Fluid sprayer

Abstract

A spray control assembly includes a spray gun (24) fluidly and electrically connected to a module (26). The spray gun (24) is configured to output a spray of fluid for application on a substrate. A trigger (34) of the spray gun (24) is operatively connected to a controller to control actuation of a solenoid that is connected to a spray valve of the spray gun to actuate the spray valve open to cause spraying by the fluid sprayer. The pressurized spray fluid is provided to the module and flows through the module and downstream to the spray gun.

Description

[0001] FLUID SPRAYER

[0002] CROSS-REFERENCE TO RELATED APPLICATION(S)

[0003] This application claims priority to U.S. Provisional Application No. 63 / 526,904 filed July 14, 2023 and entitled “SPRAY SYSTEM,” and claims priority to U.S. Provisional Application No. 63 / 542,473 filed October 4, 2024 and entitled “SPRAY SYSTEM,” and claims priority to U.S. Provisional Application No. 63 / 622,258 filed January 18, 2024 and entitled “SPRAY GUN SYSTEM,” and claims priority to U.S. Provisional Application No. 63 / 565,352 filed March 14, 2024 and entitled “FLUID SPRAYER,” the disclosures of which are hereby incorporated by reference in their entireties.

[0004] BACKGROUND

[0005] This disclosure relates generally to fluid sprayers. More specifically, this disclosure relates to airless fluid sprayers.

[0006] Fluid sprayers include pumps that pressure spray fluid and drive the spray fluid to a nozzle for outputting the spray fluid as an atomized fluid spray. Fluid sprayers include spray guns that can be held and manipulated by the user. The spray gun includes an internal valve that controls flow of the pressurized fluid to the nozzle. A trigger controls actuation of the valve between open and closed states. Typically, the trigger is mechanically connected to the valve such that the user is required to physically displace the valve from the closed state to the open state. Displacing the valve to the open state requires the user to overcome the hydraulic pressure of the spray fluid, which can lead to user fatigue and inefficient spray operations.

[0007] SUMMARY

[0008] According to an aspect of the disclosure, a cartridge for use in a spray gun having a solenoid coil includes a cartridge body defining a fluid chamber and having an inlet and an outlet; a spray valve disposed within the cartridge body, the spray valve including an actuatable seal located fluidly between the inlet and the outlet; and a plunger that is connected to the spray valve, the plunger configured to be moved by an electromagnetic field generated by the solenoid coil to actuate the spray valve to an open state in which the inlet is fluidly connected to the outlet. The cartridge body, the spray valve, and the plunger are integrated into a unitary assembly that is insertable into the spay gun and removable from the spray gun as the unitary assembly.

[0009] According to an additional or alternative aspect of the present disclosure, a spray gun includes a gun body; a solenoid coil disposed within the gun body; a handle; a trigger; a spray valve, the spray valve including an actuatable seal located fluidly between an inlet and an outlet; a plunger, the plunger configured to be moved by an electromagnetic field generated by the solenoid coil; and a rod the connects between the spray valve and the plunger such that the electromagnetic field generated by the solenoid coil moving the plunger actuates the spray valve to one or both of an open state and a closed state, wherein the rod extends at least partially into the plunger.

[0010] According to another additional or alternative aspect of the present disclosure, a cartridge for use in a spray gun having a solenoid coil includes a cartridge body defining a fluid chamber and having an inlet and an outlet; a spray valve disposed within the cartridge body, the spray valve including an actuatable seal located fluidly between the inlet and the outlet; and a plunger that is connected to the spray valve and is at least partially disposed within a plunger chamber defined by a plunger guard of the cartridge body, the plunger configured to be moved by an electromagnetic field generated by the solenoid coil to actuate the spray valve to an open state in which the fluid chamber is fluidly connected to the outlet. The cartridge body, the spray valve, and the plunger are integrated into a unitary assembly that is insertable into the spay gun and removable from the spray gun as the unitary assembly.

[0011] According to yet another additional or alternative aspect of the present disclosure, a cartridge for use in a spray gun having a solenoid coil includes a cartridge body having an upstream end and a downstream end and defining a fluid chamber, wherein an inlet and an outlet are formed through the cartridge body; a spray valve disposed within the cartridge body, the spray valve including an actuatable seal located fluidly between the inlet and the outlet; a plunger that is connected to the spray valve and is at least partially disposed within a plunger chamber defined by a plunger guard of the cartridge body, the plunger configured to be moved by an electromagnetic field generated by the solenoid coil to actuate the spray valve to an open state in which the fluid chamber is fluidly connected to the outlet; and a rod extending between the plunger and the spray valve to connect the plunger to the spray valve. The cartridge body, the spray valve, and the plunger are integrated into a unitary assembly that is insertable into the spay gun and removable from the spray gun as the unitary assembly. The first distance setting an opening distance of the spray valve.

[0012] According to yet another additional or alternative aspect of the present disclosure, a cartridge for use in a spray gun having a solenoid coil includes a cartridge body having an upstream end and a downstream end and defining a fluid chamber, wherein an inlet and an outlet are formed through the cartridge body; a spray valve disposed within the cartridge body, the spray valve including an actuatable seal located fluidly between the inlet and the outlet; and a plunger that is connected to the spray valve and is at least partially disposed within a plunger chamber defined by a plunger guard of the cartridge body, the plunger configured to be moved by an electromagnetic field generated by the solenoid coil to actuate the spray valve to an open state in which the fluid chamber is fluidly connected to the outlet. The plunger guard includes a flux permeability zone and a flux reluctance zone, wherein the flux permeability zone is formed of a first type of material and the flux reluctance zone is formed by a second type of material which makes the flux permeability of the flux permeability zone greater than the flux permeability of the flux reluctance zone. The plunger radially overlaps with the flux permeability zone and the flux reluctance zone. The cartridge body, the spray valve, and the plunger are integrated into a unitary assembly that is insertable into the spay gun and removable from the spray gun as the unitary assembly.

[0013] According to yet another additional or alternative aspect of the present disclosure, a method of setting an opening distance of a spray valve of a cartridge for use in a spray gun includes placing a plunger of a solenoid on a rod, the rod extending between the spray valve and the plunger; positioning the plunger at a set location along the rod to set a displacement distance of the solenoid, thereby setting an opening distance of the spray valve; and fixing the plunger and the rod together with the plunger at the set location.

[0014] According to yet another additional or alternative aspect of the present disclosure, a spray gun includes a gun body; a solenoid coil disposed within the gun body; a handle; a trigger; a valve housing supported by the gun body and within which the solenoid coil is at least partially disposed, the valve housing comprising a fluid receiver configured to receive spray fluid; and a coil housing mounted to the fluid receiver, the coil housing supporting the solenoid coil, wherein the coil housing extends into the fluid receive to connect to the fluid receiver; a spray valve, the spray valve including an actuatable seal located fluidly between an inlet and an outlet; and a plunger, the plunger configured to be moved by an electromagnetic field generated by the solenoid coil such that the electromagnetic field generated by the solenoid coil moves the plunger to actuate the spray valve to an open state in which the inlet is fluidly connected to the outlet.

[0015] According to yet another additional or alternative aspect of the present disclosure, a spray gun includes a gun body; a solenoid coil disposed within the gun body; a handle; a trigger; a valve housing supported by the gun body and within which the solenoid coil is at least partially disposed; a spray valve, the spray valve including an actuatable seal located fluidly between an inlet and an outlet; and a plunger, the plunger configured to be moved by an electromagnetic field generated by the solenoid coil such that the electromagnetic field generated by the solenoid coil moves the plunger to actuate the spray valve to an open state in which the inlet is fluidly connected to the outlet. The solenoid coil is axially and radially captured between an outer notch of the valve housing and in inner notch of the valve housing.

[0016] According to yet another additional or alternative aspect of the present disclosure, a spray system that outputs spray fluid through a hose having a fitting includes a spray gun, the spray gun comprising a valve, an electric actuator which actuates the valve, a handle, a trigger, and a sensor that senses actuation of the trigger; a battery; and an assembly controller configured to: receive electrical energy from the battery; in a gun pairing mode, transmit a unique identifier; receive a signal from the sensor indicating actuation of the trigger; deliver electrical energy to the electric actuator based on the signal; and based on the signal, transmit a command together with the unique identifier.

[0017] According to yet another additional or alternative aspect of the present disclosure, a spray system that outputs spray fluid through a hose having a fitting includes a spray gun, the spray gun comprising a valve, an electric actuator which actuates the valve, a handle, a trigger, and a sensor that senses actuation of the trigger; a battery; an assembly controller configured to: receive electrical energy from the battery; receive a signal from the sensor indicating actuation of the trigger; deliver electrical energy to the electric actuator based on the signal; and based on the signal, transmit a command; a pump; an electric motor configured to operate the pump; and a sprayer controller configured to: receive the command; and either start or stop the electric motor by changing a threshold pressure setpoint.

[0018] According to yet another additional or alternative aspect of the present disclosure, a spray system includes a spray gun, the spray gun comprising a valve, an electric actuator which actuates the valve, a handle, a trigger, and a sensor that senses actuation of the trigger; a battery; an assembly controller configured to: receive electrical energy from the battery; in a gun pairing mode, transmit a unique identifier to a sprayer controller of a pumping assembly; receive a signal from the sensor indicating actuation of the trigger; deliver electrical energy to the electric actuator based on the signal; and based on the signal, transmit a spray command, the spray command including spray instructions and the unique identifier; the pumping assembly comprising: a pump; an electric motor configured to operate the pump; and the sprayer controller configured to: in a sprayer pairing mode receive the unique identifier; and store, in a memory of the sprayer controller, the unique identifier as a command identifier; receive the spray command; and either start or stop the electric motor based on a comparison of the unique identifier of the spray command and the command identifier.

[0019] According to yet another additional or alternative aspect of the present disclosure, a pumping assembly for a spray system includes a pump; an electric motor configured to operate the pump; and a sprayer controller configured to: control operation of the electric motor to start or stop pumping by the pump based on a target pressure setpoint; adjust a value of the target pressure setpoint to a remapped pressure setpoint to stop the electric motor and stop pumping by the pump, wherein the remapped pressure setpoint is generated based on a measured pressure.

[0020] According to yet another additional or alternative aspect of the present disclosure, a spray system includes a spray gun, the spray gun comprising a valve, an electric actuator which actuates the valve, a handle, a trigger, and a sensor that senses actuation of the trigger; a battery; an assembly controller configured to: receive electrical energy from the battery; receive a signal from the sensor indicating actuation of the trigger; and deliver electrical energy to the electric actuator based on the signal; and a pumping assembly comprising: a pump; an electric motor configured to operate the pump; and a sprayer controller configured to start or stop the electric motor, the sprayer controller configured to control operation of the electric motor based on a threshold pressure setting. The assembly controller is configured to provide a pressure adjustment command to the sprayer controller. The sprayer controller is configured to change the target pressure setpoint based on the pressure adjustment command.

[0021] According to yet another additional or alternative aspect of the present disclosure, a spray control assembly for use with a pumping assembly that outputs spray fluid through a supply hose having a fitting includes a spray gun, the spray gun comprising a spray valve, an actuator which actuates the spray valve, a handle, a trigger, and a sensor that senses actuation of the trigger; a conduit, the conduit comprising at least one hose and at least one electrical conductor, the conduit having a far end and a near end, the far end connected to the spray gun to deliver spray fluid to the spray valve and electrical energy to the actuator; and a module comprising: an inlet fitting configured to attach to the fitting of the supply hose to receive spray fluid into the module from the sprayer pump; a battery; a module housing; and an assembly controller at least partially located within the module housing, the assembly controller configured to: receive electrical energy from the battery; receive a signal from the sensor indicating actuation of the trigger; and deliver electrical energy to the actuator via one or more of the at least one electrical conductor of the conduit.

[0022] According to yet another additional or alternative aspect of the present disclosure, a spray control assembly for use with a pumping assembly that outputs spray fluid through a supply hose having a fitting includes a spray gun, the spray gun comprising a spray valve, an actuator which actuates the spray valve, a handle, a trigger, and a sensor that senses actuation of the trigger; a conduit, the conduit comprising at least one hose and at least one electrical conductor, the conduit having a far end and a near end, the far end connected to the spray gun to deliver spray fluid to the spray valve and electrical energy to the actuator; and a module comprising: an inlet fitting configured to attach to the fitting of the supply hose to receive spray fluid into the module from the sprayer pump; a battery; a module housing; and an assembly controller at least partially located within the module housing, the assembly controller configured to: receive electrical energy from the battery; receive a signal from the sensor indicating actuation of the trigger; and deliver electrical energy to the actuator via one or more of the at least one electrical conductor of the conduit. The module does not include a pump.

[0023] According to yet another additional or alternative aspect of the present disclosure, a spray control assembly for use with a pumping assembly that outputs spray fluid through a supply hose having a fitting includes a spray gun, the spray gun comprising a spray valve, an actuator which actuates the spray valve, a handle, a trigger, and a sensor that senses actuation of the trigger; a conduit, the conduit comprising at least one hose and at least one electrical conductor, the conduit having a far end and a near end, the far end connected to the spray gun to deliver spray fluid to the spray valve and electrical energy to the actuator; and a module comprising: a module body having a main housing and a module handle spaced from the main housing; an inlet fitting supported by the module body and configured to attach to the fitting of the supply hose to receive spray fluid into the module from the sprayer pump; a battery supported by the module body; and an assembly controller at least partially located within the module housing, the assembly controller configured to: receive electrical energy from the battery; receive a signal from the sensor indicating actuation of the trigger; and deliver electrical energy to the actuator via one or more of the at least one electrical conductor of the conduit. A flowpath extends through the handle such that the spray fluid received through the inlet fitting flows within the module handle between the inlet fitting and the conduit. Dd According to yet another additional or alternative aspect of the present disclosure, a spray control assembly for use with a pumping assembly that outputs spray fluid through a supply hose having a fitting includes a spray gun, the spray gun comprising a spray valve, an actuator which actuates the spray valve, a handle, a trigger, and a sensor that senses actuation of the trigger; a conduit, the conduit comprising at least one hose and at least one electrical conductor, the conduit having a far end and a near end, the far end connected to the spray gun to deliver spray fluid to the spray valve and electrical energy to the actuator; and a module comprising: a module body; a filter manifold supported by the module body, the filter manifold at least partially disposed within the module body and including a filter housing and a filter within the filter housing; an inlet fitting supported by the filter housing and configured to attach to the fitting of the supply hose to receive spray fluid into the filter manifold; a battery supported by the module body; and an assembly controller at least partially located within the module housing, the assembly controller configured to: receive electrical energy from the battery; receive a signal from the sensor indicating actuation of the trigger; and deliver electrical energy to the actuator via one or more of the at least one electrical conductor of the conduit.

[0024] According to yet another additional or alternative aspect of the present disclosure, a spray gun includes a gun body having a gun handle; a trigger; a solenoid coil within the gun body; a cartridge mountable to the spray gun, the cartridge comprising: a cartridge body defining a fluid chamber and having an inlet and an outlet; a spray valve disposed within the cartridge body, the spray valve including an actuatable seal located fluidly between the inlet and the outlet; and a plunger that is connected to the spray valve, the plunger configured to be moved by an electromagnetic field generated by the solenoid coil to actuate the spray valve to an open state in which the inlet is fluidly connected to the outlet. The trigger remains stationary and during mounting and dismounting of the cartridge.

[0025] According to yet another additional or alternative aspect of the present disclosure, a spray gun includes a gun body having a gun handle; a trigger; a solenoid coil within the gun body; a cartridge mountable to the spray gun, the cartridge comprising: a cartridge body defining a fluid chamber and having an inlet and an outlet; a spray valve disposed within the cartridge body, the spray valve including an actuatable seal located fluidly between the inlet and the outlet; and a plunger that is connected to the spray valve, the plunger configured to be moved by an electromagnetic field generated by the solenoid coil to actuate the spray valve to an open state in which the inlet is fluidly connected to the outlet. All mechanical actuators for displacing the spray valve open and closed are part of the cartridge such that the mechanical actuators mount with the cartridge and dismount with the cartridge.

[0026] BRIEF DESCRIPTION OF THE DRAWINGS

[0027] FIG. 1 is a schematic block diagram of a spray system.

[0028] FIG. 2A shows a spray system.

[0029] FIG. 2B is an isometric view of a pumping assembly.

[0030] FIG. 3A is a block diagram illustrating a spray control assembly.

[0031] FIG. 3B is an isometric view of a spray control assembly.

[0032] FIG. 4A is an isometric view of a spray gun.

[0033] FIG. 4B is an isometric exploded view of the spray gun.

[0034] FIG. 5 is a cross-sectional view taken along line 5-5 in FIG. 4A.

[0035] FIG. 6A is a cross-sectional view showing fluid handling components of a spray gun.

[0036] FIG. 6B is an exploded view of the components shown in FIG. 6A.

[0037] FIG. 7 A is an isometric view of a mounting configuration for a plunger of a solenoid.

[0038] FIG. 7B is a cross-sectional view taken along line B-B in FIG. 7A.

[0039] FIG. 8 is an enlarged view of detail 8 in FIG. 6A.

[0040] FIG. 9 is a plot illustrating flow of electromagnetic flux.

[0041] FIG. 10 is an isometric view of a plunger assembly.

[0042] FIG. 11 is an isometric view of a plunger assembly.

[0043] FIG. 12A is a cross-sectional view showing fluid handling components of a spray gun.

[0044] FIG. 12B is an exploded view of the components shown in FIG. 12A.

[0045] FIG. 13 is a cross-sectional view showing fluid handling components of a spray gun.

[0046] FIG. 14A is a first isometric view of a module for a spray control assembly.

[0047] FIG. 14B is a second isometric view of the module.

[0048] FIG. 14C is a first isometric exploded view of the module.

[0049] FIG. 14D is a second isometric exploded view of the module.

[0050] FIG. 15 is a cross-sectional view taken along line 15-15 in FIG. 14A.

[0051] FIG. 16 is a cross-sectional view taken along line 16-16 in FIG. 14A.

[0052] FIG. 17 is an isometric view of a spray control assembly. FIG. 18A is an isometric view of a mount for a module.

[0053] FIG. 18B is a side elevational view of the mount of FIG. 18 A.

[0054] DETAILED DESCRIPTION

[0055] The present disclosure relates to spray systems. Spray systems according to the disclosure include a pump that pressurizes a spray fluid, such as paint, varnishes, lacquer, finishes, textures, adhesives, treatments, and other coatings, among other options, and drives the spray fluid through a conduit, such as a hose, to an applicator, such as a spray gun. The spray gun includes a spray valve that is actuatable between a closed state and an open state to control emission of spray fluid from the spray gun. A trigger of the spray gun is mechanically disconnected from the spray valve such that the spray gun does not mechanically displace the spray valve. An electric actuator, such as a solenoid, is connected to the spray valve to actuate the spray valve.

[0056] A spray control assembly is fluidly connected to the pump to receive fluid output by the pump. The spray gun of the spray control assembly is fluidly connected to a module of the spray control assembly. The fluid pumped by the pump can flow through the module and then downstream to the spray gun.

[0057] The spray gun can include a solenoid operatively connected to the spray valve to actuate the spray valve from the closed state to the open state. The spray gun includes a trigger that is operatively connected to the solenoid to cause actuation of the solenoid to cause actuation of the spray valve. The module of the spray control assembly can be electrically connected to the spray gun to provide electrical energy to the spray gun for powering the solenoid. The module can, in some examples, be configured to support one or more batteries for providing electrical energy.

[0058] The module can, in some examples, support a filter through which the spray fluid flows prior to flowing to the spray gun. The module can, in some examples, include a handle that can be grasped by a user. The handle can mount to a support clip to support the module during operation. The support clip can be configured to mount to the user, such as by a clip on a waistband or belt of the user.

[0059] The module can be fluidly and electrically connected to the spray gun by a conduit that extends between the module and the spray gun. The conduit includes a hose that conveys the spray fluid from the module to the spray gun. The conduit includes one or more conductive connectors, such as wires, that extend between the module and the spray gun to provide electrical connections between the module and the spray gun. The conduit can connect to the module at a rotationally restricted interface. The rotationally restricted interface prevents the conduit from completing full rotations relative to the module, protecting the conductive connectors and thus the electrical connectivity between the spray gun and the module. The rotationally restricted interface allows for come rotation of the conduit relative to the module, reducing stress in the conduit.

[0060] The spray gun can include a solenoid operatively connected to the spray valve to actuate the spray valve from the closed state to the open state. The spray valve can be disposed within a cartridge that is mountable to and dismountable from a body of the spray gun as a single unit. The cartridge can include electromagnetic components of the solenoid. In some examples, the cartridge can include a plunger of the solenoid that is caused to move due to electric current provided to a stator of the solenoid.

[0061] The solenoid plunger can be part of the cartridge that mounts to and dismounts from the gun body. The stator of the solenoid can remain mounted within and supported by the gun body with the cartridge dismounted from the gun body. The plunger can be at least partially disposed within a housing of the cartridge to protect the plunger. In some examples, the plunger can be fully enclosed within a housing of the cartridge.

[0062] The spray valve of the spray gun is configured to open a certain distance to provide quality sprays of the spray fluid. An travel distance for an armature of the solenoid can set the distance that the spray valve can open. The size of the axial gap can be set by fixing the plunger of the solenoid at a set location along a rod that connects the plunger to the spray valve.

[0063] The housing that at least partially encloses the plunger can be configured as a flux director. The housing can include a flux permeability zone configured to direct electromagnetic flux. The housing can include a flux resistance zone formed from non- ferric material. The flux permeability zone directs electromagnetic flux along an efficient flux path relative to the plunger to displace the plunger and thus cause opening of the spray valve.

[0064] A spray control assembly can be communicatively connected to a sprayer within a spray system. The communication can be wireless. The communication can be output from a spray gun or a module of the spray control assembly. The communication can be generated based on information generated at or by the spray gun or the module. The spray control assembly can, in some examples, be configured for one-way communications. In such an example, the spray control assembly can be configured to provide instructions to the sprayer, such as instructions regarding operation of the motor of the sprayer, instructions regarding pressure output from the pump, etc. The spray control assembly can be configured such that the spray control assembly cannot receive communications from the sprayer.

[0065] The spray control assembly and / or components of the spray control assembly (e.g., the spray gun and / or module) can be configured to pair with the sprayer. The pairing component can provide a unique identifier to the sprayer. The unique identifier can be stored in a memory of the sprayer as the command identifier for the spray control assembly. The sprayer can be configured to receive commands from the spray control assembly along with the unique identifier. The sprayer can control operation of the motor of the sprayer based on the command and based on the received unique identifier. Some examples of the sprayer can be configured to control operation of the electric motor based on sensed fluid parameters and / or reception of a command from the spray control assembly. For example, the sprayer can be configured to start or stop operation of the motor based on either a change in sensed pressure or reception of a command from the spray control assembly.

[0066] In some examples, the spray control assembly is configured to provide pressure commands to the sprayer. The pressure commands can cause the sprayer to adjust a target pressure setpoint for output by the pump of the sprayer. The spray control assembly can, in some examples, provide an adjustment command that causes the sprayer to incrementally adjust the target pressure setpoint. In some examples, the adjustment command is not associated with a pressure value; instead, the adjustment command causes an incremental adjustment of the target pressure setpoint regardless of the pressure value of the target pressure setpoint.

[0067] Components can be considered to radially overlap when those components are disposed at common axial locations along an axis. A radial line extending orthogonally from axis will extend through each of the radially overlapping components. Components can be considered to axially overlap when those components are disposed at common radial and circumferential locations relative to the axis. An axial line parallel to the axis will extend through the axially overlapping components. Components can be considered to circumferentially overlap when aligned about the axis, such that a circle centered on the axis passes through the circumferentially overlapping components.

[0068] FIG. 1 is a schematic block diagram of spray system 10. FIG. 2 shows a spray system 10. FIGS. 1 and 2 will be discussed together. Spray system 10 includes pumping assembly and spray control assembly 14. Pumping assembly 12 includes motor 16, stand 18, pump 20, and spray controller 22. Spray control assembly 14 includes spray gun 24, module 26, and conduit 28. Spray gun 24 includes gun body 30 having gun handle 32 and includes trigger 34, spray valve 36, solenoid 38, and nozzle 40. Module 26 includes module body 42 and assembly controller 44. Conduit 28 includes fluid hose 46, conductors 48, and sheath 50.

[0069] Spray system 10 is configured to generate pressurized flows of spray fluid and output the spray fluid as a fluid spray for spraying onto a substrate. Spray system 10 includes pumping assembly 12 that includes pump 20 that is configured to output the spray fluid under pressure. Motor 16, which can be an electric motor including a rotor and a stator, is operatively connected to pump 20 to cause pumping by pump 20. The motor 16 can be a rotor stator type electric motor, amongst other options. A drive system, such as an eccentric and crank, can convert rotational motion output by the motor 16 into linear reciprocating motor that drives a fluid displacer, such as a piston, of the pump 20. Stand 18 is configured to support other components of pumping assembly 12. Stand 18 can include legs and / or wheels, among other options.

[0070] The pumping assembly 12 can be a conventional sprayer. The pump 20 can be a piston -type pump that puts spray fluid under pressure for airless spraying (e.g., airless spray not using pressurized or flowing air to atomize paint), but could also be a diaphragm pump. Airless spraying is typically done between 500-7500 pounds per square inch (psi), and more typically between 800-3000 psi. The pump 20 is driven by motor 16. The pumping assembly 12 outputs the paint under pressure via a supply line 52. The pumping assembly 12 can draw the spray fluid from a fluid reservoir 21, such as formed by a bucket or other container.

[0071] Transducer 54 is shown. It is understood that transducer 54 may not be present in various examples. Transducer 54 is operatively associated with the spray fluid downstream of pump 20 and upstream of spray gun 24. Transducer 54 is configured to generate information regarding one or more properties of the spray fluid. In some examples, transducer 54 can be configured as a pressure sensor that is configured to generate information regarding a pressure of the spray fluid. In some examples, transducer 54 can be configured as a flow sensor configured to generate information regarding the flow of the spray fluid (e.g., flow rate among other options). It is understood that some examples that include transducer 54 can include both pressure and flow sensors, among other sensor options. Transducer 54 is configured to generate parameter information regarding a parameter of the spray fluid at a location downstream of the pump 20 and upstream of the nozzle 40. Spray controller 22 is configured to control operation of motor 16 to control output of pressurized spray fluid by pumping assembly 12. Spray controller 22 is operatively connected to other components of pumping assembly 12 to control operation of the other components of pumping assembly 12. Spray controller 22 is operatively connected to motor 16, electrically and / or communicatively, to control operation of motor 16. Spray controller 22 can be operatively connected to assembly controller 44, electrically and / or communicatively, to receive commands from spray control assembly 14. Spray controller 22 can be operatively connected to transducer 54 to receive parameter signals from transducer 54. For example, transducer 54 can be configured to provide pressure data, flow data, etc. to spray controller 22. The spray controller 22 can be configured to direct power to the electric motor 16 based on the parameter information generated by the transducer 54 and / or based on commands received from spray control assembly 14.

[0072] Spray controller 22 is configured to store software, implement functionality, and / or process instructions. Spray controller 22 is configured to perform any of the functions discussed herein, including receiving an output from any sensor referenced herein, detecting any condition or event referenced herein, and controlling operation of any components referenced herein. Spray controller 22 can be of any suitable configuration for controlling operation of components of pumping assembly 12, receiving signals from components of pumping assembly 12, gathering data, processing data, etc. Spray controller 22 can include hardware, firmware, and / or stored software, and spray controller 22 can be entirely or partially mounted on one or more circuit boards. Spray controller 22 can be of any type suitable for operating in accordance with the techniques described herein. While spray controller 22 is illustrated as a single unit, it is understood that spray controller 22 can be formed as multiple discrete controllers. In some examples, spray controller 22 can be implemented as a plurality of discrete circuity subassemblies.

[0073] Spray control assembly 14 is connected to pumping assembly 12 by supply line 52. Supply line 52 fluidly connects spray control assembly 14 to pumping assembly 12 such that spray control assembly 14 receives the pressurized spray fluid output by pump 20. Spray control assembly 14 does not include a pump. Spray control assembly 14 does not include components that move to put fluid under pressure, such as pistons or diaphragms.

[0074] The spray control assembly 14 can be worn by a user during spraying. For example, the module 26 can be worn via a strap 56 that attaches to the module 26. The module 26 can be worn in the manner of a belt or satchel via the strap 56 wrapping around the user, however other options are possible. The conduit 28 extends from the module 26 to the spray gun 24. The fluid hose 46 of the conduit 28 provides a flow passage for the flow of spray fluid, such as paint, from the module 26 to the spray gun 24. The conduit 28 can also include one or more conductors 48 that conduct signals and / or power between the module 26 and spray gun 24.

[0075] Module 26 is configured to connect to supply line 52 to receive the spray fluid output by pumping assembly 12. For example, module 26 can include an inlet fitting that attaches to the supply line 52 to mechanically and fluidly connect the module 26 to the supply line 52. During operation, paint can be drawn by suction into the pump 20 from a bucket or other reservoir and put under pressure by the pump 20 and then be output by the pump 20 and through the supply line 52 to the module 26. The spray fluid continues from module 26, through the conduit 28, and to the spray gun 24 where it is output into an atomized spray fan through nozzle 40 onto a wall or other targeted surface. It will be understood that many types of pumps and sprayers can be used with the spray control assembly 14.

[0076] Module 26 can be supported on the user by strap 56. The supply line 52 connects to module 26 to provide spray fluid to the spray control assembly 14. The supply line 52 connects to module 26 such that the weight of supply line 52 is carried by module 26. The weight of the supply line 52 is not transmitted through module 26 and up conduit 28 to be carried by the spray gun 24 and thus by the hand of the user. Instead, the weight of the supply line 52 is supported by module 26, which is supported on the user by strap 56. Such a configuration provides for easier and more ergonomic spraying by the user as the user is not required to carry and support the weight of the supply line 52 in the user’s hand. Such a configuration can be particularly useful when spraying in elevated locations such that the length of supply line 52 not on the ground and supported by the user increases which increases the weight of the supply line 52, such as when the user is on a ladder.

[0077] Module 26 receives the flow of spray fluid output by the pump 20. Conduit 28 extends between module 26 and spray gun 24. Sheath 50 encloses other components of conduit 28. Fluid hose 46 extends between module 26 and spray gun 24 to convey the spray fluid from module 26 to spray gun 24 under pressure. Conductors 48 extend between electrical components of spray gun 24 and module 26. Conductors 48 can be formed as wires, among other options. Conductors 48 are disposed external to fluid hose 46 and are not exposed to the spray fluid flowing within fluid hose 46 in the example shown. In the example shown, one more conductors 48 can extend between trigger 34 and assembly controller 44 and between solenoid 38 and assembly controller 44. Sheath 50 encloses conductors 48 and fluid hose 46. Conductors 48 are configured to transmit signals (communication and / or power) between module 26 and spray gun 24.

[0078] Spray gun 24 is configured to receive the pressurized fluid pumped by pump 20. The pressurized spray fluid flows through module 26 and conduit 28 prior to flowing to spray gun 24. The pressurized fluid flows through fluid hose 46 to spray gun 24 and is output from spray gun 24 through nozzle 40 as an atomized spray of the spray fluid. Spray gun 24 is operatively connected to assembly controller 44 for controlling emission of the spray fluid from spray gun 24.

[0079] Gun body 30 supports other components of spray gun 24. Gun handle 32 is formed as a projection that is configured to be grasped by a single hand of a user. Gun handle 32 can be formed integral with (e.g., monolithically) or separately from gun body 30.

[0080] Trigger 34 is operatively connected to assembly controller 44 to provide spray signals to the assembly controller 44. Trigger 34 is formed on a front side of gun handle 32. In the example shown, the trigger 34 is connected to assembly controller 44 by a wired connection through conduit 28. Actuation of the trigger 34 generates a spray signal that is transmitted to assembly controller 44 to cause the assembly controller 44 to initiate spraying by spray gun 24. Depressing the trigger 34 can cause the assembly controller 44 to direct power to the solenoid 38 to cause the solenoid 38 to open the spray valve 36. Upon release of the trigger 34, the assembly controller 44 can reduce power to the solenoid 38 to allow the spray valve 36 to close.

[0081] Nozzle 40 is configured to emit the spray fluid as an atomized fluid spray. Nozzle 40 forms the outlet of the spray gun 24 through which the spray fluid is sprayed. Nozzle 40 can be shaped to form the spray pattern emitted by spray gun 24.

[0082] Spray valve 36 is disposed within spray gun 24. Spray valve 36 is supported by gun body 30. Spray valve 36 is disposed upstream of nozzle 40. Spray valve 36 is configured to control flow of the spray fluid to nozzle 40 for emission from spray gun 24. Spray valve 36 is actuatable between a closed state, in which spray valve 36 prevents the spray fluid from flowing to nozzle 40, and an open state, in which the spray fluid can flow through spray valve 36 to nozzle 40 for emission from the spray gun 24. The spray valve 36 includes an actuatable seal that can be moved to allow or prevent flow of spray fluid through spray valve 36.

[0083] Solenoid 38 is operatively connected to spray valve 36 to control actuation of the spray valve 36 between closed and open states. For example, an armature of the solenoid 38 can be connected to a movable component of the spray valve 36 such that movement of the armature causes movement of valving components of the spray valve 36. Solenoid 38 can be configured as a single-acting solenoid that displaces the spray valve 36 from one state to the other (e.g., from the closed state to the open state) or a double-acting solenoid that displaces the spray valve 36 from the open state to the closed state and from the closed state to the open state. Solenoid 38 can be operatively connected to module 26 via one or more conductors 48 to receive power and / or communication signals from module 26.

[0084] Power source 58 is configured to provide power to electric powered components of spray control assembly 14 (e.g., assembly controller 44 and solenoid 38). Power source 58 can be formed as an electric battery (e.g., rechargeable lithium ion based, among other options). Power source 58 can be supported by the module body 42. In some examples, the battery forming the power source 58 can be mounted externally on module body 42. In other examples the battery forming the power source 58 can be mounted internally to the module body 42. The battery forming the power source 58 can be a type commonly used with power tools, such as that used to power electric cordless drills.

[0085] Assembly controller 44 is operatively connected to other components of spray control assembly 14 to control operation of the other components of spray control assembly 14. Assembly controller 44 is operatively connected to trigger 34, electrically and / or communicatively, such as via conductors 48, to receive control signals from trigger 34. For example, trigger 34 can be configured to provide spray signals to assembly controller 44 to cause assembly controller 44 to cause opening of spray valve 36 to cause spraying by spray gun 24. Trigger 34 can be configured to provide spray signals to assembly controller 44 to cause assembly controller 44 to cause closing of spray valve 36 to stop spraying by spray gun 24. Assembly controller 44 is operatively connected to solenoid 38, electrically and / or communicatively, such as via conductors 48, to control activation of solenoid 38 and thereby control actuation of spray valve 36.

[0086] Assembly controller 44 is configured to store software, implement functionality, and / or process instructions. Assembly controller 44 is configured to perform any of the functions discussed herein, including receiving an output from any sensor referenced herein, detecting any condition or event referenced herein, and controlling operation of any components referenced herein. Assembly controller 44 can be of any suitable configuration for controlling operation of components of spray control assembly 14, receiving signals from components of spray control assembly 14, providing control signals to pumping assembly 12, gathering data, processing data, etc. Assembly controller 44 can include hardware, firmware, and / or stored software, and assembly controller 44 can be entirely or partially mounted on one or more circuit boards. Assembly controller 44 can be of any type suitable for operating in accordance with the techniques described herein.

[0087] Control circuitry 60, in one example, is configured to implement functionality and / or process instructions. For example, control circuitry 60 can be capable of processing instructions stored in memory 62. Examples of control circuitry 60 can include one or more of a processor, a microprocessor, a controller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or other equivalent discrete or integrated logic circuitry. Control circuitry 60 can be entirely or partially mounted on one or more circuit boards.

[0088] Memory 62 can be configured to store information before, during, and / or after operation. Memory 62, in some examples, is described as computer-readable storage media. In some examples, a computer-readable storage medium can include a non- transitory medium. The term “non-transitory” can indicate that the storage medium is not embodied in a carrier wave or a propagated signal. In certain examples, a non-transitory storage medium can store data that can, over time, change (e.g., in RAM or cache). In some examples, memory 62 is a temporary memory, meaning that a primary purpose of memory 62 is not long-term storage. Memory 62, in some examples, is described as volatile memory, meaning that memory 62 does not maintain stored contents when power to assembly controller 44 is turned off. Examples of volatile memories can include random access memories (RAM), dynamic random access memories (DRAM), static random access memories (SRAM), and other forms of volatile memories. In some examples, memory 62 is used to store program instructions for execution by control circuitry 60. Memory 62, in one example, is used by software or applications to temporarily store information during program execution.

[0089] Memory 62, in some examples, also includes one or more computer-readable storage media. Memory 62 can be configured to store larger amounts of information than volatile memory. Memory 62 can further be configured for long-term storage of information. In some examples, memory 62 includes non-volatile storage elements. Examples of such non-volatile storage elements can include magnetic hard discs, optical discs, flash memories, or forms of electrically programmable memories (EPROM) or electrically erasable and programmable (EEPROM) memories.

[0090] The assembly controller 44 can include any type of circuit, such as programmable circuit, integrated circuit, or logic array, and other supporting circuitry to carry out any of the functions referenced herein. For example, assembly controller 44 can receive power from the power source 58 and can supply electrical energy to the spray gun 24 via one or more conductors 48. To control the solenoid 38 of the spray gun 24, as further discussed herein, the assembly controller 44 can receive one or more signals to indicate actuation of the trigger 34 and the need to provide power to the solenoid 38 to open and close the spray valve 36 based on whether the trigger 34 is actuated or released. In some examples, assembly controller 44 can be communicatively connected to spray controller 22, such as by communications circuitry. For example, the communications circuitry can be configured for wireless communications with spray controller 22 to facilitate spray control assembly 14 communicating with pumping assembly 12. The assembly controller 44 can be configured for communicating in any wired or wireless manner with the pumping assembly 12. For example, assembly controller 44 can command pumping assembly 12 to operate its electric motor 16 in synchrony with the spray control assembly 14 such as by opening the spray valve 36 and starting the motor 16 in sequence or at the same time.

[0091] In some examples, assembly controller 44 is configured for one-way communication with spray controller 22. For example, assembly controller 44 can be configured to include a transmitter configured to output signals and spray controller 22 can be configured to include a receiver configured to receive the signals output by the assembly controller 44. The assembly controller 44 can be configured such that assembly controller 44 does not receive wireless communication signals. The assembly controller 44 can be configured such that assembly controller 44 cannot receive wireless communication signals. The assembly controller 44 can be configured such that assembly controller 44 can provide communications to spray controller 22 but such that assembly controller 44 does not receive communications from spray controller 22.

[0092] In some examples, the spray control assembly 14 is configured to operate in a gun pairing mode. The spray control assembly 14 can be placed in the gun pairing mode and the pumping assembly 12 can be placed in a sprayer pairing mode to pair spray control assembly 14 with pumping assembly 12. In the gun pairing mode, the spray control assembly 14 can communicate a unique identifier to the pumping assembly 12. The pumping assembly 12 receives the unique identifier and can store the unique identifier in a computer readable memory 62 of the spray controller 22 as a command identifier.

[0093] In some examples, the pumping assembly 12 can output information to the user indicating that the spray control assembly 14 has been paired with the pumping assembly 12. For example, the pumping assembly 12 can provide an output via a user interface of the pumping assembly 12, such as visually via a light, graphical user interface, etc. or audibly, such as via a speaker. In some examples, the pumping assembly 12 can be configured to transmit the information and provide the output via a remote user interface, such as via an application running on a tablet or smartphone, among other options.

[0094] In some examples, the pumping assembly 12 does not provide pairing communication back to the spray control assembly 14. As such, the spray control assembly 14 can be configured to operate by providing the unique identifier to the pumping assembly 12 without receiving confirmation back from the pumping assembly 12. The pairing mode can be considered to be a one-way pairing in such examples. The spray control assembly 14 is paired to the pumping assembly 12 such that the pumping assembly 12 can recognize communications from the spray control assembly 14 based on the command identifier; however, the pumping assembly 12 is not paired to the spray control assembly 14 such that the spray control assembly 14 does not know which pumping assembly 12 the spray control assembly 14 is paired with.

[0095] The user can operate the spray system 10 with spray control assembly 14 paired with pumping assembly 12. The spray control assembly 14 can output a command signal intended to cause the pumping assembly 12 to operate the motor 16 (e.g., starting or stopping). The spray control assembly 14 outputs the unique identifier of that spray control assembly 14 as part of the command signal to identify that the command signal was generated by the spray control assembly 14. The spray controller 22 can compare the received unique identifier with the stored command identifier to determine whether the spray controller 22 should take action. The spray controller 22 can be configured to take no action if the received unique identifier does not match the command identifier stored in the memory of the spray controller 22. The spray controller 22 can be configured to take action based on the command signal, such as by starting or stopping the electric motor 16, if the transmitted unique identifier matches the command identifier stored in the memory of the spray controller 22.

[0096] In some examples, pulling of the trigger 34, as sensed by a sensor; such as a reed switch, proximity, hall effect, or other type of transducer which senses actuation of a trigger 34; directly starts the electric motor 16 of the pumping assembly 12. In some examples, release of the trigger 34, as sensed by the sensor, directly stops the electric motor 16 of the pumping assembly 12. For example, the assembly controller 44 can be configured to generate and provide a start command to the spray controller 22 based on the assembly controller 44 receiving a signal indicating actuation of the trigger 34. The assembly controller 44 can be configured to generate and provide a stop command to the spray controller 22 based on the assembly controller 44 receiving a signal indicating release of the trigger 34.

[0097] The user can cause the spray control assembly 14 to generate and send a start command signal based on the user actuating the trigger 34. The user actuating the trigger 34 can cause the sensor that senses actuation of the trigger 34 to generate a trigger actuated signal. The trigger actuated signal causes the assembly controller 44 to output the start command signal. The start command signal, which can include the unique identifier, is received by the pumping assembly 12. The pumping assembly 12 causes the electric motor 16 to start and run in response to the start command signal to cause pumping by the pump 20.

[0098] The user can cause the spray control assembly 14 to generate and send a stop command signal based on the user releasing the trigger 34. The user releasing the trigger 34 can cause the sensor that senses actuation and release of the trigger 34 to generate a trigger release signal. The trigger release signal causes the assembly controller 44 to output the stop command signal. The stop command signal, which can include the unique identifier, is received by the pumping assembly 12. The pumping assembly 12 causes the electric motor 16 stop in response to the stop command signal to stop pumping by the pump 20. It is understood that the trigger release signal can be a discrete signal generated on release of the trigger 34 or can be cessation of the trigger actuated signal.

[0099] In the pairing mode, the pumping assembly 12 is configured to control operation of the electric motor 16 based on commands that include a transmitted unique identifier that matches the command identifier. Such a configuration allows for operation of spray system 10 without interference from other spray systems 10. For example, multiple spray systems 10 may be operating concurrently. A first of the spray systems 10 includes a first spray control assembly 14 including a first unique identifier and a second of the spray systems 10 includes a second spray control assembly 14 including a second unique identifier different from the first unique identifier. Both of the first and second spray control assemblies 14 are configured to output start and stop command signals. The first pumping assembly 12 is paired to the first spray control assembly 14 such that the first pumping assembly 12 is responsive to commands including the first unique identifier. The second pumping assembly 12 is paired to the second spray control assembly 14 such that the second pumping assembly 12 is responsive to commands including the second unique identifier.

[0100] The first pumping assembly 12 and second pumping assembly 12 can receive the command signals output by both the first spray control assembly 14 and the second spray control assembly 14. However, the first pumping assembly 12 and second pumping assembly 12 are responsive only to those command signals that include a transmitted unique identifier that matches the command identifier associated with that pumping assembly 12. As such, the first pumping assembly 12 responds to command signals including the first unique identifier but not to communications including the second unique identifier while the second pumping assembly 12 responds to command signals including the second unique identifier but not to communications including the first unique identifier.

[0101] In some examples, the pumping assembly 12 is configured to operate in a dual control mode with spray system 10 in the pairing mode. In such a configuration, the pumping assembly 12 is configured to control operation of the motor 16 based on control signals from the spray control assembly 14 and based on signals from the transducer 54. For example, the pumping assembly 12 can be configured to start operation of the motor 16 based on receipt of a start command signal from the spray control assembly 14 or based on the transducer 54 indicating a drop in pressure, which drop in pressure indicates that the spray valve 36 is open for spraying by the spray gun 24. The pumping assembly 12 can be configured to stop operation of the motor 16 based on receipt of a stop command signal from the spray control assembly 14 or based on the transducer 54 indicating a rise in pressure, which rise in pressure indicates that the spray valve 36 is closed to stop spraying by spray gun 24. Such a configuration provides reliable operation of spray system 10 even if the spray control assembly 14 becomes communicatively disconnected from the pumping assembly 12.

[0102] In some examples, releasing of the trigger 34, as sensed by the sensor, does cause the electric motor 16 of the pumping assembly 12 to stop, but it does so by changing the target pressure. The target pressure setting is a pressure by which the spray controller 22 of the pumping assembly 12 decides when to turn on and turn off the electric motor 16. The target pressure setting can be provided to the spray controller 22 by the user, such as via a user interface of the pumping assembly 12. For example, when the sensed pressure, as measured by transducer 54 of the pumping assembly 12 at a location downstream of the pump 20, is below the target pressure setting, the spray controller 22 starts and / or continues spinning of the electric motor 16 to operate the pump 20. When the sensed pressure is above the target pressure setting, the spray controller 22 of the pumping assembly 12 stops the electric motor 16 to cease operation of the pump 20.

[0103] In various examples, the spray controller 22 receives a command indicating actuation of the trigger 34, such as sensed by the trigger sensor and communicated by the assembly controller 44, and in response the spray controller 22 changes the target pressure setting based on the currently sensed or measured pressure. For example, the spray controller 22 can be configured to set the target pressure setting based on pressure information generated by transducer 54. The spray controller 22 can be configured to remap the target pressure setting to generate a remapped pressure setpoint, which remapped pressure setpoint can be set as the currently sensed pressure, approximately the currently measured pressure, slightly above the currently measured pressure, slightly below the currently measured pressure, within a variance of the currently sensed pressure (e.g., such as within 10 pounds per square inch (psi)), etc. In such a configuration, the spray controller 22 can be configured to control operation of the electric motor 16 to run the electric motor 16 based on the target pressure setting during spraying such that the pump 20 is operated to drive to the target pressure setting and the spray controller 22 can be configured to control operation of the electric motor 16 to stop the electric motor based on a remapped pressure setpoint. The remapped pressure setpoint can be based on the sensed pressure when a stop control command is received by the pumping assembly 12.

[0104] Such a configuration causes a softer stop of the electric motor 16 which can minimize ramping or blasting of pressure because, when under free flow (when the trigger 34 is actuated), the sensed pressure is typically below the target pressure setpoint, such that if the trigger 34 is released and the spray valve 36 of the spray gun 24 closes, the algorithm would still instruct electric motor 16 to operate until the actual pressure reaches the target pressure setpoint, which target pressure setpoint is higher than the actual spraying pressure. Then, upon resumption of spraying by pulling of the trigger 34, the spray fluid would be at a higher pressure when initially exiting the spray gun 24 until the pressure lowers down to the pressure of free flow as previously mentioned. This can cause undesirable blasting of paint and / or spraying at multiple different pressures, particularly when the spray valve 36 of the spray gun 24 is first opened until a steady pressure is reached. Accordingly, setting the remapped pressure setpoint based on the currently sensed pressure results in immediate or near immediate cessation of the electric motor 16 without ramping up in pressure, thus avoiding a pressure blast on the next retriggering. Stopping the motor 16 based on the remapped pressure setpoint can allow the pressure in supply line 52 and through spray controller 22 assembly to even out, preventing large swings in pressure during spraying. In some examples, the spray controller 22 can be configured to restart motor 16 based on the sensed fluid pressure dropping below the remapped pressure setpoint. The spray controller 22 can then control operation of the motor 16 based on the target pressure setpoint while running the motor 16.

[0105] The pressure setpoint can be reset to an original input value (e.g., the target pressure setpoint) based on detection triggering by the sensor, and as communicated back to the spray controller 22. As such, in some examples, pulling of the trigger 34, as sensed by the trigger sensor, does cause the electric motor 16 of the pumping assembly 12 to start, but does so by changing the pressure setpoint, not by directly turning on the motor 16 without checking the sensed pressure. Further, release of the trigger 34, as sensed by the trigger sensor, does cause the electric motor 16 of the pumping assembly 12 to stop, but does so by changing the pressure setpoint, not by directly turning off the motor 16.

[0106] The spray controller 22 can be considered to remap the pressure setpoint during operation. The initial set pressure is a target pressure setpoint at which the spray controller 22 controls operation of the pump 20 to drive the spray fluid to the target pressure. The spray controller 22 causes the motor 16 to run to cause the pump 20 to pump the spray fluid to drive the sensed pressure, as indicated by the transducer 54, to the target pressure setpoint. For example, the spray controller 22 can cause the motor 16 to run and control operation of the motor 16 based on the target pressure setpoint when the spray controller 22 receives the start command signal.

[0107] The spray controller 22 can then change the pressure setpoint to generate a remapped pressure setpoint based on receipt of the stop command signal. As discussed above, the remapped pressure setpoint is utilized by the spray controller 22 for stopping of the electric motor 16. In some examples, the remapped pressure setpoint can be used for starting of the electric motor 16 based on receipt of another start command signal. The remapped pressure setpoint is less than the target pressure setpoint. The remapped pressure setpoint is set based on the sensed pressure when the stop command signal is received by the spray controller 22.

[0108] In some additional or alternative examples, the spray control assembly 14 is configured to generate and send a pressure adjust signal to the pumping assembly 12. The pressure adjust signal is communicated to the spray controller 22 and is configured to change a target pressure setting of the pumping assembly 12, which target pressure setting can set the pressure that the spray controller 22 runs the motor 16 to achieve during spraying. The pressure adjust signals can increase and decrease the target pressure setpoint that corresponds with a setting on the pumping assembly 12 in which the electric motor 16 is started when the fluid pressure, as measured downstream of the pump 20, falls below the set pressure, and the electric motor 16 is stopped when the measured pressure meets and / or exceeds the set pressure.

[0109] Providing a first input to the spray control assembly 14, such as via a user interface of the spray control assembly 14 (e.g., on spray gun 24 or on module 26) can increase the target pressure setpoint and providing a second input to the spray control assembly 14 can decrease the target pressure setpoint. Actuating the first input can cause the spray control assembly 14 to generate and transmit a pressure increase signal to the spray controller 22. The pressure increase signal can cause the spray controller 22 to increase the target pressure setpoint. The second input can cause the spray control assembly 14 to generate and transmit a pressure decrease signal to the spray controller 22. The pressure decrease signal can cause the spray controller 22 to decrease the target pressure setpoint. Such commands to increase or decrease the pressure setting can be sent wirelessly as described herein. The user inputting pressure adjust signals at spray control assembly 14 allows for quick and easy adjustment of the target pressure setpoint from the spray control assembly 14 without having to interface directly with the pumping assembly 12.

[0110] In some examples, the pressure adjust signals are configured to cause incremental adjustment of the target pressure setpoint. The pressure adjust signals may not be associated with a particular pressure value (e.g., setting to 500psi, lOOOpsi, 2000psi, etc.); instead, the pressure adjust signals cause an incremental adjustment of the target pressure setpoint regardless of the actual value of the target pressure setpoint. For example, the pressure adjust signals can cause the target pressure setpoint to adjust by a percentage of the target pressure setpoint (e.g., a 1%, 5%, or other percentage amount), by a certain pressure value (lOpsi every adjust, 25psi every adjust, etc.), etc. The pressure adjust signals incrementally adjusting the target pressure setpoint allow the user to easily adjust the target pressure setpoint during operation. The user is not required to input a new pressure value, but instead can provide minor adjustments to the spray pressure via the spray control assembly 14, which is located with and can be carried by the user. The user can adjust the target pressure setpoint during spraying to provide the desired spray pattern and coverage for the spray material. Such a configuration provides for quick and easy adjustment during spray operations and without interrupting spray operations.

[0111] FIG. 3A is a block diagram of a spray control assembly 14. FIG. 3B is an isometric view of spray control assembly 14. FIGS. 3A and 3B are discussed together. Spray gun 24, module 26, and conduit 28 of spray control assembly 14 are shown. Gun body 30 having gun handle 32, trigger 34, spray valve 36, solenoid 38, nozzle 40, and sensor 64 of spray gun 24 are shown. Module body 42, assembly controller 44, internal flowpath 66, inlet fitting 68, and filter manifold 70 of module 26 are shown. Fluid hose 46, conductors 48, and sheath 50 of conduit 28 are shown.

[0112] Module body 42 supports other components of module 26. Module body 42 can be a single piece or clamshell, amongst other options. In some examples, module body 42 is formed by multiple subparts. The module body 42 can be formed from a polymer and / or metal shell, amongst other options. Internal flowpath 66 is formed within module body 42. Internal flowpath 66 is configured to convey spray fluid through module body 42.

[0113] Module 26 can connect with a power source 58, such as a battery. In some examples, power source 58 mounts on an exterior of the module body 42, as shown in FIG. 3B. However, in some other examples, the power source 58 can be internal to the module body 42. In the illustrated example, the power source 58 slides along the module body 42 to lock to the module body 42 and can slide away to unlock from the module body 42. Both the power source 58 and the module 26 include terminals which make contact upon engagement of the power source 58 and the module body 42. Mounting of the power source 58 can form mechanical connections such that the power source 58 is supported by module 26 and can form electrical connections such that the power source 58 can provide electrical energy to the electrical components of spray control assembly 14. The power source 58 can be lithium-ion type or other type of battery. The power source 58 can be a type commonly used with power tools, such as that used to power electric cordless drills.

[0114] Filter manifold 70 is supported by module body 42. Filter manifold 70 includes a filter 72, such as a screen, that is configured to filter particulate from the spray fluid flowpath through module 26. The filter 72 is configured to filter the spray fluid prior to the spray fluid flowing downstream to spray gun 24. The filter 72 can be a mesh material through which the paint or other spray fluid can flow to filter out larger elements while letting smaller and / or more fluid elements to pass. The filter 72 can take various forms, such as the manner of a tube that filters paint introduced to the inside to the outside. The filter manifold 70 can be unthreaded from the module body 42 or other part of the module 26 to allow removal of the screen for cleaning and reassembly. In the example shown, the filter manifold 70 is at least partially outside of the module body 42 which allows for easy removal and cleaning or other servicing of the filter manifold 70, whereas the module body 42 is intended to remain closed for most or all the life of the module 26. The filter manifold 70 is structurally supported by the module body 42. The filter manifold 70 can be connected to module 26 at a location within module body 42, among other options. Inlet fitting 68 is configured to connect to a supply line 52 to connect module 26 to the supply line 52. The inlet fitting 68 can, in some examples, be threaded or quick disconnect type for connection with the supply line 52. In the example shown, the inlet fitting 68 is formed at an upstream end of the filter manifold 70. The spray fluid enters into spray control assembly 14 via inlet fitting 68 and flows through filter manifold 70 and internal flowpath 66 prior to flowing downstream via conduit 28 to spray gun 24 for spraying.

[0115] Internal flowpath 66 is disposed within module body 42 and is configured to receive the spray fluid output through filter manifold 70. The internal flowpath 66 is configured to convey the spray fluid to fluid hose 46. Internal flowpath 66 can be formed as a hose or block, amongst other options. In some examples, internal flowpath 66 is disposed within or formed by portions of filter manifold 70 downstream of filter 72. As depicted, the internal flowpath 66 can extend within the module body 42, though it is understood that in other examples an equivalent flow path is not within the module body 42.

[0116] Outlet fitting 74 is configured to connect with fluid hose 46 to provide spray fluid to fluid hose 46. Outlet fitting 74 is disposed within module body 42 in the example shown. The outlet fitting 74 can be a threaded or quick disconnect type connector which can attach to the fluid hose 46 at a near end 76 of the conduit 28. The fluid hose 46 of the conduit 28 can likewise include a quick disconnect or threaded type of fitting to connect with the outlet fitting 74 inside of the module body 42. Likewise, a far end 78 of the conduit 28 can extend into the gun body 30 to make fluid and electrical connections within the gun body 30. The spray control assembly 14 is intended to be used as an assembly of the module 26, the conduit 28, and the spray gun 24 and frequent disassembly is not anticipated or wanted, such that locating the fluid and electrical connections inside of the module body 42 and gun body 30 can protect these connections and make them more robust.

[0117] Assembly controller 44 is supported by module 26 in the example shown. Assembly controller 44 can be disposed within module body 42. As discussed above, the assembly controller 44 can include any type of circuit, such as programmable circuit, integrated circuit, or logic array, and other supporting circuitry to carry out any of the functions referenced herein. For example, assembly controller 44 can receive power from the power source 58 and can supply electrical energy to the spray gun 24 via one or more conductors 48. To control a solenoid 38 of the spray gun 24, as further discussed herein, the assembly controller 44 can receive one or more signals, such as from the sensor 64 associated with the trigger 34, to indicate actuation of the trigger 34 and the need to provide power to the solenoid 38 to open and close spray valve 36 based on whether the trigger 34 is actuated or released. Assembly controller 44 can also include components for communicating in any wired or wireless manner with the pumping assembly 12 in examples in which the pumping assembly 12 can be commanded to run or stop the motor 16 based on control signals from the assembly controller 44, as discussed above.

[0118] Spray gun 24 includes gun handle 32. Gun handle 32 can be considered to form a portion of gun body 30. It is understood that gun handle 32 can be formed integral with other portions of gun body 30, such as monolithically with those other portions, or can be formed separate from other portions of gun body 30 and connected to those portions, such as by interfaced threading among other options. In the example shown, the conduit 28 extends into the spray gun 24 through a bottom end of the gun body 30. In the example shown, the conduit 28 extends into the spray gun 24 through a bottom end of gun handle 32. It is understood, however, that conduit 28 can connect with other areas of spray gun 24 in various other examples. Gun handle 32 is intended to be gripped by a single hand of the user such that the spray gun 24 can be supported and used by the single hand of the user.

[0119] Spray gun 24 includes trigger 34. Trigger 34 is configured to be actuated by a single finger, or multiple fingers in some examples, to cause the spray gun 24 to spray when actuated and to stop spraying when released. As further shown herein, the trigger 34 does not mechanically directly open spray valve 36 inside the spray gun 24, but rather indirectly and electronically opens the spray valve 36 inside the spray gun 24 to control spraying.

[0120] Sensor 64 is configured to sense actuation and release of the trigger 34. Sensor 64 can be a proximity, hall effect, switch, or other type of transducer which senses actuation of a trigger 34 and release of the trigger 34. Sensor 64 can conduct one or more signals along the one or more conductors 48 to the assembly controller 44 to indicate actuation and release of the trigger 34. Although wired connection between the spray gun 24 and the module 26 are discussed herein, a wireless connection between the sensor 64 or other component of the spray gun 24 can be made with the assembly controller 44 of the module 26. In various other examples, part of assembly controller 44 can be within the gun body 30, however in the present example all of assembly controller 44 is located in the module 26.

[0121] The spray gun 24 includes a spray tip 80. The spray tip 80 can be rotatable, such as between a spray state and a de-clog state. The rotatable spray tip 80 can be a type that includes a barrel that can rotate within a tip guard of the spray gun 24. Rotation of the rotatable spray tip 80 reverses the flow of paint through the barrel of the rotatable spray tip 80 to remove clogs. Rotatable spray tip 80 can then be rotated back to its original position to resume spraying. Rotatable spray tip 80 includes the nozzle 40. It will be noted that not all embodiments may include a rotatable spray tip 80 but may nevertheless include nozzle 40.

[0122] In the example shown, spray gun 24 includes cartridge 82. The spray valve 36 is disposed within the cartridge 82. Cartridge 82 is configured to mount to and dismount from the gun body 30 as a single unit. In some examples, cartridge 82 can include portions of the solenoid 38 such that portions of the solenoid 38 mount with and dismount with cartridge 82. Nominally, the spray valve 36 within the cartridge 82 is closed to block paint passage until the solenoid 38 is electrically activated by the assembly controller 44 in response to sensing of actuation of the trigger 34 to open the spray valve 36 in the cartridge 82 to begin spraying fluid from the nozzle 40, until the trigger 34 is sensed to be released which causes the assembly controller 44 to cease, or otherwise reduce, delivery of electrical energy to the solenoid 38 which results in closure of the spray valve 36 within the cartridge 82. While spray gun 24 is described as including a cartridge 82, it is understood that not all examples are so limited. For example, spray valve 36 can be supported within gun body 30 and not within a cartridge 82.

[0123] Solenoid 38 is operatively connected to spray valve 36 and is configured to cause spray valve 36 to shift to an open state. It is understood that, in some examples, solenoid 38 can be configured to drive spray valve 36 to the open state and to a closed state. In other examples the solenoid 38 is configured to drive the spray valve 36 to the open state and a spring returns the spray valve 36 to the closed state.

[0124] Solenoid 38 includes a coil section 84. In examples including a cartridge 82, the coil section 84 can remain in the gun body 30 while another part of the solenoid 38 is located in the cartridge 82 and which can be removed from the gun body 30 for servicing, as further discussed herein. As such, the solenoid 38 can be distributed between various components which can be separated from each other.

[0125] Conduit 28 is configured to convey fluid and electrical signals between the module 26 and spray gun 24. Fluid hose 46 and conductors 48 are disposed within sheath 50 at locations between module 26 and spray gun 24. Fluid hose 46 is configured to provide a fluid connection between the module 26 and spray gun 24. Fluid hose 46 transports spray fluid under pressure from module 26 to the spray gun 24. A portion of the fluid hose 46 is located within the gun body 30, more specifically the gun handle 32 in this example, which can help protect the fittings. Spray fluid routed into the gun body 30 via the fluid hose 46 travels through a tube or other passage within the gun body 30 to cartridge 82 also within the gun body 30.

[0126] Conductors 48 are configured to provide electrical connections between module 26 and spray gun 24. The conductors 48 can conduct signals and / or power between the assembly controller 44, the sensor 64, and the solenoid 38, amongst other electrical components. The electrical connections made by the conductors 48 can be within the module body 42 of the module 26 and within the gun body 30 of the spray gun 24. A sheath 50 surrounds the one or more conductors 48 and the fluid hose 46 such that the component (e.g., conduit 28) that extends between the module 26 and the spray gun 24 appears as a single cord.

[0127] Conduit 28 extends from module 26. As previously mentioned, the conduit 28 can include fluid hose 46 and one or more electrical conductors 48, which extend from the module body 42 to the gun body 30. As shown, the conduit 28 extends from inside of the module body 42 outward, instead of the fittings or other connections with the conduit 28 being external to the module body 42. Such internal location of the fittings or other connections with the fluid hose 46 and / or electrical conductors 48 of the conduit 28 can help protect these components from the work environment and further reflect that disconnection is not necessary because it is anticipated that the spray gun 24 will remain attached to the module 26 via the conduit 28 for most if not all of the life of the spray control assembly 14 without breaking or making connections between fittings and electrical connections.

[0128] The conduit 28 extends to spray gun 24. In the example shown, the conduit 28 extends into the gun body 30 of the spray gun 24. The conduit 28 extends into the gun body 30 such that fittings and / or electrical connections of spray gun 24 with the conduit 28 are made internal of the gun body 30 and not external of the gun body 30.

[0129] Conduit 28 can extend from the interior of module 26 to the interior of spray gun 24. Conduit 28 can extend from the interior of module body 42 to the interior of gun body 30. The electrical conductors 48 and the fluid hose 46 can enter into the sheath 50 at a location within the module 26. The electrical conductors 48 and fluid hose 46 can exit from the sheath 50 at a location within the spray gun 24. Such a configuration protects the electrical and fluid connections between the module 26 and spray gun 24 as the fluid hose 46 and electrical conductors 48 are disposed within and protected by sheath 50 at locations outside of the module body 42 and gun body 30. During operation the spray control assembly 14 is configured to receive pressurized spray fluid through inlet fitting 68 and output a spray of the pressurized spray fluid through nozzle 40. The spray control assembly 14 does not include a pump in the example shown. No pump or other fluid mover is disposed in or supported by the module 26. No pump or other fluid mover is disposed in or supported by the spray gun 24. Instead, the spray fluid is put under pressure upstream of spray control assembly 14 and flowed to and through spray control assembly 14 under pressure.

[0130] The spray fluid enters into spray control assembly 14 through inlet fitting 68. The spray fluid flows through filter 72 and to internal flowpath 66. The spray fluid flows through internal flowpath 66 and enters into fluid hose 46 through outlet fitting 74. The spray fluid flows through the fluid hose 46 and exits from the fluid hose 46 at a location within the gun body 30. The spray fluid flows into cartridge 82. Spray valve 36 being in a closed state prevents the spray fluid from flowing downstream through nozzle 40.

[0131] The user actuates trigger 34 to cause spraying by spray gun 24. The sensor 64 senses actuation of the trigger 34. The sensor 64 provides a trigger activated signal to the assembly controller 44. The assembly controller 44 causes the solenoid 38 to actuate the spray valve 36 from the closed state to the open state in response to the trigger activated signal. For example, assembly controller 44 can cause power to be provided to coil section 84 of the solenoid 38. The user releases trigger 34 to stop spraying by spray gun 24. The sensor 64 senses release of the trigger 34. The sensor 64 provides a trigger released signal to the assembly controller 44. It is understood that the trigger release signal can be formed by a signal sent to assembly controller 44 or by cessation of provision of the trigger activated signal. The assembly controller 44 causes the spray valve 36 to shift from the open state to the closed state in response to the trigger released signal. For example, assembly controller 44 can stop provision of power to the coil section 84 of the solenoid 38 such that the coil section releases hold on the spray valve 36 such that the spray valve 36 can return to the closed state.

[0132] Spray control assembly 14 provides significant advantages. Spray control assembly 14 includes spray gun 24 that includes solenoid 38 that is electrically activated to cause opening of the spray valve 36. Solenoid 38 actuating the spray valve 36 to the open state means that the user does not have to exert physical force to overcome the pressure and open the spray valve 36, providing for more ergonomic spraying and less physical fatigue. Module 26 includes assembly controller 44 that provides power to electric components of spray gun 24. The module 26 can further support the power source 58. As discussed above, module 26 can be supported on the body of the user. The heavier components of the module 26 do not need to be in the spray gun 24 to be supported by a single hand of the user. Reducing electrical components aboard the spray gun 24 reduces weight of the spray gun 24. Signals generated at the spray gun 24 are provided to module 26 and the module 26 sends signals back to spray gun 24 to control actuation of the spray valve 36.

[0133] Assembly controller 44 is supported by module 26 in the example shown. Placing assembly controller 44 onboard module 26 reduces the amount of electrical components aboard the spray gun 24, reducing weight of spray gun 24. Further, some users may want to soak spray gun 24 in solvent after spray operations. Placing assembly controller 44 onboard module 26 places the electrical control components remote from the spray gun 24 and such solvent, protecting such electrical control components.

[0134] Spray control assembly 14 does not include a pump or other fluid mover, reducing the weight of spray control assembly 14 and simplifying operation of spray control assembly. Spray control assembly 14 receives spray fluid that is already put under pressure by an upstream pumping assembly 12 that is fluidly connected to the spray control assembly 14. The spray control assembly 14 can be used with any configuration of a pumping assembly and can be connected to any desired pumping assembly for spraying of fluid pumped by that pumping assembly.

[0135] FIG. 4A is an isometric view of spray gun 24. FIG. 4B is an isometric exploded view of spray gun 24. FIG. 5 is a cross-sectional view taken along line 5-5 in FIG. 4A. FIGS. 4A-5 are discussed together. Gun body 30 including upper housing 31 and gun handle 32, trigger 34, spray valve 36, solenoid 38, nozzle 40, cartridge 82, sensor 64, spray tip 80, and valve housing 86 of spray gun 24 are shown. Solenoid 38 includes coil section 84 and plunger 88.

[0136] Forward, rearward, upper, and lower directions are indicated in various of the figures. It is understood that components are shown in relative position to each other, particularly as viewed in FIG. 5A, and such relative positions are intended as being claimable relative to each other. It is further understood that the relative positions of various components are not intended as limiting and such components can be disposed in other locations relative to each other.

[0137] Spray gun 24 is configured to receive a flow of spray fluid under pressure and emit that flow of spray fluid as an atomized fluid spray through nozzle 40. Gun body 30 supports other components of spray gun 24. Upper housing 31 surrounds solenoid 38. Upper housing 31 supports valve housing 86. Gun handle 32extends from upper housing 31. Gun handle 32is configured to be grasped by a single hand of a user during operation of spray gun 24.

[0138] Trigger 34 projects from a front side of gun handle 32. Trigger 34 is configured to be actuated to control spraying by spray gun 24. Sensor 64 is disposed at least partially within gun body 30. In the example shown, a portion of sensor 64 is disposed in gun body 30 and a sensed component is supported by trigger 34. The sensed component can be a magnet, among other options. Pulling of the trigger 34 can cause the sensor 64 to sense the sensed component, such as the magnetic field generated by a magnet of or forming the sensed component, thereby causing the sensor 64 to generate the trigger actuated signal. Release of the trigger 34 can cause the sensor 64 to stop sensing the sensed component, thereby causing the sensor 64 to generate the trigger released signal, which trigger release signal can be cessation of the trigger actuated signal.

[0139] Conduit 28 extends through a bottom side of gun handle 32 such that a far end 78 of conduit 28 is disposed within spray gun 24. Fluid hose 46 extends out of sheath 50 and to gun fitting 90. The gun fitting 90 projects from valve housing 86, through it is understood that other configurations are possible. Conductors 48 extend out of sheath 50 at the location within the spray gun 24. In the example shown, a first subset of the conductors 48 extend to sensor 64 and provide communication between sensor 64 and assembly controller 44. In the example shown, a second subset of conductors 48 extend to solenoid 38 and provide signals (e.g., electrical power) to solenoid 38 to control operation of solenoid 38. The sheath 50 terminates at a location below the trigger 34. The fluid hose 46 and conductors 48 exit from sheath 50 at a location disposed vertically above the bottom end of the gun handle 32 and vertically below each of the locations that the components exiting from sheath 50 connect with components of spray gun 24. In the example shown, the sheath 50 terminates at a location vertically below the sensor 64, the gun fitting 90, and the coil section 84. The sheath 50 terminates at a location vertically below the upper housing 31.

[0140] Valve housing 86 is disposed at least partially within gun body 30. In the example shown, housing body 92 of valve housing 86 is partially disposed within gun body 30 and partially disposed outside of gun body 30. Valve housing 86 is disposed within and supported by upper housing 31. Valve housing 86 is connected to gun fitting 90 and fluidly connects to fluid hose 46 via gun fitting 90. Valve housing 86 is fluidly connected to fluid hose 46 to receive pressurized spray fluid from fluid hose 46. Valve housing 86 is disposed vertically above gun handle 32. Tip assembly 118 is connected to spray gun 24. Tip assembly 118 is mountable at tip mount 122. Tip mount 122 is formed as a portion of gun body 30 in the example shown. It is understood, however, that in various examples the tip mount 122 can be formed as a portion of valve housing 86. Tip mount 122 is formed as exterior threading configured to interface with a mounting portion of tip assembly 118 to mount tip housing 120 to spray gun 24. Spray tip 80 is supported by tip housing 120. Spray tip 80 includes nozzle 40 that is configured to atomize the pressurized spray fluid.

[0141] Valve housing 86 includes housing bore 94 that extends along axis VA. Housing bore 94 is open such that cartridge 82 can move into housing bore 94 in axial direction ADI along valve axis VA and can move out of housing bore 94 in axial direction AD2. In the example shown, the housing bore 94 is open in axial direction AD2 and closed in axial direction ADI. The axial direction ADI is an upstream direction along axis VA and axial direction AD2 is a downstream direction along axis VA.

[0142] Valve housing 86 is configured to connect to fluid hose 46 to receive pressurized spray fluid output by fluid hose 46. Valve housing 86 includes gun inlet 96 that extends through a wall of valve housing 86 and is in fluid communication with housing chamber 98. Gun inlet 96 forms an inlet port through valve housing 86. Housing chamber 98 is disposed at least partially defined by valve housing 86. Housing chamber 98 is formed as a radially enlarged portion of housing bore 94. Housing chamber 98 can be at least partially defined by a groove, such as an annular groove, formed in valve housing 86. Housing chamber 98 is fluidly connected to fluid hose 46 to receive pressurized spray fluid from conduit 28 and module 26. The housing chamber 98 extends annularly about the cartridge 82 to provide spray fluid to the cartridge 82.

[0143] Valve housing 86 is configured to receive cartridge 82 such that cartridge 82 is at least partially disposed within valve housing 86. Cartridge 82 is fixed to valve housing 86 when installed within spray gun 24 such that cartridge 82 is mechanically supported by valve housing 86. The cartridge 82 can thus be considered to be indirectly connected to the gun body 30 by the valve housing 86.

[0144] In the example shown, the cartridge 82 is connected to valve housing 86 at fixation 100. Fixation 100 is located respectively on the cartridge 82 and the valve housing 86 to secure the cartridge 82 to the valve housing 86. In this example, the fixation 100 is complementary threading between cartridge body 104 and housing body 92, however other attachment mechanisms are possible, such as tab-in-groove, friction fit, or bayonet connection amongst other possibilities. As such, the cartridge 82 can be rotated to move the cartridge 82 out of the housing bore 94 of the valve housing 86 or can be rotated in the opposite direction to move the cartridge 82 into the housing bore 94 of the valve housing 86.

[0145] In the example shown, fixation 100 is formed between housing mount 102 formed on the interior of valve housing 86 and cartridge mount 116 formed on an exterior of cartridge body 104. The housing mount 102 is formed as interior threads within the housing bore 94. The cartridge mount 116 is formed as exterior threads on a portion of cartridge body 104. It is understood that housing mount 102 and cartridge mount 116 can be formed as connective structure other than threads, such as projections that mate in a bayonet style connection, among other connection options. The housing mount 102 and cartridge mount 116 are configured to axially overlap each other to secure the cartridge 82 to the valve housing 86 and prevent the cartridge 82 from moving axially out of the housing bore 94.

[0146] Cartridge body 104 includes fluid housing 106 and base 108. The fluid housing 106 and base 108 can be connected together in any desired manner. For example, the fluid housing 106 and base 108 can be threaded together. In various other examples, a single housing may be provided, however in this example the fluid housing 106 forms a forward housing part that principally contains the spray valve 36 while the base 108 forms a rearward part that, in the example shown, contains the plunger 88 part of the solenoid 38. The base 108 can be exposed to the pressure within the fluid chamber 110 but does not radially surround the fluid chamber 110 and thus may not be in the manner of a pressure vessel. Fluid housing 106 does radially surround fluid chamber 110 and can thus be considered to be in the form of a pressure vessel.

[0147] Base 108 is connected to fluid housing 106 at a threaded interface in the example shown. It is understood, however, that base 108 and fluid housing 106 can be connected in any desired manner. Base 108 extends into fluid housing 106 to connect with fluid housing 106 in this example. Base 108 extends into fluid housing 106 to form the threaded interface between base 108 and fluid housing 106. Base 108 includes exterior threading and fluid housing 106 include interior threading in the example shown. The base 108 extending into the fluid housing 106 to connect to fluid housing 106 can provide for a cartridge 82 having a radially smaller footprint. In the example shown, the interface between base 108 and fluid housing 106 is disposed axially between forward seal 124 and rearward seal 126. The interface between fluid housing 106 and base 108 is disposed to radially overlap with housing chamber 98. The interface between fluid housing 106 and base 108 being axially between forward seal 124 and rearward seal 126 means that no additional sealing is required to form the interface as any fluid leakage through the interface is between fluid handling regions (e.g., housing chamber 98 and fluid chamber 110.

[0148] Outlet 112 is formed at a downstream end of cartridge body 104. Cartridge 82 is configured to emit spray fluid through outlet 112. Ports 114 are formed through cartridge body 104. Ports 114 are formed through fluid housing 106 in the example shown. Ports 114 are configured to admit spray fluid into fluid chamber 110 from housing chamber 98 of valve housing 86. Ports 114 can receive spray fluid from the channel that extends through the valve housing 86. Ports 114 form inlets of the cartridge 82 that admit spray fluid into the cartridge 82. In the example shown, an array of ports 114 are formed about the cartridge body 104.

[0149] The ports are 114 axially between a forward seal 124 and a rearward seal 126. The forward seal 124 and rearward seal 126 are disposed on opposite axial sides of the ports 114. The forward seal 124 and rearward seal 126 are disposed on opposite axial sides of the gun inlet 96 through the valve housing 86. The forward seal 124 and rearward seal 126 are configured to sealingly engage with both the valve housing 86 and the cartridge body 104. The forward seal 124 and rearward seal 126 are disposed to axially seal the housing chamber 98. The forward seal 124 and rearward seal 126 seal the cartridge 82 around the ports 114 to route all spray fluid into and through the ports 114 and therefore into the fluid chamber 110. In the example shown, forward seal 124 is disposed on and supported by fluid housing 106 and rearward seal 126 is disposed on and supported by base 108. The forward seal 124 and / or rearward seal 126 can be formed as O-rings, such as those formed from rubber or other type of compliant, sealing material.

[0150] Spray valve 36 is disposed within cartridge body 104. Spray valve 36 includes seat 128, such as a ceramic or carbide ring, which interfaces with ball 130 in the example shown. In the example shown, ball 130 is configured to interface with seat 128 and such interfacing of the ball 130 and the seat 128 closes the spray valve 36 but moving the ball 130 away from the seat 128 opens the spray valve 36 to allow spray fluid within the fluid chamber 110 to exit through the outlet 112. The spray valve 36 is actuatable between an open state, in which the fluid chamber 110 is fluidly connected to outlet 112 such that spray fluid can flow through outlet 112 and to nozzle 40, and a closed state, in which the fluid chamber 110 is fluidly disconnected from outlet 112 and nozzle 40.

[0151] Spray valve 36 is disposed at a forward end of cartridge 82. Spray valve 36 is disposed at a location axially outside of valve housing 86 in the example shown. Spray valve 36 is disposed at a location such that valve housing 86 does not radially overlap with the interface between ball 130 and seat 128. Spray valve 36 is disposed forward of gun handle 32. Spray valve 36 is disposed at a forward end of cartridge 82. The spray valve 36 is disposed at an opposite end of cartridge from plunger 88. The chamber within which spray valve 36 is disposed is axially separated from the chamber that plunger 88 is disposed within by base 108 and dynamic seal 136.

[0152] Rod 132 is configured to connect spray valve 36 to solenoid 38 such that solenoid 38 can actuate spray valve 36. Rod 132 can be a wire or other stiff, high tensile component which, in this example, extends from the plunger 88 of the solenoid to the ball holder 134. Ball 130 is mounted to ball holder 134.

[0153] Dynamic seal 136 is located around the rod 132. Dynamic seal 136 separates the high pressure within the fluid chamber 110 from the dry components, such as the solenoid 38. The dynamic seal 136 can be a rubber component compressed circumferentially around the rod 132 to prevent the escape of spray fluid from around the rod 132. Dynamic seal 136 is supported by base 108 in the example shown. Dynamic seal 136 extends at least partially within base 108 such that base 108 radially overlaps with dynamic seal 136. Dynamic seal 136 sealingly engages with rod 132 and rod 132 can slide relative to dynamic seal 136 during actuation of spray valve 36.

[0154] Spring 138 is disposed within fluid chamber 110. Spring 138 is configured to bias spray valve 36 into the closed state. Spring 138 urges the spray valve 36 towards the closed state. Spring 138 biases ball 130 into seat 128 to close spray valve 36 and maintain spray valve 36 in the closed state. The spring 138 is disposed within fluid chamber 110 in the example shown such that spring 138 is exposed to spray fluid, through it is understood that in various other examples the spring 138 can be outside of the fluid chamber 110. In some examples the spring 138 is a dry component that is not exposed to the spray fluid. In the example shown, the spring 138 radially surrounds the rod 132 such that rod 132 extends within and through spring 138. Spring 138 is disposed coaxially with rod 132 on valve axis VA. The spring 138 is disposed coaxially with spray valve 36 and outlet 112 in the example shown. The spring 138 interfaces with base 108 and ball holder 134 to bias the spray valve 36 towards the closed state.

[0155] Solenoid 38 is fully disposed within gun body 30 with cartridge 82 mounted to valve housing 86. Solenoid 38 is fully disposed within upper housing 31 with cartridge 82 mounted to valve housing 86. In the example shown, a portion of solenoid 38 is supported by the valve housing 86 such that that portion of the solenoid 38 remains mounted to the valve housing 86 with cartridge 82 dismounted. Solenoid 38 is configured to actuate spray valve 36 inside of the cartridge 82. The solenoid 38 includes coil section 84 and plunger 88. Plunger 88 can be considered to form an armature of the solenoid 38. In the example shown, coil section 84 is supported by valve housing 86. Coil section 84 remains mounted within gun body 30 with cartridge 82 dismounted. The coil section 84 forms the stator of the solenoid 38.

[0156] Coil 176 is located within the coil section 84. The coil 176 generates an electromagnetic field by running electrical current through one or more wound conductors, such as one or more copper conductors wound into a plurality of loops. The conductors can be in the form of round wire, flat ribbon strand, etc. The electromagnetic field can pull or repel magnetically sensitive materials. Such magnetically sensitive materials are located within and / or form portions of the plunger 88. For example, the plunger 88 can be formed from ferrous material that is pulled by the electromagnetic field generated by the coil 176. The plunger 88 can contain soft magnetic metal that can be easily magnetized and demagnetized at low magnetic fields. The plunger 88 can be pulled towards and / or through the pocket of the coil 176 when the coil 176 is electrically activated with electrical current. The plunger 88 can additionally or alternatively include a magnet. Such pulling overcomes the spring 138 within the cartridge 82 to open the spray valve 36.

[0157] Coil section 84 extends annularly about the plunger 88. In the example shown, the coil section 84 is partially radially overlapped with the plunger 88 and partially radially overlapped with a portion of the cartridge body 104 that axially overlaps with the plunger 88. Coil 176 does not axially overlap with plunger 88 in the example shown.

[0158] The solenoid 38 is able to actuate the valve 36 by the rod 132 that extends from within the fluid chamber 110 and through the dynamic seal 136. The rod 132 can be adhered, pinched, crimped, swaging, or otherwise attached directly to the plunger 88. In the example shown, the rod 132 extends through the plunger 88. The rod 132 can extend fully axially through the plunger along the axis VA. In the example shown, the rod 132 extends entirely through the plunger 88 such that the rod 132 extends forward and rearward of the plunger 88. However, in various other examples, the rod 132 does not extend rearward of the plunger 88. In some examples, the rod 132 terminates inside of the plunger 88.

[0159] Part of solenoid 38 is included in cartridge 82. Cartridge 82 includes the valve 36 and the plunger 88, but in this example does not include a coil, such as coil 176. Plunger 88 is located within plunger guard 140. The plunger guard 140 can be part of the cartridge body 104. In the example shown, the plunger guard 140 is formed as part of the base 108. The plunger guard 140 extends rearward beyond the plunger 88 such that the plunger 88 remains within a plunger chamber 142 of the plunger guard 140. Such a configuration is advantageous because, when the cartridge 82 is outside of the valve housing 86, the plunger 88 is still protected within the plunger guard 140. Such risks may include the bending of the rod 132 if the plunger 88 was exposed. In some examples, the plunger 88 may extend partially outside of the plunger guard 140 when the plunger 88 is pulled by the coil 176, such as in examples not including end cap 144. In various other examples, the full extent of travel of the plunger 88 still keeps the plunger 88 within the plunger guard 140 such that the plunger 88 does not extend beyond or past the plunger guard 140. As such, the plunger 88 reciprocates within the plunger guard 140. The exterior of the plunger 88 can be cylindrical and the plunger chamber 142 can likewise be cylindrical such that only a small air gap exists between the plunger 88 and the plunger guard 140. Other shapes, such as squares and hexes among other options, are possible.

[0160] Plunger 88 is disposed within a plunger chamber 142 within cartridge body 104. The plunger chamber 142 is closed in both axial directions ADI, AD2 in the example shown. A portion of base 108 and dynamic seal 136 are disposed axially between plunger chamber 142 and fluid chamber 110. In the example shown, end cap 144 blocks a rear end of plunger chamber 142. End cap 144 closes plunger chamber 142 in axial direction ADI and base 108 closes plunger chamber 142 in axial direction AD2. End cap 144 is disposed over the rear end of plunger chamber 142 to protect plunger 88 from contact damage and from contaminants. The end cap 144 can seal the plunger chamber 142 or can be vented. The end cap 144 can be a disc. The end cap 144 can be the same outer diameter as the portion of base 108 radially defining plunger chamber 142. The end cap 144 can be swaged, press fit, welded, or threaded onto the base 108, amongst other connection options. It is understood that, in various other examples, cartridge 82 does not include end cap 144 and plunger chamber 142 can be open along the axis VA.

[0161] As shown, solenoid 38 can be broken up into two solenoid parts based upon the removal of the cartridge 82. Specifically, the plunger 88 is part of the cartridge 82 and is removed and is replaced with a different but mechanically identical cartridge 82 to operate with the same coil 176. Coil section 84 is part of the valve housing 86 and remains mounted with other components of spray gun 24. Coil section 84 can operate multiple different plungers 88 of multiple different cartridges 82. Is contemplated that over the life of the spray gun 24, the cartridge 82 will be replaced while the coil section 84 will remain over the life of the spray gun 24 or at least over the life of many cartridges 822. As such, part, but not all, of the solenoid 38 will be replaced each time the cartridge 82 is replaced. In various other examples, the entirety the solenoid 38 can be part of the cartridge 82 such that the entirety a solenoid 38 is replaced with each cartridge 82 replaced. It is noted that including the plunger 88 as part of the cartridge 82 can lead to enhanced reliability because the spacing between the plunger 88 and the spray valve 36 can be particularly important, because solenoids 38 have short stroke lengths and the spray valves 36 likewise rely on short stroke lengths. As such, the position of the plunger 88 has to be located within a very small margin relative to the spray valve 36, which can best be controlled in a manufacturing environment rather than via the user, such as when threading the cartridge 82 into the housing bore 94. For example, if the user does not thread the cartridge 82 to a proper degree, then solenoid 38 may not pull the proper distance to actuate the spray valve 36. But the electromagnetic field generated by the coil 176 may be broad such that there is more operational variability in the position of the plunger 88 relative to the coil 176 so long as the plunger 88 is in a fixed, known distance from the spray valve 36, as linked via the rod 132, set under factory conditions.

[0162] Cartridge body 104 can define a travel distance of the plunger 88, thereby setting an opening distance of the spray valve 36. The opening distance of the spray valve 36, which is an axial distance that the ball 130 displaces from the seat 128 in the example shown, is set within a very small margin to properly control flow through the outlet 112 and downstream through the nozzle 40 for generation of the atomized fluid spray. Opening too large or too small can lead to low quality spray. In the example shown, the end cap 144 can define a travel limit of the plunger 88, thereby defining the opening distance of the spray valve 36.

[0163] In the example shown, the end cap 144 includes recess 146. Recess 146 is configured such that an end of rod 132 that extends through plunger 88 can extend into end cap 144 to radially overlap with structure of end cap 144. In some examples, the rod 132 extends into but does not contact the end cap 144, which protects the rod 132 from bending due to contacting the end cap 144. The recess 146 allows for rod 132 to extend fully through plunger 88 for fixing to plunger 88 on a rear side of plunger 88. The end cap 144 can define a limit of travel for the plunger 88, and thus an opening distance of the spray valve 36, while the rod 132 that projects beyond plunger 88 is received in a portion of end cap 144 to prevent bending of rod 132.

[0164] Spray gun 24 is configured for easy and ergonomic spraying. Pulling trigger 34 generates a trigger activated signal that causes electrical power to coil 176. Coil 176 generates an electromagnetic field that pulls plunger 88 in axial direction ADI. Plunger 88 displaces spray valve 36 to the open state and spray fluid flows downstream through outlet 112 and then through nozzle 40 to be output as an atomized fluid spray. Plunger 88 displaces spray valve 36 via rod 132. Rod 132 is connected to plunger 88 and ball 130 to pull ball 130 off of seat 128. The trigger 34 is not mechanically connected to spray valve 36 to actuate spray valve 36. The user does not have to overcome the pressure in fluid chamber 110 to actuate the spray valve 36 to the open state, reducing user fatigue and providing for more efficient spray operations.

[0165] The cartridge 82 mounts to and dismounts from the valve housing 86 as a single unit. The cartridge 82 is a unitary assembly that includes spray valve 36 and the actuator of spray valve 36 (such actuator formed by plunger 88 in the example shown) in the same assembly that mounts together and dismounts together. Both the actuator that opens spray valve 36 (e.g., plunger 88) and the actuator that closes spray valve (e.g., spring 138) are included in the unitary assembly of cartridge 82. The cartridge 82 includes all components that mechanically actuate the spray valve 36 to both the open state and the closed state. In the example shown, the components that electromagnetically actuate the spray valve 36 remain mounted with valve housing 86 with cartridge 82 dismounted.

[0166] The cartridge 82 can mount to and dismount the valve housing 86 by manipulation of the cartridge 82 alone. With tip assembly 118 removed, the cartridge 82 can be mounted within housing bore 94 and / or dismounted from housing bore 94 without manipulating other components of spray gun 24. The trigger 34 does not need to be shifted or manipulated to mechanically interface with any actuator of the spray valve 36. Instead, all mechanical interfaces for displacing the spray valve 36 are part of the unitary assembly of cartridge 82. In the example shown, all mechanical actuators (e.g., the spring 138 and plunger 88) for displacing the spray valve 36 are disposed within the cartridge body 104. Such mechanical actuators are enclosed within cartridge body 104 such that the components are not accessible from outside of cartridge body 104 by any other mechanical element to cause actuation of spray valve 36 during spray operations.

[0167] All mechanical actuators being part of cartridge 82 reduces wear on flow control components of cartridge 82 and can provide for a more robust and long lasting configuration. The mechanical actuators are disposed coaxially on the valve axis VA and are disposed within cartridge body 104. The mechanical actuators are coaxially aligned and no mechanical interface that could impart side loading on rod 132 is formed with cartridge 82 during mounting of cartridge 82. Spray gun 24 provides a balanced configuration that allows for easy use of spray gun 24. The cartridge 82 spans the gun handle 32 such that cartridge 82 extends forward of gun handle 32 and extends rearward of at least a portion of a rear side of gun handle 32. The valve housing 86 spans across handle such that valve housing 86 extends both forward and rearward of portions of gun handle 32. The valve housing 86 and cartridge 82 spanning the gun handle 32can balance spray gun 24 when the user is grasping the gun handle 32.

[0168] The mechanical actuators of spray valve 36 (e.g., spring 138 and plunger 88) and the electromechanical actuator of spray valve 36 (e.g., coil section 84) are disposed within support body 154 of gun body 30. The fluid hose 46 and the conductors 48 that connect to solenoid 38 pass through gun handle 32. The spray fluid enters into valve housing 86 and the electrical conductors 48 connect to solenoid 38 at locations within support body 154.

[0169] The cartridge 82 extends from within gun body 30 to outside of gun body 30 with cartridge 82 mounted to valve housing 86. The cartridge 82 extends from within valve housing 86 to outside of valve housing 86 with cartridge mounted to valve housing 86. The cartridge 82 extends out of valve housing 86 such that cartridge 82 can be accessed from outside of valve housing 86, such as by a tool (e.g., a wrench), by engaging a portion of cartridge body 104 outside of valve housing 86 to form or break the static interface formed at fixation 100.

[0170] FIG. 6A is a cross-sectional view showing fluid handling components of spray gun 24. FIG. 6B is an exploded view of the components shown in FIG. 6 A. FIGS. 6 A and 6B are discussed with continued reference to FIGS. 4A-5B. Valve housing 86 includes fluid receiver 148, coil housing 150, and solenoid cap 152. Fluid receiver 148 is fluidly connected to fluid hose 46 to receive the spray fluid from the conduit 28. Fluid receiver 148 is configured to receive and connect to cartridge 82. Fixation 100 is formed between cartridge body 104 and fluid receiver 148. In the example shown, housing bore 94 extends fully axially through fluid receiver 148. In the example shown the housing bore 94 is formed partially within the fluid receiver 148 and partially within coil housing 150. The base 108 of cartridge 82 extends into coil housing 150 to radially overlap with coil section 84 with cartridge 82 mounted to valve housing 86.

[0171] Coil housing 150 is connected to fluid receiver 148. In the example shown, support body 154 of coil housing 150 includes coil mount 156, housing portion 158a, and housing portion 158b. Coil mount 156 is configured to interface with a portion of fluid receiver 148 to mount coil housing 150 to fluid receiver 148. In the example shown, the coil mount 156 is configured to interface with the fluid receiver 148 at a threaded interface. In the example shown, the coil mount 156 includes exterior threading configured to interface with interior threading formed within the fluid receiver 148. While coil housing 150 is shown as connected to fluid housing 106 by a threaded interface, it is understood that not all examples are so limited. For example, coil housing 150 can be swaged, press fit, welded, or otherwise connected to fluid housing 106.

[0172] The coil mount 156 extends into the fluid receiver 148 to connect to the fluid receiver 148 in the example shown. The coil mount 156 extends into the fluid receiver 148 such that the coil housing 150 radially overlaps with the fluid receiver 148 at the interface between coil housing 150 and fluid receiver 148. In the example shown, a portion of the coil housing 150 is radially within a portion of the fluid receiver 148 such that a radial line extending from the valve axis VA passes first through the coil housing 150 and then through the fluid receiver 148 at the interface therebetween. The coil mount 156 extending into the valve housing 86 to connect to valve housing 86 provides for a smaller footprint for cartridge 82 and can assist in positioning coil 176 closer to plunger 88 to more efficiently actuate plunger 88.

[0173] Housing portion 158a extends from coil mount 156. Housing portion 158a projects radially outward from coil mount 156. In the example shown, housing portion 158a projects radially outward of portions of the fluid receiver 148. As such, the coil housing 150 can both radially and axially overlap with the fluid receiver 148. The housing portion 158a can brace against an axial end face of the fluid receiver 148. The coil housing 150 can be configured such that portions of coil housing 150 are disposed directly radially inward of structure of the fluid receiver 148 and portions of coil housing 150 extend radially outward of structure of the fluid receiver 148.

[0174] Housing portion 158b extends from housing portion 158a. Housing portion 158b extends axially outward from housing portion 158b. In some examples, housing portion 158b can be disposed orthogonal to housing portion 158a, though it is understood that not all examples are so limited. Housing portion 158b extends to a rearward end of valve housing 86.

[0175] In the example shown, coil section 84 is disposed within an area overlapped by housing portion 158a and housing portion 158b. The coil section 84 radially overlaps with housing portion 158b. The coil section 84 axially overlaps with housing portion 158a. In the example shown, the coil section 84 axially overlaps with fluid receiver 148.

[0176] Outer notch 160 is formed at the interface between housing portion 158a and housing portion 158b. Outer notch 160 can extend fully annularly about the axis VA. Coil section 84 is seated within outer notch 160. Coil section 84 can extend fully annularly about the axis VA. Coil section 84 being seated within outer notch 160 locates coil section 84 axially and radially relative to the housing bore 94, and thus relative to the plunger 88 that is installed with and removed with cartridge 82. It is understood, however, that coil housing 150 can receive coil section 84 within outer notch 160 regardless of whether spray valve 36 is mountable with a cartridge 82 or not. In some examples, spray valve 36 is supported by valve housing 86 but not disposed within a removable cartridge 82.

[0177] Solenoid cap 152 is connected to support body 154 of coil housing 150 in the example shown. Solenoid cap 152 can be considered to form a portion of valve housing 86. Solenoid cap 152 forms a portion of coil housing 150 in the example shown. Solenoid cap 152 is disposed at an opposite axial end of the housing bore 94 from mount opening 162 through which the cartridge 82 enters into and exits from the housing bore 94. In the example shown, solenoid cap 152 extends to close a second end of the housing bore 94 opposite the first end at which mount opening 162 is formed. The solenoid cap 152 extends such that the axis VA extends through structure of the solenoid cap 152 in the example shown. The solenoid cap 152 can be disposed coaxially with plunger 88 and rod 132 on valve axis VA. The solenoid cap 152 can be disposed coaxially with cartridge 82 with cartridge 82 mounted to valve housing 86.

[0178] In the example shown, solenoid cap 152 is mounted to support body 154 by mount flange 164 of solenoid cap 152 being captured by receiver 166 of support body 154. For example, solenoid cap 152 can be positioned on coil housing 150 and then receiver 166 can be bent to axially overlap with the radially outer portions of mount flange 164 to secure solenoid cap 152 on support body 154. It is understood, however, that solenoid cap 152 can be mounted to coil housing 150 in any desired manner, such as by interfaced threading, swaging, welding, brazing, etc.

[0179] In the example shown, solenoid cap 152 includes inner notch 168. Inner notch 168 interfaces with coil section 84 on a radially inner side of coil section 84. Inner notch 168 is formed at the interface between shoulder 170 and notch body 172. Notch body 172 extends to radially overlap with coil section 84. Notch body 172 can radially overlap with one or more coils 176 of coil section 84. Shoulder 170 is disposed between mount flange 164 and notch body 172. Shoulder 170 extends to axially overlap with coil section 84. Shoulder 170 can axially overlap with coils 176 of coil section 84.

[0180] Coil section 84 is clamped between and received within outer notch 160 and inner notch 168. Outer notch 160 and inner notch 168 can radially and axially locate the coil section 84 relative to the axis VA and housing bore 94. The stator portion of the solenoid 38 is axially captured between outer notch 160 and inner notch 168. Outer notch 160 is open radially inward and in axial direction ADI. Inner notch 168 is open radially outward and in axial direction AD2. Outer notch 160 and inner notch 168 oppose each other to capture coil section 84 therebetween.

[0181] In the example shown, an electrical connector 174 extends through solenoid cap 152 the electrical connector 174 connects with coil 176 to provide electrical power signals to coil 176. The electrical connector 174 extends axially to connect between coil 176 and conductor 48 in the example shown. It is understood, however, that in various other examples the electrical connector 174 can extend radially, such as through support body 154. Electrical connector 174 is spaced in axial direction ADI from all fluid pathways within valve housing 86 and cartridge 82, isolating the electrical connections between conductors 48 and coil section 84 from the spray fluid.

[0182] Cartridge 82 is mountable to and removable from the valve housing 86. Such removal can be facilitated by rotation to unfix the cartridge 82 from the valve housing 86. The housing bore 94 within which the cartridge 82 is at least partially disposed when mounted to valve housing 86 is disposed coaxially with cartridge 82 during mounting and dismounting of cartridge 82. The cartridge 82 can be removed for servicing and / or replacement. The same or a different cartridge 82 can then be reinserted into the housing bore 94.

[0183] In some examples, valve housing 86 can define a mounted position of the cartridge 82. For example, cartridge 82 can be configured to extend into valve housing 86 until a portion of valve housing 86 resists further movement of cartridge 82 in axial direction ADI. In the example shown, the solenoid cap 152 is configured to limit displacement of cartridge 82 into housing bore 94 in axial direction ADI. The end cap 144 can bottom out on the notch body 172 of the solenoid cap 152 to limit further displacement of cartridge 82 into housing bore 94, which can indicate to a user that cartridge 82 is fully and properly installed.

[0184] Spray gun 24 provides significant advantages. Cartridge 82 is mountable to and removable from valve housing 86 as a single unitary assembly. The cartridge body 104 supports both the spray valve 36 that controls flow of spray fluid through cartridge body 104 and the plunger 88 that is electromagnetically actuated to actuate the spray valve 36. The plunger 88 can be fixed relative to the spray valve 36 such that the plunger 88 mounts with and dismounts with the spray valve 36. The plunger 88 can be fixed at a location along the rod 132 to set the opening distance of the spray valve 36, providing for a set opening distance for each actuation of spray valve 36, providing for more consistent and high quality spraying.

[0185] Plunger 88 is at least partially disposed within cartridge body 104 in the examples shown. The cartridge body 104 can protect the plunger 88 from undesirable contact damage. The cartridge body 104 can shield the plunger 88 and prevent torquing of the plunger that could bend the rod 132.

[0186] In the example shown, the plunger 88 is fully contained within cartridge body 104 such that plunger 88 is axially and radially overlapped by structure that the plunger 88 moves relative to during actuation of spray valve 36. The end cap 144 axially overlapping with plunger 88 can set a displacement distance of the plunger 88, thereby setting an opening distance of the spray valve 36. The displacement distance of the plunger 88 being set by cartridge body 104 provides for a consistent stroke distance for the plunger 88, and thus the spray valve 36, for each actuation of the spray valve 36.

[0187] The stator of solenoid 38 is assembled by axial stacking of components along the valve axis VA. Coil housing 150 extends axially into fluid receiver 148 to connect to fluid receiver 148. The coil housing 150 being radially inward of the fluid receiver 148 at that connection interface, which connection interface connects the coil section 84 to the fluid receiver 148 that supports the cartridge 82 and thus the plunger 88, facilitates a more compact configuration of cartridge 82. The cartridge body 104 can be closely fit to the portion of coil housing 150 that defines the housing bore 94. The coil section 84 can be placed radially closer to valve axis VA and thus to plunger 88, providing for more efficient operation.

[0188] The coil section 84 is axially captured between outer notch 160 and inner notch 168. The coil section 84 can slide axially into the outer notch 160 to be positioned within the outer notch 160. The solenoid cap 152 can then be assembled to support body 154 such that inner notch 168 receives a portion of coil section 84. The coil section 84 is axially captured within the opposed notches. The coil section 84 is also radially captured by the opposed notches. Capturing the coil section 84 axially and radially locates the coil section 84 relative to housing bore 94 and thus relative to the location that plunger 88 is disposed with cartridge 82 mounted to valve housing 86.

[0189] The coil section 84 is captured between support body 154 and solenoid cap 152.

[0190] Solenoid cap 152 can shift axially relative to support body 154 to interface with support body 154. The solenoid cap 152 can axially and radially support the coil section 84. The axial stacking of the stator (e.g., coil section 84) and stator support (e.g., coil housing 150) provides for a compact configuration of the stator section of the solenoid 38. Such a configuration can provide for a smaller gun body 30 for enclosing portions of the valve housing 86, allowing for a more ergonomic and easier to manipulate spray gun 24.

[0191] FIG. 7 A is an isometric view of a cartridge 82 with a locator 178 for locating the plunger 88 along the rod 132. FIG. 7B is an isometric cross-sectional view taken along line B-B in FIG. 7A. FIGS. 7A and 7B are discussed together.

[0192] The plunger 88 is fixable at a location along the rod 132 to set an opening distance of the spray valve 36. The plunger 88 can be fixed to a particular location along the rod 132, the particular location accounting for the opening distance of the spray valve 36. The plunger 88 can be fixed at a location along the rod spaced a spacing distance from the downstream end of the cartridge body 104, the spacing distance setting the opening distance of the spray valve 36.

[0193] In the example shown, the rod 132 extends axially beyond the plunger 88. Such a configuration allows the plunger 88 to be fixed along the rod 132 from a rear side of the plunger 88 to set an opening distance of the spray valve 36. For example, the cartridge 82 can be manufactured by welding, swaging, brazing, or otherwise fixing the end of the rod 132 to the plunger 88. For example, an end of the rod 132 can be fixed to an end of the plunger 88. In some examples, an exposed part of the rod 132 that extends beyond the plunger 88 can be fixed to the plunger 88. The rod 132 may still not extend beyond the plunger guard 140. The weld may be circumferential around rod 132 and along the lip of the plunger 88 that defines the hole through which the rod 132 extends through the plunger 88. In this way, the plunger 88 may have an outer metal housing which surrounds the magnetically active components of plunger 88 therein, the weld being made to such outer metal housing.

[0194] Plunger 88 is fixed along rod 132 to set the opening distance of spray valve 36. As discussed above, the cartridge 82 can be configured such that end cap 144 defines the travel limit of the plunger 88. Plunger 88 can be fixed relative to the location of the inner face 180 of the end cap 144 to set the allowable travel distance for the plunger 88 and thus set the opening distance for the spray valve 36.

[0195] The plunger 88 is secured to the rod 132 as part of a manufacturing assembly step. The plunger 88 can be secured to the rod 132 by welding the rod 132 to the plunger 88. Alternative fastening options are possible, such as threading, gluing, swaging, or pressing the rod 132 to the plunger 88, amongst other options. In various examples, a rear end of the rod 132 is attached to a rear end of the plunger 88. In particular, before the end cap 144 is installed, the rear end of the rod 132 can be welded to the rear end of the plunger 88, among other connection options. The end cap 144 can then be secured to the cartridge body 104. However, in various examples, the cartridge 82 does not include an end cap 144.

[0196] During manufacturing, the plunger 88 can be located on a particular position along the rod 132 before being fixed to the rod 132. To locate the plunger 88 at the particular location along the rod 132, the plunger 88 can be shifted along the rod 132 until disposed at the particular location along the rod 132. To achieve ideal spacing, the plunger 88 may be set against an indexing fixture and then the rod 132 can be fixed to the plunger 88. The location of the plunger 88 on the rod 132 can be set relative to a position of the plunger guard 140 when the valve is closed, which ensures that the plunger 88 is ideally positioned to be influenced by the electromagnetic field of the coil and to open the spray valve a desired opening distance.

[0197] In the example shown, plunger 88 is first positioned over rod 132 and then a locator 178, which can be considered to form the indexing feature, is positioned at an open end of plunger chamber 142. The locator 178 includes or is formed from one or more magnets that pull the plunger 88 into contact with the locator 178. The locator 178 includes stop 182 and standoff 184. The stop 182 interfaces with the cartridge body 104 to position the locator 178 relative to the cartridge body 104. The standoff 184 extends from the stop 182 and into the plunger guard 140 by a distance equivalent to the desired travel distance for the plunger 88. The stop 182 can thereby set the spacing distance for locating the plunger 88. With the plunger 88 drawn into contact with the stop 182, the rod 132 is fixed to the plunger 88, thereby securing the plunger 88 at a desired location along the rod 132. For example, the rod 132 and plunger 88 can be accessed through locating aperture 186 that extends through the locator 178 to fix rod 132 and plunger 88 together. The locator 178 can then be removed and the end cap 144 assembled onto cartridge 82, in examples that include end cap 144.

[0198] Fixation of plunger 88 to set the opening distance of spray valve 36 provides significant advantages. The plunger 88 is the mechanical actuator of the spray valve 36 that actuates the spray valve 36 to an open state. Setting the plunger along the rod 132 provides a known, controllable opening distance for spray valve 36 that remains consistent throughout the operational life of cartridge 82. The plunger 88 remains fixed to rod 132 and mounts with and dismounts with cartridge 82. The plunger 88 being located on the rod 132 both sets the position of the plunger 88 relative to the spray valve 36 for mechanical actuation and also locates the plunger 88 within cartridge body 104 for efficient positioning relative to coil section 84 when cartridge 82 mounts to valve housing 86.

[0199] FIG. 8 is an enlarged view of detail 8 in FIG. 6A. FIG. 9 is a plot illustrating flow of electromagnetic flux. FIGS. 8 and 9 are discussed together with continued reference to FIGS. 1-7.

[0200] Plunger 88 is offset from coil 176. In the example shown, plunger is offset from coil 176 both radially and axially. A first part of the plunger 88 radially overlaps the coil 176 and a second part of the plunger 88 does not radially overlap the coil 176. The second part of the plunger 88 is closer to the spray valve 36 than the first part of the plunger 88. If this were reversed such that the part of the plunger 88 that does not radially overlap with the coil 176 is located on the opposite side of the coil 176, farther away from the spray valve 36, then the rod 132 or equivalent structure would need to span the entire distance of the coil 176, making for a less compact assembly and harder to manage spray gun 24.

[0201] Plunger 88 is radially offset from coil 176. The radial offset between plunger 88 and coil 176 generates air gaps that are disruptive to the flow of electromagnetic flux. Plunger guard 140 extends into the solenoid gap 188 formed between plunger 88 and coil section 84. The plunger guard 140 includes flux permeability zone 190 and flux reluctance zone 192. The flux permeability zone 190 is formed from a first type of material, such as ferromagnetic material, or other type of material that attracts and channels the flow of electromagnetic flux. The flux reluctance zone 192 is formed from a second type of material, such as non- ferromagnetic material, or other type of material that does not attract and channel the flow of electric magnetic flux. It can be appreciated that the zones are tubular in shape, with the plunger 88 moving radially inward of the zones while the coil housing 150 is radially outward of the zones. In this and various other examples, these different zones are formed by different structures. For example, the flux permeability zone 190 is formed from steel, such as stainless steel, while the flux reluctance zone 192 is formed by aluminum or polymer, amongst other nonferrous material options.

[0202] In the example shown, the flux permeability zone 190 is shown as formed from root part 194. The root part 194 can be contiguous with the base 108, such that the parts are formed from the same piece of material. As such, ferric material can axially overlap with plunger 88 axially between plunger 88 and spray valve 36. The ferric material can axially overlap with plunger 88 upstream of plunger 88. In some examples, a contiguous piece of ferric material can radially and axially overlap with plunger 88. The flux permeability zone 190 can, in some examples, not radially overlap with coils 176. In some examples, the flux permeability zone 190 does not radially overlap with coil section 84. The flux permeability zone 190 being spaced axially from coil section 84 assists in routing flow of electromagnetic flux to displace plunger 88 in the downstream direction. The flux permeability zone 190 is spaced axially from coil section 84 in an opposite axial direction from the axial direction that the plunger 88 displaces during opening of spray valve 36.

[0203] The flux reluctance zone 192 is shown as formed from extension part 196. In the example shown, the extension part 196 is connected to the root part 194. In particular, the extension part 196 is only connected to the root part 194 and not to other parts of cartridge body 104. The extension part 196 can be formed from aluminum, polymer, zinc, or other type of non-ferrous material. In the example shown, the extension part 196 is cantilevered from the root part 194. The extension part 196 extends to radially overlap with coils 176. The extension part 196 partially radially overlaps with coil section 84 and partially does not radially overlap with coil section 84.

[0204] The extension part 196 interfaces with the root part 194 at zone interface 198. The extension part 196 is disposed radially outward from the root part 194 at zone interface 198 in the example shown, though it is understood that in other examples root part 194 can be disposed radially outward of extension part 196. The zone interface 198 is partially formed from ferric material and partially formed from nonferric material. The zone interface 198 does not radially overlap with the coil section 84 in the example shown.

[0205] The plunger 88 is disposed within the plunger chamber 142. The plunger 88 is configured to reciprocate within the plunger chamber 142 during actuation of the spray valve 36. The plunger chamber 142 is partially defined by the flux permeability zone 190 and partially defined by the flux reluctance zone 192. The plunger chamber 142 is partially defined by root part 194 and partially defined by extension part 196. The plunger chamber 142 is axially defined by ferric material (e.g., of end cap 144 and base 108) and radially defined by ferric material (e.g., forming flux permeability zone 190) and nonferric material (e.g., flux permeability zone 190). The amount of plunger 88 radially overlapping with flux reluctance zone 192 increases with plunger 88 being electromagnetically displaced in axial direction ADI during opening of the spray valve 36. The amount of plunger 88 radially overlapping with flux reluctance zone 192 decreases with plunger 88 being displaced in axial direction AD2 during closing of spray valve 36. The amount of plunger 88 radially overlapping with flux permeability zone 190 decreases with plunger 88 being electromagnetically displaced in axial direction ADI during opening of the spray valve 36. The amount of plunger 88 radially overlapping with flux permeability zone 190 increases with plunger 88 being displaced in axial direction AD2 during closing of spray valve 36.

[0206] Having flux permeability zone 190 and flux reluctance zone 192 can coax the flow of electromagnetic flux to enhance the operation of the solenoid 38. The need to coax comes about from the presence of the plunger guard 140 which on one hand provides mechanical protection for the plunger 88 when not mounted in the spray gun 24, but provides a solenoid gap 188 between the coil 176 and the plunger 88 in which the electromagnetic field can diminish power. The entirety of the plunger guard 140 can be made of ferrous material which can help direct the flow of flux, but some parts of the plunger guard 140 being ferromagnetic can be counterproductive. Specifically, the part of the plunger guard 140 that is directly radially between the plunger 88 and the coil 176 can provide a flux short circuit, whereas axial projection of the magnetic field outward fosters better electromagnetic interaction with the whole of the plunger 88. Accordingly, the flux reluctance zone 192 is made of material that does not support the flow of electromagnetic flux whereas the material that forms the flux permeability zone 190 that is outside of the radial overlap between the coil 176 and the plunger 88 is formed from ferromagnetic material to coax the flux path out along this non-overlapping area.

[0207] In the example shown, the support body 154, solenoid cap 152, base 108 including root part 194, and end cap 144 can be formed from ferromagnetic material to support the flow of electromagnetic flux. As shown in FIG. 9, there appears to be a gap in the flow of electromagnetic flux (represented by arrows EF) along the flux reluctance zone 192 which can be formed as an air gap or can be filled with extension part 196 which is not made from ferromagnetic material. As shown, the flux within the plunger 88 extends axially outward and towards the flux permeability zone 190 which causes it to interact with more of the plunger 88 before being routed through the ferromagnetic material of the coil housing 150 back towards the coil 176. If the flux reluctance zone 192 were filled with ferromagnetic material in the same manner as the flux permeability zone 190, then significantly less of the flux would be projected along the flux permeability zone 190 and less of the flux would be flowing over the entirety of the plunger 88, diminishing the performance of the solenoid 38.

[0208] Flux permeability zone 190 and flux reluctance zone 192 provide significant advantages. Flux reluctance zone 192 does not support How of electromagnetic flux such that the electromagnetic flux is routed axially outward relative to the radial overlap between coil section 84 and plunger 88. Such a configuration facilitates stronger pull of the plunger 88, allowing for a lower voltage to be delivered to the coil 176, which can decrease heating and can allow a smaller battery to be used and can allow for longer battery life.

[0209] Plunger 88 is disposed within the plunger guard 140 that protects plunger 88 and rod 132 when cartridge 82 is disconnected from spray gun 24. The plunger guard 140 radially surrounding the plunger 88 and extending axially beyond the plunger 88 in the upstream direction ADI fully radially encloses the plunger 88 protecting from bending contact that could bend rod 132 and harm the functionality of cartridge 82. The presence of plunger guard 140 generates the large solenoid gap 188 which diminishes performance by creating one or more air gaps between coil section 84 and plunger 88. The flux reluctance zone 192 shifts material that can route electromagnetic flux axially from coil section 84 to enhance performance of solenoid 38 while also enclosing plunger 88 to protect plunger 88.

[0210] FIG. 10 is an isometric view of a plunger guard 140' and plunger 88. FIG. 10 shows a different way to change the permeability of the plunger guard 140'. Plunger guard 140' includes one or more apertures 200 that extend through the plunger guard 140. One or more ferromagnetic pads 202 are added to the base 108 within the apertures 200. In some examples, the base 108 can then be made of nonferromagnetic material, such as aluminum. The ferromagnetic pads 202 can fill apertures 200 within the plunger guard 140 to channel electromagnetic flux through the ferromagnetic pads 202. As shown, a pair of ferromagnetic pads 202 are used, although three ferromagnetic pads 202, four ferromagnetic pads 202, or other number and pattern of ferromagnetic pads 202 can be arrayed circumferentially around the axis VA to form the flux permeability zone 190. As shown, the ferromagnetic pads 202 are not placed along the flux reluctance zone 190.

[0211] FIG. 11 is an isometric view of plunger guard 140 and plunger 88 ' . FIG. 11 shows a different way to change the permeability of the plunger guard 140' '. Slots 204 are formed in the plunger guard 140" and the plunger 88' includes radial extensions 206 that extends further radially out along the slots 204 such that the radial extensions 206 of the plunger 88' are closer to the coil 176 to reduce the size of the air gap between the coil 176 and the plunger 88', whereas, as discussed before, it is the presence of a plunger guard which creates the radial gap and introduces performance inefficiency of the solenoid 38. Tabs 208 of the plunger guard 140" can still extend axially beyond the plunger 88' to protect the plunger 88 '.

[0212] FIG. 12A is a cross-sectional view showing fluid handling components of a spray gun. FIG. 12B is an exploded view of the components shown in FIG. 12 A. The valve housing 1086 and cartridge 1082 are substantially similar to the valve housing 86 and cartridge 82 (both best seen in FIGS. 4A-6B) previously described. As such, fluid handling components including valve housing 1086 and cartridge 1082 are indicated with the same reference number as fluid handling components including valve housing 86 and cartridge 82 except increased by “1000” (e.g., cartridge 82 and cartridge 1082). It is understood that components not explicitly called out or described can be identical to those for valve housing 86 and cartridge 82 and that such description is omitted for the sake of brevity.

[0213] Cartridge 1082 is the same as cartridge 82 except that cartridge body 1104 does not include an end cap 144. The plunger chamber 1142 is open in axial direction ADI away from the spray valve 1036.

[0214] Coil housing 1150 is mounted to fluid receiver 1148. An inner side 210 of coil housing 1150 is oriented axially towards the spray valve 1036 and the plunger 1088. The inner side 210 can define a travel distance of the plunger 1088. During mounting, cartridge 1082 can extend into housing bore 1094 until cartridge body 1104 bottoms out on coil housing 1150 to locate cartridge 1082 relative to valve housing 1086.

[0215] As discussed above, the plunger 1088 can be located along the rod 1132 to set the travel distance for opening of the spray valve 1036. In the example shown, the plunger 1088 can be located relative to the distal end of the plunger guard 1140 that is configured to interface with the coil housing 1150. In the example shown, the rod 1132 extends partially through the plunger 1088. However, as discussed above, the rod 1132 can extend fully axially through the plunger 1088.

[0216] FIG. 13 is a cross-sectional view showing fluid handling components of a spray gun. The valve housing 2086 and cartridge 2082 are substantially similar to the valve housing 86 and cartridge 82 (both best seen in FIGS. 4A-6B) previously described. As such, fluid handling components including valve housing 2086 and cartridge 2082 are indicated with the same reference number as fluid handling components including valve housing 86 and cartridge 82 except increased by “2000” (e.g., cartridge 82 and cartridge 2082). It is understood that components not explicitly called out or described can be identical to those for valve housing 86 and cartridge 82 and that such description is omitted for the sake of brevity.

[0217] In the example shown, cartridge 2082 does not include a plunger guard. However, to help protect the plunger 2088 when outside of the gun body, the receiving interface has been made between the plunger 2088 and the base 2108. The base 2108 includes receiving cavity 212. Receiving cavity 212 can be cylindrical, among other options. The plunger 2088 includes extension 214. The extension 214 extends into the cavity 212. The extension 214 can reciprocate within the cavity 212 during actuation of the solenoid 2038. The extension 214 can be cylindrical, among other options. A cross-sectional shape of the receiving cavity 212 normal to the axis VA can be the same as a cross-sectional shape of the extension 214 normal to the axis VA, though it is understood that other configurations are possible. The close fit of the extension 214 into the cavity 212 prevents the plunger 2088 from any dramatic movement relative to the base 2108 and the rest of the cartridge 2082, which mechanically protects impacts on the plunger 2088 from bending the rod 2132 which is one of the main concerns with the need to protect the plunger 2088. A vent 216 is made in the plunger 2088 to allow air to escape from the receiving cavity 212 during actuation. The vent 216 extends through the extension 214 and radially outward through a main body portion of the plunger 2088, in the example shown.

[0218] Rod fastener 218 connects the rod 2132 to the plunger 2088. Rod fastener 218 can be a collar that is crimped, welded, or otherwise affixed to the rod 2132. Rod fastener 218 can also be press fit, welded, or otherwise affixed to the plunger 2088 to connect the plunger 2088 to the rod 2132. Rod fastener 218 is located in a recess in the plunger 2088 in the example shown.

[0219] Bumper 220 is located around the extension 214 of the plunger 2088. The bumper 220 can be formed from rubber, or other type of plastic, or other impact dampening material. The bumper 220 can provide a shock absorber that protects the plunger 2088 and rod 2132.

[0220] The extension 214 can be formed from the magnetically active material as the rest of the core of the plunger 2088, such as ferromagnetic material or magnetizeable material, or the extension 214 may not be formed from such magnetically active material.

[0221] In the example shown, the plunger 2088 is unshrouded such that the plunger 2088 can be placed radially closer to coil section 2084 than in examples in which the plunger 2088 is shrouded by a plunger guard. The size of the air gap between coil section 2084 and plunger 2088 can be minimized, thereby improving the efficiency of the solenoid 2038. Such a configuration can thereby utilize less battery power and allow for use of a smaller battery or provide for longer spray operations.

[0222] FIG. 14A is a first isometric view of a module 26 for a spray control assembly 14. FIG. 14B is a second isometric view of the module 26. FIG. 14C is a first isometric exploded view of the module 26. FIG. 14D is a second isometric exploded view of the module 26. FIGS. 14A-14D are discussed together. Module body 42, assembly controller 44, inlet fitting 68, filter manifold 70, and user interface 222 of module 26 are shown. Module handle 224, arms 226, and main housing 228 of module body 42 are shown. Filter cap 230, filter housing 232, and filter 72 of filter manifold 70 are shown. A portion of conduit 28 is shown.

[0223] Module 26 is configured to receive pressurized spray fluid and output the pressurized spray fluid to a spray gun 24. Module 26 is configured to receive signals from spray gun 24 and is configured to control power to the solenoid 38 of the spray gun 24 in response to such signals. In the example shown the module 26 is configured as a passthrough for the spray fluid, in which the spray fluid flows through module 26 but the module 26 does not include any pump or other fluid mover that pressurizes or drives the spray fluid by mechanical displacement of the fluid mover.

[0224] Module body 42 is configured to support other components of module 26. In the example shown, the module body 42 includes main housing 228 that forms a lower part of module body 42, which contains assembly controller 44 and holds the power source 58, and includes module handle 224 that forms an upper part of module body 42. The module handle 224 is connected to the main housing 228 by arms 226. While two arms 226 are shown, a single arm or other number of arms can connect the main housing 228 to the module handle 224. Both the main housing 228 and the module handle 224 can be formed from the module body 42. Portions of the main housing 228 and module handle 224 can be formed monolithically, among other options.

[0225] As shown, the module body 42 can be formed by shells 234. Each of the shells 234 can be injection molded polymer, among other options. The two shells 234 can split the module body 42 approximately in half, laterally, with a middle seam.

[0226] Filter manifold 70 is supported by module body 42. In the example shown, filter manifold 70 is supported by module handle 224. The filter manifold 70 can be at least partially disposed within the module body 42. In the example shown, the filter manifold 70 is disposed partially within module body 42, within module handle 224 in this example, and partially outside of module body 42.

[0227] As shown, the filter housing 232 is at least partially located within the module body 42. In the example shown, filter housing 232 is located at least partially within module handle 224. Filter housing 232 is supported by module body 42. Filter 72 is contained within filter housing 232. The filter 72 can be a screen through which spray fluid can flow to filter out particulate within the spray fluid. The filter 72 can be hollow and cylindrical with a polymer frame and a web of metal mesh forming a screening surface. Filter cap 230 can mount on the filter housing 232 trap the filter 72 inside of the filter housing 232. The filter 72 can be an inside-out filter in which spray fluid flows into the interior of the filter 72 through one axial end of the filter 72 and then must move through the screen material to exit to the outside of the filter 72 and continue to move downstream. The fdter cap 230 can thread onto the filter housing 232, among other connection options. In the example shown, filter cap 230 receives a threaded ring of the filter housing 232, the filter cap 230 including internal threading complimentary to the threading of the filter housing 232.

[0228] In the example shown, the inlet fitting 68 is formed by filter cap 230. The inlet fitting 68 is supported by cap piece 236. The cap piece 236 can include threading to connect filter cap 230 to filter housing 232. The threading of the cap piece 236 can be complementary to the threading of the filter housing 232. The inlet fitting 68 can be a quick disconnect type, or can be threaded, and is configured to connect with a supply line 52 to receive pressurized spray fluid into module 26.

[0229] In some examples, the inlet fitting 68 is configured to swivel relative to the cap piece 236. For example, the inlet fitting 68 may be able to rotate for full and continuous turns, greater than 360-degrees. Such swiveling allows the supply line 52 to rotate to alleviate loops and bends while minimizing or eliminating the transfer of torque to the filter manifold 70 and / or the module 26.

[0230] Outlet fitting 74 is connected to conduit 28. Specifically, outlet fitting 74 is connected to fluid hose 46 of conduit 28 to output spray fluid to the fluid hose 46. In the example shown, the outlet fitting 74 is formed by a fitting connector that is mounted to and supported by the filter housing 232. The fitting connector can be considered to form a portion of the filter manifold 70. The fitting connector can be connected to filter housing 232 such that the fitting connector is rotationally fixed relative to filter housing 232. The fluid hose 46 connects to the outlet fitting 74 at a location within the module handle 224 in the example shown.

[0231] Conduit 28 is at least partially disposed within module body 42. In the example shown, conduit 28 extends at least partially within module handle 224. In particular is the junction of the conduit 28 in which fluid hose 46 comes together with the one or more conductors 48 and is covered by the sheath 50. The one or more conductors 48 come together with the fluid hose 46 inside of the module body 42 and both the fluid hose 46 and conductors 48 enter into the sheath 50 at a location within the module body 42. As such, by the point at which the conduit 28 exits the module body 42, the one or more conductors 48 are covered by the sheath 50. In other words, on the near end 76 of the conduit 28, the one or more conductors 48 transition from being outside of the sheath 50 to being underneath the sheath 50 within the module body 42,. in which the sheath 50 terminates (or begins) within the module body 42. Likewise, on the far end 78 of the conduit 28, the one or more conductors 48 transition from being inside of the sheath 50 to being outside of the sheath 50 within the spray gun 24, in which the sheath 50 terminates (or begins) within the spray gun 24.

[0232] Filter manifold 70 is permitted to rotate within the module body 42. In this particular example, the rotation of the filter manifold 70 is limited such that the filter manifold 70 is allowed to turn relative to the module body 42 but is not permitted to make full 360-degrree turns. The reason for this is that it is important that the conduit 28 be able to twist relative to the module body 42, otherwise binding can be experienced during the hand movements made by the spray gun 24 during spraying. The mass of the module 26 can restrict the motion of the spray gun 24 unless the conduit 28 is allowed to rotate relative to the module body 42. However, the conduit 28 must be restricted from rotating too much within the module body 42 because otherwise the one or more conductors 48 could bind and / or snap because they cannot continuously rotate, because the one or more conductors 48 branch from the fluid hose 46 and the sheath 50 within the module body 42. As such, limited rotation of the filter manifold 70 allows the conduit 28 to rotate to a limited degree but not for full rotations (e.g., not 360-degrees), which allows the one or more conductors 48 to be integrated into the conduit 28 without breaking of the one or more conductors 48.

[0233] User interface 222 is supported by module body 42. User interface 222 is supported by main housing 228 in the example shown. The user interface 222 is disposed on the lower part of the module body 42. The user interface 222 includes inputs 238a, 238b. In the example shown, the inputs 238a, 238b are formed as buttons. The user interface 222 can communicate with the assembly controller 44 to change a pressure setting of the pumping assembly 12. As discussed above, the module 26 can be configured to provide pressure commands to the pumping assembly 12 to change the target pressure setpoint. The assembly controller 44 can be configured to cause incremental adjustment of the target pressure setpoint by the spray controller 22 based on signals received from inputs 238a, 238b.

[0234] In the example shown, input 238a is configured to provide signals indicating a desired increase in pressure and input 238b is configured to provide signals indicating a desired decrease in pressure. For example, pressing input 238a can incrementally increase the target pressure setpoint and pushing input 238b can incrementally decrease the target pressure setpoint. These increases and decreases in pressure can correspond with a setting on the pumping assembly 12 in which the electric motor 16 is started when the fluid pressure, as measured downstream of the pump 20, falls below the target pressure setpoint, and the electric motor 16 is stopped when the measured pressure meets and / or exceeds the target pressure setpoint. Such commands to increase or decrease the pressure setting can be sent wirelessly by assembly controller 44 as described herein.

[0235] Power source 58 is mounted to and supported by module body 42. Power source 58 is configured to provide electrical power to electrical components of module 26 and spray gun 24. In the example shown, the power source 58 is formed as a battery that is removably mounted to module body 42. The power source 58 can mount to the module body 42 by sliding of the power source 58 relative to the module body 42. In the example shown, the power source 58 is configured to mount and dismount by axial movement along a flow axis FA through the module 26. The power source 58 is configured to mount by shifting in a downstream direction relative to the direction of fluid flow through the module handle 224. It is understood that in various other examples the power source 58 can mount by shifting vertically, up or down. In various other examples the power source 58 can be integrated into module 26 such that the power source 58 is not removable.

[0236] In the example shown, module 26 is configured to be oriented such that forward end 240 is oriented forward relative to the user and rear end 242 is oriented rearward away from the user. Such a configuration orients the conduit 28 forward relative to the user. The conduit does not need to wrap around the module body 42 or the user to reach the spray gun 24. In addition, filter manifold 70 projects out of rear end 242. As such, the supply line 52 is disposed behind the user and not in the walking path of the user which could present a tripping hazard. The forward end 240 and rear end 242 form axial ends of the module 26.

[0237] Power source 58 and user interface 222 are disposed on a same lateral side of module body 42. The power source 58 and user interface 222 are disposed on lateral side 244a of module body 42. No controls or mechanical / electrical interfaces are disposed on lateral side 244b of module body 42 opposite lateral side 244a. As discussed in more detail below, the lateral side 244a can be either an inner side oriented towards the user or an outer side oriented away from the user while the forward end 240 remains oriented forward relative to the user. Similarly, the lateral side 244b can be either an inner side oriented towards the user or an outer side oriented away from the user while the forward end 240 remains oriented forward relative to the user.

[0238] FIG. 15 is a cross-sectional view taken along line 15-15 in FIG. 14A. FIG. 16 is a cross-sectional view taken along line 16-16 in FIG. 14A. FIGS. 15 and 16 are discussed together. Module body 42, inlet fitting 68, filter manifold 70, and rotation lock 246 of module 26 are shown. Module handle 224, arms 226, and main housing 228 of module body 42 are shown. Filter cap 230, filter housing 232, and filter 72 of filter manifold 70 are shown. A portion of conduit 28 is shown.

[0239] Filter manifold 70 is at least partially disposed within module handle 224. Filter manifold 70 supports inlet fitting 68 and outlet fitting 74 in the example shown. The filter manifold 70 is configured to receive spray fluid through inlet fitting 68 and is configured to output spray fluid to conduit 28 through outlet fitting 74.

[0240] Filter manifold 70 projects out of rear end 242 of module 26. In the example shown, the filter manifold 70 projects rearward out of module handle 224. The filter housing 232 is partially disposed in module body 42 and partially disposed outside of module body 42. The filter housing 232 includes mount body 248, body connector 250, and fitting body 252. The mount body 248 is configured to interface with filter cap 230 to connect to filter cap 230. The mount body 248 receives the filter 72 such that the filter is disposed within mount body 248. The body connector 250 extends between and connects fitting body 252 on which outlet fitting 74 is formed at mount body 248. In the example shown, the mount body 248 includes exterior threads on both an upstream end and a downstream end to connect to filter cap 230 and body connector 250, respectively. The body connector 250 includes interior threading on both an upstream end and a downstream end to connect to exterior threading of the mount body 248 and fitting body 252, respectively.

[0241] Filter cap 230 is connected to filter housing 232 to enclose filter 72 within filter housing 232. Filter cap 230 can be removed from filter housing 232 to access filter 72 and for removal of filter 72. The interface between filter cap 230 and filter housing 232 is disposed outside of module body 42 such that the interface can be formed or broken from outside of module body 42. The filter housing 232 is configured to remain mounted to module body 42.

[0242] Filter cap 230 includes the inlet fitting 68 that connects to supply line 52 to receive pressurized spray fluid into module 26. The inlet fitting 68 is supported by cap piece 236. Cap piece 236 connects to filter housing 232. In the example shown, the inlet fitting 68 is connected to cap piece 236 such that inlet fitting 68, and thus supply line 52, can freely pivot on flow axis FA.

[0243] Internal flowpath 66 is disposed downstream of filter 72. Internal flowpath 66 extends between filter 72 and fluid hose 46 and is configured to provide spray fluid to fluid hose 46. The spray fluid exits from internal flowpath 66 and enters into fluid hose 46 at a location within module body 42. The internal flowpath 66 is defined by portions of filter housing 232 in the example shown.

[0244] In the example shown, module handle 224 defines handle cavity 254. The filter manifold 70 is partially disposed within handle cavity 254 and projects out of handle cavity 254 through upstream aperture 256. Upstream aperture 256 is disposed at an upstream end of handle cavity 254. The upstream aperture 256 is open through rear end 242 of module body 42. Filter manifold 70 does not extend fully axially through handle cavity 254 along flow axis FA. Instead, the conduit 28 extends into module handle 224 through downstream aperture 258. The downstream aperture 258 is open through forward end 240 of module body 42. The conduit 28 extends through downstream aperture 258 such that the fluid hose 46 and conductors 48 can enter into / exit from the sheath 50 at a location within module body 42 at which the fluid hose 46 and conductors 48 are shielded by the module body 42.

[0245] As discussed above, filter manifold 70 is mounted such that filter manifold 70 can complete partial, but not full rotations on the flow axis FA. In the example shown, rotation lock 246 interfaces with filter housing 232 to prevent filter manifold 70 from completing full rotations. Rotation lock 246 is disposed outside of filter housing 232 and within module body 42. Rotation lock 246 can extend at least partially about filter housing 232. The rotation lock 246 can, in some examples, support the filter housing 232 within the module body 42 and permit rotation of the filter housing 232 on the flow axis FA. While rotation lock 246 allows filter module 26 to rotate on flow axis FA, the rotation lock 246 prohibits full 360-degree rotation of the filter housing 232.

[0246] As best seen in FIG. 16, the rotation lock 246 includes ring body 260 and shaft 262. The ring body 260 extends about the filter housing 232. The filter housing 232 can extend through the ring body 260 such that the filter housing 232 projects out of the ring body 260 in both an upstream direction UD and the downstream direction DD along the flow axis FA. Shaft 262 projects from ring body 260 and is disposed within module body 42. The shaft 262 is configured to interface with module body 42 to prevent the rotation lock 246 from rotating relative to the module body 42. In the example shown, the shaft 262 extends into an arm 226 of the module body 42. The shaft 262 can interface with the module body 42 to be fixed axially along the flow axis FA.

[0247] Inner tab 264 projects from ring body 260. Inner tab 264 projects from a radially inner side of ring body 260 and towards the filter housing 232. Filter manifold 70 includes housing tab 266 that projects from filter housing 232. The housing tab 266 extends outwards away from flow axis FA. The housing tab 266 is configured to circumferentially overlap with inner tab 264 such that inner tab 264 blocks housing tab 266, and thus filter housing 232, from making full 360-degree rotations on the flow axis FA. Engagement of the housing tab 266 of the filter housing 232 with the inner tab 264 of the rotation lock 246 blocks full 360-degree rotation of the filter manifold 70.

[0248] In some examples, rotation lock 246 can axially retain filter manifold 70 relative to module body 42. For example, rotation lock 246 can interface with filter housing 232 such that rotation lock 246 prevents filter housing 232 from shifting axially along flow axis FA. In some examples, multiple retainers can interface with filter manifold 70 to rotationally limit filter manifold 70 and axially retain filter manifold 70.

[0249] In the example shown, locating groove 268 is formed about filter manifold 70. Locating groove 268 is partially formed by filter housing 232 and partially formed by body connector 250. In the example shown, a lock ring 270 extends into the locating groove 268 to axially locate filter manifold 70 relative to module body 42. The lock ring 270 is formed by one or more ribs of the module body 42 in the example shown. The ribs can be formed as portions of the shells 234 that form module body 42. The lock ring 270 can extend partially or fully about the filter housing 232. In the example shown, the retainer that axially retains the filter manifold 70 (e.g., lock ring 270) is disposed downstream of the retainer that rotationally limits the filter manifold 70 (e.g., rotation lock 246), though it is understood that not all examples are so limited.

[0250] During operation, the spray fluid enters into module 26 through inlet fitting 68. It is understood that inlet fitting 68 can connect directly to the supply line 52 or can connect to another hose assembly that fluidly connects the supply line 52 to the inlet fitting 68. The spray fluid flows through filter 72 and into internal flowpath 66. The spray fluid flows through internal flowpath 66 and is output to fluid hose 46 through outlet fitting 74. The spray fluid that is flowing within and through module body 42 is disposed only within the module handle 224 and not within other portions of the module body 42. All portions of the fluid pathways within module body 42 are isolated from the electronic assembly controller 44 which is disposed in the main housing 228. The fluid connections that are formed within module body 42 can be considered to form permanent connections in some examples, as such connections are not intended to be broken over the operational life of module 26. Fluid hose 46 is connected to outlet fitting 74 and is intended to remain connected to outlet fitting 74 throughout the life of module 26. The connections formed in module body 42 are fixed such that the components (e.g., conduit 28 and filter manifold 70) are not rotatable relative to each other. Such fixed connections can be more robust and prevent leakage.

[0251] Module 26 provides significant advantages. The conduit 28 is connected to the filter manifold 70 at the outlet fitting 74. The fluid hose 46 and filter manifold 70 are fixed together. Fluid hose 46 and conductors 48 extend into sheath 50. The conductors 48 are disposed outside of the fluid hose 46 such that continuous rotations of conduit 28 can bind or snap the conductors 48. Filter manifold 70 is secured within module body 42 such that the filter manifold 70 can rotate relative to module body 42 allowing for stress relief on conduit 28 and for easier manipulation and operation by a user, but filter manifold 70 is prevented from rotating beyond a particular point. In various examples, the point is less than 360-degrees. The filter manifold 70 being rotatable relative to module body 42 allows the conduit 28 to rotate relative to module body 42 which can relieve stress on conduit 28 and provide for easier operation of spray control assembly 14. However, preventing full rotations protects conductors 48 and thus the electrical connections between module 26 and spray gun 24 that are formed through conduit 28.

[0252] FIG. 17 is an isometric view of a spray control assembly 14. Spray gun 24, module 26, conduit 28, and mount 272 of spray control assembly 14 are shown. Mount body 274, mount arms 276, mount tabs 278, mount hooks 280, mount aperture 282, and support 284 of mount 272 are shown. Outer side 286 and inner side 288 of mount body 274 are shown.

[0253] Mount 272 is configured to support module 26 on a user such that the user is not required to carry module 26 by hand during operation. Instead, the mount 272 can be attached to a belt with a clip, hook, fastener, loop or other connector that can be integrated in the mount 272. The mount 272 can connect to other worn items besides the belt, such as a strap, harness, vest, backpack, or other wearable item. In the example shown, support 284 is configured to attach to the user to support module 26 on the user. The support 284 is formed as a clip in the example shown. The support 284 is disposed on inner side 288 of mount body 274. The inner side 288 is configured to be oriented towards the user with the mount 272 attached to the user. The outer side 286 is configured to be oriented outward away from the user with mount 272 attached to the user. Mount arms 276 extend from mount body 274. As shown, the module 26 can be held by the mount arms 276. In various examples, the module handle 224 can be held by the mount arms 276. The mount arms 276 permit the module 26 to be easily mounted and dismounted by vertical motion, as the mount arms 276 includes upward facing openings. The mount arms 276 can be configured to snap fit onto the module handle 224. The snap fit can secure the module handle 224 in the mount arms 276 when snapped into place such that spring force of the mount arms 276 must be overcome to dismount the module handle 224 from within the mount arms 276. Even with the module 26 mounted, the mount arms 276 allow the module handle 224 (and hoses connected to module 26) to rotate along the flow axis FA through the module handle 224, which can aid in comfort and maneuverability. As shown, the mount arms 276 extends through a module aperture 290 that extends through the module body 42. The module aperture 290 is formed between module arms 226, module handle 224, and main housing 228 in the example shown.

[0254] Mount tabs 278 are formed on mount arms 276. Cutouts 292 are formed in mount arms 276 to define the mount tabs 278. The cutouts 292 provide space for the mount tabs 278 to flex during mounting and dismounting of module 26 on mount 272. Mount tabs 278 are configured to interface with module body 42 to limit rotation of the module handle 224 within the mount arms 276. During mounting, the module handle 224 can be inserted into the mount arms 276 by vertical movement. The module 26 can then be rotated such that the mount tabs 278 pass over a top side of the main housing 228 and through the module aperture 290. The mount tabs 278 can snap onto the main housing 228. The mount tabs 278 interfacing with the main housing 228 can prevent the module 26 from rotating away from the user during operation and as the user moves about the job side, providing improved comfort and maneuverability. However, the module 26 is still able to rotate towards the user and away from the mount tabs 278, further assisting in improved comfort and maneuverability. It is understood, however, that not all examples are so limited. In some examples, the mount 272 does not include mount tabs 278 that rotationally limit the module 26. In such an example the module 26 can freely rotate on the module handle 224 within the mount arms 276.

[0255] Mount hooks 280 are configured to interface with spray gun 24 to support spray gun 24 on mount 272. In the example shown, the mount hooks 280 extend from the mount arms 276. The mount hooks 280 extend away from the mount body 274. The mount hooks 280 extend such that mount hooks 280 define openings that are oriented vertically. In the example shown, the openings are oriented vertically upwards. While mount hooks 280 are shown as extending from mount arms 276, it is understood that not all examples are so limited. For example, mount hooks 280 can extend from mount body 274 among other locations. In some examples, one or more mount hooks 280 can be formed on or by module body 42 such that the spray gun 24 can be supported on and by module body 42. In the example shown, the mount 272 includes multiple mount hooks 280, two in this example, but it is understood that mount 272 can include a single mount hook 280 or more than two mount hooks 280.

[0256] The mount hooks 280 provide locations that the spray gun 24 can be mounted on mount 272 to be supported by mount 272. For example, the user can place a portion of the spray gun 24, such as a portion of gun body 30, such as top hook 294, into the opening of a mount hook 280. With the portion of spray gun 24 interfacing with mount hook 280, the spray gun 24 can hang from the mount hook 280 to be supported by the mount 272. Such a configuration allows the user to let go of the spray gun 24 without setting the spray gun 24 down or dragging the spray gun 24. The mount hook 280 supports the spray gun 24 at a location that is easily accessible by the user. The multiple mount hooks 280 shown allow the user to approach the mount hooks 280 with the spray gun 24 from the forward end 240 of module 26 regardless of whether module 26 is worn on the right or left side of the user.

[0257] Mount aperture 282 extends through mount body 274. Mount aperture 282 can extend fully through mount body 274. In some examples, mount aperture 282 can extend through support 284. Mount aperture 282 facilitates supporting mount 272 on other structure such that mount 272 can fully support spray control assembly 14 off of the ground surface even when mount 272 is not worn by the user. As shown in FIG. 2, the pumping assembly 12 can include a holder. For example, the holder can be formed by a housing of a filter assembly of the pumping assembly 12, which filter assembly can house an upstream filter. The holder can be cylindrical, among other options. The holder can pass through the mount aperture 282 to support the mount 272 on the pumping assembly 12.

[0258] Module 26 can be supported on mount 272 such that forward end 240 of module 26 is oriented forward relative to the user. In such a configuration, the conduit 28, which exits from forward end 240 of module 26, does not have to wrap around the user or module 26 to reach the spray gun 24 that is being held by the user. Mount 272 is configured to support module 26 on either the left or right sides of the user, providing a convenient and ergonomic interface whether the user sprays with the user’s left or right hand, while the module 26 is oriented with the forward end 240 oriented forward relative to the user. Mount 272 is configured such that the forward end 240 of module 26 faces forward with the user. Inner side 288 of mount 272 is configured to be oriented inwards towards the user regardless of the location on the user that mount 272 is located. If the mount 272 is disposed on a lefthand side of the user, then the module 26 can be mounted as shown in FIG. 17 such that the lateral side 244a of module 26 is oriented outward away from the user and lateral side 244b of module 26 is oriented inwards towards the user. If mount 272 is disposed on a righthand side of the user, then the module 26 can be mounted such that lateral side 244a is oriented inward toward the user and lateral side 244b is oriented outwards away from the user. Mount 272 thereby facilitates mounting of module 26 in multiple different orientations relative to the user while maintaining forward end 240 oriented forward.

[0259] Mount 272 is configured to support module 26 on the user. The supply line 52 connects to module 26 to provide spray fluid to the spray control assembly 14. The supply line 52 connects to module 26 such that the weight of supply line 52 is carried by module 26. The weight of the supply line 52 is not transmitted through module 26 and up conduit 28 to be carried by the spray gun 24 and thus by the hand of the user. Instead, the weight of the supply line 52 is supported by module 26, which is supported on the user by mount 272. Such a configuration provides for easier and more ergonomic spraying by the user as the user is not required to carry and support the weight of the supply line 52 in the user’s hand. Such a configuration can be particularly useful when spraying in elevated locations such that the length of supply line 52 not on the ground and supported by the user increases which increases the weight of the supply line 52, such as when the user is on a ladder.

[0260] While the invention has been described with reference to an exemplary embodiment(s), 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 invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims. Any single feature, or any combination of features from one embodiment show herein, may be utilized in a different embodiment independent from the other features shown in the embodiment herein. Accordingly, the scope of the invention(s) and any claims thereto are not limited to the particular to the embodiments and / or combinations of the features shown herein, but rather can include any combination of one, two, or more features shown herein.

Claims

CLAIMS:

1. A cartridge for use in a spray gun, the spray gun comprising a solenoid coil, the cartridge comprising: a cartridge body defining a fluid chamber and having an inlet and an outlet; a spray valve disposed within the cartridge body, the spray valve including an actuatable seal located fluidly between the inlet and the outlet; and a plunger that is connected to the spray valve, the plunger configured to be moved by an electromagnetic field generated by the solenoid coil to actuate the spray valve to an open state in which the inlet is fluidly connected to the outlet; wherein the cartridge body, the spray valve, and the plunger are integrated into a unitary assembly that is insertable into the spay gun and removable from the spray gun as the unitary assembly.

2. The cartridge of claim 1 , wherein the cartridge body includes a fluid housing and a base connected to the fluid housing.

3. The cartridge of claim 2, wherein the spray valve is disposed in the fluid housing and the plunger is disposed in the base.

4. The cartridge of any one of claims 2 and 3, wherein the inlet is formed through the fluid housing and the outlet is formed through the fluid housing.

5. The cartridge of any one of claims 2-4, wherein the cartridge further comprises a rod that extends within both the fluid housing and the base.

6. The cartridge of claim of any one of claims 3-5, further comprising an end cap mounted to the base.

7. The cartridge of claim 6, wherein the end cap encloses a plunger chamber within the base that the plunger is disposed within.

8. The cartridge of any one of claims 6 and 7, wherein the end cap defines a limit of travel for the plunger.

9. The cartridge of any one of claims 6-8, wherein the end cap blocks the plunger from being removed from the base.

10. The cartridge of any one of claims 6-9, wherein the cap is directly attached to the cartridge body.

11. The cartridge of any one of claims 2-10, wherein the base is threadedly connected to the fluid housing.

12. The cartridge of any preceding claim, wherein: a fluid chamber is located within the cartridge body; the spray valve is located at least partially within the fluid chamber; the spray valve controls release of spray fluid from within the fluid chamber; and the fluid chamber receives the spray fluid via the inlet.

13. The cartridge of any preceding claim, further comprising: a spring located within the cartridge body, the spring urging the valve towards a closed state.

14. The cartridge of any one of claims 1-4 and 6-11, further comprising: a rod that extends within the cartridge body, the rod connecting the plunger to the spray valve.

15. The cartridge of claim 14, further comprising: a seal located around the rod, the rod configured to reciprocate within the seal.

16. The cartridge of any one of claims 14 and 15, wherein the rod extends at least partially within the plunger.

17. The cartridge of any one of claims 14-16, wherein the rod extends fully through the plunger.

18. The cartridge of any one of claims 14-17, wherein the rod is attached to a rear side of the plunger.

19. The cartridge of any one of claims 14-18, wherein the rod is welded to the plunger.

20. The cartridge of any one of claims 14-19, wherein.

21. The cartridge of any preceding claim, wherein the plunger is located within the cartridge body and reciprocates relative to the cartridge body such that the cartridge body extends rearward of the plunger.

22. The cartridge of claim 21, wherein the cartridge body comprises a cylindrical cavity in which the plunger is located.

23. The cartridge of claim 22, wherein the cylindrical cavity includes an opening on a back side of the cartridge body.

24. The cartridge of any preceding claim, wherein the entirety of the magnetically active material on which the coil electromagnetically acts to actuate the spray valve is located within the cartridge body.

25. The cartridge of any preceding claim, wherein a first seal and a second seal are spaced axially along an exterior of the cartridge body, and wherein the inlet is disposed between the first seal and the second seal.

26. The cartridge of any preceding claim, wherein exterior threading is formed on the cartridge body, the exterior threading configured to interface with inner threading of the spray gun.

27. The cartridge of any preceding claim, wherein the spray valve comprises a ball and a ring seat, the ball interfacing with the ring seat to seal the outlet, and the ball moving away from the ring seat to allow flow out of the outlet.

28. The cartridge of any preceding claim, further comprising a plunger guard which at least partially covers the plunger and extends axially beyond the plunger.

29. The cartridge of claim 28, wherein the plunger guard comprises a flux permeability zone and a flux reluctance zone.

30. The cartridge of claim 29, wherein the flux permeability zone is formed of a first type of material and the flux reluctance zone is formed by a second type of material which makes the flux permeability of the flux permeability zone greater than the flux permeability of the flux reluctance zone.

31. A spray gun comprising: a valve housing defining a housing bore; a trigger; the cartridge of any preceding claim, wherein the cartridge is configured to mount to the valve housing such that the cartridge is at least partially disposed within the valve housing, and such that the plunger is operatively aligned with the solenoid coil.

32. The spray gun of claim 31, wherein the solenoid coil surrounds the plunger with the cartridge received within the housing bore.

33. A spray gun comprising: a gun body; a solenoid coil disposed within the gun body; a handle; a trigger; a spray valve, the spray valve including an actuatable seal located fluidly between an inlet and an outlet; anda plunger, the plunger configured to be moved by an electromagnetic field generated by the solenoid coil; and a rod the connects between the spray valve and the plunger such that the electromagnetic field generated by the solenoid coil moving the plunger actuates the spray valve to one or both of an open state and a closed state, wherein the rod extends at least partially into the plunger.

34. The spray gun of claim 33, wherein the rod is directly connected to each of the spray valve and the plunger.

35. The spray gun of any one of claims 33 and 34, wherein the rod extends fully through the plunger.

36. The spray gun of any one of claims 33-35, wherein the rod is attached directly to the plunger.

37. The spray gun of any one of claims 33-36, wherein the rod is attached to a rear side of the plunger.

38. The spray gun of any one of claims 33-37, wherein the rod is welded to the plunger.

39. The spray gun of any one of claims 33-38, wherein the plunger is fixed to a particular location along the rod, the particular location accounting for an opening distance of the spray valve.

40. A method of making the spray gun of any one of claims 33-39, the method comprising: attaching a first end of the rod to the spray valve; and after attaching the first end of the rod to the valve, indexing a position of the plunger on the rod and then fixing the plunger on the rod.

41. A cartridge for use in a spray gun, the spray gun comprising a solenoid coil, the cartridge comprising: a cartridge body defining a fluid chamber and having an inlet and an outlet; a spray valve disposed within the cartridge body, the spray valve including an actuatable seal located fluidly between the inlet and the outlet; and a plunger that is connected to the spray valve and is at least partially disposed within a plunger chamber defined by a plunger guard of thecartridge body, the plunger configured to be moved by an electromagnetic field generated by the solenoid coil to actuate the spray valve to an open state in which the fluid chamber is fluidly connected to the outlet; wherein the cartridge body, the spray valve, and the plunger are integrated into a unitary assembly that is insertable into the spay gun and removable from the spray gun as the unitary assembly.

42. The cartridge of claim 41, wherein the plunger is fully disposed within the plunger guard.

43. The cartridge of any one of claims 41 and 42, wherein the plunger guard includes a flux permeability zone and a flux reluctance zone, wherein the flux permeability zone is formed of a first type of material and the flux reluctance zone is formed by a second type of material which makes the flux permeability of the flux permeability zone greater than the flux permeability of the flux reluctance zone.

44. The cartridge of claim 43 , wherein the first type of material is ferromagnetic and the second type of material is non-ferromagnetic.

45. The cartridge of any one of claims 43 and 44, wherein the flux reluctance zone extends in an upstream direction beyond the plunger.

46. The cartridge of any one of claims 41-45, wherein the cartridge body comprises: a fluid housing within which the spray valve is disposed; a base connected to the fluid housing, the base including the plunger guard.

47. The cartridge of claim 46, wherein the inlet is formed in the fluid housing and the outlet is formed in the fluid housing.

48. The cartridge of any one of claims 46 and 47, wherein the base is not a pressure vessel.

49. The cartridge of any one of claims 46-48, wherein a first seal is supported on an exterior of the fluid housing and a second seal is supported on an exterior of the base.

50. The cartridge of claim 49, wherein exterior threading is formed on the exterior of the cartridge body, the cartridge mount disposed axially between the first seal and the outlet and the cartridge mount disposed axially between the second seal and the outlet.

51. The cartridge of any one of claims 49 and 50, wherein the inlet is disposed axially between the first seal and the second seal.

52. The cartridge of any one of claims 46-51, further comprising: an end cap connected to the base and axially overlapping with the plunger chamber.

53. The cartridge of claim 52, wherein the end cap includes a recess aligned on the axis, the recess open to the plunger chamber.

54. The cartridge of claim 53, further comprising: a rod extending between and connecting the plunger and the spray valve.

55. The cartridge of claim 54, wherein the rod extends into the recess and radially overlaps with the end cap with the spray valve in the open state.

56. The cartridge of any one of claims 52-55, wherein the end cap defines a limit of travel for the plunger in an upstream direction.

57. The cartridge of any one of claims 46-53, further comprising: a rod extending between and connecting the plunger and the spray valve; and a dynamic seal disposed axially between the fluid chamber and the plunger chamber, the dynamic seal engaging with an exterior of the rod.

58. The cartridge of claim 57, wherein the dynamic seal is supported by the base.

59. The cartridge of any one of claims 46-58, wherein the base defines an upstream end of the fluid chamber and the fluid housing defines a downstream end of the fluid chamber.

60. The cartridge of any one of claims 41-59, further comprising: a spring configured to bias the spray valve into the closed state.

61. The cartridge of claim 60, wherein the spring is disposed within the fluid chamber.

62. A cartridge for use in a spray gun, the spray gun comprising a solenoid coil, the cartridge comprising: a cartridge body having an upstream end and a downstream end and defining a fluid chamber, wherein an inlet and an outlet are formed through the cartridge body; a spray valve disposed within the cartridge body, the spray valve including an actuatable seal located fluidly between the inlet and the outlet; a plunger that is connected to the spray valve and is at least partially disposed within a plunger chamber defined by a plunger guard of thecartridge body, the plunger configured to be moved by an electromagnetic field generated by the solenoid coil to actuate the spray valve to an open state in which the fluid chamber is fluidly connected to the outlet; and a rod extending between the plunger and the spray valve to connect the plunger to the spray valve; wherein the cartridge body, the spray valve, and the plunger are integrated into a unitary assembly that is insertable into the spay gun and removable from the spray gun as the unitary assembly; and wherein the first distance setting an opening distance of the spray valve.

63. The cartridge of claim 62, wherein the rod extends fully axially through the plunger.

64. The cartridge of any one of claims 62 and 63, wherein the rod is fixed to an upstream side of the plunger.

65. The cartridge of any one of claims 62-64, wherein the plunger chamber is closed in both an upstream direction and a downstream direction.

66. The cartridge of any one of claims 62-65, wherein the cartridge body includes an end cap disposed on an opposite side of the plunger from the fluid chamber, the end cap axially overlapping with the plunger to define a travel limit of the plunger.

67. A cartridge for use in a spray gun, the spray gun comprising a solenoid coil, the cartridge comprising: a cartridge body having an upstream end and a downstream end and defining a fluid chamber, wherein an inlet and an outlet are formed through the cartridge body; a spray valve disposed within the cartridge body, the spray valve including an actuatable seal located fluidly between the inlet and the outlet; a plunger that is connected to the spray valve and is at least partially disposed within a plunger chamber defined by a plunger guard of the cartridge body, the plunger configured to be moved by an electromagnetic field generated by the solenoid coil to actuate the spray valve to an open state in which the fluid chamber is fluidly connected to the outlet; wherein the plunger guard includes a flux permeability zone and a flux reluctance zone, wherein the flux permeability zone is formed of afirst type of material and the flux reluctance zone is formed by a second type of material which makes the flux permeability of the flux permeability zone greater than the flux permeability of the flux reluctance zone; wherein the plunger radially overlaps with the flux permeability zone and the flux reluctance zone; and wherein the cartridge body, the spray valve, and the plunger are integrated into a unitary assembly that is insertable into the spay gun and removable from the spray gun as the unitary assembly.

68. The cartridge of claim 67, wherein the cartridge body comprises: a fluid housing at least partially defining the fluid chamber and within which the spray valve is disposed; a base connected to the fluid housing, wherein the plunger guard is formed as a portion of the base; wherein the base is formed such that the first type of material radially overlaps with the plunger and axially overlaps with the plunger.

69. The cartridge of any one of claims 67 and 68, wherein the flux reluctance zone does not axially overlap with the plunger.

70. The cartridge of any one of claims 67-69, wherein the flux reluctance zone extends to the downstream end.

71. A method of setting an opening distance of a spray valve of a cartridge for use in a spray gun, the method comprising: placing a plunger of a solenoid on a rod, the rod extending between the spray valve and the plunger; positioning the plunger at a set location along the rod to set a displacement distance of the solenoid, thereby setting an opening distance of the spray valve; and fixing the plunger and the rod together with the plunger at the set location.

72. The method of claim 71, wherein positioning the plunger at the set location along the rod comprises: magnetically drawing the plunger in an upstream direction away from the spray valve to the set location.

73. The method of claim 71, wherein positioning the plunger at the set location along the rod comprises:placing a magnetic locator over an upstream end of the cartridge such that the magnetic locator magnetically pulls the plunger in an upstream direction away from the spray valve and to the set location; wherein the magnetic locator extends at least partially into the cartridge to space the plunger from the upstream end of the cartridge.

74. The method of claim 73, wherein fixing the plunger and the rod together with the plunger at the set location comprises: accessing the rod through an aperture formed in the locator; and fixing the rod to the plunger.

75. The method of any one of claims 71-74, further comprising: fixing an end cap to the cartridge body, the end cap defining an upstream limit of travel for the plunger.

76. A spray gun comprising: a gun body; a solenoid coil disposed within the gun body; a handle; a trigger; a valve housing supported by the gun body and within which the solenoid coil is at least partially disposed, the valve housing comprising: a fluid receiver configured to receive spray fluid; and a coil housing mounted to the fluid receiver, the coil housing supporting the solenoid coil, wherein the coil housing extends into the fluid receive to connect to the fluid receiver; a spray valve, the spray valve including an actuatable seal located fluidly between an inlet and an outlet; and a plunger, the plunger configured to be moved by an electromagnetic field generated by the solenoid coil such that the electromagnetic field generated by the solenoid coil moves the plunger to actuate the spray valve to an open state in which the inlet is fluidly connected to the outlet.

77. The spray gun of claim 76, wherein the coil housing includes exterior threading interfacing with interior threading of the fluid receiver.

78. The spray gun of any one of claims 76 and 77, wherein the coil housing includes:a coil mount interfacing with the fluid receiver to connect the coil housing to the fluid receiver; a first housing portion extending outward from the coil mount away from the axis; a second housing portion extending away from the first housing portion an in an upstream direction; wherein the solenoid coil is disposed in a housing notch formed at an intersection between the first housing portion and the second housing portion.

79. The spray gun of claim 78, further comprising: a solenoid cap connected to the coil housing, wherein the solenoid coil is disposed in a cap notch formed by the solenoid cap.

80. The spray gun of claim 79, wherein the housing notch is open inwards towards the axis and in an upstream direction and the cap notch is open outwards away from the axis and in a downstream direction.

81. The spray gun of any one of claims 79 and 80, wherein the solenoid coil is axially clamped between the solenoid cap and the coil housing.

82. The spray gun of any one of claims 79-81, wherein the solenoid cap radially overlaps with the solenoid coil.

83. The spray gun of any one of claims 79-82, wherein an electrical connector extends through the solenoid cap to connect to the solenoid coil.

84. The spray gun of any one of claims 78-83, wherein the first housing portion axially overlaps with the fluid receiver.

85. A spray gun comprising: a gun body; a solenoid coil disposed within the gun body; a handle ; a trigger; a valve housing supported by the gun body and within which the solenoid coil is at least partially disposed; a spray valve, the spray valve including an actuatable seal located fluidly between an inlet and an outlet; and a plunger, the plunger configured to be moved by an electromagnetic field generated by the solenoid coil such that the electromagnetic fieldgenerated by the solenoid coil moves the plunger to actuate the spray valve to an open state in which the inlet is fluidly connected to the outlet; wherein the solenoid coil is axially and radially captured between an outer notch of the valve housing and in inner notch of the valve housing.

86. The spray gun of claim 85, wherein the solenoid coil is disposed rearward of the trigger.

87. The spray gun of any one of claims 85 and 86, wherein the solenoid coil extends annularly about a housing bore within the valve housing.

88. The spray gun of any one of claims 85-87, wherein the valve housing includes: a solenoid cap connected to a main body of the valve housing, wherein the solenoid cap defines the inner notch.

89. The spray gun of claim 88, wherein the solenoid cap is connected to a coil housing of the valve housing, the coil housing connected to a fluid receiver configured to receive spray fluid into the valve housing.

90. The spray gun of claim 89, wherein the coil housing defines the outer notch.

91. The spray gun of any one of claims 89 and 90, wherein an electrical connector extends through the valve housing to electrically connect to the solenoid coil.

92. The spray gun of claim 91, wherein the electrical connector extends axially through the valve housing.

93. The spray gun of any one of claims 89-92, wherein the coil housing extends into the fluid receiver to connect to the fluid receiver.

94. The spray gun of any one of claims 85-93, wherein the solenoid coil is disposed rearward of a housing inlet through the valve housing, the housing inlet configured to admit spray fluid into the valve housing.

95. The spray gun of any one of claims 85-94, further comprising: a cartridge including a cartridge body defining a fluid chamber, including the spray valve, and including the plunger; wherein the cartridge is mountable to and removable from a housing bore within the valve housing.

96. The spray gun of claim 95 , wherein a portion of the plunger radially overlaps with the solenoid coil with the cartridge mounted to the valve housing.

97. A spray system that outputs spray fluid through a hose having a fitting, the spray gun system comprising: a spray gun, the spray gun comprising a valve, an electric actuator which actuates the valve, a handle, a trigger, and a sensor that senses actuation of the trigger; a battery; and an assembly controller configured to: receive electrical energy from the battery; in a gun pairing mode, transmit a unique identifier; receive a signal from the sensor indicating actuation of the trigger; deliver electrical energy to the electric actuator based on the signal; and based on the signal, transmit a command together with the unique identifier.

98. The spray system of claim 97, further comprising: a pump; an electric motor configured to operate the pump; and a sprayer controller configured to: in a sprayer pairing mode, receive the unique identifier; store the unique identifier in a memory of the sprayer controller as a command identifier; receive the command together with the unique identifier; based on the command, either start or stop the electric motor.

99. The spray system of claim 98, wherein the sprayer controller is configured to, based on the command, either start or stop the electric motor by changing a threshold pressure setpoint.

100. The spray system of claim 99, wherein changing the threshold pressure setpoint comprises either: setting the threshold pressure setpoint to either at or below a current pressure to cause stoppage of the electric motor; and setting the threshold pressure setpoint above the current pressure to resume operation of the electric motor.

101. The spray system of any one of claims 99-100, wherein any command that is received by the sprayer controller that does not include the unique identifier does not cause the sprayer controller to start or stop the electric motor.

102. A spray system that outputs spray fluid through a hose having a fitting, the spray gun system comprising: a spray gun, the spray gun comprising a valve, an electric actuator which actuates the valve, a handle, a trigger, and a sensor that senses actuation of the trigger; a battery; an assembly controller configured to: receive electrical energy from the battery; receive a signal from the sensor indicating actuation of the trigger; deliver electrical energy to the electric actuator based on the signal; and based on the signal, transmit a command; a pump; an electric motor configured to operate the pump; and a sprayer controller configured to: receive the command; and either start or stop the electric motor by changing a threshold pressure setpoint.

103. The spray system of claim 102, wherein the system controller is configured to: in a sprayer pairing mode, receive a unique identifier from the assembly controller; store the unique identifier in a memory of the system controller as a command identifier; receive the command together with the unique identifier; based on the command, either start or stop the electric motor.

104. The spray gun system of any one of claims 102 and 103, wherein the sprayer controller is configured to change the threshold pressure setpoint by setting the threshold pressure setpoint to either at or below a current measured pressure to cause stoppage of the electric motor.

105. The spray system of claim 104, wherein the sprayer controller is configured to change the threshold pressure setpoint by setting the threshold pressure setpoint above the current measured pressure to resume operation of the electric motor.

106. The spray system of claim 105, wherein the sprayer controller is configured to set the threshold pressure setpoint above the current measured pressure to resume operation of the electric motor by setting the threshold pressure setpoint to a pressure setting that is based on a user input pressure.

107. A spray system comprising: a spray gun, the spray gun comprising a valve, an electric actuator which actuates the valve, a handle, a trigger, and a sensor that senses actuation of the trigger; a battery; an assembly controller configured to: receive electrical energy from the battery; in a gun pairing mode, transmit a unique identifier to a sprayer controller of a pumping assembly; receive a signal from the sensor indicating actuation of the trigger; deliver electrical energy to the electric actuator based on the signal; and based on the signal, transmit a spray command, the spray command including spray instructions and the unique identifier; the pumping assembly comprising: a pump; an electric motor configured to operate the pump; and the sprayer controller configured to: in a sprayer pairing mode receive the unique identifier; and store, in a memory of the sprayer controller, the unique identifier as a command identifier; receive the spray command; and either start or stop the electric motor based on a comparison of the unique identifier of the spray command and the command identifier.

108. The spray system of claim 107, wherein the pumping assembly is configured to receive the unique identifier and is configured to not transmit signals to the spray gun when in the sprayer pairing mode.

109. The spray system of any one of claims 107 and 108, wherein the assembly controller and the sprayer controller are configured for one-way communication in which the sprayer controller receives communications from the assembly controller and the assembly configured does not receive communications from the system controller.

110. The spray system of any one of claims 107-109, further comprising: a user interface, the user interface configured to generate a pressure adjustment command; wherein the assembly controller is configured to output the pressure adjustment command to the sprayer controller; and wherein the sprayer controller is configured to change a target pressure setpoint based on the pressure adjustment command.

111. The spray system of claim 110, wherein the sprayer controller is configured to increment the target pressure setpoint based on the pressure adjustment command.

112. The spray system of any one of claims 110 and 111, wherein: the user interface includes a first input and a second input; the first input is configured to generate a first pressure adjustment command that causes the system controller to adjust the threshold pressure setting upwards; and the second input is configured to generate a second pressure adjustment command that causes the system controller to adjust the threshold pressure setting downwards.

113. The spray system of claim 112, wherein the first input is a first button and the second input is a second button.

114. The spray system of any one of claims 110-113, further comprising: a module supporting the battery, the module connected to a supply hose that provides pressurized spray fluid from the pump, wherein the module is fluidly connected to the spray gun to provide the pressurized spray fluid to the spray gun; and wherein the user interface is formed on the module.

115. The spray system of claim 114, wherein the assembly controller is at least partially disposed within a module body of the module.

116. A pumping assembly for a spray system, the pumping assembly comprising: a pump; an electric motor configured to operate the pump; and a sprayer controller configured to: control operation of the electric motor to start or stop pumping by the pump based on a target pressure setpoint; adjust a value of the target pressure setpoint to a remapped pressure setpoint to stop the electric motor and stop pumping by the pump, wherein the remapped pressure setpoint is generated based on a measured pressure.

117. The pumping assembly of claim 116, wherein the sprayer controller is configured to start the electric motor based on the target pressure setpoint and stop the electric motor based on the remapped pressure setpoint.

118. The pumping assembly of any one of claims 116 and 117, wherein the system controller is configured to generate the remapped pressure setpoint based on the system controller receiving a stop spray command.

119. The pumping assembly of claim 118, wherein the stop spray command is generated based on release of a trigger of a spray gun fluidly connected to the pump to receive pressurized spray fluid output by the pump.

120. The pumping assembly of any one of claims 116-118, wherein the sprayer controller is configured to control operation of the electric motor based on the target pressure threshold based on the spray controller receiving a start spray command.

121. The pumping assembly of claim 120, wherein the start spray command is generated based on pull of a trigger of a spray gun fluidly connected to the pump to receive pressurized spray fluid output by the pump.

122. A spray system comprising: a spray gun, the spray gun comprising a valve, an electric actuator which actuates the valve, a handle, a trigger, and a sensor that senses actuation of the trigger; a battery; an assembly controller configured to: receive electrical energy from the battery; receive a signal from the sensor indicating actuation of the trigger; anddeliver electrical energy to the electric actuator based on the signal; and a pumping assembly comprising: a pump; an electric motor configured to operate the pump; and a sprayer controller configured to start or stop the electric motor, the sprayer controller configured to control operation of the electric motor based on a threshold pressure setting; wherein the assembly controller is configured to provide a pressure adjustment command to the sprayer controller; and wherein the sprayer controller is configured to change the target pressure setpoint based on the pressure adjustment command.

123. The spray system of claim 122, wherein the assembly controller and the sprayer controller are configured for one-way communication in which the sprayer controller receives communications from the assembly controller and the assembly configured does not receive communications from the system controller.

124. The spray system of any one of claims 122 and 123, further comprising: a user interface, the user interface configured to generate the pressure adjustment command.

125. The spray system of claim 124, wherein the sprayer controller is configured to increment the target pressure setpoint based on the pressure adjustment command.

126. The spray system of any one of claims 124 and 125, wherein: the user interface includes a first input and a second input; the first input is configured to generate a first pressure adjustment command that causes the system controller to adjust the threshold pressure setting upwards; and the second input is configured to generate a second pressure adjustment command that causes the system controller to adjust the threshold pressure setting downwards.

127. The spray system of claim 126, wherein the first input is a first button and the second input is a second button.

128. The spray system of any one of claims 122-127, further comprising: a module supporting the battery, the module connected to a supply hose that provides pressurized spray fluid from the pump, wherein the moduleis fluidly connected to the spray gun to provide the pressurized spray fluid to the spray gun; and wherein the user interface is formed on the module.

129. The spray system of any one of claims 122-128, wherein the sprayer controller is configured to increment the target pressure setpoint based on the pressure adjustment command.

130. A spray control assembly for use with a pumping assembly that outputs spray fluid through a supply hose having a fitting, the spray control assembly comprising: a spray gun, the spray gun comprising a spray valve, an actuator which actuates the spray valve, a handle, a trigger, and a sensor that senses actuation of the trigger; a conduit, the conduit comprising at least one hose and at least one electrical conductor, the conduit having a far end and a near end, the far end connected to the spray gun to deliver spray fluid to the spray valve and electrical energy to the actuator; and a module comprising: an inlet fitting configured to attach to the fitting of the supply hose to receive spray fluid into the module from the sprayer pump; a battery; a module housing; and an assembly controller at least partially located within the module housing, the assembly controller configured to: receive electrical energy from the battery; receive a signal from the sensor indicating actuation of the trigger; and deliver electrical energy to the actuator via one or more of the at least one electrical conductor of the conduit.

131. The spray gun system of claim 130, wherein the module housing supports the battery, the inlet fitting, and the assembly controller.

132. The spray gun system of claim 131, wherein the spray fluid received via the inlet fitting is routed into the module housing and then through the at least one hose to the spray gun.

133. The spray gun system of any one of claims 131 and 132, wherein the near end of the conduit extends into the module housing such that a fluid connection with the near end of the conduit is made inside of the module housing.

134. The spray gun system of any one of claims 131-133, wherein the assembly controller controls operation of the actuator.

135. The spray gun system of any one of claims 131-134, wherein the battery mounts to an exterior of the module housing such that the battery is accessible without opening the module housing.

136. The spray gun system of any one of claims 131-135, further comprising: a mount connected to the module body, the mount configured to facilitate attachment of the module housing to a body of a user such that the module housing can be warn.

137. The spray gun system of claim 136, wherein the mount attaches to a strap.

138. The spray gun system of claim 137, wherein the strap is a belt.

139. The spray gun system of any one of claims 130-138, wherein the module further comprises a fluid filter located downstream of the inlet fitting.

140. The spray gun system of claim 139, wherein the fluid filter is accessible for cleaning from an exterior of the module.

141. The spray gun system of any one of claims 139 and 140, wherein the fluid filter is disposed within a filter housing, wherein the filter housing is partially disposed in the module body and partially disposed outside of the module body, and wherein the inlet fitting is connected to the filter housing.

142. The spray gun system of any one of claims 130-141, further comprising a sheath that extends over the at least one hose and the at least one electrical conductor.

143. The spray gun system of any one of claims 130-141 , wherein the far end of the conduit extends into the spray gun such that connections with the at least one hose and the at least one electrical conductor are made inside of the spray gun.

144. The spray gun system of any one of claims 130-143, wherein the assembly controller is configured to send a start signal to the pumping assembly that causes the pumping assembly to start operating an electric motor of the pumping assembly to drive a pump of the pumping assembly.

145. The spray gun system of claim 144, wherein the assembly controller is configured to send the start signal to the pumping assembly based on receiving an indication from the sensor that the trigger is actuated.

146. The spray gun system of any one of claims 130-145, wherein the assembly controller is configured to send a stop signal to the pumping assembly that causes the pumping assembly to stop pumping of the spray fluid.

147. The spray gun system of claim 146, wherein the assembly controller is configured to send the stop signal to the sprayer based on receiving an indication from the sensor that the trigger is released from actuation.

148. The spray gun system of any one of claims 130-147, wherein the assembly controller communicates with the pumping assembly via a wired connection along the supply hose but not inside the supply hose.

149. The spray gun system of any one of claims 130-147, wherein the control circuitry communicates with the sprayer pump via a wireless connection.

150. The spray gun system of any one of claims 130-149, wherein the module does not comprise a pump.

151. The spray gun system of any one of claims 130-150, wherein the spray gun does not comprise a battery.

152. The spray gun system of any one of claims 130-151, wherein all control circuitry that operates, communicates with, and / or powers the spray gun is the assembly controller of the module.

153. The spray gun system of any one of claims 130-152, wherein the module comprises a filter manifold that contains a filter, the filter removable from the filter manifold.

154. The spray gun system of claim 153, wherein the filter manifold is at least partially contained within the module housing.

155. The spray gun system of claim 154, wherein the module housing entirely contains the assembly controller.

156. The spray gun system of any one of claims 154 and 155, wherein the filter manifold can rotate within and relative to the module housing.

157. The spray gun system of claim 156, wherein the filter manifold is rotatable within and relative to the module housing but is blocked from making a full 360-degree rotation.

158. The spray gun system of claim 157, wherein the filter manifold is blocked from making the full 360-degree rotation by a ring having at least one blocking tab.

159. The spray gun system of claim 158, wherein the ring is located around the filter manifold.

160. The spray gun system of any one of claims 156-159, wherein the filter manifold being rotatable allows the conduit to rotate.

161. The spray gun system of claim 160, wherein the conduit is rotatable within the module housing.

162. The spray gun system of any one of claims 155-161, wherein the filter manifold include a filter housing and a filter cap which threads into the filter housing, wherein the filter cap removeable from the filter housing while the filter manifold is retained within the module housing.

163. The spray gun system of claim 162, wherein the supply hose attaches to the filter cap.

164. The spray gun system of any one of claims 155-163, wherein a swivel is located between the supply hose and the filter manifold allowing the supply hose to rotate relative to the filter manifold.

165. The spray gun system of any one of claims 130-164, wherein the module further comprises a module handle so that the module can be carried while spraying without the module being worn.

166. The spray gun system of claim 165, wherein the handle connects to a mount that is worn.

167. The spray gun system of claim 166, wherein the handle is detachable from the mount.

168. The spray gun system of claim 167, wherein the module handle attaches to the mount by resting in one or more hook arms of the mount.

169. The spray gun system of any one of claims 167 and 168, wherein the handle is rotatable relative to the mount while held by the mount.

170. The spray gun system of any one of claims 167-169, wherein the handle is cylindrical.

171. The spray gun system of any one of claims 167-170, wherein a flow path for spray fluid axially through the handle along a flow axis through the handle.

172. The spray gun system of any one of claims 167-171, wherein the assembly controller and the battery are located below the handle.

173. The spray gun system of any one of claims 167-172, wherein the handle is formed by module housing.

174. The spray gun system of claim 173, wherein an aperture is located directly below the module handle and directly above a part of the module housing which contains the assembly controller and supports the battery.

175. The spray gun system of any one of claims 130-174, wherein the conduit comprises a sheath that extends over and around the at least one hose and the at least one electrical conductor, wherein the sheath extends from inside of the spray gun to inside of the module body, the at least one electrical conductor emerging from underneath the sheath within the module body.

176. The spray gun system of claim 175, wherein the at least one electric conductor emerges from underneath the sheath within the spray gun.

177. A spray control assembly for use with a pumping assembly that outputs spray fluid through a supply hose having a fitting, the spray control assembly comprising: a spray gun, the spray gun comprising a spray valve, an actuator which actuates the spray valve, a handle, a trigger, and a sensor that senses actuation of the trigger; a conduit, the conduit comprising at least one hose and at least one electrical conductor, the conduit having a far end and a near end, the far end connected to the spray gun to deliver spray fluid to the spray valve and electrical energy to the actuator; and a module comprising: an inlet fitting configured to attach to the fitting of the supply hose to receive spray fluid into the module from the sprayer pump; a battery; a module housing; and an assembly controller at least partially located within the module housing, the assembly controller configured to: receive electrical energy from the battery; receive a signal from the sensor indicating actuation of the trigger; and deliver electrical energy to the actuator via one or more of the at least one electrical conductor of the conduit; wherein the module does not include a pump.

178. A spray control assembly for use with a pumping assembly that outputs spray fluid through a supply hose having a fitting, the spray control assembly comprising:a spray gun, the spray gun comprising a spray valve, an actuator which actuates the spray valve, a handle, a trigger, and a sensor that senses actuation of the trigger; a conduit, the conduit comprising at least one hose and at least one electrical conductor, the conduit having a far end and a near end, the far end connected to the spray gun to deliver spray fluid to the spray valve and electrical energy to the actuator; and a module comprising: a module body having a main housing and a module handle spaced from the main housing; an inlet fitting supported by the module body and configured to attach to the fitting of the supply hose to receive spray fluid into the module from the sprayer pump; a battery supported by the module body; and an assembly controller at least partially located within the module housing, the assembly controller configured to: receive electrical energy from the battery; receive a signal from the sensor indicating actuation of the trigger; and deliver electrical energy to the actuator via one or more of the at least one electrical conductor of the conduit; wherein a flowpath extends through the handle such that the spray fluid received through the inlet fitting flows within the module handle between the inlet fitting and the conduit.

179. The spray control assembly of claim 178, wherein the conduit is fluidly connected to the flowpath at a location within the handle.

180. The spray control assembly of any one of claims 178 and 179, wherein the inlet fitting is disposed outside of the module body.

181. The spray control assembly of any one of claims 178-180, wherein a filter manifold is supported by the module body, the filter manifold at least partially disposed within the handle.

182. The spray control assembly of claim 181, wherein the filter manifold includes a filter housing disposed at least partially within the module handle and a filter disposed within the filter housing.

183. The spray control assembly of any one of claims 181 and 182, wherein the filter manifold is rotatable relative to the handle and is prevented from completing full 360- degree rotations.

184. The spray control assembly of claim 183, wherein the conduit is connected to the filter manifold such that the conduit is rotatable with the filter manifold.

185. The spray control assembly of any one of claims 178-184, wherein a plurality of module arms extend between and connect the module handle and the main housing.

186. The spray control assembly of claim 185, wherein a module aperture is formed in the space between the module handle, the main housing, and the plurality of module arms.

187. The spray control assembly of any one of claims 178-1866, wherein the assembly controller is disposed in the main housing and the battery is supported by the main housing.

188. The spray control assembly of any one of claims 178-187, wherein a sheath of the conduit terminates within the module handle such that the at least one hose and the at least one electrical conductor exit from under the sheath at a location within the module handle.

189. A spray control assembly for use with a pumping assembly that outputs spray fluid through a supply hose having a fitting, the spray control assembly comprising: a spray gun, the spray gun comprising a spray valve, an actuator which actuates the spray valve, a handle, a trigger, and a sensor that senses actuation of the trigger; a conduit, the conduit comprising at least one hose and at least one electrical conductor, the conduit having a far end and a near end, the far end connected to the spray gun to deliver spray fluid to the spray valve and electrical energy to the actuator; and a module comprising: a module body; a filter manifold supported by the module body, the filter manifold at least partially disposed within the module body and including a filter housing and a filter within the filter housing;an inlet fitting supported by the filter housing and configured to attach to the fitting of the supply hose to receive spray fluid into the filter manifold; a battery supported by the module body; and an assembly controller at least partially located within the module housing, the assembly controller configured to: receive electrical energy from the battery; receive a signal from the sensor indicating actuation of the trigger; and deliver electrical energy to the actuator via one or more of the at least one electrical conductor of the conduit.

190. The spray control assembly of claim 189, wherein the filter manifold is rotatable relative to the module body, the filter manifold prevented from making full 360- degree rotations.

191. The spray control assembly of claim 190, wherein a ring extends about an exterior of the filter housing, the ring interfacing with the filter housing to rotationally restrict the filter manifold.

192. The spray control assembly of claim 191, wherein the ring includes a ring tab and the filter housing includes a filter tab, the ring tab circumferentially overlapping with the filter tab to inhibit full rotation of the filter tab about the axis.

193. The spray control assembly of any one of claims 190-192, wherein the conduit is connected to the filter manifold such that the conduit is rotationally fixed relative to the filter manifold.

194. The spray control assembly of any one of claims 189-193, further comprising: an axial retainer projecting into a groove formed on an exterior of the filter housing, wherein the axial retainer prevents axial displacement of the filter manifold relative to the module body.

195. The spray control assembly of any one of claims 189-194, wherein the filter manifold includes a filter cap, the filter cap mountable to the filter housing to secure the filter within the filter housing, wherein the filter cap includes the inlet fitting.

196. The spray control assembly of any one of claims 189-195, wherein the inlet fitting includes a swivel that is freely rotatable relative to the module body.

197. A spray gun comprising:a gun body having a gun handle; a trigger; a solenoid coil within the gun body; a cartridge mountable to the spray gun, the cartridge comprising: a cartridge body defining a fluid chamber and having an inlet and an outlet; a spray valve disposed within the cartridge body, the spray valve including an actuatable seal located fluidly between the inlet and the outlet; and a plunger that is connected to the spray valve, the plunger configured to be moved by an electromagnetic field generated by the solenoid coil to actuate the spray valve to an open state in which the inlet is fluidly connected to the outlet; wherein the trigger remains stationary and during mounting and dismounting of the cartridge.

198. A spray gun comprising: a gun body having a gun handle; a trigger; a solenoid coil within the gun body; a cartridge mountable to the spray gun, the cartridge comprising: a cartridge body defining a fluid chamber and having an inlet and an outlet; a spray valve disposed within the cartridge body, the spray valve including an actuatable seal located fluidly between the inlet and the outlet; and a plunger that is connected to the spray valve, the plunger configured to be moved by an electromagnetic field generated by the solenoid coil to actuate the spray valve to an open state in which the inlet is fluidly connected to the outlet; wherein all mechanical actuators for displacing the spray valve open and closed are part of the cartridge such that the mechanical actuators mount with the cartridge and dismount with the cartridge.

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