Liquid sprayer and air cap for a liquid sprayer

Abstract

A spray gun comprises a spray head with a nozzle configured to expel a spray liquid. An air cap is configured to direct streams of pressurized gases toward the liquid outlet to shape and / or atomize the spray liquid. The air cap is configured to deliver larger volume flows toward the surfaces of the spray outlet. Adjusting the larger volume flow changes the pattern size of the spray liquid.

Description

CROSS-REFERENCE TO RELATED REGISTRATIONS

[0001] This application claims the benefits of the preliminary US application No. 63 / 654,465 filed on May 31, 2024, entitled “FLUID SPRAYER AND AIR CAP FOR A FLUID SPRAYER”. BACKGROUND

[0002] This revelation refers to sprayers. More specifically, this revelation refers to air caps for sprayers.

[0003] Spray guns can be used to spray liquids onto surfaces. For example, spray guns can be used to spray paint, varnish, coatings, dielectric material, and other coatings onto furniture, cabinets, appliances, equipment, components, etc.

[0004] The spray fluid is typically pressurized by a piston, diaphragm, or other positive displacement pump. The pump can pressurize the spray fluid to a pressure between 34.5 and 345 bar (500 to 5,000 pounds per square inch (psi)), although higher and lower pressures are also possible. The pump delivers the pressurized spray fluid through a flexible hose. A spray gun, attached to the end of the hose opposite the pump, is used to apply the spray fluid. In this way, the spray gun does not contain a pump but instead delivers spray fluid that is pumped through the hose to the spray gun. The spray gun atomizes the pressurized spray fluid into a spray pattern that is applied to a surface.

[0005] Some spray guns, also known as air-assisted airless spray guns, expel streams of air to aid in the atomization and / or shaping of the liquid jet. These spray guns spray the liquid through a nozzle and release the air streams close to the liquid spray. Such spray guns contain valves to control the liquid flow and one or more air streams. SUMMARY

[0006] According to one aspect of the present disclosure, an air cap for a spray gun comprises a cap body with a central opening, wherein the central opening is arranged on a body axis of the cap body; a plurality of projections extending from an outside of the cap body; and a first set of passages extending through the cap body, wherein the first set of passages extends to a plurality of openings that are open on the outside.The plurality of openings comprises a first subset of openings arranged circumferentially between a first projection of the plurality of projections and a second projection of the plurality of projections, wherein the first subset of openings is oriented such that it directs a first plurality of airflows towards the body axis and towards a first surface of the spray pattern; and a second subset of openings arranged circumferentially between the first projection and the second projection, wherein the second subset of openings is opposite the first subset of openings, such that the second subset of components is oriented such that it directs a second plurality of airflows towards the body axis and towards a second surface of the spray pattern.

[0007] According to an additional or alternative aspect of the present disclosure, a spray cap arrangement for use with a spray gun comprises a spray head and an air cap. The spray head comprises a head body with a spray opening formed through it; and a head recess formed in the head body, the head recess extending laterally such that a spray pattern emitted by the spray head is laterally extended, with the spray opening opening into the head recess. The air cap comprises a cap body supporting the spray head, the cap body having a central opening arranged on a body axis of the cap body; a plurality of projections extending from an outside of the cap body; and a first set of passages extending through the cap body, the first set of passages extending to a plurality of openings that are open on the outside.The plurality of openings comprises a first subgroup of openings arranged circumferentially between a first projection of the plurality of projections and a second projection of the plurality of projections, and a second subgroup of openings arranged circumferentially between the first projection and the second projection. The first subgroup of openings is oriented to direct a first plurality of airflows along the body axis and toward a first broad area of ​​the spray pattern. The second subgroup of openings is opposite the first subgroup of openings, such that the second subgroup of components is oriented to direct a second plurality of airflows toward the body axis and toward a second broad area of ​​the spray pattern.

[0008] According to a further additional or alternative aspect of the present disclosure, a method for spraying a coating liquid comprises dispensing the coating liquid through a spray head, wherein the spray head atomizes the coating liquid into a jet of liquid shaped to have a width between a first pattern side and a second pattern side and a thickness between a first pattern side and a second pattern side, the width being greater than the thickness; dispensing pressurized gases through an air cap and in the direction of the spray pattern, such that a first part of the pressurized gas is dispensed through a first plurality of openings and in the direction of the first pattern side, and a second part of the pressurized gas is dispensed through a second plurality of openings and in the direction of the second pattern side;and adjusting the flow rate of the first fraction of the pressurized gas and the second fraction of the pressurized gas to change the width of the spray pattern, wherein an increase in the flow rate of the first fraction of the pressurized gas and the second fraction of the pressurized gas increases the width and a decrease in the flow rate of the first fraction of the pressurized gas and the second fraction of the pressurized gas decreases the width. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1A is an isometric rear view of a spray gun. Fig. 1B is an isometric front view of the spray gun. Fig. 1C is a side view of the spray gun. Fig. Figure 2 is an enlarged cross-sectional view of a flow control section of the spray gun. Fig. 3A is an enlarged, isometric partial view of a spray gun showing the exit of coating fluid and pressurized gases. Fig. 3B is a cross-sectional view along line BB in Fig. 3A. Fig. 4A is a front view of an air cap. Fig. 4B is a first isometric view of the air cap. Fig. 4C is a second isometric view of the air cap. Fig. 4D is a cross-sectional view along the DD line in Fig. 4A. Fig. 4E is a cross-sectional view along line EE in Fig. 4A. Fig. 4F is a cross-sectional view along line FF in Fig. 4A. Fig. Figure 5 is a top view of a cap arrangement showing the discharge of spray fluid. Fig. 6A is a cross-sectional view of a spray head. Fig. 6B is a side view of a spray head. Fig. Figure 7 shows an initial spray pattern applied to a surface. Fig. Figure 8 shows a second spray pattern applied to a surface. DETAILED DESCRIPTION

[0009] This disclosure relates to the spraying of liquids. More specifically, this disclosure relates to air-assisted airless spray guns. An air-assisted airless spray gun (AA) is configured to emit a spray mist of liquid, such as paints, varnishes, coatings, fine lacquers, high-gloss lacquers, water-based coatings, solvent-based coatings, dielectric materials, etc. The air-assisted airless spray gun can be used to apply coatings to surfaces, furniture, cabinets, appliances, equipment, finished parts, electronics, etc. The air-assisted airless spray gun also emits compressed air. An auxiliary air component of the compressed air is configured to assist in mixing the spray tails to prevent tail formation and achieve a smooth, even finish.A portion of the compressed air supplied by the blower assists in atomizing the spray liquid and shaping the spray pattern. The spray liquid is dispensed through a spray nozzle, and the air is dispensed through an air cap. The spray gun is configured to spray at a liquid pressure of up to 34.5 megapascals (MPa) (approximately 5,000 pounds per square inch (psi)). In some examples, the spray gun is configured to spray at a liquid pressure of up to approximately 10 MPa (approximately 1,500 psi). In some examples, the spray gun is configured to spray at air pressures of up to approximately 0.7 MPa (approximately 100 psi).

[0010] According to the aspects of the disclosure, an air cap and a spray head are configured to form a head assembly. The spray head is mounted relative to the air cap to properly align the spray pattern emitted by the spraying device. By aligning the spray head, the spray pattern is matched to the compressed air emitted by the air cap. Such alignment ensures the desired effect of the compressed gas on the emitted spray liquid.

[0011] A spray head can be configured to at least partially atomize the spray liquid. The spray head can be configured to dispense the spray liquid in a spray pattern. For example, the spray head can have a shaped outlet, such as a cat's eye configuration, which helps to shape the liquid jet dispensed by the spray head. The spray head is arranged such that a spray plane, along which the dispensed pattern widens and narrows, subdivides the blower air inlets of the air cap into subgroups. The spray plane extends through the prongs of the air cap.

[0012] Fig. 1A is an isometric rear view of spray gun 10. Fig. 1B is an isometric front view of spray gun 10. Fig. 1C is a side view of spray gun 10. Fig. Figures 1A-1C are explained together. Shown are the pistol body 12, the trigger 14, the cap assembly 16, the collar 18, the button 20, the fluid tube assembly 22, and the trigger lock 24. The pistol body 12 comprises a grip 26, a front end 28, and a rear end 30. The cap assembly 16 comprises an air cap 32 and a spray head 34. The fluid tube assembly 22 comprises the fluid tube 36, the lower fluid port 38, the upper fluid port 40, the air port 42, and the port 44.

[0013] The spray gun 10 is configured to receive spray liquid and pressurized gases and to dispense liquid jets. The gun body 12 carries various components of the spray gun 10. The cap assembly 16 is configured to dispense the liquid jet. The air cap 32 is designed for the venting of pressurized gases. The spray head 34 is configured to dispense spray liquid. The spray head 34 may be at least partially located within the air cap 32. In some examples, the spray head 34 extends through the air cap 32 to dispense spray liquid. The spray head 34 may have a shaping orifice, such as a cat's eye, configured to shape the liquid jet dispensed by the spray head 34. The spray head 34 is configured to at least partially atomize the liquid ejected by the spray head 34. The collar 18 secures the cap assembly 16 to the gun body 12.The trigger 14 is attached to the pistol body 12 and configured to actuate both air and fluid valves, as explained in more detail below. The trigger lock 24 is movable between a firing and a loaded state. In the firing state, the trigger lock 24 is connected to the trigger 14 to prevent its actuation. In the loaded state, the trigger lock 24 is spaced away from the trigger 14, allowing the trigger 14 to be actuated. In the example shown, the trigger lock 24 is configured to be horizontally oriented in the firing state and vertically oriented in the loaded state. The knob 20 extends from the rear end 30 of the pistol body 12 and is located above the grip 26. The knob 20 can interact with an air valve in the pistol body to set an opening through that air valve, as explained in more detail below.

[0014] The fluid tube assembly 22 is attached to the gun body 12. The lower fluid port 38 is configured to connect to a hose for receiving spray fluid. The fluid tube 36 extends between the lower fluid port 38 and the upper fluid port 40. The fluid tube 36 directs the spray fluid to the upper fluid port 40. The upper fluid port 40 is connected to a block in the gun body 12, which directs the spray fluid to a fluid valve in the gun body 12. The air port 42 is connected to the handle 26 and supplies compressed air to the airflow paths in the gun body 12. The port 44 extends between the lower fluid port 38 and the air port 42, ensuring the required distance between them.The connector 44 can be a strip of material, such as plastic or metal, that maintains the distance and the connection.

[0015] During operation, the user can grip the handle 26 of the gun body 12 with one hand and operate the spray gun 10 with that same hand. The user can also use one hand to pull the trigger 14 to initiate spraying. Pulling the trigger 14 opens the air and fluid valves, allowing the spray gun 10 to expel both spray fluid and air. When the trigger 14 is released, the valves return to their normally closed position, stopping the flow of spray fluid and air. Fig. Figure 2 is a partial cross-sectional view of spray gun 10, showing the flow control and spray components of spray gun 10. Fig. 3A is an enlarged isometric partial view of the spray gun 10, showing the exit of coating fluid and pressurized gases. Fig. 3B is a cross-sectional view along line BB in Fig. 3A. The pistol body 12, the trigger 14, the cap assembly 16, the collar 18, the button 20, the handle 26, the fluid valve 46, the auxiliary air valve 48, the blower air valve 50, and the blower control valve 52 of the spray gun 10 are shown. The spray gun 10 can operate as disclosed in International Application No. PCT / US2021 / 037433 of Graco Minnesota, Inc., the disclosure of which is hereby incorporated in full by reference.

[0016] The gun body 12 carries other components of the spray gun 10. The spray gun 10 receives a spray fluid stream, such as liquids like paint, among other options, and receives streams of pressurized gases. The fluid valve 46 controls the flow of the spray fluid to the spray head 18.

[0017] Compressed air can be drawn in through the air inlet bore 54 in the handle 26. The auxiliary air valve 48 controls the flow of an atomizing portion of the compressed gas to the air cap 32. The blower air valve 50 controls the supply of a blower air portion of the compressed gas to the air cap 32. In the example shown, the blower air valve 50 and the auxiliary air valve 48 are connected for simultaneous actuation. The movable valve element 56 forms the movable component of both the blower air valve 50 and the auxiliary air valve 48. It goes without saying, however, that not all examples are limited to this.

[0018] The blower control valve 52 is configured to control the flow of the blower air component of the pressurized gas to the air cap 32. The blower control valve 52 is designed separately from the blower air valve 50. The blower control valve 52 can be adjusted independently of the blower air valve 50. The blower control valve 52 can be set to open further to increase the flow of the blower air component to the air cap 32 and can be set to close further to decrease the flow of the blower air component to the air cap 32. In the example shown, the auxiliary air valve 48 and the blower air valve 50 are controlled by the trigger 14, while the blower control valve 52 can be adjusted independently and is unaffected by the trigger. However, it is understood that the blower control valve 52 need not be included in all examples.In an automatic spray gun, compressed gases are routed to the spray gun through one or more supply lines. Some examples of such a spray gun may have three supply lines: a first for the supply of blower air, a second for the supply of auxiliary air, and a third for the supply of compressed gases to actuate the trigger and initiate the spraying process. With such an automatic spray gun, the flow of compressed gas can be remotely controlled, for example from a control station, to adjust the flow of blower air and / or auxiliary air to the air cap 32.

[0019] Auxiliary air can flow downstream to air cap 32 when auxiliary air valve 48 is open. The flow of auxiliary air is not affected by the opening state of blower control valve 52. Blower air can flow downstream to air cap 32 when blower air valve 50 is open. With blower control valve 52 open, blower air can continue to flow downstream to air cap 32. In the example shown, several valves must be open simultaneously for the blower air section, while only a single valve needs to be open for the auxiliary air section.

[0020] While the blower air component FA and the auxiliary air component AA are shown flowing through the first and second flow paths, respectively, in other embodiments of the spray gun 10, the blower air component FA can be directed into the second flow path and the auxiliary air component AA into the first flow path, depending on the internal duct configurations for guiding the air downstream from the auxiliary air valve 48 and the blower air valve 50. The inlet air flow (IF) flows through the inlet bore 54 in the handle 26 and to the air valve bore 58. The inlet bore 54 extends through the handle 26 to the air valve bore 58. The blower air bore 60 and the auxiliary air bore 62 extend from the air valve bore 58.

[0021] Flow channels 64 and 66 direct pressurized gases to the air cap 32. Flow channels 64 and 66 are configured to direct streams of pressurized gases to the air cap 32. Flow channels 64 and 66 are configured to supply separate streams of pressurized gases to the air cap 32. In the example shown, flow channel 64 directs the auxiliary air component and flow channel 66 directs the blower air component.

[0022] Flow channels 64 and 66 are fluidically separated to provide the blower air and auxiliary air components separately. This configuration allows for discrete control of the individual pressurized gas components, thus enabling the shaping and configuration of the spray pattern. In the example shown, flow channels 64 and 66 are fluidically separated by an air pipe 68, preventing the gas flowing in one channel from mixing with the gas flowing in the other and preventing crossover between the channels.

[0023] The trigger 14 is attached to the gun body 12. The trigger 14 is configured to control the actuation of various valves to regulate the flow of the coating fluid to the spray head 34 and the flow of the pressurized gas to the air cap 32. The trigger 14 is spaced apart from the handle 26. In the example shown, the spray gun 10 is configured as a manual spray gun, with the user gripping the handle 26 and actuating the trigger 14 with one hand. However, it is understood that the spray gun 10 can be configured as an automatic spray gun in various other examples (e.g., pneumatically actuated, electrically actuated, etc.) to control the actuation of the valves.

[0024] The cap assembly 16 is mounted on the gun body 12. The cap assembly 16 is configured to atomize the spray liquid into a spray pattern. The spray head 34 is at least partially located in the air cap 32. The air cap 32 and the spray head 34 form the cap assembly 16, which is configured to atomize the coating liquid and form the spray pattern emitted by the spray gun 10.

[0025] The spray head 34 is arranged downstream of the fluid valve 46 to receive the spray fluid from the fluid valve 46. The spray head 34 comprises a head body 70. The spray opening 72 is formed in the head body 70. The spray opening 72 is aligned with the spray axis SA, along which the coating fluid exits the spray gun 10. A head recess 74 is formed in the head body 70. The head recess 74 extends laterally. The spray opening 72 opens into the head recess 74, so that the coating fluid is expelled through the spray opening 72 and the head recess 74. In the example shown, the head recess 74 is formed as a cut in the outer surface of the head body 70. In the example shown, the head recess 74 is formed as a V-shaped cut, although other configurations are of course possible.In the example shown, the head body 70 has a curved outer surface, and the head recess 74 extends into the curved outer surface of the head body 70.

[0026] The air cap 32 is attached to the pistol body 12. In the example shown, the air cap 32 is attached to the pistol body 12 by the collar 18, although other configurations are of course possible. The air cap 32 comprises a cap body 76. The cap body 76 defines a central opening 78, which is arranged on the spray axis SA. The spray head 34 can be arranged at least partially in the central opening 78. The prongs 96 project outwards. In the example shown, the prongs 96 hold the spray jet of the spray head 34 so that a width W of the spray outlet SO extends laterally between the prongs 96.

[0027] The air cap 32 is configured to discharge both the blower air component of the pressurized gas and the auxiliary air component of the pressurized gas. The air cap 32 discharges the blower air component through blower openings 80. The blower openings 80 are arranged on opposite sides of the spray outlet SO, such that the subgroup of openings 82a is oriented to direct the blower air onto the surface 100a of the spray outlet SO, and the subgroup of openings 82b is oriented to direct the blower air onto the opposite surface 100b of the spray outlet SO. The subgroup of openings 82a is arranged on the opposite side of the spray plane SP, along which the spray pattern can be widened and narrowed relative to the subgroup of openings 82b.In the example shown, all blower openings 80 of the subgroup of openings 82a are arranged on one side of the spray plane SP, which is opposite all blower openings 80 of the subgroup of openings 82b.

[0028] The collar 18 is connected to the air cap 32 and one end of the gun body 12. The collar 18 holds the air cap 32 in its position relative to other parts of the spray gun 10 and connects the air cap 32 to the gun body 12. The collar 18 can secure the air cap 32 so that the spray head 34 is supported by the air cap 32. In the example shown, the collar 18 has a threaded interface, although other connection types are also possible. The collar 18 can hold the air cap 32 on the spray gun 10. In the example shown, the collar 18 overlaps the cap flange 84 to connect to the air cap 32 and clamp the air cap 32 onto the spray gun 10.

[0029] The knob 20 is located outside the pistol body 12 and is accessible to the user. In the example shown, the knob 20 is connected to the blower control valve 52, so that the opening distance of the blower control valve 52 can be adjusted by grasping and operating the knob 20. For example, the knob 20 can be turned to open or close the blower control valve 52 further.

[0030] During the spraying process, spray fluid and compressed air are supplied to the spray gun 10. The spray fluid is supplied through the fluid hose. The fluid valve 46 is closed and prevents the coating fluid from flowing to the spray head 34. The compressed gases are supplied through the handle 26 via the air inlet bore 54. The compressed gases enter the air chamber through the air valve bore 58. The auxiliary air valve 48 and the blower air valve 50 are initially closed and prevent compressed gases from flowing to the air cap 32. The blower control valve 52 can be moved to a desired open position to configure the spray pattern.

[0031] The user grasps the handle 26 and pulls the trigger 14 towards the handle 26 to start spraying. The trigger 14 moves, allowing the auxiliary air valve 48 and the blower air valve 50 to move to their respective open states. In some examples, the spray gun 10 is configured so that pressurized gases begin flowing to the cap assembly 16 before the fluid valve 46 opens and the coating fluid flows to the spray head 34. The auxiliary air valve 48 and the blower air valve 50 can be configured to move to their respective open states simultaneously. An auxiliary air portion of the compressed air flows through the auxiliary air valve 48 and to the air cap 32. The auxiliary air is expelled through the air cap 32. The auxiliary air portion is vented from the perimeter openings 86 (best in Fig. 4A, Fig. 4B and Fig. 4F to be seen) of the air cap 32. The edge openings 86 can be formed by prongs 96. The auxiliary air section is on the pattern edges 98a, 98b ( Fig. 5) of the spray outlet SO. The auxiliary air section is directed towards the thickness T of the spray outlet SO. The auxiliary air section is directed towards the pattern edges 98a, 98b and can assist the blending of the tails in the spray pattern. The auxiliary air section also protects the air cap 32 by blowing the coating fluid away from the tines 96, thus helping to keep the air cap 32 clean.

[0032] A portion of the compressed air flows through the blower air valve 50. In the example shown, the flow of the blower air to the air cap 32 is controlled by the blower control valve 52. When the blower control valve 52 is closed, the blower air flow to the air cap 32 is prevented, and no blower air is expelled from the spray gun 10. When the blower control valve 52 is open, the blower air flows through the blower control valve 52 and is expelled through the air cap 32. The blower control valve 52 can be set to various positions between fully open and fully closed to control the flow of the blower air to the air cap 32. The opening position of the blower control valve 52 controls the flow of the blower air, thereby varying the spray pattern.In the example shown, the width W of the spray pattern increases with increasing flow rate in the blower air section, while it decreases with decreasing flow rate. The blower air section can aid in the atomization of the coating fluid and the formation of the spray pattern.

[0033] The blower air section is expelled from the blower openings 80 of the air cap 32. The blower air section is directed towards the pattern surfaces 100a, 100b of the spray outlet SO. The blower air section is directed towards the width W of the spray outlet SO. As shown in the Fig. 3A and Fig. As can be best seen in Figure 3B, the subgroup of openings 82a directs a first set of airflows onto the pattern area 100a, and the subgroup of openings 82b directs a second set of airflows onto the pattern area 100b. Each subgroup of openings 82a, 82b comprises the same number of blower openings 80 in the example shown. The subgroup of openings 82a includes the central opening 88a and the side openings 90a, 90b. The subgroup of openings 82b includes the central opening 88b and the side openings 90c, 90d. The subgroups of openings 82a and 82b are arranged opposite each other and configured to direct the blower air onto the surfaces 100a and 100b of the spray pattern. The spray plane SP extends between the subgroup of openings 82a, 82b, such that the subgroup of openings 82a, 82b are arranged on opposite sides of the spray plane SP.

[0034] In the example shown, the blower openings 80 are configured to direct the blower air to different points of the spray pattern. The central openings 88a, 88b are arranged opposite each other. The central openings 88a, 88b are aligned such that their outlets intersect at point L1 along the spray axis SA. Point L1 is axially spaced outwards from the spray head 34 along the spray axis SA. Point L1 forms a focal point for the outlets of the central openings 88a, 88b.

[0035] The central openings 88a, 88b orient their respective outlets axially outward along the spray axis SA and radially inward in the direction of the spray axis SA. In the example shown, the central openings 88a, 88b do not orient their respective outlets laterally. Instead, the central openings 88a, 88b orient their respective outlets directly onto the spray axis SA. In the example shown, the central openings 88a, 88b are arranged such that a plane extends orthogonally to the spray plane SP and along the spray axis SA through both central openings 88a, 88b. Such a plane can bisect the central openings 88a, 88b. The outlets of the central openings 88a, 88b can be directed along this plane and in the direction of the spray axis SA. The outlets can be aligned planar with this orthogonal plane in the direction of the spray axis SA. In the example shown, the central opening 88a outputs the central current 92a and the central opening 88b outputs the central current 92b.Central current 92a and central current 92b are both directed towards point L1.

[0036] In the example shown, side openings 90a and 90b are arranged opposite each other. Side opening 90a is configured to emit a side stream 94a. Side opening 90b is configured to emit a side stream 94b. The multiple side openings 90a and 90b of the subgroup of openings 82a direct their respective outlets laterally inwards towards the spray axis SA. The multiple side openings 90a and 90b of the subgroup of openings 82a are configured to direct streams to a common point L2 along the spray axis SA.

[0037] In the example shown, side openings 90c and 90d are arranged opposite each other. Side opening 90c is configured to emit a side stream 94c. Side opening 90d is configured to emit a side stream 94d. The multiple side openings 90c and 90d of the subgroup of openings 82b direct their respective outlets laterally inwards towards the spray axis SA. The multiple side openings 90c and 90d of the subgroup of openings 82b are configured to direct streams to a common point L2 along the spray axis SA.

[0038] In the example shown, side openings 90a, 90b of the subgroup of openings 82a and side openings 90c, 90d of the subgroup of openings 82b are opposite each other. Side openings 90a, 90b of the subgroup of openings 82a and side openings 90c, 90d of the subgroup of openings 82b each direct their exit towards a common focal point at location L2. In the example shown, side openings 90a, 90c are arranged on the same side of the central openings 88a, 88b. Side openings 90b, 90d are arranged on the same side of the central openings 88a, 88b and on a side of the central openings 88a, 88b opposite side openings 90a, 90c. Side openings 90a and 90c are oriented such that their outlets are directed in the same lateral direction relative to the spray axis SA. Side openings 90b and 90d are oriented such that their outlets are directed in the same lateral direction relative to the spray axis SA.The side openings 90a, 90c are oriented such that their outflows point in the opposite direction to one of the side openings 90b, 90d.

[0039] In the example shown, the air cap 32 is configured to direct the blower air portion onto several focal points arranged along the spray axis SA. In this example, the focal point for the central openings 88a, 88b is located at position L1, and the focal point for the side openings 90a-90d is located at position L2. Position L1 is axially closer to the spray head 34 than position L2. In this example, a greater number of outlets converge on the focal point located axially farther from the spray head 34 than on the focal point located axially closer to the spray head 34. In this example, the outlets located axially farther from the spray head 34 are laterally oriented, while the outlets located axially closer to the spray head 34 are not laterally oriented.

[0040] The multiple focal points for the blower air outlets of the air cap 32 facilitate the effective and efficient shaping and atomization of the spray outlet SO. The laterally oriented outlets are axially farther from the spray head 34 than the central openings 88a, 88b. This configuration facilitates pattern formation and atomization of the spray outlet from the central openings 88a, 88b, which are not laterally oriented. The multiple side openings 90a-90d are also farther from the spray head 34 than the central openings 88a, 88b. The outlets from the multiple side openings 90a-90d can further atomize and shape the spray outlet SO from the spray head 34.

[0041] The user releases the trigger 14 to stop spraying. The fluid valve 46 closes, for example by a spring, and the flow of spray fluid downstream through the spray head 34 stops. The auxiliary air valve 48 and the blower air valve 50 are returned to their respective closed states, for example by one or more springs. When the auxiliary air valve 48 is closed, the flow of auxiliary air downstream to the air cap 32 stops. When the blower air valve 50 is closed, the blower air flow downstream to the air cap 32 is interrupted. In the example shown, the blower control valve 52 can remain in an open state, thus maintaining the size of the constriction through the blower control valve 52 and therefore the desired flow for atomization and shaping of the spray pattern for the next trigger pull.In some examples, the fluid valve 46 is configured to close before the auxiliary air valve 48 and the blower air valve 50 close. In this way, the spray gun 10 can be configured to stop dispensing spray fluid before it stops dispensing pressurized gases.

[0042] In some examples, both the fluid valve 46 and the airflow valves (auxiliary air valve 48 and blower air valve 50) are spring-operated. The spring that closes the fluid valve 46 can have a higher spring constant than the spring that closes the air valves, so that the discharge of coating fluid is stopped before the discharge of pressurized gases. The continued discharge of pressurized gases after the discharge of the coating fluid has ceased prevents unwanted material deposits and blockages.

[0043] The spray gun 10 offers significant advantages. The cap assembly 16 facilitates the efficient atomization and shaping of the coating fluid dispensed by the spray gun 10. The spray head 34 is configured to atomize the coating fluid through the spray head 34. The spray head 34 shapes the coating fluid into a basic pattern with a width W and a thickness T. The spray pattern extends laterally along a spray plane SP. The air cap 32 is configured to discharge pressurized gas streams toward surfaces 100a, 100b of the spray pattern. The blower openings 80 discharge multiple discrete streams toward the opposite surfaces 100a, 100b of the spray pattern. The spray plane SP is located between the subset of openings 82a, 82b, and the multiple blower openings 80 are configured to direct their outlets toward the surfaces of the spray plane SP.The outlets of the individual blower openings 80 are oriented perpendicular to the spray plane SP and not along and within the spray plane SP.

[0044] The blower openings 80 are directed towards different focal points along the spray axis SA. These multiple focal points are spaced apart along the spray axis SA. The blower openings 80 directed towards each of the multiple focal points are oriented such that their outlets run perpendicular to the spray plane SP. This arrangement facilitates efficient atomization by striking the coating liquid at multiple points along the spray axis SA and perpendicular to the spray plane SP. This configuration perpendicular to the spray plane SP also facilitates intuitive pattern control, such that the width W increases with increasing gas flow through the blower openings 80, while decreasing gas flow through the blower openings 80 results in a decrease in the width W.

[0045] Fig. 4A is a front view of the air cap 32. Fig. 4B is an isometric view of the air cap 32. Fig. 4C is an isometric rear view of the air cap 32. Fig. 4D is a cross-sectional view along line AA in Fig. 4A. Fig. 4E is a cross-sectional view along line EE in Fig. 4A. Fig. 4F is a cross-sectional view along line FF in Fig. 4A. Fig. Figure 5 is a top view of the cap assembly 16, showing a spray pattern emission in relation to the air cap 32. Fig. Items 4A-5 will be discussed together.

[0046] The air cap 32 comprises the cap body 76, the central opening 78, the blower openings 80, the edge openings 86, the head mount 102, and the flow groove 104. The cap body 76 is arranged around the body axis BA. The body axis BA is configured to be coaxial with the spray axis SA when the air cap 32 is mounted on a spray gun 10. The central opening 78 extends through the cap body 76. The central opening 78 extends fully axially through the cap body 76 and is open in both axial directions along the body axis BA. The air cap 32 is configured to at least partially accommodate the spray head 34 within the central opening 78 to form the cap assembly 16.

[0047] The prongs 96 extend axially outwards from the outer surface 106 of the cap body 76 in a first axial direction AD1. The prongs 96 can be considered part of the cap body 76. The prongs 96 can, among other things, be monolithic with other parts of the cap body 76. The prongs 96 are arranged on opposite sides of the central opening 78. The central opening 78 can be considered to be framed by the prongs 96. The prongs 96 retain the spray pattern emitted by the cap assembly 16. The prongs 96 laterally retain the spray pattern so that the spray outlet extends in width between the prongs 96. The prongs 96 are arranged such that the spray plane SP passes through the prongs 96. In some examples, the spray plane SP can bisect each prong 96.

[0048] The blower openings 80 are formed in the outer surface 106 of the cap body 76. The blower openings 80 are oriented such that they direct pressurized gas flows to the surfaces 100a, 100b of the spray outlet SO of the spray head 34. The blower openings 80 are arranged in a subgroup of openings 82a and a subgroup of openings 82b. The subgroup of openings 82a is located on the circumferential side of each tine 96 opposite the subgroup of openings 82b. The subgroups of openings 82a and 82b are arranged radially outside the central opening 78. The subgroups of openings 82a and 82b are located on opposite sides of the spray plane SP. All blower openings 80 of the subgroup of openings 82a are arranged on one side of the spray plane SP, and all blower openings 80 of the subgroup of openings 82b are arranged on the opposite side of the spray plane SP.

[0049] In the example shown, each subgroup of openings 82a, 82b comprises three blower openings 80. However, it is understood that a different number of blower openings 80 is also possible within each subgroup of openings 82a, 82b. The subgroup of openings 82a comprises the central opening 88a and the side openings 90a, 90b. The subgroup of openings 82b comprises the central opening 88b and the side openings 90c, 90d. Each blower opening 80 is oriented such that its outlet is directed onto a surface 100a, 100b of the spray plane SP. In the example shown, each blower opening 80 is oriented such that its outlet is directed onto the body axis BA. The blower openings 80 are configured to deliver discrete blower air streams. The blower openings 80 do not overlap, but are separated from each other on the outside 106.

[0050] Between the blower openings 80 and the inlet openings 110, blower passages 108 are formed by the cap body 76. The inlet openings 110 are arranged on one side of the cap body 76 opposite the blower openings 80. In the example shown, each blower passage 108 extends along a channel axis PA. The blower passages 108 are designed such that the passage axes PA of the central openings 88a, 88b intersect at a first focal point along the body axis BA. The blower passages 108 are designed such that the passage axes PA of the side openings 90a-90d intersect at a second focal point along the body axis BA. The second focal point is axially farther from the spray head 34 than the first focal point. The focal points are spaced in axial direction AD1 from the spray head 34, with the axial direction AD1 extending outwards with respect to the spray direction.

[0051] In some examples, each blower opening 80 has the same diameter as the other blower openings 80. In some examples, the blower openings 80 have a different diameter than parts of the blower passage 108. In some examples, the blower opening 80 may have a larger diameter than the blower passage 108 that feeds it. The diameter of this blower opening 80 can be measured along a plane perpendicular to the passage axis PA. The opening of the blower opening 80 that terminates on the outside 106 is elongated. The larger diameter of the blower opening 80 compared to the blower passage 108 can help to distribute the output from the blower opening 80 and aid in the atomization and shaping of the pattern.

[0052] In the example shown, the blower openings 80 extend through side sections 114a and 114b of the cap body 76. In some examples, several, up to all, blower openings 80 are formed entirely within a single side section 114a, 114b. The side sections 114a, 114b are arranged on opposite sides of the central opening 78. Side section 114a is located on a circumferential side of the two prongs 96 opposite side section 114b. In the example shown, the side sections 114a, 114b are aligned axially with the body axis BA. In some examples, the side sections 114a, 114b may be arranged in a common plane, with the common plane being perpendicular to the body axis BA. In some examples, the side sections 114a, 114b may be arranged in a common plane that is orthogonal to the spray plane SP.

[0053] The blower passages 108 of the central openings 88a, 88b are best in Fig. 4D. As shown, the blower passage 108 is inclined such that the inlet opening 110 is radially farther from the body axis BA than the blower opening 80. The blower passage 108 is inclined such that the blower air is directed radially inwards and in the direction of the body axis BA. In the example shown, the central openings 88a, 88b are inclined at an angle α to direct the flow in the direction of the body axis BA. The central openings 88a, 88b are inclined at the same angle α to focus the outlets of both central openings 88a, 88b onto a common focal point.

[0054] The blower passages 108 of the side openings 90a, 90d are best in Fig. Figure 4E shows that the blower passage 108 is inclined such that the inlet opening 110 is radially farther from the body axis BA than the blower opening 80. The blower passages 108 are also inclined laterally such that the inlet openings 110 supplying the side openings 90a-90d are positioned laterally further outward than the side openings 90a-90d. The blower passages 108 associated with the side openings 90a-90d are configured to direct the blower air radially inward and in the direction of the body axis BA. In the example shown, the blower passages 108 associated with the side openings 90a and 90d are inclined at an angle β to direct the flow in the direction of the body axis BA. The side openings 90a, 90d are inclined at the same angle β to emit a current in the direction of the body axis BA.The side openings 90a and 90d are inclined at the same angle β to direct the outputs of both side openings 90a and 90d to a common focal point. It is understood that the side openings 90b and 90c can be configured in the same way as the side openings 90a and 90d.

[0055] In the example shown, angle β is shallower than angle α. For example, angle β can be approximately 35 degrees, while angle α can be approximately 45 degrees, although other configurations are of course possible. The shallower angle β directs the outlets of the side openings 90a-90d to a focal point that is axially further out from the spray head 34 than the focal point for the outlets of the central openings 88a, 88b.

[0056] The inlet openings 110 are spaced further apart circumferentially by the outer surface 106 than the blower openings 80. The side openings 90a, 90b are oriented such that the blower passages 108 of the side openings 90a, 90b converge towards the central opening 88a between the inlet openings 110 and the side openings 90a, 90b. This arrangement directs the outlets of the side openings 90a, 90b laterally inwards in the direction of the body axis BA. The blower passages 108 associated with the side openings 90c, 90d converge towards the central opening 88b between the inlet openings 110 and the side openings 90c, 90d. This configuration directs the outlets of the side openings 90c, 90d laterally inwards in the direction of the body axis BA.

[0057] In the example shown, the blower openings 80 within each subgroup of openings 82a, 82b are radially offset relative to other blower openings 80 in the same subgroup of openings 82a, 82b. In the example shown, the central openings 88a, 88b are arranged radially closer to the body axis BA than the side openings 90a-90d. The blower openings 80 can be considered as arranged in a chevron configuration within each subgroup of openings 82. However, it is understood that not all examples are so limited. For example, the multiple blower openings 80 within a subgroup of openings 82a, 82b may be aligned linearly with each other, the central openings 88a, 88b may be arranged radially outside the side ports 90a-90d, among other options.

[0058] The edge openings 86 are best in Fig. 4F can be seen. The edge openings 86 are aligned with the tines 96. In some examples, the edge openings 86 may be formed at least partially within the tines 96. The edge openings 86 are fluidically isolated from the blower openings 80. The pressurized gases supplied to the edge openings 86 do not mix with the pressurized gases supplied to the blower openings 80 at locations within the air cap 32. Such fluid isolation allows for separate control of the auxiliary air flowing through the edge openings 86 and the blower air flowing through the blower openings 80. The edge openings 86 are inclined to direct their outlets axially outwards from the spray head 34. The edge openings 86 are aligned with the edges 98a, 98b of the spray outlet SO and can be aligned along the spray plane SP.The edge openings 86 are configured to direct flows laterally along the spray plane SP and, in some examples, perpendicular to it. The outlets from the edge openings 86 of the multiple edge openings 86 can be directed towards the body axis BA. In some examples, each edge opening 86 has the same diameter as the other edge openings 86.

[0059] In the example shown, the blower openings 80 are larger than the edge openings 86. Each blower opening 80 can expel a larger volume of pressurized gases than each edge opening 86. In some examples, the diameter of a blower opening 80 can be at least twice the diameter of an edge opening 86. In some examples, the diameter of the blower passage 108 can be larger than the diameter of the edge opening 86. In some examples, the diameter of the blower passage 108 can be at least 1.5 times the diameter of the edge opening 86.

[0060] The head holder 102 extends in the second axial direction AD2, which is directed inwards along the body axis BA with respect to the spray outlet. The head holder 102 extends at least partially around the central opening 78. The head holder 102 is configured to accommodate the spray head 34. The head holder 102 can interact with the spray head 34 to secure the spray head 34 to the air cap 32. In the example shown, the head holder 102 is formed monolithically with other parts of the cap body 76. In the example shown, the head holder 102 is configured as a ring extending in the second axial direction AD2. The head holder 102 can also be cylindrical, among other configurations.

[0061] The positioning device 112 is configured to interact with the spray head 34 to align the spray head 34 relative to the air cap 32. In the example shown, the positioning device 112 forms a rotation lock configured to prevent rotation of the spray head 34 about the body axis BA. By rotating the spray head 34, the spray plane SP is held in a desired orientation relative to the blower openings 80 and the edge openings 86 of the air cap 32. In the example shown, the positioning device 112 is formed as a recess in the head holder 102. The recess formed by the positioning device 112 is configured to accommodate a projection extending from the spray head 34 to rotatably lock the spray head 34 relative to the air cap 32, as shown in Fig. Figure 3B shows the positioning device 112. In the example shown, the positioning device 112 is formed at a location circumferentially between the prongs 96 of the air cap 32. Although the positioning device 112 is depicted as a recess, it can have any suitable configuration for fixing the relative orientations of the air cap 32 and the spray head 34. For example, the head holder 102 can have a contoured inner surface and the spray head 34 a contoured outer surface that mesh with the contoured inner surface at a wedged interface, with the positioning device 112 being formed by the contoured inner surface. In other examples, the positioning device 112 can be configured as a projection that is received in a slot of the spray head 34.In the example shown, the positioning device 112 is configured to allow unidirectional mounting of the spray head 34. The spray head 34 can be mounted in a single orientation, such that the head recess 74, and thus the spray plane SP, extends laterally. It is understood that in various other examples, the air cap 32 can be configured to rotatably fix the spray head 34 in a variety of orientations. For example, the spray head 34 can be mounted in two orientations 180 degrees apart to align it to produce the laterally extended spray jet.

[0062] The flow groove 104 is located in the cap body 76. In the example shown, the flow groove 104 is at least partially bounded by the head support 102. The flow groove 104 connects several of the blower openings 80 to receive the blower air. In the example shown, the inlet openings 110, which supply each of the blower openings 80, open into the flow groove 104 to receive blower air from the flow groove 104. In the example shown, the flow groove 104 extends completely in a ring around the body axis BA, although not all examples are bounded in this way. The flow groove 104 is open in the second axial direction AD2 to receive pressurized gases into the flow groove 104. The pressurized gases in the flow groove 104 are expelled through the blower opening 80.

[0063] The flange 84 is arranged on a radially outer side of the cap body 76. The flange 84 is configured to interact with the collar 18 so that the collar 18 can secure the air cap 32 to the spray gun 10. In the example shown, the air cap 32 incorporates a variety of flanges 84, but it is understood that not all examples are so limited.

[0064] The air cap 32 offers significant advantages. The air cap 32 is configured so that the blower openings 80 direct flows to surfaces 100a and 100b of the spray pattern. The blower openings 80 are larger than the edge openings 86, allowing them to deliver a larger flow of pressurized gas. This larger flow through the blower openings 80, directed towards the broad side of the spray pattern, facilitates more efficient atomization and shaping by the pressurized gases delivered by the air cap 32. The subgroup of openings 82a, 82b arranged on opposite sides of the spray plane SP direct the blower air in the direction of the width W and enable intuitive control, whereby an increase in the flow through the blower openings 80 increases the width W and a decrease in the flow through the blower openings 80 decreases the width W.The edge openings 86 are aligned in the direction of the pattern edges 98a, 98b and facilitate the mixing of the strips to achieve a smooth, uniform coating.

[0065] Fig. 6A is a cross-sectional view of the spray head 34. Fig. 6B is a side view of spray head 34. Fig. 6A and Fig. 6B are considered together. The spray head 34 comprises the head body 70, the opening 72, the head recess 74, the head dome 116, the holder 118 and the projection 120.

[0066] The spray head 34 receives a stream of spray liquid and releases the spray liquid as a spray mist that is at least partially atomized. In the example shown, the head body 70 consists of the head housing 122 and the head section 124. The head section 124 is arranged inside the head housing 122. The head section 124 is made of a hardened material, such as carbide, and other materials like metals, ceramics, and others. The holder 118 is arranged inside the head housing 122. The holder 118 can secure the head section 124 inside the head housing 122.

[0067] The spray head 34 is configured to be attached to the air cap 32. The spray head 34 can be rotatably attached to the air cap 32 to prevent rotation of the spray head 34 relative to the air cap 32 about the spray axis SA. In the example shown, the projection 120 extends from the head body 70. In the example shown, the projection 120 extends outward from an outer surface of the head housing 122. The projection 120 is configured to interact with a portion of the air cap 32 to fix the orientation of the spray head 34 relative to the air cap 32. In the example shown, the projection 120 is configured to be engaged by the positioning device 112 to align the spray head 34 relative to the air cap 32.

[0068] The head dome 116 is located at the downstream end of the head body 70. The head dome 116 has a convex outer surface, which may be partially spherical. The head recess 74 is formed in the head body 70. In the example shown, the head recess 74 is formed in the spray section 124. In the example shown, the head recess 74 is formed in the head dome 116.

[0069] The head recess 74 is elongated laterally. The head recess 74 can be formed as a cut in the head body 70. The head recess 74 can be formed as a V-shaped cut. The head recess 74 can be considered a cat's eye shape. The head recess 74 intersects with the opening 72, so that the coating liquid exiting through the opening 72 is sprayed through the head recess 74 and then out of the spray head 34.

[0070] During operation, the spray coating fluid flows through the spray head 18 from the upstream end to the opening 72. The spray fluid is ejected through the opening 72 and the head recess 74. The head recess 74 assists in the initial formation of the spray pattern, as the spray plane SP is formed by the head recess 74. The spray plane SP can extend laterally with the head recess 74. By aligning the head recess 74, the spray pattern emitted by the spray head 34 is aligned. The laterally elongated head recess 74 positions the spray plane SP between the subgroup of openings 82a and the subgroup of openings 82b, thus facilitating the pattern formation and atomization by the air emitted through the blower openings 80.

[0071] Fig. Figure 7 shows a spray coating SC1 applied to a surface by means of a conventional cap arrangement. Fig. Figure 8 shows a spray coating SC2 applied to a surface by the cap arrangement 16. Fig. 7 and Fig. 8 are considered together. In a conventional cap arrangement, the spray plane is aligned through each of the partial openings of the air cap and divides the partial openings. The spray plane extends between the tines and not through the tines. As in Fig. Figure 7 shows that the SC1 spray coating exhibits tails T1 and T2 at its edges. The SC1 spray coating was applied using pressurized gases at 6.2 bar (90 psi).

[0072] As in Fig.As shown in Figure 8, the SC2 spray coating applied by the cap assembly 16 contains no tails. The SC2 spray coating on the surface is a mixed, uniform, and smooth pattern. Furthermore, the SC2 spray coating offers greater coverage and a wider pattern than the SC1 spray coating. The SC2 spray coating was applied using pressurized gases at 2.1 bar (30 psi).

[0073] Unlike conventional air caps, where the spray plane is orthogonal to the spray plane SP of the cap assembly 16 and extends along the spray axis SA, the configuration of the cap assembly 16 facilitates intuitive pattern control and ensures uniform mixing and efficient pneumatic atomization of the coating fluid. With a conventional cap assembly, the pattern width decreases when the pressure of the pressurized gas is increased, while it increases when the pressure of the pressurized gas is decreased. The cap assembly 16 offers more intuitive control because increasing the pressure of the pressurized gas at the blower openings 80 increases the pattern width, and decreasing the pressure of the pressurized gas at the blower openings 80 decreases the pattern width.

[0074] If the blower openings 80 are oriented such that the outlets are perpendicular to the spray plane SP and the spray plane lies between and separates subgroups 82a and 82b, efficient atomization of the coating fluid is facilitated. The alignment of subgroups 82a and 82b with opposite surfaces 100a and 100b of the spray outlet facilitates efficient atomization and provides additional pneumatic atomization to the hydraulic atomization by the spray head 34. The cap arrangement 16 facilitates efficient mixing of the coating fluid to ensure a uniform, consistent coating. The cap arrangement 16 can enable efficient mixing at lower pressure, resulting in cost and material savings.

[0075] The edge openings 86 are aligned with the edges 98a and 98b of the spray pattern. The discharge from the edge openings 86 promotes blending at the pattern edges 98a and 98b, prevents the formation of streaks, and ensures a smooth, blended coating on the target surface.

[0076] The following is a summary of some aspects of the present revelation: 1. An air cap for a spray gun, wherein the air cap comprises: - a cap body with a central opening, wherein the central opening is arranged on a body axis of the cap body; - a multitude of projections extending from an outer surface of the cap body; and - a first set of passages extending through the cap body, wherein the first set of passages extends to a plurality of openings open on the outside, the plurality of openings comprising: - a first subgroup of openings arranged circumferentially between a first projection of the plurality of projections and a second projection of the plurality of projections, the first subgroup of openings being oriented such that it directs a first plurality of airflows towards the body axis and towards a first surface of the spray pattern; and - a second subset of openings arranged circumferentially between the first projection and the second projection, wherein the second subset of openings is opposite the first subset of openings, such that the second subset of components is oriented to direct a second plurality of airflows to the body axis and to a second surface of the spray pattern. 2. Air cap according to aspect 1, which also includes the following: - a first marginal opening formed in the first projection and oriented in the direction of the body axis, wherein the first marginal opening is configured to emit a first marginal flow in the direction of a first edge of the spray pattern. 3. Air cap according to aspect 2, which further includes the following - a second edge opening formed in the second projection and oriented in the direction of the body axis, wherein the second edge opening is configured to emit a second edge stream in the direction of a second edge of the spray pattern. 4. Air cap according to one of aspects 1-3, the first subgroup comprising openings: - a first side opening configured to output a first side stream; - a second side opening configured to discharge a second side stream; and - a first central opening configured to output a first central flow, the first central opening being located between the first side opening and the second side opening. 5. Air cap according to aspect 4, wherein the first central opening is configured to direct the first central flow to a first point along the body axis. 6. Air cap according to aspect 5, wherein the first side opening and the second side opening are configured to direct the first side flow and the second side flow to a second location along the body axis. 7. Air cap according to aspect 6, wherein the second position is axially further away from the central opening than the first position. 8. Air cap according to one of aspects 4-7, wherein the first central opening is oriented such that it discharges the first central flow axially along the body axis and radially inwards in the direction of the body axis. 9. Air cap according to one of aspects 4-8, wherein the first side opening is oriented such that it discharges the first lateral flow laterally inwards to the body axis, vertically to the body axis and axially along the body axis. 10. Air cap according to aspect 9, wherein the second side opening is oriented such that it discharges the second lateral flow laterally inwards towards the body axis, vertically towards the body axis and axially along the body axis. 11. Air cap according to one of aspects 4-10, wherein the first side opening and the second side opening are arranged opposite each other so that the first side stream and the second side stream cross each other. 12. Air cap according to one of aspects 4-10, wherein the first side opening is formed as a mirror image of the second side opening. 13. Air cap according to one of aspects 4-12, wherein the first central opening is radially offset from the first side opening and the second side opening. 14. Air cap according to aspect 13, wherein the first central opening is radially closer to the body axis than the first side opening and the second side opening. 15. Air cap according to one of aspects 4-14, wherein the first central opening is designed as an elongated opening. 16. Air cap according to one of aspects 4-15, wherein the first side opening is an elongated opening. 17. Air cap according to aspect 16, wherein the second side opening is an elongated opening. 18. Air cap according to one of aspects 4-17, the second subgroup comprising openings: - a third side opening configured to discharge a third side stream; - a fourth side port configured to discharge a fourth side stream; and - a second central opening configured to output a second central stream, the second central opening being located between the third side opening and the fourth side opening. 19. Air cap according to aspect 18, wherein the second central opening is configured to direct the second central flow to a third point along the body axis. 20. Air cap according to aspect 19, wherein the third side opening and the fourth side opening are configured to direct the third side flow and the fourth side flow to a fourth point along the body axis. 21. Air cap according to aspect 20, wherein the fourth position is axially further away from the central opening than the third position. 22. Air cap according to one of aspects 18-21, wherein the second central opening is oriented such that it discharges the second central flow axially along the body axis and radially inwards in the direction of the body axis. 23. Air cap according to one of aspects 18-22, wherein the third side opening is oriented such that it discharges the third side flow laterally inwards to the body axis, vertically to the body axis and axially along the body axis. 24. Air cap according to aspect 23, wherein the fourth side opening is oriented such that it discharges the fourth lateral flow laterally inwards to the body axis, vertically to the body axis and axially along the body axis. 25. Air cap according to one of aspects 18-24, wherein the third side opening and the fourth side opening are arranged opposite each other, so that the third side stream and the fourth side stream cross each other. 26. Air cap according to aspect 4, wherein: - the second subgroup of openings includes: - a third side opening configured to discharge a third side stream; - a fourth side port configured to discharge a fourth side stream; and - a second central opening configured to output a second central stream, the second central opening being arranged between the third side opening and the fourth side opening; and - the first central opening is arranged opposite the second central opening in such a way that the first central current is directed towards the second central current and the second central current is directed towards the first central current. 27. Air cap according to aspect 26, wherein the first side opening is arranged opposite the second side opening such that the first side flow is directed towards the second side flow and the second side flow is directed towards the first side flow. 28. Air cap according to one of aspects 26 and 27, wherein the first side opening is arranged opposite the third side opening, such that the first side stream is directed towards the third side stream and the third side stream is directed towards the first side stream. 29. Air cap according to one of aspects 26-28, wherein the first side opening is arranged opposite the fourth side opening, such that the first side stream is directed towards the fourth side stream and the fourth side stream is directed towards the first side stream. 30. Air cap according to one of aspects 26-29, wherein the first lateral opening is oriented to direct the first lateral flow to a second location along the body axis, the second lateral opening is oriented to direct the second lateral flow to the second location, the third lateral opening is oriented to direct the third lateral flow to the second location, and the fourth lateral opening is oriented to direct the fourth lateral flow to the second location. 31. Air cap according to aspect 30, wherein the first central opening is oriented to direct the first central flow to a first point along the body axis, and the second central opening is oriented to direct the second central flow to the first point. 32. The air cap of aspect 31, wherein the first position is arranged axially closer to the central opening than the second position. 33. Air cap according to one of aspects 26-32, wherein the first central opening radially overlaps the second central opening. 34. Air cap according to one of aspects 26-33, wherein the first side opening radially overlaps the third side opening. 35. Air cap according to one of aspects 26-34, wherein the second side opening radially overlaps the fourth side opening. 36. Air cap according to one of aspects 26-35, wherein the third side opening is formed as a mirror image of the fourth side opening. 37. Air cap according to one of aspects 26-36, wherein the second central opening is radially offset from the third side opening and the fourth side opening. 38. Air cap according to aspect 37, wherein the second central opening extends radially closer to the body axis than the third side opening and the fourth side opening. 39. Air cap according to one of aspects 26-38, wherein the second central opening is designed as an elongated opening. 40. Air cap according to one of aspects 26-39, wherein the third side opening is an elongated opening. 41. Air cap according to aspect 40, wherein the fourth side opening is an elongated opening. 42. Air cap according to one of aspects 1-41, furthermore encompassing: - a head mount configured to work in conjunction with a spray head to hold the spray head on the cap body. 43. Air cap according to aspect 42, wherein the head support extends at least partially around the body axis. 44. Air cap according to one of aspects 42 and 43, wherein the head support is designed as an axially projecting ring. 45. Air cap according to aspect 44, wherein the head mount includes a positioning device configured to interact with the spray head to prevent rotation of the spray head about the body axis. 46. ​​Air cap according to aspect 45, wherein the positioning device is designed as a recess in the ring. 47. Air cap according to one of aspects 42-46, further comprising a flow groove extending into an inside of the cap body, wherein the flow groove is in fluid communication with several passages of the plurality of passages, wherein the flow groove is at least partially defined by the positioning device. 48. Air cap according to one of aspects 1-46, further comprising a flow groove extending into an inside of the cap body, the flow groove being in fluid communication with several channels of the plurality of channels. 49. Air cap according to aspect 48, wherein the flow groove is in fluid contact with each pass of the plurality of passes. 50. Air cap according to one of aspects 48 and 49, wherein the flow groove extends completely in a ring shape around the body axis. 51. Air cap according to one of aspects 48-50, wherein each passage of the multitude of passages through a bottom of the flux groove is open. 52. Air cap according to one of aspects 1-51, wherein: - the outer side has a first inclined section with a first surface directed towards the body axis and a second inclined section with a second surface directed towards the body axis; - the first subgroup of openings is formed at least partially through the first surface; and - the second subgroup of openings is formed at least partially through the second surface. 53. Air cap according to one of aspects 1-52, wherein: - each opening of the first subgroup of openings extends between a first opening inlet and a first opening outlet, the first opening outlet being formed by the outside; - each opening of the second subgroup of openings extends between a second opening inlet and a second opening outlet, the second opening outlet being formed through the outside. 54. Air cap according to aspect 53, wherein the first opening inlet of a first opening of the first subgroup of openings is arranged radially further away from the body axis than the first opening outlet of the first opening. 55. A spray cap assembly for use with a spray gun, the spray cap assembly comprising: - a spray head including: - a head body with a spray opening formed within it; and - a head recess formed in the head body, wherein the head recess extends laterally, so that a spray pattern emitted from the spray head is laterally elongated, with the spray opening opening into the head recess; and - an air cap consisting of: - a cap body that carries the spray head, wherein the cap body has a central opening that is arranged on a body axis of the cap body; - a multitude of projections extending from an outer surface of the cap body; and - a first set of passages extending through the cap body, wherein the first set of passages extends to a plurality of openings open on the outside, the plurality of openings comprising: - a first subgroup of openings arranged circumferentially between a first projection of the plurality of projections and a second projection of the plurality of projections; and - a second subgroup of openings arranged circumferentially between the first projection and the second projection; wherein the first subgroup of openings is oriented such that it directs a first plurality of airflows towards the body axis and towards a first broad area of ​​the spray pattern; and wherein the second subgroup of openings is opposite the first subgroup of openings, such that the second subgroup of components is oriented such that a second plurality of airflows is directed towards the body axis and towards a second broad area of ​​the spray pattern. 56. Spray cap arrangement according to aspect 55, wherein the head recess is designed as a V-cut. 57. Spray cap arrangement according to one of aspects 55 and 56, wherein the head recess is formed in a curved outer surface of the head body. 58. Spray cap arrangement according to one of aspects 55-57, wherein the spray head is rotatably locked to the cap body to prevent rotation of the spray head about the body axis. 59. Spray cap arrangement according to aspect 58, wherein the spray head is rotatably locked to the cap body by a projection which extends into a recess. 60. Spray cap arrangement according to aspect 59, wherein the projection extends from the head body and the recess is formed in the cap body. 61. Method for spraying a coating liquid, the method comprising: - Dispensing the coating liquid through a spray head, wherein the spray head atomizes the coating liquid into a jet of liquid shaped to have a width between a first pattern side and a second pattern side and a thickness between a first pattern side and a second pattern side, the width being greater than the thickness; - Release of pressurized gases through an air cap and in the direction of the spray pattern, so that: - a first part of the pressurized gas is released through a first plurality of openings and in the direction of the first pattern surface; and - a second part of the pressurized gas is released through a second plurality of openings and in the direction of the second pattern surface; and - Adjusting the flow rate of the first fraction of the pressurized gas and the second fraction of the pressurized gas to change the width of the spray pattern, whereby increasing the flow rate of the first fraction of the pressurized gas and the second fraction of the pressurized gas increases the width and decreasing the flow rate of the first fraction of the pressurized gas and the second fraction of the pressurized gas decreases the width.

[0077] Although the invention has been described with reference to one or more exemplary embodiments, the person skilled in the art understands that various modifications can be made and equivalent elements replaced by others without infringing the scope of the invention. Furthermore, many modifications can be made to adapt a particular situation or material to the teachings of the invention without departing from its essential scope. It is therefore intended that the invention is not limited to the particular embodiment(s) disclosed, but rather that the invention encompasses all embodiments that fall within the scope of the attached aspects. REFERENCE MARK LIST 10 spray gun 12 slope bodies 14 deduction 16 Cap Arrangement 18 collars 20 buttons 22 Liquid pipe arrangement 24 Trigger lock 26 handle 28 Front end 30 Rear end 32 air cap 34 spray head 36 Liquid pipe 38 lower fluid connection 40 upper fluid connection 42 Air connection 44 connection 46 Fluid valve 48 Auxiliary air valve 50 Blower air valve 52 Blower control valve 54 Air intake bore 56 movable valve element 58 Air valve bore 60 blower air bore 62 Auxiliary air bore 64 Flow channel 66 Flow channel 68 Air pipe 70 head bodies 72 spray opening 74 Head recess 76 cap bodies 78 Central opening 80 blower openings 82a-82b Subgroup of openings 84 flange 86 edge openings 88a-88b Central openings 90a-90d side openings 92a-92b Central currents 94a-94d Side currents 96 prongs 98a-98b Pattern borders 100a-100b Sample area 102 Head mount 104 River groove 106 Outside 108 blower passes 110 entrance openings 112 Positioning device 114a-114b Section 116 Dome 118 bracket 120 lead 122 Head housings 124 Head section AA Auxiliary air component BA body axis FA blower air proportion IF Inlet Airflow SA Spray Axle SO spray outlet SP spray plane W width QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] US 63 / 654,465

[0001] US 2021 / 037433

[0015]

Claims

[1] Air cap (32) for a spray gun (10), wherein the air cap (32) comprises: - a cap body (76) with a central opening (78), wherein the central opening (78) is arranged on a body axis (BA) of the cap body (76); - a multitude of projections (120) extending from an outer surface (106) of the cap body (76); and - a first set of passages extending through the cap body (76), wherein the first set of passages extends to a plurality of openings open on the outside (106), the plurality of openings comprising: - a first subgroup of openings (82a) arranged circumferentially between a first projection of the plurality of projections (120) and a second projection of the plurality of projections (120), the first subgroup of openings (82a) being oriented such that it directs a first plurality of airflows towards the body axis (BA) and towards a first surface (100a) of the spray pattern; and - a second subgroup of openings (82b) arranged circumferentially between the first projection and the second projection, wherein the second subgroup of openings (82b) is opposite the first subgroup of openings (82a) such that the second subgroup of components is oriented to direct a second plurality of airflows to the body axis (BA) and to a second surface (100b) of the spray pattern. [2] Air cap (32) according to claim 1, further comprising: - a first edge opening (86) formed in the first projection (120) and oriented in the direction of the body axis (BA), wherein the first edge opening (86) is configured to discharge a first edge flow in the direction of a first edge of the spray pattern. [3] Air cap (32) according to claim 2, further comprising the following - a second edge opening (86) formed in the second projection (120) and oriented in the direction of the body axis (BA), wherein the second edge opening (86) is configured to discharge a second edge stream in the direction of a second edge of the spray pattern. [4] Air cap (32) according to one of claims 1 to 3, wherein the first subgroup of openings comprises (82a): - a first side opening (90a) configured to output a first side stream (94a); - a second side opening (90b) configured to output a second side stream (94b); and - a first central opening (88a) configured to output a first central stream (92a), wherein the first central opening (88a) is arranged between the first side opening (90a) and the second side opening (90b). [5] Air cap (32) according to claim 4, wherein the first central opening (88a) is configured to direct the first central flow (92a) to a first point along the body axis (BA). [6] Air cap (32) according to claim 5, wherein the first side opening (90a) and the second side opening (90b) are configured to direct the first side flow (94a) and the second side flow (94b) to a second location along the body axis (BA). [7] Air cap (32) according to claim 6, wherein the second position is axially further away from the central opening (78) than the first position. [8] Air cap (32) according to one of claims 4 to 7, wherein the first central opening (88a) is oriented such that it discharges the first central flow (92a) axially along the body axis (BA) and radially inwards in the direction of the body axis (BA), and wherein the first side opening (90a) is oriented such that it discharges the first side flow (94a) laterally inwards in the direction of the body axis (BA), vertically in the direction of the body axis (BA) and axially along the body axis (BA). [9] Air cap (32) according to one of claims 4 to 8, wherein the first side opening (90a) and the second side opening (90b) are arranged opposite each other such that the first side flow (94a) and the second side flow (94b) cross each other. [10] Air cap (32) according to one of claims 4 to 9, wherein the first side opening (90a) is designed as a mirror image of the second side opening (90b). [11] Air cap (32) according to any one of claims 4 to 10, wherein the first central opening (88a) is radially offset from the first side opening (90a) and the second side opening (90b). [12] Air cap (32) according to claim 11, wherein the first central opening (88a) is radially closer to the body axis (BA) than the first side opening (90a) and the second side opening (90b). [13] Air cap (32) according to any one of claims 4 to 12, wherein: - the second subgroup of openings (82b) includes: - a third side opening (90c) configured to output a third side stream (94c); - a fourth side opening (90d) configured to output a fourth side stream (94d); and - a second central opening (88b) configured to output a second central stream (92b), the second central opening (88b) being arranged between the third side opening (90c) and the fourth side opening (90d); and - the first central opening (88a) is arranged opposite the second central opening (88b) such that the first central current (92a) is directed towards the second central current (92b) and the second central current (92b) is directed towards the first central current (92a). [14] Air cap (32) according to claim 13, wherein the first side opening (90a) is oriented such that it directs the first side flow (94a) to a second location along the body axis (BA), the second side opening (90b) is oriented such that it directs the second side flow (94b) to the second location, the third side opening (90c) is oriented such that it directs the third side flow (94c) to the second location, and the fourth side opening (90d) is oriented such that it directs the fourth side flow (94d) to the second location. [15] Air cap (32) according to claim 14, wherein the first central opening (88a) is oriented such that it directs the first central flow (92a) to a first location along the body axis (BA), and the second central opening (88b) is oriented such that it directs the second central flow (92b) to the first location, and the first location is arranged axially closer to the central opening (78) than the second location. [16] Air cap (32) according to one of claims 1 to 15, further comprising a flow groove (104) extending into an inside of the cap body (76), wherein the flow groove (104) is in fluid communication with several channels of the plurality of channels. [17] Air cap (32) according to any one of claims 1 to 16, wherein: - the outer surface (106) has a first inclined section with a first surface directed towards the body axis (BA) and a second inclined section with a second surface directed towards the body axis (BA); - the first subgroup of openings (82a) is formed at least partially through the first surface (100a); and - the second subgroup of openings (82b) is formed at least partially through the second surface (100b). [18] Air cap (32) according to any one of claims 1 to 17, wherein: - each opening of the first subgroup of openings (82a) extends between a first opening inlet and a first opening outlet, the first opening outlet being formed by the outer surface (106); - each opening of the second subgroup of openings (82b) extends between a second opening inlet and a second opening outlet, the second opening outlet being formed through the outer surface (106). [19] Spray cap assembly (16) for use with a spray gun (10), the spray cap assembly (16) comprising: - a spray head (34) including: - a head body (70) with a spray opening (72) formed therein; and - a head recess (74) formed in the head body (70), wherein the head recess (74) extends laterally, so that a spray pattern emitted from the spray head (34) is laterally elongated, wherein the spray opening (72) opens into the head body (74); and - an air cap (32), consisting of: - a cap body (76) which carries the spray head (34), wherein the cap body (76) has a central opening (78), the central opening (78) being arranged on a body axis (BA) of the cap body (76); - a multitude of projections (120) extending from an outer surface (106) of the cap body (76); and - a first set of passages extending through the cap body (76), wherein the first set of passages extends to a plurality of openings open on the outside (106), the plurality of openings comprising: - a first subgroup of openings (82a) arranged circumferentially between a first projection of the plurality of projections (120) and a second projection of the plurality of projections (120); and - a second subgroup of openings (82b) arranged circumferentially between the first projection and the second projection; wherein the first subgroup of openings (82a) is oriented such that it directs a first plurality of airflows towards the body axis (BA) and towards a first broad area of ​​the spray pattern; and wherein the second subgroup of openings (82b) is opposite the first subgroup of openings (82a) such that the second subgroup of components is oriented such that a second plurality of airflows is directed towards the body axis (BA) and towards a second broad area of ​​the spray pattern. [20] Method for spraying a coating liquid, the method comprising: - Dispensing the coating liquid through a spray head (34), wherein the spray head (34) atomizes the coating liquid into a liquid jet shaped such that it has a width (W) between a first pattern side and a second pattern side and a thickness (T) between a first pattern surface (100a) and a second pattern surface (100b), wherein the width (W) is greater than the thickness (T); - Release of pressurized gases through an air cap (32) and in the direction of the spray pattern, such that: - a first part of the pressurized gas is released through a first plurality of openings (80) and in the direction of the first pattern surface (100a); and - a second part of the pressurized gas is released through a second plurality of openings (80) and in the direction of the second pattern surface (100b); and - Adjusting the flow rate of the first fraction of the pressurized gas and the second fraction of the pressurized gas to change the width (W) of the spray pattern, wherein increasing the flow rate of the first fraction of the pressurized gas and the second fraction of the pressurized gas increases the width (W) and decreasing the flow rate of the first fraction of the pressurized gas and the second fraction of the pressurized gas decreases the width (W).

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