41 includes a radial flange 41a and an axial flange 41b. The tool body 32 defines a chamber 42 configured to receive at least a portion of the air cap assembly 18 during alignment of the spray tip 22. The alignment tool 14 may be additively manufactured and may be formed, for example, from a material such as nylon that does not chemically interact with fluids such as paint or solvents.

[0049] The alignment tool 14 includes flare receiving openings 44 formed in the closed end 38. Each flare receiving opening 44 is at least partially defined by an engagement surface 45 and is capable of receiving an air flare 26. When the alignment tool 14 is mounted on the air cap housing 24, each air flare 26 can extend at least partially through the corresponding flare receiving opening 44. When the air flare 26 extends through the flare receiving opening 44, the engagement surface 45 is positioned adjacent to a circumferential side of the air flare 26, as shown in FIG. Figures 5A to 6B . The engagement surface 45 is configured to directly contact the air flare 26 and apply a rotational force to the air flare 26 to rotate the air cap 22 about the spray axis AA. The air flare 26 extends through a flare receiving opening 44 that passes through the closed end 38. In the example shown, the flare receiving opening 44 extends through the closed end 38 such that the flare receiving opening 44 is a closed opening. Thus, the flare receiving opening 44 is axially open to allow the air flare 26 to extend through the opening 44, but is closed on the radial / circumferential side.

[0050] Indicator 34 is an axial protrusion of alignment tool 14 and may include a sharpened tip that extends axially from a radial flange 41a of annular rim 41 adjacent to open end 40. Indicator 34 extends axially beyond open end 40 and away from closed end 38. In the illustrated example, alignment tool 14 also includes indicator guards 46 on either circumferential side of indicator 34. In the depicted example, indicator guards 46 are axial protrusions extending from radial flange 41a of annular rim 41. Indicator 34 and each indicator guard 46 each have a respective axial length defined by the axial distance from radial flange 41a to the distal end of each axial protrusion distal to radial flange 41a. Indicator guards 46 have a greater axial length than indicator 34. Indicator guards 46 are configured to protect indicator 34 from damage. For example, if the alignment tool 14 is dropped, the indicator guard 46 will contact any surface before the indicator 34 contacts the surface, thereby preventing undesirable contact damage that could cause the indicator 34 to deform.

[0051] An end tab 36 extends from a closed end 38 of the alignment tool 14. The end tab 36 extends axially away from the closed end 38 and can be positioned between flared receiving openings 42. The end tab 36 can be lifted through the flared receiving openings 44. In the illustrated example, the end tab 36 defines a blocking chamber 47 that axially aligns with the spray orifice 30 of the air cap assembly 18 when the alignment tool 14 is mounted to the spray gun 12. The blocking chamber 47 is spaced apart from the spray orifice 30 when the alignment tool 14 is mounted to the spray gun 12. The end tab 36 and blocking chamber 47 protect the user from the discharge of paint or other material if the spray gun 12 is triggered while the alignment tool 14 is mounted on the air cap 22. In the illustrated embodiment, the end tab 36 includes a tab opening 48 that extends at least partially along a sidewall of the end tab 36 adjacent the flared receiving opening 44. The protrusion opening 48 and the flare-receiving opening 44 together define a flare-receiving orifice through which the air flare 26 extends. In the illustrated example, the protrusion opening 48 and the flare-receiving opening 44 are defined by sequentially removing material, such that a single orifice defines both the flare-receiving opening 44 and the adjacent protrusion opening 48. The protrusion opening 48 extends axially relative to a radial line R that projects relative to the center axis CA of the alignment tool 14. The center axis CA can be configured to align with the spray axis AA when the alignment tool 14 is mounted on the spray gun 12. The protrusion opening 48 extends axially between its intersection with the flare-receiving opening 44 and the opposite end of the protrusion opening 48. In the illustrated example, the protrusion opening 48 extends both axially and radially. When the spray gun 12 is triggered while the alignment tool 14 is mounted, the resulting spray enters the blocking chamber 47 and is ejected through the protrusion opening 48. The output pressure is dissipated to prevent injection or other injuries.

[0052] Figure 5A is a top plan view showing the alignment tool 14 mounted to the air cap assembly 18 with the air cap 22 in a home position. Figure 5B is a front elevation view showing the alignment tool 14 mounted to the air cap assembly 18 with the air cap 22 in a home position. Figure 6A is a plan view showing the alignment tool 14 mounted to the air cap assembly 18 with the air cap 22 in the desired spraying position. Figure 6B is a front elevation view showing the alignment tool 14 mounted to the air cap assembly 18 with the air cap 22 in the desired spraying position. Figures 5A to 6BThe gun body 16 and indicia 28 are shown. The tool body 32, indicator 34, end protrusion 36, flare receiving opening 44 and engagement surface 45 of the alignment tool 14 are shown. The air flare 26 of the air cap 22 is shown.

[0053] The alignment tool 14 is configured to adjust the orientation of the air cap 22 and, therefore, the spray orifice 30 (e.g., Figure 3A 1 and 2. The spraying plane SS of the spray gun 12 is oriented about the spraying axis AA. The air cap 22 and the spray tip 20 may need to be removed from the spray gun 12 for cleaning, repair, replacement or other maintenance. This maintenance allows a new air cap 22 to be connected to the spray gun 12. It should be noted that the "new" air cap is so named to distinguish it from an air cap that is in a state of being removed from the spray gun. The new air cap can be, for example, a previously unused air cap, a refurbished air cap or an original air cap that has been cleaned, refurbished or otherwise maintained. Once the air cap 22 is connected to the spray gun 12, the spray tip 20 is in the starting position. The alignment tool 14 can then be mounted to the spray gun 12 to align the spray tip 20 to the desired spraying position.

[0054] During use of the alignment tool 14, the alignment tool 14 is mounted to the spray gun 12 to directly engage the air cap 22. In some examples, the alignment tool 14 can completely enclose and cover the air cap 22. For example, the alignment tool 14 can include an enclosing protrusion for receiving the air horn 26. In the example shown, the alignment tool 14 partially encloses the air cap 22, wherein the air horn 26 extends through the horn receiving opening 44. The alignment tool 14 can be mounted to the air cap housing 24 of the spray gun 12, as shown. Figures 5A to 6B In some embodiments, the alignment tool 14 can be removably mounted to the air cap housing 24, while in other embodiments, the alignment tool 14 can be integrated with the air cap housing 24. The alignment tool 14 can be used during alignment of the spray tip 20 after the spray tip 20 and the air cap 22 have been attached to the spray gun 12.

[0055] The alignment tool 14 is configured to engage the air cap 22 and reposition the spray tip 20 at any angle by rotating the air cap 22 about the spray axis AA. In the illustrated example, the alignment tool 14 engages the air horn 26 to engage the air cap 22. The engagement between the alignment tool 14 and the air cap 22 can be achieved through direct or indirect contact between the alignment tool 14 and the air horn 26. The tool body 32 of the alignment tool 14 can cover and receive the air cap 22. In the illustrated example, the alignment tool 14 receives the air cap housing 24 within a chamber 42 of the alignment tool 14. The rotation of the alignment tool 14 and the resulting torque applied to the air cap 22 to cause the air cap 22 to rotate can occur in either a clockwise or counterclockwise circumferential direction relative to the spray axis AA. After rotation, the spray tip 20 is oriented at the desired spray position, and during use of the spray gun 12, the fan orientation of the sprayed fluid will correspond to the desired spray position of the spray tip 20. The angular offset θ achieved by this rotation is indicated by reference numeral 28. Figures 6A to 6B In the example depicted in , the alignment tool has been rotated in a counter-clockwise circumferential direction.

[0056] The user can visually confirm the orientation of the air cap 22 based on the position of the indicator 34 relative to the marking 28. In the example shown, the marking 28 includes a number indicating the angular offset from the vertical plane VV, which is indicated by the "0" or neutral marking in the marking 28. The user rotates the alignment tool 14 until the indicator 34 is aligned with the marking 28 associated with the desired spray orientation. The air cap 22 and the spray tip 20 are thus placed at the rotational position associated with the desired spray position. The spray tip 20 is thus aligned to emit the spray pattern at the desired orientation.

[0057] In the example shown, the alignment tool 14 is removably mounted to the spray gun 12 and can be removed from the spray gun 12 after the spray tip 20 is oriented at the desired spraying position. However, it should be understood that the alignment tool 14 can be engaged with the spray gun 12 in any desired manner suitable for quickly and efficiently manipulating the angular orientation of the air cap 22 to the precise, desired angular orientation. For example, the interface can include one or more of a click-type knob, a spring-loaded connection, clocked threads on a retaining ring of the air cap housing 24, or another desired interface. In some examples, the alignment tool 14 can be integrated with the spray gun 12. This can be achieved by incorporating indicia onto the air cap housing 24 and including an indicator feature on a non-removable component, incorporating an indicator feature onto the air cap assembly 18 or retaining ring, or elsewhere on the spray gun 12.

[0058] The alignment tool 14 provides significant advantages. The alignment tool 14 engages the air cap 22 to apply torque to the air cap 22 and change the angular position of the air cap 22. The alignment tool 14 also provides a visual indication of the angular position. Thus, the alignment tool 14 facilitates quickly and easily aligning the spray tip 20 to the desired position for spraying. The air cap 22 does not need to be adjusted multiple times through a trial and error process, but can be quickly and effectively aligned using the alignment tool 14. Thus, the alignment tool 14 reduces downtime, improves operating efficiency, and reduces costs and material waste. In addition, the alignment tool 14 can prevent user injury by blocking the fluid spray while the alignment tool 14 is mounted on the spray gun 12.

[0059] Figure 7 FIG1 is a top elevation view of an air cap assembly 118 of a spray gun 112. The spray gun 112 includes a gun body 116 and an air cap assembly 118. The air cap assembly 118 includes a spray tip 120, an air cap 122, and an air cap housing 124. In the example shown, the air cap 122 includes an air bell 126. The air cap housing 124 secures the air cap 122 to the gun body 116.

[0060] Spray gun 112 is substantially similar to spray gun 12, differing primarily in the location of indicia 128, which is substantially similar to indicia 28. The air cap housing 124 of spray gun 112 includes indicia 128. Indicia 128 is configured to indicate the angular position of air cap 122 relative to gun body 116. In the example shown, indicia 128 includes a series of graduated markings disposed at least partially around the circumference of air cap housing 124. As shown in FIG. Figure 2 3, the markings 128 include angle indicators to provide the user with a visual indication of the angular offset of the air cap 122. An alignment tool, such as the alignment tool 14 described above (in Figures 4A to 4C 124 ), may be configured to engage the air bell 126 and have an indicator 34 that engages with the indicia 128. The alignment tool may extend only partially axially, such that the alignment tool axially overlaps up to a portion of the air cap housing 124. Use of the alignment tool with the spray gun 112 provides substantially the same advantages as described above.

[0061] Figure 82 is an isometric view of a manual spray gun 212. The manual spray gun 212 is operated by pressing a trigger 215 supported by the body 216 of the spray gun 212. A user can manipulate the orientation of the manual spray gun 212 and cause spraying through the manual spray gun 212 by grasping a gun handle 219 with a single hand. Pressing the trigger 215 opens a spray valve within the body 216, releasing spray liquid from the nozzle 230 of the spray gun 212. In examples that include an air cap assembly, pressing the trigger 215 directs compressed air to the air cap 222 for firing from the spray gun 212. The air cap assembly 218 (including the cap housing 224 and the air cap 222) is supported by the gun body 216.

[0062] Figure 9 is a schematic block diagram showing an alignment tool 214 having a path indicator 250 disposed on a spray gun 312. The alignment tool 214 is substantially similar to the alignment tool 14 (in FIG. Figures 4A to 4C ), and the alignment tool 214 may include the same features as the alignment tool 14, such as for aligning the air cap to obtain the desired spray pattern orientation. The alignment tool 214 also includes a path indicator 250 that provides orientation and feedback for operating the spray gun 312 on which the alignment tool 214 is used. The alignment tool 214 is substantially similar to the alignment tool 14 and has the reference numerals "200" increased relative to similar / identical components of the alignment tool 14. The alignment tool 214 is mounted on the spray gun 312, which may be an automatic spray gun (similar to the spray gun 12 ( Figure 2 ) or spray gun 112 ( Figure 7 )) or manual spray gun (similar to spray gun 212 ( Figure 8 )).

[0063] Path indicator 250 is arranged on the outside of the tool body 232 of alignment tool 214. Path indicator 250 can provide feedback about the interval between spray gun 312 and target object. Path indicator 250 is configured to provide the indication of the distance between spray gun 312 and target surface TS. During spraying, it is desirable to have a gap distance D1 of consistent width between spray gun 312 and target surface TS, to provide consistent, high-quality finished surface. The feedback provided by path indicator 250 can provide the indication of the actual gap distance D1 between spray gun 312 and target object before actually carrying out spraying operation. This feedback can be useful in automatic spraying operation, to provide suitable path and and in spray chamber positioning target object for automatic sprayer. This feedback can be useful in manual spraying operation, to provide for obtaining and maintaining the training of desired gap distance during spraying.

[0064] In some examples, an alignment tool 214 is provided on an automated spray gun 312 that is machine-oriented during operation. Before the actual spraying event occurs, a path indicator 250 provides feedback to the operator regarding the proposed tool path of the spray gun 312 relative to the target object (e.g., target surface TS). The feedback provided by the path indicator 250 can prevent undesired contact between the spray gun 312 and the target surface TS of the object to be sprayed by ensuring a desired spacing before the spraying event, as such contact could damage the object and / or the spray gun 312.

[0065] This feedback can also be useful for manual spray guns 312 held in the user's hand. For manual spray guns, operators are trained to maintain a desired gap distance D2 between the nozzle and the target surface TS during spraying to provide a coating with a desired pattern, thickness, finished surface quality, etc. The feedback provided by the path indicator 250 can inform the operator of the actual distance they are maintaining between the spray gun 312 and the target surface TS. The path indicator 250 provides feedback without spraying any fluid from the spray gun 312, thereby saving materials and costs during operator training and providing a cleaner training environment.

[0066] The path indicator 250 can be configured to provide feedback in any desired manner. For example, the path indicator 250 can be configured to provide visual feedback, audio feedback, etc. In the example shown, the path indicator 250 includes a protrusion 252 extending outward relative to the tool body 232. The protrusion 252 extends axially outward away from the tool body 232. The protrusion 252 extends outward to provide information about the gap distance D1. The actual gap distance D1 is the actual distance between the spray gun 312 and the target surface TS. The expected gap distance D2 is the gap distance indicated by the protrusion 252. The expected gap distance D2 is the gap distance expected during the spraying operation. In the example shown, the expected gap distance D2 is indicated at the intersection 256 between the protrusions 252, but it should be understood that not all examples are so limited.

[0067] The path indicator 250 can be formed as one or more physical protrusions 252 that extend from the alignment tool 214 and away from the sprayer 312. The protrusions 252 can be configured to converge to intersect at an intersection location 256 in front of the nozzle of the sprayer 312. Among other positioning options, the intersection location 256 can be positioned coaxially with the spray axis SA of the spray gun 312. In some examples, the intersection location 256 provides a desired gap distance D2, which is the gap distance indicated by the path indicator 250. In some examples, the path indicator 250 includes another protrusion that extends axially away from the tool body 232 and the intersection location 256, and in such examples, the distal end of the other protrusion can indicate the desired gap distance D2.

[0068] The protrusion 252 can indicate the desired distance for applying the spray fluid on the target surface TS. A physical protrusion that contacts the workpiece, such as a physical protrusion mounted on an automated sprayer with an alignment tool 214, can visually indicate such contact to the user, and in some examples, the protrusion 252 can be caused to spring back into position after passing over the workpiece, thereby providing audio feedback to the user. The physical protrusion 252 provides a visual indication to the user during training using the manual spray gun 312 to indicate the actual distance the user is maintaining.

[0069] In some examples, the path indicator 250 can be light-based. For example, the path indicator 250 can include one or more laser diodes that emit very narrow, coherent, low-power visible laser beams, which form protrusions 252. In one example, the path indicator 250 can include multiple protrusions 252 (such as two, three, four, or more) oriented so that the multiple beams converge at an intersection location 256 indicating the desired gap distance D2. Such protrusions 252 can be angled to project the beams inward toward the spray axis SA. The path indicator 250 can be oriented so that the intersection locations 256 between the multiple beams are aligned on the spray axis SA, among other options. The convergence of the multiple beams indicates the desired gap distance D2 to the operator, such as for tool paths for automated sprayers and / or for training manual spray guns 312.

[0070] In some examples, the path indicator 250 can be manipulated to reorient the protrusion 252 to obtain a larger or smaller desired gap distance D2. For example, the protrusion 252 can be manipulated so that the intersection location 256 is closer to the tool body 232, thereby providing a smaller desired gap distance D2, or so that the intersection location 256 is farther away from the tool body 232, thereby providing a larger desired gap distance D2.

[0071] In the example of a physical protrusion 252, the protrusion 252 can be mounted to be movable along the spray axis SA to move closer to or further away from the nozzle 230. For example, multiple protrusions 252 (such as two, three, four, or more) can extend from the alignment tool 214 and converge at an intersection 256. The protrusion 252 can be displaced relative to the tool body 232 along the spray axis SA to adjust the size of the desired gap distance D2 indicated by the alignment tool 214. For example, the protrusion 252 can be retracted into the tool body 232 or extended from the tool body 232 to adjust the desired gap distance D2. In some examples, the protrusion 252 can be configured as a telescopic protrusion in which a first portion can be retracted into a second portion or extended from the second portion to change the axial length of the protrusion 252. In some examples, the physical protrusion can be pivoted to change the desired gap distance D2.

[0072] The protrusion 252 and / or the support portion of the tool body 232 can include an indicator (e.g., a digital indicator, etc.) that provides information about the actual size of the desired gap distance for the associated position of the protrusion 252. For example, the physical protrusion 252 can include markings that indicate various distances depending on the position of the protrusion 252 relative to the tool body 232 (e.g., indicating a shorter distance when retracted and a longer distance when extended). The light-based protrusion 252 can include markings that indicate the actual size of the desired gap distance D2 depending on the orientation of the light beam. For example, the light source can be movably mounted, such as on a pivot, and indicator markings can be provided on the movable light source and / or the static support structure to provide an indication of the actual size of the desired gap distance D2 associated with a particular orientation of the light-based protrusion 252. For example, when the light source is pivoted outward away from the tool body 232, the desired gap distance D2 will increase, causing the light beam to extend further along the spray axis SA, and when the light source is pivoted inward toward the tool body 232, the desired gap distance D2 will decrease, causing the light beam to extend a smaller distance along the spray axis SA before intersecting the spray axis SA.

[0073] In some examples of light-based indicators, the path indicator can be configured to project a visual indication of the desired spray pattern onto the target surface. For example, a plurality of laser diodes can be directed to project the desired pattern, and the pattern becomes narrower as the gap distance becomes smaller, and becomes wider as the gap distance becomes larger. Such a path indicator 250 may include one or more retainers 254 that are angled to project the beam protrusion 252 away from the spray axis SA or along the spray axis SA. Such pattern indications are particularly useful for training with a manual sprayer 212 to provide a visual indication of the desired pattern shape and size.

[0074] In some examples, the light source can be configured as a distance sensor that emits a beam (e.g., an optical beam or an audio beam) and generates data based on the reflection time back to the path indicator 250. In such an example, data regarding the actual gap distance D1 can be generated based on the distance information generated by the path indicator 250. The path indicator 250 can be configured as a transmitter or transceiver to wirelessly transmit the distance data to a computer-based controller having a processor and computer memory, which generates the distance data based on the distance information from the path indicator 250. In such an example, the path indicator 250 can be mounted on the alignment tool 214 coaxial with the spray axis SA (among other mounting location options).

[0075] Figure 10A is an isometric view of the alignment tool 214 mounted on the automatic spray gun 12. Figure 10B is a first isometric view of the alignment tool 214 . Figure 10C is a second isometric view of the alignment tool 214 . Figure 10D It is along Figure 10B A cross-sectional view of the alignment tool 214 taken along line DD in FIG. 10A to 10D The alignment tool 214 includes a tool body 232 , an annular rim 241 , a receiving opening 244 , a path indicator 250 , a tab 258 , an inner protrusion 260 , and a retainer 254 . The tool body 232 includes a closed end 238 , a sidewall 239 , and an open end 240 .

[0076] Alignment tool 214 is substantially similar to alignment tool 14 (in Figures 4A to 4C As best seen in FIG, alignment tool 214 can be mounted above an air cap (e.g., air cap 22, air cap 122, air cap 222) such that the air flare extends within and through receiving opening 244. Alignment tool 214 can then be rotated to adjust the orientation of the air cap. For example, alignment tool 214 can engage air flare 226 of air cap 222 to apply a rotational force to air cap 222. Alignment tool 214 is shown including indicator 234 (similar to indicator 34 of alignment tool 14) to provide visual feedback to the user regarding the orientation of air cap 222 about spray axis SA. While alignment tool 214 is shown as including indicator 234, it should be understood that not all examples are so limited.

[0077] The alignment tool 214 is configured to be secured to the spray gun 312 (either an automatic spray gun or a manual spray gun) such that the alignment tool 214 remains mounted on and supported by the spray gun 312 when released by a user. The tool body 232 is configured to extend over and at least partially surround the portion of the spray gun 312 where the alignment tool 214 is mounted. The tool body 232 extends along a tool axis TA. The tool axis TA can be coaxially disposed with the spray axis SA where the alignment tool 214 is mounted on the spray gun 312.

[0078] Tabs 258 are formed on the tool body 232. In the example shown, the tabs 258 are formed by portions of the sidewall 239. The tabs 258 are connected to the tool body 232 at the sidewall 239. In the example shown, each tab 258 is connected to the sidewall 239 at a position intermediate the closed end 238 and the open end 240, and the tabs 258 protrude toward the open end 240. In the example shown, the tabs 258 protrude such that the free ends 264 of the tabs 258 form a portion of the annular edge 241 of the alignment tool 214. However, it should be understood that not all examples are so limited. For example, the annular edge 241 may be formed as a solid ring, with the free ends 264 recessed from the structure forming the annular edge 241 and spaced apart from the structure forming the annular edge 241 in the first axial direction AD1.

[0079] The tab 258 is cantilevered, such that the tab 258 includes a connected end 262 located at an interface with the tool body 232 and a free end 264 opposite the connected end 262. In the illustrated example, the interface between the tab 258 and the tool body 232 is formed between the tab 258 and the sidewall 239. In the illustrated example, the tab 258 projects toward the open end 240. The tab 258 projects from the tool body 232 in the second axial direction AD2 to the free end 264 of the tab 258. It should be understood that in some examples, the tab 258 may project from the connected end 262 to the free end 264 in the first axial direction AD1. For example, the tab 258 may be connected to the tool body 232 at or near the open end 240, such that the free end 264 is disposed between the closed end 238 and the open end 240. In such an example, the connected end 262 may form part of the annular edge 241.

[0080] Tab 258 is configured to flex when alignment tool 214 is installed on and removed from spray gun 312. Tab 258 is configured to engage with a portion of spray gun 312 (such as cap housing 224 of air cap 222) where alignment tool 214 is installed, and secure alignment tool 214 to spray gun 312. Alignment tool 214 can be mounted to spray gun 312 such that alignment tool 214 remains mounted to spray gun 312 even when alignment tool 214 is released by a user. A user can remove alignment tool 214 by pulling alignment tool 214 away from spray gun 312 (e.g., in first axial direction AD1), thereby causing tab 258 to flex as tab 258 passes over a portion of spray gun 312. Tab 258 can be considered to form a snap-on interface with the spray gun (e.g., manually or automatically), but it should be understood that other types of securement are possible.

[0081] In the example shown, inner protrusion 260 is configured to engage with the spray gun (e.g., with a portion of air cap assembly 218) to secure alignment tool 214 to the spray gun. Inner protrusion 260 is formed on tab 258. Inner protrusion 260 is formed on the radially inner side of tab 258 and is oriented inwardly toward chamber 242. In the example shown, inner protrusion 260 extends into chamber 242. Inner protrusion 260 can pass over the mounting surface of spray gun 312, and tab 258 can cause inner protrusion 260 to spring radially inward to engage the mounting surface of spray gun 312. Inner protrusion 260 is configured to prevent alignment tool 214 from sliding off spray gun 312 in a first axial direction AD1, wherein inner protrusion 260 engages the mounting surface of spray gun 312.

[0082] The inner protrusion 260 is configured to engage with a portion of the spray gun 312 to retain the alignment tool 214 on the spray gun 312. The mounting surface 266a is formed as an inclined surface of the inner protrusion 260. The mounting surface 266a extends radially inward from the inner surface of the tab 258 toward the tool axis TA and extends axially in the second axial direction AD2. The mounting surface 266a is configured to engage with a portion of the spray gun to mount the alignment tool 214 on the spray gun.

[0083] Mounting surface 266b is provided on the side of inner protrusion 260 opposite mounting surface 266a. Mounting surface 266b is formed as an inclined surface of inner protrusion 260. Mounting surface 266b extends radially inward from the inner surface of tab 258 toward tool axis TA and axially in first axial direction AD1. When alignment tool 214 is displaced in second axial direction AD2, mounting surface 266b can engage a portion of the spray gun during installation. Mounting surface 266b is inclined to engage spray gun 312, and a force applied to mounting surface 266b bends tab 258 outward away from tool axis TA, allowing tab 258 to pass over a portion of spray gun 312 and retract into a locked position on the sprayer.

[0084] Inner surface 268 extends between mounting surface 266a and mounting surface 266b. Inner surface 268 is configured to slide on a portion of spray gun 312 during installation and removal of alignment tool 214. Inner surface 268 can be configured as a smooth surface to prevent wear of alignment tool 214 and / or spray gun due to relative sliding. Inner surface 268 can be formed as a flat surface. Inner surface 268 can be formed as a curved surface that extends arcuately about tool axis TA.

[0085] Retainers 254 are provided on the exterior side of the tool body 232. In the example shown, the retainers 254 can be considered to form a housing for the path indicator 250. In the example shown, each retainer 254 is configured to engage with a protrusion 252 to retain the protrusion 252 on the alignment tool 214. In a light-based example, the retainers 254 can be formed as a housing for a laser diode that generates a light beam that forms the protrusion 252. In the example shown, the alignment tool 214 includes two retainers 254 associated with two protrusions 252, but it should be understood that other numbers (such as one, three, four, five, or more) are also possible.

[0086] Each retainer 254 extends radially outward from an outer surface of the tool body 232. In the example shown, the retainers 254 are axially elongated. In the example shown, each retainer 254 includes a slot 270 extending through the retainer 254. In the example shown, the slot 270 is axially elongated. The slot 270 extends along a slot axis LA. The slot axis LA can be arranged parallel to the tool axis TA. Additionally or alternatively, the slot axis LA can be arranged parallel to the spray axis SA, wherein the alignment tool 214 is mounted to the spray gun.

[0087] In the example shown, the slot 270 extends completely through the retainer 254 between the retainer opening 272a and the retainer opening 272b, and the associated path indicator 250 protrudes through the retainer opening 272a, and the associated path indicator 250 protrudes through the retainer opening 272b. However, it should be understood that not all examples are so limited. For example, the retainer 254 may include a single opening, and the path retainer 254 protrudes through this single opening (e.g., retainer opening 272a). For example, the retainer 254 can be configured to have an internal reel supporting the protrusion 252, so that the protrusion 252 can be retracted into the retainer 254 through the retainer opening 272a to be wound on the reel, and the protrusion 252 can extend through the retainer opening 272a to unwind.

[0088] In the example shown, the retainer 254 is formed on an exterior surface of the tab 258. It should be understood that other examples of the alignment tool 214 may include a retainer 254 disposed on other exterior surfaces of the tool body 232. For example, the retainer 254 may be partially disposed on the tab 258 and partially disposed on other portions of the tool body 232. The retainer 254 may be partially or completely disposed on the sidewall 239 of the tool body 232.

[0089] In the example shown, the retainers 254 are positioned on opposite sides of the alignment tool 214. Specifically, the retainers 254 are shown as being spaced 180 degrees apart from one another about the tool axis TA. Because the protrusions 252 converge at the path indicator tip 276, the retainers 254 positioned opposite one another relative to the tool axis TA align the distal end 274 of the path indicator 250 on the tool axis TA. It should be understood that in the example shown, the path indicator tip 276 can be considered to form the intersection 256.

[0090] The protrusions 252 extend away from the tool body 232 in the first axial direction AD1. The protrusions 252 extend axially in the first axial direction AD1 and radially inward toward the axis SA to converge at the path indicator tip 276. It should be understood that the protrusions 252 do not necessarily contact each other at the intersection 256. Rather, the intersection 256 is a position where the ends of the protrusions 252 converge and are held relative to each other. In the illustrated example, the protrusions 252 are disposed in the indicator housing 282 and do not contact each other, but it should be understood that not all examples are so limited. In some examples, the protrusions 252 may converge to contact each other at the intersection 256.

[0091] The path indicator tip 276 extends along the first axial direction AD1 between the intersection location 256 and the distal end 274. The path indicator tip 276 forms an extension extending along the tool axis TA. In the illustrated example, the path indicator tip 276 is axially elongated. The path indicator tip 276 can extend along the tool axis TA such that the path indicator tip 276 is aligned on the tool axis TA, although it should be understood that not all examples are so limited.

[0092] The path indicator tip 276 includes an indicator housing 282 and an indicator protrusion 284. The indicator protrusion 284 is configured to align on the tool axis TA to provide an indication of the aligned position on the tool axis TA. In the example shown, the protrusion 252 is mounted to the indicator housing 282, as discussed in more detail below. The protrusion 252 can be removably mounted to the path indicator tip 276 to facilitate installation and removal of the path indicator 250 from the alignment tool 214. In the example shown, the distal end 274 is formed at the tip of the indicator protrusion 284.

[0093] In the example shown, the protrusion 252 extends completely through the slot 270 of the retainer 254. A stop 278 is formed on each protrusion 252. The stop 278 is formed on a portion of the protrusion 252 that is disposed on a side of the retainer 254 opposite the path indicator tip 276. In the example shown, the stop 278 is formed at the end of the protrusion 252 opposite the path indicator tip 276.

[0094] The stop 278 is configured to prevent the protrusion 252 from being removed from the tool body 232. The stop 278 is configured to prevent the protrusion 252 from being pulled out of the retainer 254. The stop 278 can set the maximum desired gap distance D2 for the alignment tool 214. In the illustrated example, the stop 278 is an enlarged member that does not fit within the slot 270 but instead engages the body of the retainer 254 to prevent further movement of the protrusion 252 in the first axial direction AD1. During operation, if the protrusion 252 is pulled in the first axial direction AD1 to increase the desired gap distance D2, the stop 278 will engage the retainer 254 when the protrusion 252 is at the maximum distance from the tool body 232. It should be understood that not all examples include the stop 278. In some examples, the protrusion 252 is mounted within the slot 270 with an interference fit that inhibits displacement of the protrusion 252 within the slot 270.

[0095] The path indicator 250 is configured so that the desired gap distance D2 indicated by the alignment tool 214 can be adjusted. In the example shown, the protrusion 252 is movable relative to the retainer 254 to adjust the desired gap distance D2 indicated by the path indicator 250. In the example shown, the protrusion 252 can be moved in the second axial direction AD2, such that the protrusion 252 slides through the slot 270 to reduce the distance between the tool body 232 and the path indicator tip 276, and the protrusion 252 can be moved in the first axial direction AD1, such that the protrusion 252 slides through the slot 270 to increase the distance between the tool body 232 and the path indicator tip 276. The stop 278 engages with the retainer 254 to limit the movement of the protrusion 252 in the first axial direction AD1.

[0096] In some examples, the protrusion 252 may include a distance indicator that provides an indication of the desired gap distance D2 when the protrusion 252 is positioned at various positions relative to the tool body 232. For example, markings may be formed on the exterior of the protrusion 252 at various intervals (such as one inch or a fraction of an inch), and aligned with a static indicator, such as formed on an axial end of the retainer 254 (e.g., the end of the retainer 254 where the retainer opening 272a is formed), to provide a visual indication of the gap distance D2.

[0097] The path indicator 250 can be configured to assist in removing the alignment tool 214 from the spray gun. In the example shown, a user can grasp the physical protrusion 252 and pull in the first axial direction AD1. The path indicator 250 can apply an axial force to the tool body 232 to remove the tool body 232 from the spray gun. In the example shown, the protrusion 252 can apply an axial driving force to the tool body 232 through the interface between the stop 278 and the retainer 254 to remove the alignment tool 214 from the spray gun.

[0098] Figure 11 FIG2 is a cross-sectional view of a portion of a spray gun 312 showing the alignment tool 214 mounted on the spray gun 312. The gun body 316, spray valve 321, and air cap assembly 318 of the spray gun 312 are shown. The air cap assembly 318 includes an air cap 322 and a cap housing 324. The tool body 232, annular rim 241, receiving opening 244, tab 258, inner protrusion 260, and retainer 254 of the alignment tool 214 are shown. The tool body 232 includes a closed end 238, a sidewall 239, and an open end 240.

[0099] An air cap assembly 318 is mounted to the gun body 216 of the spray gun 312. The air cap assembly 318 is substantially similar to the air cap assembly 18 ( Figure 2)、air cap assembly 118( Figure 7 ) and air cap assembly 218 ( Figure 8 ). Similar or identical components of the air cap assembly 318 have the same reference numbers as the air cap assembly 18 except for the addition of "300", may have the same reference numbers as the air cap assembly 118 except for the addition of "200", and may have the same or similar reference numbers as the air cap assembly 218 except for the addition of "100".

[0100] It should be understood that the spray gun 312 can be an automatic spray gun (e.g., spray gun 12 (in Figure 2 Best visible in), spray gun 112 ( Figure 7 )) or a manual spray gun (e.g., spray gun 212 ( Figure 8 )). An air cap 322 is disposed above the end of the spray gun 312. The air cap 322 is configured to emit an air flow, for example, for atomizing and / or shaping the spray liquid output from the nozzle 300 of the spray gun 312. The needle of the spray valve 321 is configured to be displaced in the second axial direction AD2 to open the spray valve 321 to release the spray of the spray liquid, and is configured to be displaced in the first axial direction AD1 to close the spray valve 321 to stop the emission of the spray liquid.

[0101] The cap housing 324 engages the air cap 322 and secures the air cap 322 to the gun body 316. The cap housing 324 extends around the air cap 322. In the example shown, the cap housing 324 engages the gun body 316 at a threaded interface. The air horn 326 extends through the receiving opening 244.

[0102] The alignment tool 214 can be mounted to the spray gun 312 and is configured to engage with a portion of the spray gun 312 to maintain the alignment tool 214 mounted on the spray gun 312 when the alignment tool 214 is released by the user. The alignment tool 214 does not need to be manually held on the spray gun 312 throughout operation. In the example shown, the alignment tool 214 engages with a portion of the cap housing 324 to mount the alignment tool 214 on the spray gun 312, but it should be understood that the alignment tool 214 can be configured to engage with any desired portion of the spray gun 312. The alignment tool 214 can be mounted to the spray gun 312 so that the tool axis TA is coaxial with the spray axis SA, which coaxial arrangement is indicated by the common axis CA in Figure 10.

[0103] Tab 258 is configured to engage with spray gun 312 to mount alignment tool 214 on spray gun 312. In the example shown, inner protrusion 260 extends from an inner surface of tab 258 and extends inwardly toward common axis CA. In the example shown, inner protrusion 260 is configured to engage cap housing 324 to retain alignment tool 214 on spray gun 312. Alignment tool 214 can be configured such that inner protrusion 260 on tab 258 is the only protrusion that extends to engage spray gun 312 to inhibit axial movement of alignment tool 214 away from spray gun 312. In some examples, alignment tool 214 does not include any other protrusions that extend from an inner surface of tool body 232 to engage spray gun 312. In the example shown, tabs 258 are disposed on opposite sides of alignment tool 214. Specifically, tabs 258 are shown as being spaced 180 degrees apart from one another about common axis CA.

[0104] The inner protrusion 260 extends radially inward toward the spray axis SA of the spray gun. The mounting surface 266a is oriented in a first axial direction AD1. The mounting surface 266a is formed as an inclined surface. The mounting surface 266a is configured to engage with the mounting surface 280 of the spray gun 312 to retain the alignment tool 214 on the air cap 322. In the example shown, the mounting surface 280 is formed by a portion of the cap housing 324. The mounting surface 280 is oriented in a second axial direction AD2. The mounting surface 280 is formed as an inclined surface that engages with the inclined mounting surface 266a to retain the alignment tool 214 on the spray gun 312.

[0105] The angled engagement between mounting surface 280 and mounting surface 266a extends both axially and radially and facilitates removal of alignment tool 214 from spray gun 312. Alignment tool 214 is pulled relative to spray gun 312 in a first axial direction AD1 to remove alignment tool 214 from spray gun 312. Mounting surface 266a slides on mounting surface 280, which applies a radial force to inner protrusion 260, pushing tabs 258 radially outward as alignment tool 214 is displaced in first axial direction AD1. Tabs 258 bend outward, and inner protrusion 260 passes over the exterior of cap housing 324 and can engage and slide over the exterior of cap housing 324. Alignment tool 214 is thus removed and can be stored or used on another sprayer for other operations, such as alignment, tool path control, and / or training.

[0106] In the illustrated example, the inner protrusion 260 further includes a mounting surface 266b. The mounting surface 266b is formed on the axial side of the inner protrusion 260 opposite the mounting surface 266a. The mounting surface 266b is inclined similarly to the mounting surface 266a. The mounting surface 266b is formed as an inclined surface of the inner protrusion 260. The mounting surface 266b extends both radially inward toward the axis CA and axially in the first axial direction. The mounting surface 266b is configured as a first portion of the inner protrusion 260 to engage with the spray gun 312 during installation of the alignment tool 214 on the spray gun 312. During installation, the alignment tool 214 is displaced in the second axial direction AD2, and the mounting surface 266b engages a portion of the cap housing 324. The engagement between the mounting surface 266b and the cap housing 324 biases the tabs 258 outward. In the illustrated example, this bias increases the radial width between the opposing inner protrusions 260. The inner protrusion 260 is displaced along the cap housing 324 until it passes over the mounting surface 280 , and then the tabs 258 snap radially inward to axially overlap the inner protrusion 260 with the cap housing 324 .

[0107] Tab 258 can be formed from a material having sufficient elasticity such that tab 258 is resiliently returned to its unbent state by the material of tab 258 being displaced back to its unbent state. In some examples, tab 258 can be configured such that tab 258 tilts radially inward as tab 258 extends from connected end 262 to free end 264. Thus, free end 264 can be radially inward from connected end 262 when tab 258 is in its unbent state. In this configuration, tab 258 can be in a bent state when alignment tool 214 is mounted on spray gun 312. In this configuration, tab 258 can be configured such that tab 258 remains in a bent state when alignment tool 214 is mounted on spray gun 312.

[0108] Tab 258 can be configured to exert a radially inward force on spray gun 312, such that tab 258 can be considered to be clamped onto spray gun 312. The spring force exerted by tab 258 can bias mounting face 266a into engagement with mounting surface 280 to clamp alignment tool 214 onto spray gun 312. In some examples, the spring force can bias the inner surface of tab 258 into engagement with the outer surface of cap housing 324, such that the body of tab 258 exerts a clamping force. This clamping can inhibit rotation of alignment tool 214 on spray gun 312. This rotation inhibition can be in addition to or in lieu of extending air horn 226 into receiving opening 244. However, it should be understood that tab 258 can be configured to axially lock alignment tool 214 relative to spray gun 312 (e.g., through engagement between mounting face 266a and mounting surface 280) without exerting a clamping force on spray gun 312.

[0109] In the example shown, the inner protrusion 260 also includes an inner surface 268. The inner surface 268 is oriented radially inward. The inner surface 268 extends between the mounting surface 266a and the mounting surface 266b. In the example shown, the inner surface 268 is formed as a flat surface. The inner surface 268 can be formed as an arcuate surface extending about the axis CA. Additionally or alternatively, the inner surface 268 can be formed as a flat surface. The inner surface 268 is configured to engage with the outer surface of the cap housing 324 during installation and removal of the alignment tool 214.

[0110] During installation and removal of alignment tool 214 on spray gun 312, inner surface 268 engages the outer surface of air cap assembly 318 as alignment tool 214 is displaced in first axial direction AD1 and second axial direction AD2. Tabs 258 are bent during installation and removal so that tabs 258 are biased radially inward and engage the exterior of cap housing 324. Inner surface 268 is formed as a flat surface to provide a bearing surface that slides on cap housing 324, thereby reducing wear caused by such relative sliding.

[0111] The retainer 254 protrudes outward from the outer surface of the tool body 232. In the example shown, the retainer 254 is formed on the tab 258. The slot 270 extends through the retainer 254 between the retainer opening 272a and the retainer opening 272b. The slot 270 extends axially along the slot axis LA in the example shown. The slot axis LA can be parallel to the common axis CA. The retainer opening 272a is oriented in the first axial direction AD1. The retainer opening 272b is oriented in the second axial direction AD2. The retainer 254 is configured so that the protrusion 252 can extend completely through the slot 270 and extend out of both the retainer opening 272a and the retainer opening 272b.

[0112] In the illustrated example, retainer opening 272a is spaced apart from the exterior side of closed end 238 of tool body 232 in second axial direction AD2. Retainer opening 272a is positioned so that protrusion 252 exits slot 270 at a position axially closer to the opening of nozzle 330 than the exterior of closed end 238. This configuration provides a more accurate reading of the gap distance between nozzle 330 and target surface TS than measuring such distance from the exterior of closed end 238. This can be particularly useful in examples where protrusion 252 includes a distance indicator that provides an indication of the gap distance when protrusion 252 is positioned at various positions relative to cap housing 324. However, it should be understood that retainer opening 272a can be positioned at any desired location along cap housing 324. The indicator providing gap distance information can be configured to account for the distance between the position of nozzle 330 and the location where protrusion 252 extends from retainer opening 272a.

[0113] The alignment tool 214 provides significant advantages. The alignment tool 214 is configured to be mounted on the spray gun 312 for support by the spray gun 312. In the example shown, the tabs 258 are configured to flex during installation and removal and are configured to engage with the spray gun 312 to secure the alignment tool 214 to the spray gun 312. The example shown includes an inner protrusion 260 that engages the cap body 324 of the air cap 322.

[0114] The alignment tool 214 is configured to provide information about the desired gap distance D2 between the spray gun 312 and the target surface TS. A path indicator 250 protrudes beyond the alignment tool 214 to indicate where the spray liquid will be sprayed. The path indicator 250 provides feedback about the actual gap distance before the spraying operation actually begins.

[0115] Figure 12 It is along Figure 10B FIG2 is a cross-sectional view of the indicator tip 276 taken along line 12-12 in FIG2 . The projections 252 are mounted to the indicator tip 276. In the example shown, each projection 252 extends into a tip aperture 286 formed in the indicator housing 282. The tip aperture 286 is open in the second axial direction AD2. In the example shown, the tip aperture 286 does not extend completely axially through the indicator housing 282. In the example shown, the projections 252 are mounted to the indicator tip 276 by an interference fit.

[0116] An indicator boss 284 extends from the indicator housing 282. The indicator boss 284 extends from an axial end of the indicator housing 282 opposite the end into which the protrusion 252 extends. The indicator boss 284 is disposed on the tool axis TA. In the example shown, the indicator boss 284 extends from a location between the tip apertures 286. The indicator boss 284 extends to the distal end 274.

[0117] Although the present invention has been described with reference to exemplary (multiple) embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present invention. The specific offsets and ratios illustrated and described herein are provided by way of example only and are not intended to be limiting. 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, the present invention is not intended to be limited to the specific (multiple) embodiments disclosed, but rather, the present invention will include all embodiments falling within the scope of the appended claims.

Claims

1. An alignment tool for a spray gun, the alignment tool comprising: a tool body extending about an axis between a first end and a second end, the second end being open to receive a forward end of the lance into a cavity defined by the tool body; and A path indicator is supported by the tool body, the path indicator including a first protrusion extending outwardly away from the tool body.

2. The alignment tool according to claim 1, wherein The projection extends inwardly toward the axis.

3. The alignment tool according to claim 1, wherein The path indicator includes a second protrusion extending outwardly away from the tool body.

4. The alignment tool according to claim 3, wherein The first and second projections extend to an intersecting location axially spaced from the first end.

5. The alignment tool according to claim 4, wherein The first and second protrusions are movable relative to the tool body to increase and decrease a distance between the first end and a distal end of the path indicator.

6. The alignment tool according to claim 5, wherein The first projection extends into a first opening of a first receiver that protrudes from an exterior of the tool body.

7. The alignment tool according to claim 6, wherein The first protrusion extends out of the first receiver through the second opening of the first receiver such that the first protrusion extends completely through a slot through the first receiver, the slot extending between the first opening and the second opening.

8. The alignment tool of claim 6, wherein: The second projection extends into a first opening of a second receiver that protrudes from an exterior of the tool body.

9. The alignment tool of claim 8, wherein: The first receiver is disposed on an opposite side of the tool body from the second receiver.

10. The alignment tool of claim 8, wherein: The first receiver is positioned 180 degrees about the axis from the second receiver.

11. The alignment tool of claim 8, wherein The tool body comprises: A first tab extends from an interface with a sidewall of the tool body to a distal end of the first tab, wherein the first receiver extends from an exterior side of the first tab.

12. The alignment tool of claim 11, wherein The first tab is cantilevered from the interface.

13. The alignment tool of claim 11, wherein: An inner protrusion extends inwardly from an inner side of the first tab.

14. The alignment tool of claim 13, wherein: The inner protrusion extends into the cavity.

15. The alignment tool of claim 13, wherein: The inner protrusion includes a first inclined surface oriented in a first axial direction along the axis, the first inclined surface configured to engage a blocking surface of the spray gun to mount the alignment tool to the spray gun.

16. The alignment tool of claim 15, wherein: The inner protrusion includes a second inclined surface oriented in a second axial direction along the axis, the second axial direction being opposite to the first axial direction.

17. The alignment tool of claim 11, wherein: The first receiver is completely disposed on the first tab.

18. The alignment tool of claim 1 , further comprising: a first engagement surface disposed at the first end, the first engagement surface at least partially defining a first opening configured to receive a first air horn portion of an air cap of the spray gun; and a second engagement surface disposed at the first end, the second engagement surface at least partially defining a second opening configured to receive a second air horn portion of the air cap; The first engagement surface is configured to engage with the first air horn portion, and the second engagement surface is configured to engage with the second air horn portion to apply a rotational force on the air cap about a spraying axis passing through the air cap.

19. The alignment tool of claim 1, wherein: The path indicator includes: an indicator housing having a first tip aperture extending into a first end of the indicator housing and a second tip aperture extending into the first end of the indicator housing; and a second protrusion extending outwardly away from the tool body; wherein the first protrusion is mounted to the indicator housing within the first tip aperture, and the second protrusion is mounted to the indicator housing within the second tip aperture.

20. The alignment tool of claim 19, wherein The indicator housing includes an indicator boss extending from the second end of the indicator housing.

21. An alignment tool for a spray gun, the alignment tool comprising: a tool body extending about an axis between a first end and a second end, the second end being open to receive a forward end of the lance into a cavity defined by the tool body; a tab supported to be connected to the tool body at an interface between the tab and the tool body, the tab supporting an inner protrusion extending inwardly from an inner side of the tab, the inner protrusion being configured to engage the spray gun to mount the alignment tool on the spray gun; and A path indicator is supported by the tool body, the path indicator including a first protrusion extending outwardly away from the tool body.

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