Multi-component sprayer and cartridge for multi-component sprayer

Abstract

The multiple-component sprayer receives individual streams of components and combines the components together to form a multiple-component material for application onto a surface. The cartridge includes valves for controlling the flow of the components to a mixing chamber within which the components combine to form the multiple-component material. The cartridge is attachable to and detachable from the gun body of the multiple-component sprayer as a single unit.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims priority to U.S. Provisional Application No. 63 / 422,505, entitled "Dosing Piston for Solvent Dosing and Spray Applicators," filed November 4, 2022, which claims priority to U.S. Provisional Application No. 63 / 444,502, entitled "Cartridge for Multi-Component Spray Guns," filed February 9, 2023, which claims priority to U.S. Provisional Application No. 63 / 459,484, entitled "Cartridge for Multi-Component Sprayers," filed April 14, 2023, the disclosures of which are incorporated herein by reference in their entireties.

[0002] (Technical field) The present disclosure relates to atomization of multiple component mixtures. More particularly, the present disclosure relates to atomizers and atomizer components for atomizing multiple component mixtures. [Background technology]

[0003] Spray foam, typically made by mixing isocyanate and polyol resin components, is one broad type of sprayable multi-component fluid. The multi-component can be glue, adhesive, coating, or other material. For example, an epoxy can be sprayed. The individual components flow to a spray gun, where they are mixed to form a multi-component material, which is sprayed as a single solution. Because the single solution is formed from multiple components, it can be called a multi-component material.

[0004] The components are typically mixed within the spray gun and then sprayed within milliseconds due to the rapid reactivity and hardening of the fluids. Mixing can occur within a mixing chamber within the gun, which, in various embodiments, can form part of the gun's nozzle. Due to the rapid hardening nature of composite fluids, special care must be taken in maintaining the gun. Any component residue left within the gun, for example, in or around the mixing chamber, can react with or otherwise dry out when exposed to its complementary component. Clogging and other blockages can interfere with the mechanical operation of the spray gun and prevent proper mixing and spraying. Various aspects of the present disclosure relate, among other things, to improved maintenance to extend service life and / or improve spray performance. Summary of the Invention

[0005] According to one aspect of the present disclosure, a cartridge is configured for use with a multiple-component spray gun having a spray gun body and is configured to receive first and second component materials to be mixed to form a multiple-component material. The cartridge includes a valve body extending between a first body end and a second body end, a first flow valve disposed within the valve body, a second flow valve disposed within the valve body, and a mixing chamber cavity extending into the first body end of the valve body along a spray axis and configured to receive at least a portion of a mixing chamber of the multiple-component spray gun. The cartridge is removable from the spray gun body as a single module. If the mixing chamber has not already been removed from the cartridge, removing the cartridge from the spray gun body necessarily disconnects the mixing chamber from any connection with the spray gun body.

[0006] According to an additional or alternative aspect of the present disclosure, a multiple-component spray gun configured to accept a first component material and a second component material and output a spray of multiple-component materials includes a gun body, a handle protruding from the gun body, a trigger supported by the gun body, a cartridge removably attachable to the gun body, and a mixing chamber. The cartridge includes a valve body extending between a first body end and a second body end, the second body end configured to interface with the gun body to connect the cartridge to the gun body, a first flow valve disposed within the valve body, a second flow valve disposed within the valve body, and a mixing chamber cavity extending into the first body end of the valve body along a spray axis. The cartridge is removable from the spray gun body as a single module. The mixing chamber is attachable within the mixing chamber cavity. If the mixing chamber has not already been removed from the cartridge, removing the cartridge from the gun body necessarily disconnects the mixing chamber from any connection with the spray gun body.

[0007] According to another additional or alternative aspect of the present disclosure, a cartridge is configured for use with a multiple-component spray gun having an actuator assembly including a spray gun body and a displacer, the cartridge configured to receive first and second component materials to be mixed to form a multiple-component material, the cartridge including: a valve body extending along an axis between a first body end and a second body end, a mixing chamber cavity formed within the valve body, a first flow valve disposed within the valve body, a second flow valve disposed within the valve body, a valve mount configured to interface with the actuator assembly at a dynamic interface for receiving a mechanical input to actuate the first flow valve and the second flow valve between respective first states in which flow of the first and second component materials to the mixing chamber cavity is closed and respective second states in which flow of the first and second component materials to the mixing chamber cavity is open, and a body mount formed on the valve body and configured to interface with the actuator assembly at a static interface to attach the cartridge to the spray gun body. The cartridge is attachable to and detachable from the actuator assembly as a single unit.

[0008] According to yet another additional or alternative aspect of the present disclosure, a cartridge is configured for use with a multiple-component sprayer having an actuator assembly including a spray gun body and a displacer, the cartridge configured to receive first and second component materials to mix to form a multiple-component material. The cartridge includes a valve disc extending along an axis between a first body end and a second body end, the valve disc including a body mount configured to interface with the spray gun body to secure the valve disc to the spray gun body, a mixing chamber cavity formed in the valve disc and opening through the first body end, and a valve assembly supported by the valve disc, the valve assembly movable along the axis and relative to the valve disc to open and close a flow path for the first and second component materials to flow to the mixing chamber cavity, the valve assembly including a valve mount configured to interface with the displacer to secure the valve assembly to the displacer. The cartridge is attachable to and detachable from the actuator assembly as a single unit.

[0009] According to yet another additional or alternative aspect of the present disclosure, a cartridge for a multiple-component sprayer has an actuator assembly including a spray gun body and a displacer, the cartridge configured to receive first and second component materials that mix to form a multiple-component material, the cartridge including a valve body extending along an axis between first and second body ends, and a valve assembly. The valve body includes a block body, a mixing chamber cavity extending into the block body in a first axial direction along the axis, a first valve orifice extending into the block body in a second axial direction along the axis, wherein a first flow chamber and a first gas chamber configured to receive a first component material are disposed in the first valve orifice, and the second axial direction is opposite to the first axial direction, a second valve orifice extending into the block body in the second axial direction, wherein a second flow chamber and a second gas chamber configured to receive a second component material are disposed in the second valve orifice, a gas passage extending into the block body in the second axial direction, and a body mount configured to interface with the spray gun body to secure the valve body to the spray gun body. The valve assembly includes a first valve member supported by the valve body and at least partially disposed in the first valve orifice, the first valve member being movable relative to the block body between a first member first state in which the first gas chamber is fluidly connected to the mixing chamber cavity and the first flow chamber is fluidly isolated from the mixing chamber cavity, and a first member second state in which the first flow chamber is fluidly connected to the mixing chamber cavity and the first gas chamber is fluidly isolated from the mixing chamber cavity; and a second valve member at least partially disposed in the second valve orifice. a second valve member movable relative to the block body between a second member first state in which the second gas chamber is fluidly connected to the mixing chamber cavity and the second flow chamber is fluidly isolated from the mixing chamber cavity, and a second member second state in which the second flow chamber is fluidly connected to the mixing chamber cavity and the second gas chamber is fluidly isolated from the mixing chamber cavity; and a valve mount configured to interface with the displacer to secure the valve assembly to the displacer.The cartridge is attachable to and detachable from the actuator assembly as a single unit.

[0010] According to yet another additional or alternative aspect of the present disclosure, a multiple-component spray gun configured to receive a first component material and a second component material and output a spray of the multiple-component materials includes an actuator assembly including a gun body and a displacer movable relative to the gun body along an axis, and a cartridge removably attachable to the actuator assembly by a static interface formed between the cartridge and the gun body and a dynamic interface formed between the cartridge and the displacer, the dynamic interface configured to actuate a first flow valve of the cartridge to control a flow of the first component material to a mixing chamber cavity formed in the cartridge, and the dynamic interface configured to actuate a second flow valve of the cartridge to control a flow of the second component material to the mixing chamber cavity. The cartridge is attachable to and detachable from the actuator assembly as a single unit.

[0011] According to yet another additional or alternative aspect of the present disclosure, a cartridge is configured for use with a multi-component spray gun having an actuator assembly including a spray gun body and a displacer, the cartridge being configured to receive first and second component materials that mix to form a multi-component material. The cartridge includes a valve body extending along an axis between a first body end and a second body end, a mixing chamber cavity formed in the valve body and opening through the first body end, a first valve orifice formed in the valve body and opening through the second body end, a second valve orifice formed in the valve body and opening through the second body end, a valve assembly supported by the valve body, the valve assembly including a first valve member disposed at least partially within the first valve orifice and a second valve member disposed at least partially within the second valve orifice, a first flow valve formed in the first valve orifice, the first valve member forming a valve component of the first flow valve, and a second flow valve formed in the second valve orifice, the second valve member forming a valve component of the second flow valve. The valve assembly is movable to operate the first and second flow valves between respective first and second states in which the flow of the first and second components to the mixing chamber cavity is blocked and respective second states in which the flow of the first and second components to the mixing chamber cavity is not blocked. The cartridge is attachable to and detachable from the actuator assembly as a single unit.

[0012] According to yet another additional or alternative aspect of the present disclosure, a cartridge is configured for use with a multiple-component spray gun having an actuator assembly including a spray gun body and a displacer, the cartridge configured to receive first and second component materials to be mixed to form a multiple-component material. The cartridge includes a valve body extending along an axis between a first body end and a second body end, a mixing chamber cavity formed in the valve body and opening through the first body end, a first valve orifice formed in the valve body and opening through the second body end, a second valve orifice formed in the valve body and opening through the second body end, and a valve assembly supported by the valve body. The valve assembly includes a coupler at least partially disposed within the valve body, a first valve member connected to the coupler and at least partially disposed within the first valve orifice, and a second valve member connected to the coupler and at least partially disposed within the second valve orifice. The coupler is configured to impart a force to the first valve member to displace the first valve member along the first valve orifice between a first member first state in which the flow of the first component material into the mixing chamber cavity is blocked so that the first component material is prevented from flowing into the mixing chamber cavity and a first member second state in which the flow of the first component material into the mixing chamber cavity is not blocked so that the first component material can flow into the mixing chamber cavity. The coupler is configured to impart a force to the second valve member to displace the second valve member along the second valve orifice between a second member first state in which the flow of the second component material into the mixing chamber cavity is blocked so that the second component material is prevented from flowing into the mixing chamber cavity and a second member second state in which the flow of the second component material into the mixing chamber cavity is not blocked so that the second component material can flow into the mixing chamber cavity. The cartridge is attachable to and detachable from the actuator assembly as a single unit such that the valve body and valve assembly are attached and detached together.

[0013] According to yet another additional or alternative aspect of the present disclosure, a multiple-component sprayer is configured to receive a first component material and a second component material and emit a spray of the multiple-component material formed by combining the first and second component materials, the multiple-component sprayer including a gun body, a displacer at least partially disposed within the gun body, a mixing chamber configured to receive the first and second component materials and emit the multiple-component material, and a cartridge removably attachable to the gun body and the displacer as a single unit. The cartridge includes a valve body extending along an axis between a first body end and a second body end, a mixing chamber cavity formed within the valve body and opening through the first body end, the mixing chamber cavity being at least partially disposed within the mixing chamber cavity, a first valve orifice formed within the valve body and opening through the second body end, a second valve orifice formed within the valve body and opening through the second body end, and a valve assembly supported by the valve body. The valve assembly includes a first valve member at least partially disposed within the first valve bore and a second valve member at least partially disposed within the second valve bore. The first valve member is movable relative to the first valve bore between a first member first state in which the flow of the first component material to the mixing chamber cavity is blocked so that the first component material is prevented from flowing into the mixing chamber cavity and a first member second state in which the flow of the first component material to the mixing chamber cavity is not blocked so that the first component material can flow into the mixing chamber cavity. The second valve member is movable relative to the second valve bore between a second member first state in which the flow of the second component material to the mixing chamber cavity is blocked so that the second component material is prevented from flowing into the mixing chamber cavity and a second member second state in which the flow of the second component material to the mixing chamber cavity is not blocked so that the second component material can flow into the mixing chamber cavity.

[0014] According to yet another additional or alternative aspect of the present disclosure, a multiple-component sprayer configured to receive a first component material and a second component material and emit a spray of the multiple-component material formed by combining the first and second component materials includes a gun body, a displacer disposed at least partially within the gun body, a mixing chamber configured to receive the first and second component materials and emit the multiple-component material, a first flow valve configured to control a flow of the first component material to the mixing chamber, a second flow valve configured to control a flow of the second component material to the mixing chamber, and a shutoff supported by the gun body and connected to the first flow valve and the second flow valve, the shutoff configured to operate the first flow valve to block the flow of the first component material to the mixing chamber and to operate the second flow valve to block the flow of the second component material to the mixing chamber.

[0015] A multiple-component sprayer configured to receive a first component material and a second component material and emit a spray of the multiple-component material formed by combining the first and second component materials includes a gun body, a displacer disposed at least partially within the gun body, a mixing chamber configured to receive the first and second component materials and emit the multiple-component material from a spray orifice in a first axial direction along a spray axis, a valve assembly configured to control a flow of the first component material to the mixing chamber and a flow of the second component material to the mixing chamber, the valve assembly connected to the displacer actuated along the spray axis, and a shutoff connected to the valve assembly and configured to actuate the valve assembly in a second axial direction along the spray axis opposite the first axial direction to shut off the flow of the first component material and the second component material to the mixing chamber. [Brief explanation of the drawings]

[0016] [Figure 1A] FIG. 1 is a first isometric view of the atomizer. [Figure 1B]FIG. 12 is a second isometric view of the atomizer. [Figure 1C] FIG. 2 is an exploded view of the sprayer. [Figure 2A] 2 is a cross-sectional view taken along line 2-2 of FIG. 1A, showing the atomizer in a non-atomizing state. [Figure 2B] 2 is a cross-sectional view taken along line 2-2 of FIG. 1A, showing the atomizer in the atomizing state. [Figure 3] FIG. 3 is a cross-sectional view taken along line 3-3 of FIG. 1A. [Figure 4A] FIG. 4 is an enlarged view of detail 4A of FIG. 3. [Figure 4B] 4B is a cross-sectional view taken along line 4B-4B of FIG. 3, showing the interface between the cartridge and the manifold. [Figure 5A] FIG. 1 is an isometric view of a cartridge and mixing assembly. [Figure 5B] FIG. 1 is an exploded view of the cartridge and mixing assembly. [Figure 5C] FIG. 1 is an isometric view of the cartridge. [Figure 6A] FIG. 5B is a cross-sectional view taken along line AA in FIG. 5A. [Figure 6B] FIG. 5B is a cross-sectional view taken along line BB in FIG. 5A. [Figure 6C] FIG. 5B is a cross-sectional view taken along line CC in FIG. 5A. [Figure 7A] 7 is a cross-sectional view taken along line 7-7 of FIG. 5A showing the valve assembly in a position associated with the flow valves in their respective first open states. [Figure 7B] 7 is a cross-sectional view taken along line 7-7 of FIG. 5A showing the valve assembly in a position associated with each flow valve in a closed state. [Figure 7C] 7 is a cross-sectional view taken along line 7-7 of FIG. 5A showing the valve assembly in a position associated with the flow valves in their respective second open states. [Figure 8A] FIG. 1 is an isometric view of the cartridge from the rear side of the cartridge. [Figure 8B] FIG. 10 is an enlarged isometric view of the cartridge from the rear side of the cartridge with the gas stem removed for clarity. [Figure 8C] FIG. 1 is an enlarged isometric view of the actuator assembly. [Figure 9] FIG. 1 is an exploded view of the valve assembly showing the interface between the valve member and the coupler. [Figure 10A] FIG. 1 is an isometric view of a coupler. [Figure 10B] FIG. 10 is an elevation view of the rear side of the coupler. [Figure 11A] 1B is a partial cross-sectional view taken along line 11-11 of FIG. 1A showing the shutoff in an unlocked state. [Figure 11B] FIG. 11B is a partial cross-sectional view similar to FIG. 11A, showing the shutoff in a locked state. [Figure 12A] FIG. 10 is a first exploded view of the shutoff and drive piston. [Figure 12B] FIG. 10 is a second exploded view of the shutoff and drive piston. [Figure 13A] FIG. 10 is an isometric view of the shutoff and drive piston showing the shutoff in an unlocked state. [Figure 13B] FIG. 10 is an isometric view of the shutoff and drive piston showing the shutoff in a locked position. DETAILED DESCRIPTION OF THE INVENTION

[0017] The present disclosure generally relates to a multiple-component sprayer. The cartridge of the present disclosure provides for fast and efficient assembly of the spray gun for spraying and fast and efficient disassembly for maintenance. The cartridge is attachable to and detachable from the spray gun's actuator assembly as a single unit. The cartridge includes a valve component that controls the flow of component materials to a mixing chamber for combining into a multiple-component material and for spraying. The valve component can control the flow of component materials and compressed air to the mixing chamber.

[0018] A cartridge according to the present disclosure can include a mixing chamber at least partially disposed within and supported by a cartridge body of the cartridge, the mixing chamber being attachable to the cartridge body such that the mixing chamber can remain attached to the cartridge body when the cartridge is attached to or removed from the spray gun.

[0019] Removal of the cartridge from the actuator assembly of the spray gun may entail removal of the mixing chamber from the other components of the spray gun.

[0020] A cartridge according to the present disclosure is attachable to a spray gun at a dynamic connection interface that transmits mechanical force to a valve of the cartridge to actuate the valve between various flow conditions, and the cartridge includes a valve fitting configured to receive mechanical force from an actuator assembly of the spray gun and transmit the mechanical force to the valve component to actuate the valve component.

[0021] A cartridge according to the present disclosure is attachable to a spray gun at a static connection interface. The static interface secures the cartridge to a gun body of the spray gun. The static interface prevents relative movement of the cartridge along the spray axis to keep the cartridge attached to the gun body. A body joint of the cartridge interfaces with the gun body to attach the cartridge to the gun body. The body joint of the static interface and the valve joint of the dynamic interface can be configured for attachment to the spray gun such that the dynamic connection interface and the static connection interface are simultaneously made during attachment and simultaneously broken during removal.

[0022] The spray gun according to the present disclosure includes a manual shutoff that allows a user to manually actuate a valve component of the cartridge to shut off the flow of the components. The shutoff actuates the valve component of the cartridge to shut off the flow of the components to the mixing chamber, thereby stopping the spraying of the multiple-component material. The shutoff can be configured to lock the spray gun in a non-spraying state so that the spray gun cannot be actuated to a spraying state even when the trigger is pulled.

[0023] Components are considered to be radially overlapping when they are disposed at a common axial position along an axis. A radial line extending from the axis extends through each of the radially overlapping components. Components are considered to be axially overlapping when they are disposed at a common radial and circumferential position relative to the axis such that an axial line parallel to the axis extends through the axially overlapping components. Components are considered to be circumferentially overlapping when aligned about an axis such that a circle centered on the axis passes through the circumferentially overlapping components.

[0024] FIG. 1A is a first isometric view of sprayer 10. FIG. 1B is a second isometric view of sprayer 10. FIG. 1C is an exploded view of sprayer 10. FIGS. 1A-1C are described collectively. Sprayer 10 includes actuator assembly 12, gun body 30, cartridge 14, mixing assembly 16, manifold 18, fastener 20, shutoff 22, trigger 24, gas fitting 26, and spray orifice 28. Gun body 30 of actuator assembly 12 is shown. Gun body 30 includes housing 32 and handle 34. Air cap 36 of mixing assembly 16 is shown.

[0025] The sprayer 10 is configured as a multi-component sprayer. The sprayer 10 is configured to receive streams of individual components and combine the components into a multi-component material that is output from the sprayer 10 as a spray. The sprayer 10 is configured to receive individual streams of components, such as two or more components, combine the components to form a multi-component material, and emit a spray of the resulting multi-component material. The sprayer 10 may also be referred to as a spray gun.

[0026] In some examples, the sprayer 10 can be configured as a foam spray gun capable of spraying various foams, such as polyurea, and other multi-component foamable fluids that cure or set in place. A typical foam spraying system includes a first pump and a second pump (not shown). The first pump supplies a first component material, and the second pump supplies a second component material. Multi-component spray foams are typically made by mixing a first component material (e.g., an isocyanate) with a second component material (e.g., a polyol resin) to form the resulting foam. While the sprayer 10 is described as a foam spray gun, it is understood that foam is one broad type of sprayable multi-component material. Multi-component materials can be glues, adhesives, coatings, epoxies, and other materials. While spray foam is used as an example, the component materials can be any type of component fluid that can be mixed and sprayed. The mixture is combined in the sprayer 10 and sprayed as a single solution.

[0027] The terms component A and component B are used herein to refer to liquids that can be mixed and then sprayed as a single fluid. While spray foam is used as an example, component A and component B can be any type of component fluid that can be mixed and sprayed. The mixture is combined in the atomizer 10 and sprayed as a single solution. The single solution can be referred to as a multi-component material because it is formed from multiple components (e.g., component A and component B). While component A and component B are used herein for illustrative purposes, it is understood that some multi-component materials can be formed from more than two components, and that the disclosure herein is not limited to multi-component materials formed from two components.

[0028] The components are typically mixed within the atomizer 10 and then atomized within milliseconds due to the rapid reactivity and hardening properties of the fluid. The mixing may occur within a mixing chamber within the atomizer 10, which may, in various embodiments, form part of the nozzle of the atomizer 10. The atomization orifice 28 may be formed by the mixing chamber. The mixing chamber may be connected to an air cap 36, which may form a component of the mixing assembly 16, as discussed in more detail below.

[0029] The actuator assembly 12 is configured to support the cartridge 14 and to actuate valves within the cartridge 14 between various flow states. The actuator assembly 12 can actuate the valves of the cartridge 14 to start and stop spraying of the multiple-component material by the sprayer 10. The actuator assembly 12 can include an outer housing (e.g., formed by the gun body 30) and various internal components. The actuator assembly 12 includes a displacer that provides force to the valves of the cartridge 14 to actuate the valves and control the flow of the component materials into the mixing chamber.

[0030] A gun body 30, which may also be referred to as an air body, supports the other components of the sprayer 10. A handle 34 extends from the housing 32. The gun body 30 is configured to receive a flow of compressed gas, such as compressed atmospheric air, and transfer the compressed gas to the other components of the sprayer 10. A gas fitting 26 extends from the gun body 30 and is configured to connect to a hose extending from a compressed gas source (e.g., a pressurized tank, a compressor, etc.). The hose provides compressed gas to the sprayer 10 at the gas fitting 26. The gas fitting 26 may be configured to connect to the hose in any desired manner. For example, the gas fitting 26 may be configured as a quick-connect fitting, may include external threads, etc.

[0031] The housing 32 contains an actuator, such as a piston, configured to actuate a valve component of the cartridge 14 to control the flow of the component material to the spray orifice 28. The gun body 30 is configured to transfer compressed gas to a chamber within the housing 32 to displace the actuator, which is configured to transfer the compressed gas to the cartridge 14. The cartridge 14 transfers the compressed gas to the mixing assembly 16 for output from the air cap 36 and from the spray orifice 28.

[0032] The handle 34 can be used to grip the sprayer 10 with one hand so that the sprayer 10 can be picked up, supported, and operated with one hand of a user. The sprayer 10 includes a trigger 24 supported by the gun body 30. Operation of the trigger 24 by one or more fingers of the user can cause spraying from the sprayer 10, and release of the trigger 24 can stop spraying from the sprayer 10.

[0033] The cartridge 14 is configured to be attached to the gun body 30. The cartridge 14 is attachable to and detachable from the gun body 30. The cartridge 14 is detachable as a single module. When the cartridge is removed, the flow paths of the first and second component materials do not remain attached to or disposed within the actuator assembly. The cartridge 14 includes internal valve components configured to control the flow of the component materials to the mixing assembly 16. The internal valve components may be configured to control at least a portion of the flow of compressed gas to the mixing assembly 16. In the illustrated example, the cartridge 14 is configured to interface directly with the housing 32 for attachment to the gun body 30. The cartridge 14 includes fluid handling components. The cartridge 14 is configured to transfer the component materials and compressed gas to the mixing assembly 16.

[0034] The manifold 18 is supported by the gun body 30. In the illustrated example, the manifold 18 is attached to the cartridge 14 and is supported by the gun body 30 via the cartridge 14. The build material is supplied to the cartridge 14 via the manifold 18. In various other embodiments, the build material may be introduced via a channel through the gun body 30. However, in the illustrated embodiment and various other embodiments, the build material does not flow through the gun body 30 but rather flows directly to the cartridge 14 via the manifold 18. In the illustrated example, the gun body 30 does not redirect the build material flow, and the build material does not flow within the gun body 30.

[0035] The manifold 18 is attached directly to the cartridge 14. The manifold 18 is not attached to the gun body 30. As shown, the manifold 18 is attached to the cartridge 14 via fasteners 20. In the illustrated example, the fasteners 20 are formed as threaded bolts, although different types of connections are possible. In the illustrated example, the fasteners 20 extend through a portion of the manifold 18 and into the cartridge 14.

[0036] The manifold 18 is configured to connect to component lines that provide individual streams of the component materials to the manifold 18. The manifold 18 includes a material inlet 38 that accepts the component materials into the manifold 18. The material inlet 38 may be formed as a fitting configured to connect to the component line (e.g., hose) that supplies the component material to the manifold 18. The material inlet 38 may be formed in any desired configuration for connecting with a supply line, such as a quick connect, threaded, etc. The manifold 18 routes the component materials to the cartridges 14. The component materials are maintained in separate, fluidly separated paths within the manifold 18. The component materials do not mix within the manifold 18. The component materials are provided to the cartridges 14 as separate, separated streams.

[0037] The manifold 18 includes a material valve 40 that is actuable between an open state and a closed state. The material valve 40 can be actuated by a user by accessing a handle of the material valve 40 from outside the manifold 18. When the material valve 40 is in the closed state, the flow path through the manifold 18 is closed and the component material associated with that material valve 40 is prevented from flowing downstream to the cartridge 14. When the material valve 40 is in the open state, the flow path through the manifold 18 is open and the component material associated with that material valve 40 can flow to the cartridge 14.

[0038] The mixing assembly 16 is removably attached to the cartridge 14. The air cap 36 is configured to output compressed gas proximate to the spray orifice 28. The spray orifice 28 is oriented through a central opening in the air cap 36. The spray orifice 28 is oriented along a spray axis SA, and the sprayer 10 is configured to output the multiple-component material along the spray axis. The spray orifice 28 is configured to emit a spray of the multiple-component material from the sprayer 10. During spraying, the fluid mixture is emitted from the spray orifice 28. In various examples, the spray orifice 28 is at least partially supported by the air cap 36. The air cap 36 can be a retainer for a mixing chamber, as described in more detail below. The spray orifice 28 can be formed by the mixing chamber.

[0039] The shutoff 22 is supported by the gun body 30. A knob 42 of the shutoff 22 is accessible on the exterior of the sprayer 10. The shutoff 22 is actuable between a locked state and an unlocked state. When the shutoff 22 is in the locked state, the sprayer 10 is locked in a non-spraying state such that the valve components within the cartridge 14 cannot be actuated to open a flow path for the components to flow to the mixing assembly 16. When the shutoff is in the unlocked state, the sprayer 10 can be placed in a spraying state, such as by actuating the trigger 24, such that the valve components within the cartridge 14 can be actuated to open a flow path for the components to flow to the mixing assembly 16. In the illustrated example, the knob 42 provides a user interface for the shutoff 22. The knob 42 can be actuated by a user to shift the shutoff 22 between the locked state and the unlocked state. For example, a user can rotate the knob 42 to shift the shutoff 22 between the locked state and the unlocked state.

[0040] The shutoff 22 can be configured to actuate the sprayer 10 from a spraying state to a non-spraying state. For example, if the compressed gas supply to the sprayer 10 is lost during operation while the sprayer 10 is in a spraying state, the shutoff 22 can be actuated to a locked state, which displaces a valve component of the cartridge 14 and places the sprayer 10 in a non-spraying state. The shutoff 22 can be actuated from an unlocked state to a locked state regardless of the operating state of the sprayer 10. The shutoff 22 that actuates the sprayer 10 to a non-spraying state can shut off spraying of the multiple-component material even if power is lost to the actuator that displaces the valve component of the cartridge 14, providing a manual shutoff for such situations.

[0041] In operation, the sprayer 10 is assembled by connecting the cartridge 14 to the actuator assembly 12. The manifold 18 is attached to the cartridge 14 by fasteners 20. The mixing assembly 16 is attached to the cartridge 14. It is understood that the mixing assembly 16 may be attached to the cartridge 14 before the cartridge 14 is attached to the actuator assembly 12 or after the cartridge 14 is attached to the actuator assembly 12. Compressed gas is supplied to the sprayer 10 and enters the gun body 30 at gas fitting 26. The makeup material is pumped into the manifold 18 and enters the manifold at material inlet 38. The material valve 40 is placed in an open position to allow the makeup material to flow to the cartridge 14.

[0042] When shutoff 22 is in the unlocked state, a user actuates trigger 24, shifting a valve component in cartridge 14 and allowing the components to flow into mixing assembly 16. For example, compressed gas can displace an actuator within housing 32 to displace the valve component. The components flow into the mixing chamber, where they combine to form the multi-component material. The multi-component material is expelled as a spray through spray orifice 28.

[0043] The user releases trigger 24 to stop spraying by sprayer 10. When the user releases trigger 24, compressed gas is redirected within gun body 30, displacing the actuator in the opposite direction. The actuator displaces a valve component of cartridge 14 to block the flow of component materials to mixing assembly 16. Spraying of the multiple-component material through spray orifice 28 is stopped.

[0044] The sprayer 10 offers significant advantages. The cartridge 14 receives a flow of component materials from the manifold 18 and a flow of compressed gas from the gun body 30. The gun body 30 does not handle the component materials. The component materials do not flow within the gun body 30. The gun body 30 does not contain any paths fluidly connected to the paths of the multi-component material. Isolating the gun body 30 from the component materials prevents accidental mixing within the gun body 30 and reduces the number of components requiring component cleaning after spraying. The gun body 30 is protected and isolated from the component materials so that operation of the gun body 30 is maintained even if undesired hardening occurs in any of the material paths through the sprayer 10.

[0045] The cartridge 14 transfers both the component materials and compressed gas to the mixing assembly 16. The cartridge is removable from the gun body 30 as a single unit. The cartridge 14 can be removed from the gun body 30 and replaced with a new cartridge 14 if undesired hardening occurs within the material passageway of the cartridge 14. The cartridge 14, which isolates the component materials from the gun body 30, protects the gun body 30 and isolates any crossover between the component materials that could result in undesired hardening within the cartridge 14. The cartridge 14 can be removed and replaced without repairing other components of the sprayer 10.

[0046] Cartridge 14 includes valve components that control the flow of components to mixing assembly 16. The valve components, including the movable and stationary portions of the valve components, form the portions of cartridge 14 that are attached to and removed from actuator assembly 12 along with cartridge 14. The valve components integrated into cartridge 14 facilitate the attachment and removal of component-handling components of sprayer 10.

[0047] The manifold 18 is connected to the cartridge 14. The manifold 18 does not have any flow paths fluidly connected to the gun body 30. The manifold 18 transfers only the components to the cartridge 14. The components do not mix within the manifold 18, and the manifold 18 does not include any fluid connections between the component paths.

[0048] The sprayer 10 includes a gun body 30 that routes compressed gas, a manifold 18 that routes components, and a cartridge 14 that routes the components for combination in a mixing assembly 16 that is supported by the cartridge 14 and routes compressed gas for discharge from the sprayer 10. The cartridge 14 being removable as a single unit allows for quick and easy assembly and disassembly of the sprayer 10. The cartridge 14 being removable as a single unit reduces the number of parts and reduces the complexity and time required to disassemble and assemble the valve components because the valve components are part of the cartridge 14.

[0049] Figure 2A is a cross-sectional view taken along line 2-2 in Figure 1A, showing the nebulizer 10 in a non-nebulizing state. Figure 2B is a cross-sectional view taken along line 2-2 in Figure 1A, showing the nebulizer 10 in a nebulizing state. Figure 3 is a cross-sectional view taken along line 3-3 in Figure 1A. Figures 2A-3 will be described together with continued reference to Figures 1A-1C.

[0050] The sprayer 10 includes an actuator assembly 12, a cartridge 14, a mixing assembly 16, a manifold 18, a fastener 20, a shutoff 22, a trigger 24, a gas fitting 26, a spray orifice 28, a gas valve 44, a drive piston 46, and a dosing piston 48. The actuator assembly 12 includes a gun body 30 and a dosing piston 48. The drive piston 46 includes a piston shaft 50, a piston head 52, and a drive mount 54. The gun body 30 includes a housing 32 and a handle 34. The housing 32 includes a housing mount 56. Shown are flow valves 58a, 58b, valve element 60, outer body 62, valve assembly 64, valve holes 66a, 66b, mixing chamber cavity 68, flow chambers 70a, 70b, gas chambers 72a, 72b, gas channel 74b, seal bodies 76a, 76b, retainers 78a, 78b, gas check 80b, gas stem 82, and body mount 84 of cartridge 14. Valve assembly 64 includes valve members 88a, 88b, coupler 90, and valve mount 92. Each valve member 88a, 88b includes a flow head 98, a flow neck 100, a member body 102, a mount neck 104, a mount head 106, and a tail 108. Mixing assembly 16 includes air cap 36 and mixing chamber 110. Shutoff 22 includes knob 42, converter 112, and connector 114. The converter 112 includes a converter body 116 and a positioner 118. The connector 114 includes a connector head 122 and a connector shaft 120.

[0051] The atomizer 10 is configured to receive individual streams of the constituent materials, mix the constituent materials to form a multi-component material, and discharge the resulting multi-component material through the atomizing orifice 28. The atomizer 10 sprays along a atomizing axis SA. The axis also designates an upstream or upstream direction and a downstream or downstream direction, with the constituent materials generally flowing from the upstream direction to the downstream direction. In the illustrated example, with respect to the atomizing axis SA, the first axial direction AD1 is generally downstream, and the second axial direction AD2 is generally upstream. The mixing chamber 110 containing the atomizing orifice 28 is coaxial with the axis SA.

[0052] The actuator assembly 12 is configured to support the cartridge 14 and to actuate the flow valves 58 a, 58 b of the cartridge 14 between various states. The actuator assembly 12 is configured to support the cartridge by a static interface 126 between the gun body 30 and the valve element 60. The actuator assembly 12 is configured to actuate the valve assembly 64 of the cartridge 14 via a dynamic interface 128 between the valve assembly 64 and the drive piston 46.

[0053] In the illustrated example, static interface surface 126 is disposed radially outward of dynamic interface 128. Static interface 126 may radially overlap dynamic interface 128 during at least some stages of operation. The relative positions of static interface 126 and dynamic interface 128 align forces and provide efficient transmission of mechanical forces to valve assembly 64 along spray axis SA. Dynamic interface 128 may move axially relative to static interface 126 during operation.

[0054] Gun body 30 is configured to support the other components of sprayer 10 during spraying. Handle 34 is a portion of gun body 30 configured to be grasped by a user's hand to orient and manipulate sprayer 10. Handle 34 protrudes from the underside of housing 32. Handle 34 may be formed separately from the housing and may be connected to housing 32 by one or more fasteners, such as bolts, among other options.

[0055] The housing 32 supports the other components of the sprayer 10. The housing 32 is configured to receive a flow of compressed gas and defines a flow path that directs this flow within the sprayer 10. The compressed gas can be used for several functions, including purging, valve actuation, mixing, and propulsion, among other options. The compressed gas can be compressed air, among other options. The compressed gas can be formed from an inert gas, such as nitrogen gas. A gas fitting 26 is supported by the housing 32. The gas fitting 26 is configured to connect to a hose or other delivery device that supplies compressed gas to the sprayer 10. The gas fitting 26 can be configured to connect to the hose in any desired manner, such as by an interface thread or in a quick-connect manner, among other options.

[0056] The gas valve 44 is disposed within the gun body 30. In the illustrated example, the gas valve 44 is disposed within the housing 32. The gas valve 44 is configured to direct compressed gas within the sprayer 10. The gas valve 44 is configured to be actuated by the trigger 24 to transfer the compressed gas to cause operation of the sprayer 10 between an atomizing state and a non-atomizing state. For example, when the trigger 24 is pulled to place the sprayer 10 in the atomizing state, the gas valve 44 can transfer compressed gas to a first axial side of the drive piston 46, displacing the drive piston 46 in a first axial direction AD1. When the trigger 24 is released to place the sprayer 10 in the non-atomizing state, the gas valve 44 can transfer compressed gas to a second axial side of the drive piston 46, displacing the drive piston 46 in a second axial direction AD2.

[0057] The trigger 24 is supported by the gun body 30. The trigger 24 is located in front of the handle 34 so that a person holding the handle 34 can actuate the trigger 24 with the fingers of the hand holding the handle 34. The trigger 24 is positioned so that the front surface of the trigger 24 is accessible by the fingers of a user who will actuate the trigger 24. Actuation of the trigger 24 can operate a gas valve 44 in the gun body 30 to redirect and / or shut off compressed gas within the sprayer 10, opening and closing the valve.

[0058] A drive piston 46 is supported by the gun body 30. The drive piston 46 is disposed within the housing 32. A piston head 52 divides the piston chamber within the housing 32 into fluidly separated drive chambers. Compressed gas is provided to a first one of the drive chambers to displace the drive piston 46 in a first axial direction AD1. Compressed gas is provided to a second one of the drive chambers to displace the drive piston 46 in a second axial direction AD2. The drive piston 46 can be considered to form a displacer for the actuator assembly 12.

[0059] The piston shaft 50 extends from the piston head 52 in a first axial direction AD1. The piston shaft 50 extends axially through the gun body 30 and is configured to interface with the cartridge 14 at a dynamic interface 128. In the illustrated example, the piston shaft 50 protrudes from a shaft bore formed in the housing 32 to form the dynamic interface 128 with the cartridge 14. The drive piston 46 transfers mechanical motion to the valve assembly 64 at the dynamic interface 128 to open and close a material flow path through the cartridge 14. In the illustrated example, the drive piston 46 is disposed coaxially with the mixing chamber 110 on the spray axis SA.

[0060] A dosing piston 48 is disposed within the drive piston 46. The dosing piston 48 is configured to dosing solvent into the stream of compressed gas provided from the gun body 30 to the cartridge 14. The compressed gas provided through the dosing piston 48 and the drive piston 46 may be referred to as B-side gas, which is provided to a component flow path associated with a B-side component. The dosing piston 48, in the illustrated example, is movable relative to the drive piston 46. The dosing piston 48 may be configured to dosing solvent into the B-side gas.

[0061] The cartridge 14 is attached to the gun body 30. As described further herein, the cartridge 14 is removable from the gun body 30 as a unitary body for quick replacement of the components, and in some instances, the valve controlling the flow of compressed gas, to the mixing chamber 110. The cartridge 14 is attached to the gun body 30 by a static interface 126 between the cartridge 14 and the gun body 30. The static interface 126 includes no moving parts. The static interface 126 supports the cartridge 14 on the gun body 30. In the illustrated example, the static interface 126 is formed between the cartridge 14 and the housing 32. More specifically, the static interface 126 is formed between the valve disc 60 and the housing 32. In the illustrated example, the static interface 126 is formed between a protrusion and a receiver into which the protrusion extends. In the illustrated example, the protrusion 130 is formed by the cartridge 14, and the receiver 132 is formed by the gun body 30.

[0062] In the illustrated example, static interface 126 forms a pneumatic connection between cartridge 14 and actuator assembly 12 where compressed gas transferred through spray gun body 30 is further transferred into valve body 60 .

[0063] A cartridge seal 124 is disposed between and engages the cartridge 14 and the gun body 30. In the illustrated example, the cartridge seal 124 engages and seals against the valve disc 60 and the housing 32. The cartridge seal 124 may be an O-ring or a gasket, among other options. The cartridge seal 124 is disposed within a receiver 132. The cartridge seal 124 interfaces with the protrusion 130 to allow the transfer of pressurized gas from the gun body 30 to the cartridge 14 for purging air. While the cartridge seal 124 is shown as being supported by the gun body 30 so that the cartridge 14 moves into and out of engagement with the cartridge seal 124 during installation and removal, it will be understood that the cartridge seal 124 may alternatively be disposed on the cartridge 14 for installation and removal therewith. For example, the cartridge seal 124 may be disposed on and supported by the valve disc 60.

[0064] The valve element 60 defines a flow path for the component material and compressed gas. The valve element 60 extends between a first body end 94 and a second body end 96. The valve element 60 extends along a spray axis SA between the first body end 94 and the second body end 96. The first body end 94 is oriented in a first axial direction AD1. The first body end 94 is considered to form the downstream end of the cartridge 14. The second body end 96 is oriented in a second axial direction AD2. The second body end 96 is considered to form the upstream end of the cartridge 14. The cartridge 14 is configured such that the first body end 94 is the spray output end of the valve element 60, from which the spray (e.g., multi-component material, compressed gas) is emitted from the cartridge 14. The cartridge 14 is configured such that a connection with the actuator assembly 12 (e.g., a drive connection at the dynamic interface 128 and a support connection at the static interface 126) is formed at the second body end 96. In the illustrated example, the valve body 60 does not receive the component material through the second body end 96. In the illustrated example, the valve body 60 receives the compressed gas at the second body end 96. The valve body 60 is configured such that the multi-component material and the compressed gas are output from the first body end 94.

[0065] A body mount 84 is formed on the cartridge 14. In the illustrated example, the body mount 84 is formed on the second body end 96 of the valve disc 60. The body mount 84 is configured to interface with the housing mount 56 of the gun body 30 to form a static interface 126. For example, the static interface 126 may be formed as a protrusion-receiver interface between the body mount 84 and the housing mount 56, as described in more detail below. The static interface 126 supports the cartridge 14 on the gun body 30. The static interface 126 does not shift along the spray axis SA during operation of the sprayer 10.

[0066] The outer body 62 is supported by the gun body 60. The outer body 62 forms the exterior of the cartridge 14. The outer body 62 may also be referred to as a cover. In some examples, the outer body 62 is formed from a polymer, and the valve disc 60 is formed from a metal, such as aluminum, among other options. In the illustrated example, the outer body 62 is open in both a first axial direction AD1 and a second axial direction AD2, such that the valve disc 60 is axially exposed in both directions.

[0067] The valve body 60 defines a mixing chamber cavity 68. The mixing chamber cavity 68 extends from the first body end 94 into the valve body 60. The mixing chamber cavity 68 does not extend completely axially through the valve body 60. The mixing chamber cavity 68 is open in the first axial direction AD1 and closed in the second axial direction AD2. The mixing chamber cavity 68 is open in one axial direction such that the mixing chamber 110 cannot pass through the mixing chamber cavity 68. The mixing chamber cavity 68 is configured to allow the mixing chamber 110 to pass into the mixing chamber cavity 68 through a single opening oriented in the first axial direction AD1. The mixing chamber cavity 68 is open in the downstream direction and closed in the upstream direction such that the mixing chamber 110 cannot pass through the second body end 96 of the valve body 60.

[0068] The mixing chamber cavity 68 is open in the downstream direction and closed on the upstream side of the cartridge 14. The mixing chamber 110 can be inserted into the mixing chamber cavity 68 from the downstream direction and removed from the downstream direction, but cannot move through the cartridge 14 and valve body 60 in the upstream direction.

[0069] The mixing assembly 16 is mountable to the cartridge 14 so as to be supported by the cartridge 14. In the illustrated example, the mixing assembly 16 is mounted to the valve body 60. In the illustrated example, the mixing assembly 16 is mounted to the first body end 94 of the valve body 60. The air cap 36 is configured to direct compressed gas around the spray orifice 28, for example, to clean the spray orifice 28. The air cap 36 can be mounted to the mixing chamber 110 such that the air cap 36 and the mixing chamber 110 are connected to one another as a single assembly. For example, the mixing chamber 110 can include external threads and the air cap 36 can include internal threads such that the air cap 36 can be threaded onto the mixing chamber 110. The mixing assembly 16 is configured such that a user can mount the mixing chamber 110 within the mixing chamber cavity 68 by grasping and manipulating the air cap 36 without grasping the mixing chamber 110.

[0070] The air cap 36 is attached to the cartridge 14 and holds the mixing chamber 110 within the mixing chamber cavity 68. In the illustrated example, the air cap 36 includes external threads that engage with internal threads on the cartridge 14 to attach the air cap 36 to the valve body 60. The threaded interface between the air cap 36 and the valve body 60 may radially overlap with the external threads on the mixing chamber 110 when the mixing assembly 16 is attached to the cartridge 14. The air cap 36 may receive compressed gas from the cartridge 14 and release such compressed gas around the mixing chamber 110, for example, near the spray orifice 28. Such air may be referred to as clean-off air configured to remove residue from the exterior of the mixing chamber 110.

[0071] The mixing chamber 110 is disposed within the mixing chamber cavity 68 in the cartridge 14. More specifically, in the particular embodiment shown, the mixing chamber 110 is primarily within the valve body 60 and partially extends outward from the valve body 60. The mixing chamber 110 can be removed from or inserted into the mixing chamber cavity 68 while the cartridge 14 is attached to the gun body 30. The mixing chamber 110 can be removed from or inserted into the mixing chamber cavity 68 while the cartridge 14 is attached to the gun body 30. The mixing chamber 110 can also be removed from or inserted into the mixing chamber cavity 68 while the cartridge 14 has already been removed from the gun body 30. Alternatively, the mixing chamber 110 can be attached within the mixing chamber cavity 68 of the cartridge 14, and the air cap 36 can be attached to the cartridge 14 while the cartridge 14 is attached to the gun body 30. The cartridge 14 supports the mixing chamber 110 so that the mixing chamber 110 does not contact or extend into the gun body 30. In the illustrated example, the mixing chamber 110 does not radially overlap any portion of the gun body 30. The mixing chamber 110 does not contact the spray gun body 30 during spraying.

[0072] The spray orifice 28 is formed at the downstream end of the mixing chamber 110. In the illustrated example, the spray orifice 28 is formed by the mixing chamber 110. In the illustrated example, the mixing chamber 110 is configured as a fixed mixing chamber 110 that does not shift along the spray axis SA to operate the sprayer 10 between the spraying state and the non-spraying state. The mixing chamber 110 is configured to remain stationary when the flow valves 58a, 58b are actuated to turn on and off the flow of component materials to the mixing chamber 110.

[0073] The valve holes 66a, 66b extend into the valve body 60. In the illustrated example, the valve holes 66a, 66b extend only partially axially through the valve body 60. The valve holes 66a, 66b are open in the second axial direction AD2 and closed in the first axial direction AD1. The valve holes 66a, 66b are open to allow the valve members 88a, 88b to pass into the valve holes 66a, 66b. The valve holes 66a, 66b are closed in the first axial direction AD1 so that the valve members 88a, 88b cannot pass axially completely through the valve holes 66a, 66b.

[0074] Each valve hole 66a, 66b extends along a valve axis VA. In the illustrated example, the valve axis VA is parallel to and radially offset from the spray axis SA. In some examples, a plane along which the spray axis SA and each of the two valve axes VA extend may be disposed through the cartridge 14.

[0075] The valve holes 66a, 66b extend into the valve body 60 from the second body end 96 of the valve body 60. The valve holes 66a, 66b define flow paths for the flow of the component material and compressed gas to the mixing chamber 110. In the illustrated example, each valve hole 66a, 66b opens to the body chamber 86 that extends into the second body end 96 of the valve body 60. The valve holes 66a, 66b are radially offset from the spray axis SA. A portion of the valve holes 66a, 66b extend radially overlapping with the mixing chamber cavity 68. This configuration provides a compact cartridge 14.

[0076] Valve holes 66a, 66b include flow chambers 70a, 70b, respectively. Flow chambers 70a, 70b are fluidly connected to manifold 18 to receive component material therefrom. Each flow chamber 70a, 70b is fluidly connected to manifold 18 at all times during operation. Flow valves 58a, 58b control the flow of component material from flow chambers 70a, 70b to mixing chamber 110. In the illustrated example, flow chambers 70a, 70b are separated from mixing chamber 110 in a second axial direction AD2 when mixing assembly 16 is mounted on cartridge 14. Flow chambers 70a, 70b are positioned upstream of mixing chamber 110 such that flow chambers 70a, 70b do not radially overlap mixing chamber 110. In the illustrated example, the cartridge 14 is configured such that the flow passages containing the constituent materials within the cartridge 14 do not radially overlap the mixing chamber 110 when the atomizer 10 is in a non-atomizing state.

[0077] In the illustrated example, the valve holes 66a, 66b include gas chambers 72a, 72b, respectively. The gas chambers 72a, 72b are fluidly connected to a compressed gas flow provided to the sprayer 10. In some examples, one or both of the gas chambers 72a, 72b are fluidly connected to the compressed gas flow throughout operation of the sprayer 10, both when the sprayer 10 is in an atomizing state and when the sprayer 10 is in a non-atomizing state. In some examples, one of the gas chambers 72a, 72b (but not the other) is fluidly connected to receive compressed gas throughout operation, and the other gas chamber 72a, 72b is configured to receive the compressed gas flow when the sprayer 10 is in a non-atomizing state.

[0078] Within each valve orifice 66a, 66b, the flow chamber 70a, 70b and gas chamber 72a, 72b of that valve orifice 66a, 66b are fluidly isolated from one another by a respective valve member 88a, 88b that is operable to fluidly connect the gas chamber 72a, 72b to the mixing chamber 110 when the sprayer 10 is in a non-atomizing state, and to fluidly connect the chamber 70a, 70b to the mixing chamber 110 when the sprayer 10 is in an atomizing state.

[0079] Feed channels 134a, 134b are formed in the valve body 60. The feed channels 134a, 134b extend between the valve holes 66a, 66b and fluidly connect the valve holes 66a, 66b, respectively, with the mixing chamber cavity 68. The build material and compressed gas flow through the feed channels 134a, 134b to and into the mixing chamber 110. In the illustrated example, the feed channels 134a, 134b extend radially outward relative to the spray axis SA. However, it will be understood that not all embodiments are so limited. For example, the feed channels 134a, 134b can extend both axially and radially, such that the feed channels 134a, 134b extend transversely rather than perpendicularly to the spray axis SA.

[0080] Gas channels 74a and 74b (gas channel 74b shown in FIGS. 3, 7A-8A, and 8C, and gas channel 74a shown in FIGS. 8B and 8C) extend within the valve body 60. The gas channels 74a and 74b are configured to transfer compressed gas to the gas chambers 72a and 72b, respectively. The gas channel 74a is fluidly connected to the valve orifice 66a, and the gas channel 74b is fluidly connected to the valve orifice 66b. The gas channel 74b is fluidly connected to the gas chamber 72b. In the illustrated example, at least a portion of the gas channel 74b is arranged coaxially with the spray axis SA. In the illustrated example, the gas channel 74b does not extend completely axially through the valve body 60.

[0081] Gas check 80b is configured to prevent backflow through gas channel 74b. Gas check 80b is configured to allow compressed gas flow in a downstream direction and prevent backflow in an upstream direction. For example, if a component leaks into the gas channel of cartridge 14 or expands beyond mixing chamber 110, gas check 80b prevents backflow into the air passages within actuator assembly 12, thereby protecting actuator assembly 12 from undesired contamination by the component.

[0082] A gas stem 82 extends between and fluidly connects the cartridge 14 and the gun body 30. In the illustrated example, the gas stem 82 is configured to transfer compressed gas to gas channel 74b. The gas stem 82 includes a bore extending completely axially therethrough, which is configured to transfer compressed gas to the block body 61. In the illustrated example, the gas stem 82 is formed as a static component that does not shift along the spray axis SA during operation. In the illustrated example, the gas stem 82 is attached to the valve body 60, extends axially into the drive piston 46, and interfaces with the drive piston 46 at a sliding interface. The sliding interface of the gas stem 82 is an interface that expands and contracts as the drive piston 46 moves relative to the gas stem 82. The gas stem 82 extends completely axially through the body chamber 86, connecting gas channel 74b with the compressed gas flow path through the drive piston 46. As described in more detail below, the gas flows to the gas flow paths 74a, 74b are maintained fluidly separated within the cartridge 14 to facilitate introduction of solvent into the mixing chamber 110, for example, by only one of the compressed gas flows.

[0083] While the gas stem 82 is shown as being supported by the valve body 60, it will be understood that not all examples are so limited. For example, the gas stem 82 can be connected to the drive piston 46 and extend into the valve body 60. In such examples, the gas stem 82 can move along the spray axis SA with the drive piston 46 relative to the valve body 60. The gas stem 82 can extend and retract relative to the stationary valve body 60 in such examples. The gas check 80b can be located within the drive piston 46 in such examples.

[0084] A body chamber 86 is formed within the valve body 60. The body chamber 86 opens in the second axial direction AD2. Each of the valve holes 66a, 66b opens into the body chamber 86. A coupler 90 of the valve assembly 64 is at least partially disposed within the body chamber 86. The body chamber 86 provides an open volume for reciprocation of the coupler 90 along the spray axis SA, as described in more detail below.

[0085] The seal bodies 76a, 76b are disposed within the valve bores 66a, 66b, respectively. Each seal body 76a, 76b is mounted within a respective valve bore 66a, 66b. The seal bodies 76a, 76b are configured to interface with the valve members 88a, 88b, respectively, to open and close a flow path for the compressed gas and the component materials to flow to the mixing chamber 110. In the illustrated example, each seal body 76a, 76b is formed as multiple components mounted within the valve bores 66a, 66b. However, it will be understood that not all embodiments are so limited. For example, the seal bodies 76a, 76b may be monolithically formed, among other options.

[0086] The seal bodies 76a, 76b can form seats for the flow valves 58a, 58b, against which movable components (e.g., valve members 88a, 88b) of the flow valves 58a, 58b move relative to open and close flow paths through the flow valves 58a, 58b. In the illustrated example, each seal body 76a, 76b can be considered to form a material seat with which the valve members 88a, 88b interface to block the flow of component material, and from which the valve members 88a, 88b can disengage to allow the component material to flow into the mixing chamber 110. In the illustrated example, each seal body 76a, 76b can also be considered to form a gas seat with which the valve members 88a, 88b interface to block the flow of compressed gas, and from which the valve members 88a, 88b can disengage to allow the compressed gas to flow into the mixing chamber 110.

[0087] The retainers 78a, 78b are attached to the valve body 60. The retainers 78a, 78b are attached to the valve holes 66a, 66b, respectively. For example, each retainer 78a, 78b may be attached to the valve body 60 by a threaded interface, among other options. The retainers 78a, 78b are configured to retain the seal bodies 76a, 76b within the valve holes 66a, 66b, respectively.

[0088] The shaft seal 136 is supported by the retainers 78a, 78b. The shaft seal 136 is configured to engage and seal with the outer surfaces of the valve members 88a, 88b. The shaft seal 136 interfaces with the valve members 88a, 88b at a dynamic seal interface when the valve members 88a, 88b move relative to the shaft seal 136 during operation. The shaft seal 136 is considered to form a sliding seal due to the sliding interface between the shaft seal 136 and the valve members 88a, 88b. The shaft seal 136 engages with the valve members 88a, 88b to prevent leakage of structural material from the valve holes 66a, 66b in the second axial direction AD2.

[0089] The valve assembly 64 is configured to control the flow of the makeup material and compressed gas into the mixing chamber 110. The valve assembly 64 is connected to the drive piston 46 at the dynamic interface 128. The drive piston 46 is configured to displace the valve assembly 64 axially along the spray axis SA to shift the sprayer 10 between a non-spraying state and a spraying state. The valve assembly 64 is configured to shift along the spray axis SA to actuate the flow valves 58 a, 58 b between a first open state, a second open state, and a closed state. The valve assembly 64 is supported by the valve body 60.

[0090] When flow valves 58a, 58b are in their first open states (shown in FIG. 2A ), gas chambers 72a, 72b are fluidly connected to mixing chamber 110 such that compressed gas can flow into mixing chamber 110 and be released through spray orifice 28. Such compressed gas may also be referred to as purge gas. The purge gas flows through mixing chamber 110 to blow away any residual material within mixing chamber 110 and prevent undesired hardening within mixing chamber 110. When flow valves 58a, 58b are in their respective first open states, flow chambers 70a, 70b are fluidly isolated from mixing chamber 110 such that component material cannot flow into mixing chamber 110.

[0091] When flow valves 58a, 58b are in a second open state (shown in FIG. 2B ), gas chambers 72a, 72b are fluidly isolated from mixing chamber 110 such that compressed gas is prevented from flowing into mixing chamber 110. When flow valves 58a, 58b are in a second open state, flow chambers 70a, 70b are fluidly connected to mixing chamber 110 such that the constituent materials flow into mixing chamber 110, combine within mixing bore 138 of mixing chamber 110, form the multi-component material, and are emitted from spray orifice 28 as a spray of the multi-component material.

[0092] When the flow valves 58a, 58b are closed, the gas chambers 72a, 72b and the flow chambers 70a, 70b are fluidly isolated from the mixing chamber 110. The flow valves 58a, 58b in the closed state prevent the flow of the build material and compressed gas into the mixing chamber 110. The flow valves 58a, 58b transition between a first open state and a second open state. The flow valves 58a, 58b move from the first open state to a closed state and then to a second open state, allowing the build material to flow into the mixing chamber 110. The flow valves 58a, 58b move from the second open state to a closed state and then to the first open state, blocking the flow of the build material and allowing the compressed gas to flow into the mixing chamber 110. Flow valves 58a, 58b in a closed state intermediate their first and second open states prevent crossover flow between flow chambers 70a, 70b and gas chambers 72a, 72b.

[0093] The valve assembly 64 is formed by valve members 88a, 88b attached to a coupler 90. In the illustrated example, each valve member 88a, 88b is formed as a shuttle configured to shift axially along a valve axis VA. The valve members 88a, 88b form movable valve components of the cartridge 14. The valve members 88a, 88b form movable valve components of the flow valves 58a, 58b. Each valve member 88a, 88b is movable along the valve axis VA. In the illustrated example, the valve axis VA is radially offset from and parallel to the spray axis SA. The valve members 88a, 88b are movable along the valve axis VA to actuate the flow valves 58a, 58b between their respective first open, closed, and second open states.

[0094] Movement of the valve member 88a (e.g., parallel to the spray axis SA) opens and closes the flow valve 58a. The flow valve 58a transfers either the component A constituent material or the compressed gas through the supply channel 134a to the mixing chamber 110, depending on the state of the flow valve 58a. The state of the flow valve 58a depends on whether the valve member 88a is in a first position, a second position, or a third position. The valve member 88a in the first position (FIG. 2A) is associated with the flow valve 58a in a first open state. The valve member 88a in the second position (FIG. 2B) is associated with the flow valve 58a in a second open state. The valve member 88a in a third position, axially between the first and second positions, is associated with the flow valve 58a in a closed state.

[0095] Movement of the valve member 88b (e.g., parallel to the spray axis SA) opens and closes the flow valve 58a. The flow valve 58b transfers either the component B constituent material or the compressed gas to the mixing chamber 110 through the supply channel 134b, depending on the state of the flow valve 58b. The state of the flow valve 58b depends on whether the valve member 88b is in a first position, a second position, or a third position. The valve member 88b in the first position (FIG. 2A) is associated with the flow valve 58b in a first open state. The valve member 88b in the second position (FIG. 2B) is associated with the flow valve 58b in a second open state. The valve member 88b in a third position, axially between the first and second positions, is associated with the flow valve 58b in a closed state.

[0096] Each valve member 88a, 88b includes a flow head 98, a flow neck 100, a member body 102, a mounting neck 104, a mounting head 106, and a tail 108. The flow head 98 is configured to interface with the seal body 76 (e.g., either directly with the seal body 76 or with a seal supported by the seal body 76) to control the flow of the makeup material and compressed gas into the mixing chamber 110. The flow neck 100 extends between and connects the flow head 98 and the member body 102. The flow neck 100 has a smaller diameter than the flow head 98. The smaller diameter of the flow neck 100 relative to the flow head 98 allows the makeup material to flow around the flow neck 100 and into the mixing chamber 110 when the flow valve 58 is in the second, open state.

[0097] The member body 102 extends axially between the flow neck 100 and the mounting neck 104. The member body 102 interfaces with a shaft seal 136. The member body 102 is configured to slide axially relative to the shaft seal 136 and engages with the shaft seal 136 when the flow valves 58a, 58b are in any of the first open state, the second open state, and the closed state. The member body 102 interfaces with the flow neck 100 at a location within the valve body 60 and extends axially from each of the valve holes 66a, 66b. In the illustrated example, the member body 102 has a larger diameter than the flow neck 100.

[0098] The mount neck 104 extends axially between the member body 102 and the mount head 106. The mount neck 104 extends axially through the coupler 90. The mount neck 104 is configured to be disposed within a slot in the coupler 90 to mount the valve members 88a, 88b to the coupler 90. The mount neck 104 has a smaller diameter than the member body 102 and the mount head 106. The larger diameter of the member body 102 and the mount head 106 relative to the mount neck 104 facilitates the coupler 90 transmitting a driving force to the valve members 88a, 88b to displace the valve members 88a, 88b in either the first axial direction AD1 or the second axial direction AD2. The coupler 90 applies an axial driving force to the member body 102 to displace the valve members 88a, 88b in the first axial direction AD1. The coupler 90 applies an axial driving force to the mount head 106 to displace the valve members 88a, 88b in a second axial direction.

[0099] In the illustrated example, the valve members 88a, 88b include a tail 108 extending axially from the mount head 106. The tail 108 projects axially away from the mount neck 104 and is disposed axially opposite the mount head 106 from the mount neck 104. The tail 108 is configured to provide a tool interface that facilitates removal of the valve assembly 64 from the cartridge 14, for example, for cleaning or replacement. For example, with the cartridge 14 removed from the gun body 30, the tail 108 can be grasped with pliers and pulled in the second axial direction AD2 to pull the valve assembly 64 in the second axial direction AD2, thereby removing the valve assembly 64 from the cartridge 14.

[0100] It should be noted that while the valve members 88a, 88b are shown as a single piece in this embodiment, in alternative embodiments they may be comprised of multiple pieces secured relative to one another. Each valve member 88a, 88b may include a head separate from the body and / or a tail separate from the body, etc.

[0101] Each valve member 88a, 88b extends into but does not pass through the valve bores 66a, 66b. The valve members 88a, 88b are configured to interface with the seal bodies 76a, 76b to seal the flow path to the mixing chamber 110. The flow head 98 interfaces with a portion of the seal bodies 76a, 76b separated in the second axial direction AD2 from the supply channels 134a, 134b when the flow valves 58a, 58b are in the first open state. The flow head 98 interfaces with a portion of the seal bodies 76a, 76b separated in the first axial direction AD1 from the supply channels 134a, 134b when the flow valves 58a, 58b are in the second open state. The flow head 98 interfaces with a portion of the seal bodies 76a, 76b axially on either side of the supply channels 134a, 134b when the flow valves 58a, 58b are in the closed state. The flow head 98 radially overlaps and covers the supply channels 134a, 134b when the flow valves 58a, 58b are in a closed state.

[0102] The valve members 88a, 88b are connected to a coupler 90 for simultaneous actuation along a valve axis VA. The coupler 90 is at least partially disposed within the body chamber 86 and is movable relative to the valve disc 60. The coupler 90 is connected to the drive piston 46 at a dynamic interface 128. The dynamic interface 128 transfers mechanical motion from the drive piston 46 to the coupler 90 to cause displacement of the valve members 88a, 88b and actuate the flow valves 58a, 58b between various operating states.

[0103] The cartridge 14 includes a valve mount 92 attached to the drive mount 54 of the drive piston 46 to form a dynamic interface 128 between the cartridge 14 and the gun body 30. The dynamic interface 128 transfers mechanical motion to actuate the flow valves 58a, 58b between various states. The valve mount 92, as part of the dynamic interface 128, is movable relative to the static interface 126 between the cartridge 14 and the gun body 30. The dynamic interface 128 is configured to shift axially along the spray axis SA during operation of the sprayer 10. In the illustrated example, the valve mount 92 is formed on the coupler 90.

[0104] The manifold 18 is attached to the cartridge 14. In the illustrated example, the manifold 18 is attached to the cartridge 14 such that the entire weight of the manifold 18 is supported by the cartridge 14. The entire weight of the manifold 18 is transferred through the cartridge 14 to the gun body 30. In the illustrated example, fasteners 20 extend through the manifold 18 and into the valve body 60, attaching the manifold 18 to the valve body 60. The fasteners 20 secure the manifold 18 to the valve body 60.

[0105] The shutoff 22 is supported by the gun body 30. The shutoff 22 is connected to the drive piston 46. The shutoff 22 is connected to the valve assembly 64 via the drive piston 46. The connector 114 is connected to the drive piston 46. In the illustrated example, the connector head 122 is at least partially disposed within the piston head 52 of the drive piston 46. The connector head 122 is connected to the drive piston 46 such that the connector 114 and the drive piston 46 move simultaneously along the spray axis SA. The connector shaft 120 extends in a second axial direction AD2 away from the drive piston 46.

[0106] The converter 112 extends between and connects the knob 42 and the connector 114. The converter 112 is configured to convert rotational motion of the knob 42 into axial motion of the connector 114, and therefore axial motion of the drive piston 46 and the valve assembly 64. In the illustrated example, the converter body 116 is connected to the knob 42 by a shutoff fastener 142. The shutoff fastener 142 secures the converter body 116 and the knob 42 together. The converter body 116 is connected to the knob 42 for simultaneous rotation, such that rotating the knob 42 causes rotation of the converter body 116. In the illustrated example, the converter 112 is disposed coaxially with the spray axis SA, and the converter body 116 is configured to rotate on the spray axis SA.

[0107] The positioner 118 is supported by the connector 114. In the illustrated example, the positioner 118 is supported by the connector shaft 120. More specifically, in the illustrated example, the positioner 118 extends through the connector shaft 120. The positioner 118 extends radially outward from the connector shaft 120. The positioner 118 interfaces with the converter body 116. The positioner 118 and the converter body 116 together convert rotational movement of the knob 42 into axial movement of the connector 114 along the spray axis SA. The positioner 118 extends into a slot formed in the converter body 116, as described in more detail below.

[0108] The knob 42 is disposed outside the gun body 30 and is accessible from the exterior of the sprayer 10. The knob 42 is accessible by a user to actuate the shutoff 22 between a locked state and an unlocked state. The knob 42 is configured to rotate on the spray axis SA to actuate the shutoff 22 between a locked state and an unlocked state. When the shutoff 22 is in the locked state, the sprayer 10 is locked in a non-spraying state such that the valve components within the cartridge 14 cannot be actuated to open a flow path for the components to flow to the mixing chamber 110. When the shutoff is in the unlocked state, the drive piston 46 is movable along the spray axis SA and the sprayer 10 can be placed in a spraying state such that the valve components within the cartridge 14 can be actuated to open a flow path for the components to flow to the mixing assembly 16. In the illustrated example, the knob 42 provides a user interface for the shutoff 22.

[0109] In operation, the trigger 24 is actuated and released to actuate the sprayer 10 between a non-atomizing state and an atomizing state. Compressed gas is directed against either side of the piston head 52 of the drive piston 46 to axially displace the drive piston 46 and actuate the flow valves 58a, 58b between various operating states. The sprayer 10 is initially in the non-atomizing state shown in FIG. 2A. Compressed gas is supplied to the sprayer 10 through the gas fitting 26 and transferred to the cartridge 14 through the gun body 30. The build material is supplied to the manifold 18 and transferred from the manifold 18 to the cartridge 14.

[0110] When the sprayer 10 is in a non-spraying state, each of the flow valves 58a, 58b is in a first open state. The components are allowed to flow into the flow chambers 70a, 70b but are prevented from flowing downstream into the mixing chamber 110 by the valve members 88a, 88b. The compressed gas is allowed to flow into the gas chambers 72a, 72b, through the supply channels 134a, 134b, and into the mixing chamber 110.

[0111] Actuation of trigger 24 causes gas valve 44 to direct compressed gas into a chamber on the side of piston head 52 oriented in second axial direction AD2. The compressed gas displaces drive piston 46 in first axial direction AD1 (downstream direction). Drive piston 46 displaces valve assembly 64 in first axial direction AD1. Drive piston 46 applies an axial force to valve assembly 64 at dynamic interface 128, displacing valve assembly 64 in first axial direction AD1. In the illustrated example, drive piston 46 applies an axial force to coupler 90. Coupler 90 applies an axial driving force to valve members 88a, 88b to axially displace valve members 88a, 88b.

[0112] The valve members 88a, 88b are displaced to their respective second positions (FIG. 2B). With the valve member 88a in the second position, component A liquid can flow from the flow chamber 70a (which receives component A liquid from the material inlet 38a of the manifold 18) to the feed channel 134a and enter the mixing chamber 110. While in the second position, the valve member 88a blocks the flow path for compressed gas from the gas chamber 72a to the feed channel 134a and to the mixing chamber 110. The gas chamber 72a can be pressurized with compressed gas, but while the valve member 88a is in the second position, the valve member 88a fluidly blocks the flow of compressed gas into the feed channel 134a. The state of the valve member 88a in the second position corresponds to the trigger 24 being actuated for spraying, and such actuation causes the drive piston 46 to be in a second spraying position (e.g., in a forward or downstream direction in this case).

[0113] With the valve member 88b in the second position, component B liquid can flow from the flow chamber 70b (which receives component B liquid from the material inlet 38b of the manifold 18) to the feed channel 134b and enter the mixing chamber 110. While in the second position, the valve member 88b blocks the flow path for compressed gas from the gas chamber 72b to the feed channel 134b and to the mixing chamber 110. The pressurized gas chamber 72b can be pressurized with compressed gas, but can be fluidly blocked from flowing into the feed channel 134b by the valve member 88b while the valve member 88b is in the second position. The state of the valve member 88b in the second position corresponds to the state of the trigger 24 being actuated for spraying, and such actuation causes the drive piston 46 to be in a second spraying position (e.g., in a forward or downstream direction in this case).

[0114] The constituent materials flow from the flow chambers 70a, 70b into the feed channels 134a, 134b. The constituent materials enter the mixing chamber 110 through the chamber bores 140a, 140b aligned with the feed channels 134a, 134b and interact within the mixing bore 138 to form the multi-component material. The multi-component material flows through the mixing bore 138 and is discharged from the atomizing orifice 28. Compressed gas can flow to the air cap 36 and be discharged from the air cap 36 at a location around the atomizing orifice 28 while the flow valves 58a, 58b are in their respective second open states.

[0115] The trigger 24 is released to stop spraying by the sprayer 10. Releasing the trigger 24 shifts the gas valve 44 to direct compressed gas to a chamber within the housing 32 on the side of the piston head 52 oriented in the first axial direction AD1. The compressed gas provided to that chamber exerts an axial force on the drive piston 46, displacing it in the second axial direction AD2. Additionally, the gas valve 44 fluidly connects another chamber within the housing 32 to an exhaust 144 formed through the handle 34 to expel compressed gas from the sprayer 10.

[0116] Upon release of trigger 24, the compressed gas displaces drive piston 46 to a first, non-spraying position (e.g., in this case, a rearward or upstream direction). In this particular embodiment, the first position of drive piston 46 is in the upstream direction, and the second position of drive piston 46 is in the downstream direction. This movement of piston 46 in the second axial direction AD2 moves valve members 88a, 88b to their respective first positions. Drive piston 46 displaces valve assembly 64 in the second axial direction AD2. Drive piston 46 applies an axial force to valve assembly 64 at dynamic interface 128, displacing valve assembly 64 in the second axial direction AD2. In the illustrated example, drive piston 46 applies an axial force to coupler 90, which applies an axial driving force to valve members 88a, 88b, displacing valve members 88a, 88b axially rearward.

[0117] When valve member 88a is moved to a first position (such first position being further upstream than the second position), such as upon release of trigger 24, valve member 88a moves to unblock gas chamber 72a from flowing into supply channel 134a and directing compressed gas to mixing chamber 110, but such positioning resumes blocking the flow of component A liquid from flow chamber 70a to supply channel 134a. In the illustrated example, valve member 88a transitions through a third position before returning from the second position to the first position. When valve member 88a is in the third position, associated with a closed state of flow valve 58a, the flow of compressed gas from gas chamber 72a to mixing chamber 110 is blocked, and the flow of component A liquid from flow chamber 70a to mixing chamber 110 is blocked.

[0118] Valve member 88a is in one of two positions when sprayer 10 is discharging from spray orifice 28: the second position blocks compressed gas from entering mixing chamber 110 while allowing component A liquid to enter mixing chamber 110 for spraying, and the first position blocks component A liquid from entering mixing chamber 110 while allowing compressed gas to enter mixing chamber 110 for purging. Actuation of trigger 24 moves valve member 88a to the second position, and release of trigger 24 moves valve member 88a to the first position.

[0119] When valve member 88b is moved to a first position (such first position being further upstream than the second position), such as upon release of trigger 24, valve member 88b moves to unblock gas chamber 72b from flowing into supply channel 134b and directing compressed gas to mixing chamber 110, but such positioning resumes blocking the flow of component B liquid from flow chamber 70b to supply channel 134b. In the illustrated example, valve member 88b transitions through a third position, associated with the closed state of flow valve 58b, before returning from the second position to the first position. When valve member 88b is in the third position, the flow of compressed gas from gas chamber 72b to mixing chamber 110 is blocked, and the flow of component B liquid from flow chamber 70b to mixing chamber 110 is blocked.

[0120] Valve member 88b is in one of two positions when sprayer 10 is discharging from spray orifice 28: the second position blocks compressed gas from entering mixing chamber 110 while allowing component B liquid to enter mixing chamber 110 for spraying, and the first position blocks compressed gas from entering mixing chamber 110 for purging while preventing component B liquid from entering mixing chamber 110. Actuation of trigger 24 moves valve member 88b to the second position, and release of trigger 24 moves valve member 88b to the first position.

[0121] Each valve member 88 is attached to a coupler 90 for simultaneous actuation. Mechanical motion from the drive piston 46 is transferred from the actuator assembly 12 to the cartridge 14 by a dynamic interface 128 for actuating the flow valves 58 a, 58 b between various states. The drive piston 46 is directly connected to the coupler 90 or indirectly connected to the coupler 90 by one or more intermediate components, depending on the embodiment. The valve members 88 a, 88 b are directly or indirectly connected to the puller 90. Thus, actuation of the trigger 24 moves the drive piston 46 between a first position and a second position, thereby correspondingly moving the valve members 88 a, 88 b to the first or second position to block and unblock the flow of component liquids A and B and compressed gas to the mixing chamber 110. The dynamic interface 128 can be broken to remove the cartridge 14 from the gun body 30, as described further herein.

[0122] While the mechanical motion for moving the valve members 88a, 88b comes from pneumatic actuation initiated by the trigger 24, in the unlikely event that air pressure is lost while the sprayer 10 is in a spraying state and spraying, the trigger 24 cannot pneumatically move the piston 46 via the gas valve 44, necessitating a quick manual shutoff of the component material flow to stop spraying of the multiple-component material. Such motion is provided by the shutoff 22. The knob 42 is accessible by the user to activate the shutoff 22. The knob 42 can be located on the rear or upstream side of the gun body 30 opposite the spray orifice 28. The knob 42 can be rotated about the spray axis SA, among other options. Actuation of the knob 42 provides a mechanical input to the converter 112. In this embodiment, the converter 112 converts rotary motion into linear motion. More specifically, the knob 42 can be rotated to provide a rotational input to the converter body 116. The converter body 116 displaces the positioner 118 along a slot formed in the converter body 116 that exerts an axial driving force on the positioner 118. The positioner 118 is connected to the connector 114 to exert an axial driving force on the connector 114. The connector 114 is attached to the drive piston 46 and can mechanically displace the drive piston 46.

[0123] The shutoff 22 is attached to the drive piston 46 and can displace the drive piston 46 in a second axial direction AD2 to pull the valve members 88a, 88b rearward to actuate the flow valve 58a to block the flow of component A to the mixing chamber 110 and actuate the flow valve 58b to block the flow of component B to the mixing chamber 110. The positioner 118 can include a pin, knob, or other protrusion that interfaces with a helical structure on the converter body 116. The helical structure can wrap partially or completely around the spray axis SA, among other options. The positioner 118 can be fixed so that it can only translate linearly along the spray axis SA, such that an interface with the rotating helical structure causes a pin, knob, or other protrusion to move linearly along the spray axis SA. The positioner 118 can be directly or indirectly connected (in the illustrated example via a connector 114) to the drive piston 46, which is indirectly connected to the valve members 88a, 88b via the coupler 90.

[0124] Cartridge 14 is coaxially disposed with shutoff 22 and drive piston 46 on spray axis SA. Cartridge 14 is configured to shift in a second axial direction AD2 relative to gun body 30 during installation into actuator assembly 12, and cartridge 14 is configured to shift in a first axial direction AD1 relative to gun body 30 during removal from actuator assembly 12. Mixing chamber cavity 68 is coaxially disposed with piston bore 146 through which piston shaft 50 of drive piston 46 extends for interfacing with valve assembly 64 at dynamic interface 128.

[0125] In the illustrated example, the cartridge 14 interfaces with the actuator assembly 12 at three distinct locations. A first interface is formed between the valve disc 60 and the gun body 30 at a static interface 126. The static interface 126 connects the cartridge 14 to the gun body 30 to secure the cartridge 14 thereto. A second interface is formed between the valve assembly 64 and the drive piston 46 at a dynamic interface 128. The dynamic interface 128 transmits mechanical force from the actuator assembly 12 to the cartridge 14 to actuate the flow valves 58a, 58b between various operating states, thereby controlling the flow of the build material and compressed gas into the mixing chamber 110. A third interface is formed between the cartridge 14 and the drive piston 46. More specifically, the third interface is formed between the gas stem 82 and the drive piston 46. The third interface does not transmit mechanical driving force between the actuator assembly 12 and the cartridge 14. In the illustrated example, the third interface is formed as a telescoping interface where components of the actuator assembly 12 move relative to components of the cartridge 14 (in the illustrated example, the drive piston 46 moves relative to the gas stem 82). Compressed gas is transferred from the actuator assembly 12 to the cartridge 14 at the third interface.

[0126] The sprayer 10 offers significant advantages. The cartridge 14 is attached to the actuator assembly 12 at a static interface 126 and a dynamic interface 128. The static interface 126 connects the cartridge 14 to the gun body 30 and mechanically supports the cartridge 14 on the gun body 30. The dynamic interface 128 transfers mechanical motion from the drive piston 46 to the valve assembly 64, actuating the flow valves 58a, 58b between various operating states. The static interface interface 126 and the dynamic interface 128 are both formed during installation of the cartridge 14 and both are broken during removal of the cartridge 14. The static interface 126 and the dynamic interface 128 provide for easy and quick installation and removal of the cartridge 14.

[0127] The cartridge 14 includes the flow valves 58a, 58b such that the flow valves 58a, 58b are installed and removed with the cartridge 14. Thus, the flow valves 58a, 58b, which control the flow of components to the mixing chamber 110, are installed and removed with the cartridge 14. The complete containment of the flow valves 58a, 58b by the cartridge 14 allows for quick and easy removal and replacement of the valve components, for example, by installing a new cartridge 14.

[0128] The shutoff 22 can lock the sprayer 10 in a non-spraying state to prevent actuation of the sprayer 10 into the spraying state. The shutoff 22 can also actuate the flow valves 58a, 58b to shut off the flow of component materials to the mixing chamber 110. The shutoff 22 provides a single mechanism that can both lock the sprayer 10 in the spraying state and provide actuation in the event of loss of driving force to the drive piston 46. The shutoff 22 provides a simple configuration that is easily accessible by the user and provides multiple functions with a single assembly.

[0129] FIG. 4A is an enlarged view of detail 4A of FIG. 3. FIG. 4B is a cross-sectional view taken along line 4B-4B of FIG. 3, showing the interface between the cartridge 14 and the manifold 18. FIGS. 4A and 4B will be discussed together with continued reference to FIGS. 1A-3. The cartridge 14, manifold 18, fastener 20, and gun body 30 of the sprayer 10 are shown. The valve body 60, valve bores 66a, 66b, cartridge inlets 148a, 148b, inlet checks 150a, 150b, bore inlets 152a, 152b, and fastener opening 154 of the cartridge 14 are shown. Each cartridge inlet 148a, 148b includes an inlet body 156, an inlet orifice 158, an inlet seal 160, a shoulder 162, and a flange 164. Shown are manifold body 166, manifold valves 168a, 168b, manifold passages 170a, 170b, manifold brace 172, valve caps 174a, 174b, and valve housings 176a, 176b of manifold 18. Shown is body slot 178 of gun body 30.

[0130] The manifold 18 is connectable to a makeup material line to receive the makeup material from the pump. The manifold 18 is configured to transfer the makeup material to the cartridge 14. The manifold body 166 supports the other components of the manifold 18. The manifold passages 170a, 170b define flow paths for the makeup materials to flow to the cartridge 14. The manifold passages 170a, 170b are fluidly separated from one another within the manifold body 166. The makeup materials are separated from one another within the manifold body 166 and do not mix within the manifold body 166.

[0131] The manifold brace 172 is formed by the manifold body 166. The manifold brace 172 protrudes from other portions of the manifold body 166. The manifold brace 172 is configured to interface a portion of the gun body 30 with the manifold 18 attached to the cartridge 14. In the illustrated example, the manifold brace 172 extends into a body slot 178 formed in the housing 32 of the gun body 30. The body slot 178 is formed on the underside of the housing 32. The manifold brace 172 protrudes into the body slot 178 and can interface with the portion of the gun body 30 that forms the body slot 178. The manifold brace 172 interfacing with the gun body 30 in the body slot 178 prevents rotation of the cartridge 14 relative to the gun body 30 and about the spray axis SA during operation of the sprayer 10. Removing the manifold 18 from the cartridge 14 allows the cartridge 14 to be rotated relative to the gun body 30, thereby removing the cartridge 14 from the gun body 30. It is understood that while the manifold 18 may interface directly with the gun body 30 to lock the orientation of the cartridge 14 during operation, the manifold 18 is not directly connected to the gun body 30; instead, the manifold 18 is attached directly to the cartridge 14 such that the cartridge 14 fully supports the manifold 18.

[0132] Manifold valves 168a, 168b are disposed within manifold passages 170a, 170b, respectively. Manifold valves 168a, 168b are configured as normally closed valves that are actuated to an open state by cartridge 14. Manifold valves 168a, 168b are not check valves that are opened and closed by flow through the valves. Instead, manifold valves 168a, 168b are configured to remain in their respective closed states until actuated open by cartridge 14, which interfaces with manifold valves 168a, 168b and drives them to their respective open states. Cartridge 14 can maintain manifold valves 168a, 168b in their respective open states throughout the time manifold 18 is attached to cartridge 14. In the illustrated example, manifold valves 168a, 168b are spring-biased ball valves, although it will be understood that other configurations are possible.

[0133] Valve housings 176a, 176b are attached to the manifold body 166. Valve housing 176a is at least partially disposed within manifold passage 170a. Valve housing 176b is at least partially disposed within manifold passage 170b. Valve housings 176a, 176b include an array of openings that allow construction material to enter valve housings 176a, 176b from the associated manifold passages 170a, 170b. Valve caps 174a, 174b are attached to the manifold body 166. Valve caps 174a, 174b can form seats for movable valve components (e.g., balls in the illustrated example) of manifold valves 168a, 168b.

[0134] The cartridge inlets 148a, 148b protrude from the valve body 60. In the illustrated example, the cartridge inlets 148a, 148b extend from the block body 61 of the valve body 60. The cartridge inlet 14a extends from the valve body 60 at a first position between the first body end 94 and the second body end 96. The cartridge inlet 14b extends from the valve body 60 at a second position between the first body end 94 and the second body end 96. The cartridge inlets 148a, 148b may also be referred to as material inlets that receive constituent materials into the cartridge 14. In the illustrated example, the cartridge inlets 148a, 148b protrude vertically downward away from the valve body 60. The cartridge inlets 148a, 148b extend away from the spray axis SA as the cartridge inlets 148a, 148b protrude from the valve body 60. The cartridge inlets 148a, 148b are radially offset from the spray axis SA. The cartridge inlets 148a, 148b are in fluid communication with the valve orifices 66a, 66b, respectively, via bore inlets 152a, 152b formed in the valve body 60. The bore inlets 152a, 152b extend radially relative to the valve axes VA of the valve orifices 66a, 66b to which they are fluidly connected. The bore inlets 152a, 152b define flow paths for the component material to flow from the cartridge inlets 148a, 148b to the chambers 70a, 70b of the valve orifices 66a, 66b.

[0135] In the illustrated example, cartridge 14 is configured so that the first and second components do not enter cartridge 14 through either axial end of cartridge 14. The first and second components do not enter valve body 60 through either first body end 94 or second body end 96.

[0136] In the illustrated example, bore inlet 152a, flow chamber 70a, and supply channel 134a form a material flow path for a first component material to flow through valve body 60 to mixing chamber cavity 68 when flow valve 58a is in its second open state. In the illustrated example, bore inlet 152b, flow chamber 70b, and supply channel 134b form a material flow path for a second component material to flow through valve body 60 to mixing chamber cavity 68 when flow valve 58b is in its second open state.

[0137] For each cartridge inlet 148a, 148b, an inlet body 156 is connected to the valve disc 60. The inlet body 156 defines a flow path for the constituent material to flow to the respective valve orifice 66a, 66b. The inlet body 156 may be connected to the valve disc 60 in any desired manner, such as interface threading, among other options. In some examples, the inlet body 156 may be monolithically formed with the valve disc 60. The inlet body 156 protrudes from the underside 180 of the valve disc 60. The inlet body 156 protrudes away from the valve disc 60. In the illustrated example, each inlet body 156 forms a separate protrusion extending away from the valve disc 60.

[0138] An inlet orifice 158 is formed through the inlet body 156. The inlet orifices 158 form openings through which the build material flows from the manifold 18 into the cartridge 14. In the illustrated example, each cartridge inlet 148a, 148b includes an array of inlet orifices 158 arranged about the inlet body 156. Each inlet body 156 includes a plurality of inlet orifices 158 in the illustrated example.

[0139] A shoulder 162 is formed by the inlet body 156. The shoulder 162 projects inward within the inlet body 156 and forms a seat for the inlet checks 150a, 150b of its cartridge inlets 148a, 148b. An inlet seal 160 is disposed on the exterior of the cartridge inlets 148a, 148b. The inlet seal 160 is configured to interface with the manifold 18 to prevent leakage of components between the inlet body 156 and the manifold 18. In the illustrated example, the inlet seal 160 is supported by the inlet body 156 and interfaces with the inner surfaces of the valve caps 174a, 174b. A flange 164 projects outward from the inlet body 156 and is configured to retain the inlet seal 160 on the inlet body 156.

[0140] Inlet checks 150a, 150b are disposed within cartridge 14. Inlet checks 150a, 150b are configured to prevent backflow from cartridge 14 into manifold 18. Inlet checks 150a, 150b thereby protect manifold 18 from backflow, such as when component crossover occurs within valve body 60, resulting in a multi-component material within the flow path within cartridge 14. Inlet checks 150a, 150b prevent the flow of multi-component material into manifold 18, which could harden within manifold 18 and render manifold 18 inoperable.

[0141] The fasteners 20 attach the manifold 18 to the cartridge 14. The fasteners 20 extend through the manifold body 166 and into the fastener openings 154 formed in the valve disc 60. In the illustrated example, the fasteners 20 are formed as threaded fasteners including external threads that mate with internal threads formed in the valve disc 60. The fasteners 20 extend completely through the manifold body 166 to interface with the valve disc 60.

[0142] With the manifold 18 attached to the cartridge 14, the manifold 18 can interface with the gun body 30 and the underside 180 of the valve body 60. The fasteners 20 extend axially into the valve body 60 at a location disposed between a first interface 182a between the manifold brace 172 and the gun body 30 and a second interface 182b between the valve caps 174a, 174b and the underside 180. The fasteners exert a clamping force to attach the manifold 18 to the cartridge 14. The clamping force is balanced between the two interfaces 182a, 182b to provide a rigid connection while maintaining the orientation between the cartridge inlets 148a, 148b and the flow paths through the manifold 18.

[0143] During assembly of the sprayer 10, the cartridge 14 is attached to the actuator assembly 12 to form a static interface 126 and a dynamic interface 128, as described in more detail below. The manifold 18 is attached to the cartridge 14 with the cartridge 14 attached to the actuator assembly 12. One of the manifold 18 and cartridge 14 is shifted relative to the other of the manifold 18 and cartridge 14 so that cartridge inlets 148a, 148b enter the manifold 18. The cartridge inlets 148a, 148b enter the manifold 18 through valve caps 174a, 174b, respectively. The distal end of the inlet body 156 contacts the manifold valves 168a, 168b, displacing the manifold valves 168a, 168b to an open state. In the illustrated example, the distal end of the inlet body 156 contacts the balls of the manifold valves 168a, 168b, urging the balls away from their seats. The inlet body 156 holds the manifold valves 168a, 168b in their open states, which remain open along with the manifold 18 attached to the cartridge 14.

[0144] The fasteners 20 are inserted through the manifold 18 and connected to the valve body 60. The fasteners 20 secure the manifold 18 to the cartridge 14.

[0145] During disassembly of the sprayer 10, the fastener 20 is disconnected from the valve body 60. The manifold 18 can then be withdrawn from the cartridge 14. The cartridge inlets 148a, 148b are withdrawn from the manifold 18, and the manifold valves 168a, 168b return to their closed states. The manifold valves 168a, 168b prevent leakage from the manifold 18 when the manifold 18 is not attached to the sprayer 10. The manifold valves 168a, 168b, which automatically return to their closed states when the manifold 18 is removed from the cartridge 14, prevent material within the manifold passages 170a, 170b but downstream of the material valves 40a, 40b from leaking from the manifold 18. Once the manifold 18 is removed from the cartridge 14, the static interface 126 and the dynamic interface 128 can be destroyed, and the cartridge 14 can be removed from the actuator assembly 12.

[0146] Figure 5A is an isometric view of the cartridge 14 with the mixing assembly 16 attached to it. Figure 5B is an exploded view of the cartridge 14 and the mixing assembly 16. Figure 5C is an isometric view of the cartridge 14 with the mixing assembly 16 removed to expose the mixing chamber cavity 68. Figures 5A-5C will be described together with continued reference to Figures 1A-4B. The valve disc 60, outer body 62, valve assembly 64, mixing chamber cavity 68, cartridge inlets 148a, 148b, and fastener opening 154 of the cartridge 14 are shown. The valve members 88a, 88b and coupler 90 of the valve assembly 64 are shown. The air cap 36, mixing chamber 10, chamber seal 184, and locator 186 of the mixing assembly 16 are shown.

[0147] The cartridge 14 is configured to be installed and removed as a single module from the gun body 30 of the sprayer 10. The valve body 60 is disposed within the outer body 62. The cartridge inlets 148a, 148b project from the valve body 60 and extend into the manifold 18 and are configured to receive individual streams of the components therefrom.

[0148] The valve assembly 64 is at least partially disposed within the valve body 60. The valve assembly 64 is removable from the valve body 60 for maintenance or replacement of the valve assembly 64. For example, the valve assembly 64 can be pulled in the second axial direction AD2 to remove the valve members 88a, 88b from the valve holes 66a, 66b. An identical or new valve assembly 64 can be attached to the valve body 60 by shifting the valve assembly 64 in the first axial direction AD1 relative to the valve body 60 to insert the valve members 88a, 88b into the valve holes 66a, 66b. The valve assembly 64 is movable relative to the valve body 60 during operation of the sprayer 10. The valve members 88a, 88b are attached to a coupler 90. The coupler 90 is connected to the drive piston 46 at a dynamic interface 128. Coupler 90 transfers axial drive force from drive piston 46 to valve members 88a, 88b to axially displace valve members 88a, 88b during operation.

[0149] The mixing assembly 16 is detachably attached to the cartridge 14. The mixing assembly 16 can remain attached to the cartridge 14 during installation of the cartridge 14 to the gun body 30 and during removal of the cartridge 14 from the gun body 30. The mixing chamber 110 is configured to be at least partially disposed within the mixing chamber cavity 68 during operation of the sprayer 10. A mixing chamber seal 184 is mounted on the mixing chamber 110 and configured to interface with the valve disc 60 at a location within the mixing chamber cavity 68. The mixing chamber seal 184 engages the mixing chamber 110 and the valve disc 60 to prevent leakage (e.g., of compressed gas or components) between the mixing chamber 110 and the valve disc 60.

[0150] A locator 186 extends from the mixing chamber 110. A positioning groove 188 is formed in the valve body 60 and extends axially and radially. The locator 186 is configured to be disposed within the positioning groove 188 to ensure orientation between the chamber bores 140a, 140b of the mixing chamber 110 and the feed channels 134a, 134b that carry the mixing chamber 110 when attached to the cartridge 14. The locator 186 disposed within the positioning groove 188 limits axial displacement of the mixing chamber 110 during attachment and detachment of the mixing chamber 110 to and from the cartridge 14.

[0151] The air cap 36 is attachable to the mixing chamber 110. The air cap 36 is configured to guide and output compressed air around the atomizing orifice 28 of the mixing chamber 110. Such compressed air may also be referred to as clean-off air, which prevents the material in the mixing chamber 110 from blowing out. The air cap 36 can be attached to the cartridge 14 by rotating the air cap 36 relative to the mixing chamber 110. In the illustrated example, a cap chamber 190 is formed in the first body end 94 of the valve body 60. The cap chamber 190 extends in a first axial direction AD1 relative to the mixing chamber cavity 68. The cap chamber 190 includes female threads configured to interface with male threads on the air cap 36 to attach the air cap 36 to the cartridge 14.

[0152] Figure 6A is a cross-sectional view taken along line AA in Figure 5A. Figure 6B is a cross-sectional view taken along line BB in Figure 5A. Figure 6C is a cross-sectional view taken along line CC in Figure 5A. Figures 6A-6C will be described together with continued reference to Figures 1A-5C. Figures 6A-6C show the gas passageway through cartridge 14. Cartridge 14 and mixing assembly 16 are shown. Valve body 60, outer body 62, valve assembly 64, valve holes 66a, 66b, mixing chamber cavity 68, gas chambers 72a, 72b, gas channels 74a, 74b, gas checks 80a, 80b, and gas stem 82 of cartridge 14 are shown. Air cap 36 and mixing chamber 110 of mixing assembly 16 are shown.

[0153] The cartridge 14 is shown removed from the actuator assembly 12 having the mixing assembly 16 attached thereto. The cartridge 14 is configured to provide a flow of component materials to the mixing assembly 16 for mixing in the mixing chamber 110 to form a multi-component material that is emitted as a spray. The cartridge 14 is further configured to provide a flow of compressed gas to the mixing assembly 16 to flow through the mixing chamber 110 to purge the mixing chamber 110 of residual materials and to the air cap 36 for emission around the atomizing orifice 28. In the illustrated example, the cartridge 14 is configured to route a separate flow of compressed gas to the mixing assembly 16. However, it will be understood that not all embodiments are so limited. For example, the cartridge 14 may include a single gas passageway that branches within the valve body 60 to provide compressed gas to both gas chambers 72 a, 72 b.

[0154] Maintaining the gas flows as separate streams within cartridge 14 can provide significant advantages. For example, some examples of sprayer 10 can be configured to intermittently provide solvent to mixing chamber 110 throughout operation. The solvent helps remove residue from mixing chamber 110 while sprayer 10 is in a non-spraying mode, which may also be referred to as a purging state because purge air is flowed into and through mixing chamber 110. The solvent can slow the reaction process of the multi-component material and dissolve uncured multi-component material to inhibit curing within mixing chamber 110.

[0155] In the illustrated example, gas channel 74b is configured to direct compressed gas containing the dispensed solvent to mixing chamber 110. Providing the solvent only through gas channel 74b prevents mixing of the solvent with the component A material provided through valve orifice 66a at a location upstream of mixing chamber 110. For example, valve orifice 66b can be configured to provide a resin component to mixing chamber 1110, and valve orifice 66a can be configured to provide an isocyanate component. Isocyanates are moisture sensitive and can harden when exposed to liquids such as solvents. Hardened isocyanates can form crystals that can cause scoring or other damage to soft seals and clog pathways through cartridge 14. Flowing the solvent to mixing chamber 110 through the same port as the resin (e.g., through supply channel 134b) prevents mixing of the solvent and isocyanate within cartridge 14 at a location upstream of mixing chamber 110. In the illustrated example, dosing piston 48 is configured to dose solvent into the compressed gas stream supplied to gas channel 74b.

[0156] The gas channel 74b extends through the valve body 60 between the gas inlet 192b and the gas chamber 72b. At least a portion of the gas channel 74b is coaxial with the mixing chamber cavity 68 on the spray axis SA. The gas inlet 192b is formed through the chamber wall 87 and opens into the body chamber 86 when the gas stem 82 is not attached to the valve body 60. In the illustrated example, the gas channel 74b includes a first gas path 194b that extends axially in the first axial direction AD1 and extends radially outward within the valve body 60 relative to the spray axis SA. The second gas path 196b intersects the first gas path 194b at a location radially offset from the spray axis SA and from the valve axis VA of the valve bore 66b. The second gas passage 196b extends radially toward the valve axis VA of the valve bore 66b and intersects with the gas chamber 72b at a location spaced apart in the first axial direction AD1 from the supply channel 134b. The gas channel 74b does not open through the first body end 94 of the valve disc 60. In the illustrated example, the gas channel 74b does not extend completely through the valve disc 60.

[0157] In the illustrated example, the gas stem 82 is connected to the valve body 60 at the gas inlet 192b. The gas stem 82 extends axially in the second axial direction AD2. The gas stem 82 extends through an opening 198 in the coupler 90. The gas stem 82 is configured to extend into the drive piston 46 to interface with the drive piston 46 during operation of the sprayer 10. In the illustrated example, the gas stem 82 is attached to the valve body 60 such that the gas stem 82 remains stationary during operation while the drive piston 46 moves along the spray axis SA to displace the valve assembly 64. The gas stem 82 protrudes fully through the opening 198 when the sprayer 10 is in the spraying state and when the sprayer 10 is in the non-spraying state. The gas stem 82 extends fully through the body chamber 86 and beyond the second body end 96 of the valve body 60. A portion of the gas channel 74b upstream of the gas check 80b is formed within the gas stem 82.

[0158] The stem seal 200 is attached to the gas stem 82. The stem seal 200 is configured to engage the inner surface of the drive piston 46 to prevent leakage of compressed gas around the exterior of the gas stem 82. While the gas stem 82 is shown attached to the valve disc 60, it will be understood that not all examples are so limited. For example, the gas stem 82 can be attached to the drive piston 46 for movement therewith and can extend into and seal with the valve disc 60. In such an example, the stem seal 200 can be mounted to interface with and slide relative to the valve disc 60 as the gas stem 82 moves with the drive piston 46. In both examples, the gas stem 82 bridges the axial gap between the valve disc 60 and the drive piston 46 along the spray axis SA. Gas stem 82 provides a conduit for transmitting compressed gas from drive piston 46 to valve body 60 while maintaining the flow of compressed gas separate from the flow of compressed gas transmitted through gas channel 74a.

[0159] The gas check 80b is configured to prevent backflow through the gas channel 74b. In the illustrated example, the gas check 80b is disposed within the valve body 60. In the illustrated example, the gas check 80b is disposed coaxially with the spray axis SA. In the illustrated example, the gas check 80b is a spring-loaded ball valve, but it is understood that the gas check 80b can have any desired configuration suitable for allowing one-way flow through the gas channel 74b. In the illustrated example, the gas stem 82 forms a seat for the gas check ball 80b. While the gas check 80b is shown as being disposed within the valve body 60, it is understood that not all examples are so limited. For example, the gas check 80b can be disposed within the drive piston 46, such as in an example where the gas stem 82 is attached to the drive piston 46 and moves with the drive piston 46.

[0160] The gas flow passage 74a extends through the valve body 60. The gas flow passage 74a is configured to output compressed gas to the gas chamber 72a and the air cap 36. The gas channel 74a is configured to receive compressed gas through a gas inlet 192a. The gas inlet 192a is formed through the chamber wall 87. The gas inlet 192a is open to the body chamber 86 and is configured to receive compressed gas from the body chamber 86. In some examples, the body chamber 86 is pressurized with compressed gas through operation of the sprayer 10. The body chamber 86 is in fluid communication with a passage through the gun body 30 that outputs compressed gas from the gun body 30 to the cartridge 14.

[0161] Gas channel 74a is radially offset from atomizing axis SA. Gas channel 74a is configured to provide compressed gas to gas chamber 72a and air cap 36 for release around atomizing orifice 28. Gas passage 74 opens through valve body 60 in both axial directions AD1 and AD2.

[0162] In the illustrated example, the gas channel 74b includes a first gas passage 194b extending axially in the first axial direction AD1 within the valve body 60. The first gas passage 194b extends to a gas outlet 202 formed through the first body end 94 of the valve body 60. Compressed gas is output from the gas outlet 202 to the air cap 36. The compressed gas is output to the air cap 36 at a location radially outside the cap chamber 190. The air cap 36 outputs the compressed gas around the spray orifice 28. The gas passage 74a can continuously output compressed gas from the gas outlet 202 to the air cap 36 regardless of the operating state of the sprayer 10. In this manner, the air cap 36 can output compressed gas around the spray orifice 28 throughout operation, with the sprayer 10 in either an atomizing state or a non-atomizing state, as the sprayer 10 transitions between states.

[0163] The second gas path 196a intersects the first gas path 194a at a location radially offset from the spray axis SA and from the valve axis VA of the valve orifice 66a. The second gas path 196a extends radially toward the valve axis VA of the valve orifice 66a and intersects the gas chamber 72a at a location separated from the supply channel 134a in the first axial direction AD1. The second gas path 196a intersects the first gas path 194a at a location separated from the gas outlet 202 in the second axial direction AD2. Compressed gas from the gas chamber 72a can flow through the supply channel 134a to the mixing chamber 110 when the atomizer 10 is in a non-atomizing state.

[0164] The gas check 80a is configured to prevent backflow through the gas channel 74a. In the illustrated example, the gas check 80a is disposed within the valve body 60. The gas check 80a is disposed radially offset from the spray axis SA and each valve axis VA. In the illustrated example, the gas check 80a is a spring-loaded ball valve, but it will be understood that the gas check 80a can have any desired configuration suitable for allowing unidirectional flow through the gas channel 74a. A valve seat 204 is attached to the valve body 60 and forms a seat for the gas check 80a. For example, the valve seat 204 may be attached to the valve body 60 via a threaded interface, among other options. The gas check 80a is mounted within the valve body 60 proximate the gas inlet 192a.

[0165] While cartridge 14 is described as including two separate gas channels 74 a, 74 b within valve body 60 that route compressed gas and do not intersect with one another, it will be understood that not all examples are so limited. For example, some configurations of cartridge 14 may include a single gas channel within valve body 60 that branches to both valve holes 66 a, 66 b within valve body 60.

[0166] As shown, the coupler 90 is at least partially disposed within the body chamber 86 but is separated from the wall of the protrusion 130 that defines the body chamber 86. The gap between the coupler 90 and the body chamber 86 allows compressed gas to flow into and pressurize the body chamber 86. The body chamber 86 is not pressurized to displace the coupler 90, but instead is pressurized to provide compressed gas to the gas passages in the valve body 60. Compressed gas can flow through the gap between the coupler 90 and the body chamber 86. The body chamber 86 does not form an actuation chamber that is pressurized to cause displacement of the valve assembly 64. Instead, the valve assembly 64 receives mechanical input via the dynamic interface 128 to actuate the flow valves 58a, 58b between various states.

[0167] The cartridge 14 offers significant advantages. The compressed gas streams supplied to the gas chambers 72a and 72b are fluidly separated within the cartridge 14 and do not mix until they enter the mixing chamber 110. The fluidically separated gas channels 74a and 74b facilitate the flow of solvent to the mixing chamber 110 through a path that is free of moisture-sensitive constituent materials. Maintaining the fluidically separated gas channels 74a and 74b prevents hardening of such moisture-sensitive materials upstream of the mixing chamber 110 and protects the seal interface. Gas channel 74a, a gas passageway that neither receives nor transmits solvent, supplies compressed gas to the air cap 36 to purge the mixing chamber 110. Gas channel 74a provides dry, solvent-free air, preventing excessive solvent use and reducing material costs.

[0168] Figure 7A is a cross-sectional view taken along line 7-7 in Figure 5A, showing the valve assembly 64 in a position associated with the flow valves 58a, 58b in their respective first open states. Figure 7B is a cross-sectional view taken along line 7-7 in Figure 5A, showing the valve assembly 64 in a position associated with the flow valves 58a, 58b in their respective closed states. Figure 7C is a cross-sectional view taken along line 7-7 in Figure 5A, showing the valve assembly 64 in a position associated with the flow valves 58a, 58b in their respective second open states. Figures 7A-7C will be described together with continued reference to Figures 1A-6C.

[0169] Shown are flow valves 58a, 58b, valve element 60, outer body 62, valve assembly 64, valve holes 66a, 66b, mixing chamber cavity 68, flow chambers 70a, 70b, gas chambers 72a, 72b, gas channel 74b, seal bodies 76a, 76b, retainers 78a, 78b, gas check 80b, gas stem 82, body mount 84, and protrusion 130 of cartridge 14. Valve assembly 64 includes valve members 88a, 88b, coupler 90, and valve mount 92. Each valve member 88a, 88b includes a flow head 98, a flow neck 100, a member body 102, a mount neck 104, a mount head 106, and a tail 108. Each seal body 76a, 76b includes a material control body 206, a gas control body 208, and a body spacer 210. The mixing assembly 16 includes an air cap 36 and a mixing chamber 110 .

[0170] The cartridge 14 is attachable to and detachable from the gun body 30 as a unitary body for quick replacement of the components, and in some instances, the valve controlling the flow of compressed gas, to the mixing chamber 110. A protrusion 130 is formed on the second body end 96 of the valve element 60. A body mount 84 is formed on the protrusion 130 and configured to interface with a portion of the gun body 30, forming a static interface between the cartridge 14 and the gun body 30.

[0171] The valve disc 60 defines a flow path for the component material and compressed gas. The valve disc 60 extends between a first body end 94 and a second body end 96. The cartridge 14 is configured such that the first body end 94 is the spray output end of the valve disc 60, from which the spray (e.g., multi-component material, compressed gas) is emitted from the cartridge 14. The cartridge 14 is configured such that a connection with the actuator assembly 12 (e.g., a drive connection at the dynamic interface 128 and a support connection at the static interface 126) is formed at the second body end 96. In the illustrated example, the valve disc 60 does not receive the component material through the second body end 96. In the illustrated example, the valve disc 60 receives the compressed gas at the second body end 96. The valve disc 60 is configured such that the multi-component material and compressed gas are output from the first body end 94.

[0172] The mixing chamber cavity 68 is formed within the valve body 60. The mixing chamber cavity 68 extends from the first body end 94 into the valve body 60 and opens through the first body end 94 in the first axial direction AD1. The mixing chamber cavity 68 does not extend axially completely through the valve body 60 and does not open through the second body end 96. The mixing chamber cavity 68 does not open through the chamber wall 87. The mixing chamber cavity 68 does not extend all the way to the valve body 87. The mixing chamber 110 does not extend through two axially aligned openings. Instead, the mixing chamber 110 can move only through the opening of the mixing chamber cavity 68 oriented in the first axial direction AD1, and this movement occurs during installation and removal of the mixing chamber 110, not during spraying operations.

[0173] The cap chamber 190 extends from the mixing chamber cavity 68 in the first axial direction AD1. The cap chamber 190 is disposed coaxially with the mixing chamber cavity 68 on the spray axis SA. The cap chamber 190 has a larger diameter than the mixing chamber cavity 68. The cap chamber 190 opens through the first body end 94 of the valve body 60. In the illustrated example, the cap chamber 190 includes threads configured to interface with threads on the air cap 36 to attach the air cap 36 to the valve body 60.

[0174] The mixing assembly 16 is mountable to the cartridge 14 so as to be supported by the cartridge 14. In the illustrated example, the mixing assembly 16 is mounted to the valve body 60. In the illustrated example, the mixing assembly 16 is mounted to the first body end 94 of the valve body 60. When the mixing assembly 16 is mounted to the cartridge 14, the air cap 36 extends at least partially into the valve body 60 and radially overlaps a portion of the valve body 60. In the illustrated example, the air cap 36 is mounted to the cartridge 14 by interface threads formed on the air cap 36 and the valve body 60. The threads on the valve body 60 are formed within a cap chamber 190. The cap chamber 190 extends in a first axial direction AD1 relative to the mixing chamber cavity 68. The cap chamber 190 has a larger diameter than the mixing chamber cavity 68. In the illustrated example, the threads on the valve body 60 that interface with the air cap 36 are formed as female threads. Although the air cap 36 is described as being attached to the cartridge 14 by interface threads, it is understood that other connection types are possible, such as a bayonet connection, among other options.

[0175] The spray orifice 28 is formed at the downstream end of the mixing chamber 110. In the illustrated example, the spray orifice 28 is formed by the mixing chamber 110. In the illustrated example, the mixing chamber 110 is configured as a fixed mixing chamber 110 that does not shift along the spray axis SA to operate the sprayer 10 between the spraying state and the non-spraying state. The mixing chamber 110 is configured to remain stationary as the flow valves 58a, 58b are actuated between various states to turn on and off the flow of component material to the mixing chamber 110.

[0176] The valve holes 66a, 66b extend into the valve body 60. In the illustrated example, the valve holes 66a, 66b extend only partially axially through the valve body 60. The valve holes 66a, 66b are open in the second axial direction AD2 and closed in the first axial direction AD1. The valve holes 66a, 66b are open in the second axial direction AD2 to allow the valve members 88a, 88b to pass into the valve holes 66a, 66b. The valve holes 66a, 66b are closed in the first axial direction AD1 so that the valve members 88a, 88b cannot pass completely axially through the valve holes 66a, 66b. The valve assembly 64 can be removed from the valve body 60 by pulling the valve assembly 64 in the second axial direction AD2. A new or identical valve assembly 64 can be installed in the cartridge 14 by aligning the valve members 88a, 88b with the valve holes 66a, 66b, respectively, and shifting the valve assembly 64 in the first axial direction AD1 so that the valve members 88a, 88b enter the valve holes 66a, 66b.

[0177] Each valve orifice 66a, 66b extends along a valve axis VA. In the illustrated example, the valve axis VA is parallel to and radially offset from the spray axis SA. In some examples, the plane along which the spray axis SA and each of the two valve axes VA extend may be disposed through the cartridge 14. The valve orifices 66a, 66b define a flow path for the build material and compressed gas to flow into the mixing chamber 110.

[0178] The valve holes 66a, 66b open through a chamber wall 87 of the valve body 60. The chamber wall 87 forms the downstream end of the body chamber 86. A protrusion 130 extends from the chamber wall 87 in the second axial direction AD2. The protrusion 130 extends from the block body 61 of the valve body 60 in the second axial direction AD2. The body chamber 86, which opens in the second axial direction AD2 through the second body end 96, is defined at least in part by the chamber wall 87 and the protrusion 130. The chamber wall 87 is separated from the distal end of the protrusion 130 in the first axial direction AD1. The chamber wall 87 is separated from the body mount 84 in the first axial direction AD1. In the illustrated example, the gas channels 74a, 74b and the valve holes 66a, 66b each open through the chamber wall 87.

[0179] The block body 61 of the valve element 60 defines various passageways through the cartridge 14. In the illustrated example, the valve holes 66a, 66b and the mixing chamber cavity 68 are each formed within the block body 61. The valve holes 66a, 66b extend within the block body 61 in a first axial direction AD1, and the mixing chamber cavity 68 extends within the block body 61 in a second axial direction AD2. The gas channels 74a, 74b are formed through the block body 61. The protrusion 130 extends from the block body 61 to the second body end 96. In the illustrated example, the chamber wall 87 forms the end of the block body 61 in the second axial direction AD2.

[0180] The valve holes 66a, 66b include flow chambers 70a, 70b, respectively. The flow chambers 70a, 70b are fluidly connected to the manifold 18 to receive the build material therefrom. The flow valves 58a, 58b control the flow of the build material from the flow chambers 70a, 70b to the mixing chamber 110. In the illustrated example, the valve holes 66a, 66b include gas chambers 72a, 72b, respectively. The gas chambers 72a, 72b are fluidly connected to a compressed gas flow provided to the sprayer 10. The flow valves 58a, 58b control the flow of compressed gas from the gas chambers 72a, 72b to the mixing chamber 110. The gas chambers 72a, 72b are positioned to radially overlap the mixing chamber 110 when the mixing chamber 110 is attached to the cartridge 14. The gas chambers 72a, 72b radially overlap the mixing chamber cavity 68.

[0181] Flow chamber 70a is arranged coaxially with gas chamber 72a on the valve axis VA of valve orifice 66a, and flow chamber 70b is arranged coaxially with gas chamber 72b on the valve axis VA of valve orifice 66b.

[0182] Within each valve orifice 66a, 66b, the flow chamber 70a, 70b and gas chamber 72a, 72b of that valve orifice 66a, 66b are fluidly isolated from one another by a respective valve member 88a, 88b that is operable to fluidly connect the gas chamber 72a, 72b to the mixing chamber 110 when the sprayer 10 is in a non-atomizing state, and to fluidly connect the chamber 70a, 70b to the mixing chamber 110 when the sprayer 10 is in an atomizing state.

[0183] Feed channels 134a, 134b extend between valve holes 66a, 66b and fluidly connect valve holes 66a, 66b, respectively, with mixing chamber cavity 68. Build material and compressed gas flow through feed channels 134a, 134b to and into mixing chamber 110. In the illustrated example, feed channels 134a, 134b are aligned with one another such that a radial line extending from atomization axis SA can extend through each feed channel 134a, 134b along its entire length without intersecting the walls defining either of the feed channels 134a, 134b.

[0184] A gas stem 82 extends between and fluidly connects the cartridge 14 and the gun body 30. In the illustrated example, the gas stem 82 is configured to transfer compressed gas to the gas channel 74b. The gas stem 82 extends through an opening 198 formed in the coupler 90. The valve assembly 64 is movable relative to the gas stem 82 when the flow valves 58a, 58b are actuated between various states. A body chamber 86 is formed in the valve body 60. The body chamber 86 opens in the second axial direction AD2. Each of the valve holes 66a, 66b opens into the body chamber 86. The coupler 90 of the valve assembly 64 is at least partially disposed within the body chamber 86 and is capable of reciprocating within the body chamber 86 during operation of the sprayer 10.

[0185] The seal bodies 76a, 76b are disposed within the valve bores 66a, 66b, respectively. Each seal body 76a, 76b is mounted within a respective valve bore 66a, 66b. The seal bodies 76a, 76b are configured to interface with the valve members 88a, 88b, respectively, to open and close a flow path for the compressed gas and the component materials to flow to the mixing chamber 110. In the illustrated example, each seal body 76a, 76b is formed as multiple components mounted within the valve bores 66a, 66b. However, it will be understood that not all embodiments are so limited. For example, the seal bodies 76a, 76b may be monolithically formed, among other options.

[0186] In the illustrated example, each seal body 76a, 76b includes a gas control body 208 mounted within the valve bore 66a, 66b. The gas control body 208 at least partially defines the gas chamber 72a, 72b. The gas control body 208 is configured to interface with the flow head 98 of the valve member 88a, 88b to seal the gas chamber 72a, 72b and prevent the flow of compressed gas into the mixing chamber 110 when the flow valve 58a, 58b is in the second open state. The gas control body 208 can be considered to form a gas seat for the flow valve 58a, 58b. It will be understood that the gas control body 208 can be configured to interface directly with the flow head 98 to seal the gas chamber 72a, 72b, or the gas control body 208 can support a sealing element (e.g., an O-ring) that interfaces directly with the flow head 98 to seal the gas chamber 72a, 72b.

[0187] Body seal 214a is disposed around the gas control body 208 and interfaces with the gas control body 208 and the valve body 60. Body seal 214a prevents compressed gas from leaking around the exterior of the gas control body 208.

[0188] Each seal body 76a, 76b further includes a material control body 206 mounted within the valve bore 66a, 66b. The material control body 206 at least partially defines the flow chamber 70a, 70b. The material control body 206 is configured to interface with the flow head 98 of the valve member 88a, 88b to seal the flow chamber 70a, 70b and prevent the flow of component material into the mixing chamber 110 when the flow valve 58a, 58b is in a first open state. The material control body 206 can be considered to form a material seat for the flow valve 58a, 58b. It will be understood that the material control body 206 can be configured to interface directly with the flow head 98 to seal the flow chamber 70a, 70b, or the material control body 206 can support a sealing element (e.g., an O-ring) that interfaces directly with the flow head 98 to seal the flow chamber 70a, 70b.

[0189] Body seals 214b are disposed around the material control body 206 and interface with the material control body 206 and the valve body 60. The body seals 214b prevent the constituent material from leaking around the exterior of the gas control body 208. In the illustrated example, a pair of body seals 214b are attached to the upstream and downstream sides of each material control body 206. The body seals 214b are disposed axially on either side of the bore inlets 152a, 152b that provide the constituent material to the valve holes 66a, 66b.

[0190] A body spacer 210 is axially disposed between the gas control body 208 and the material control body 206. The body spacer 210 can interface with each of the gas control body 208 and the material control body 206. Outlet ports are formed through the body spacer 210 aligned with the supply channels 134a, 134b to facilitate flow from within the seal bodies 76a, 76b to the supply channels 134a, 134b and, therefore, to the mixing chamber cavity 68. The outlet ports through the body spacer 210 form the outlet ports of the seal bodies 76a, 76b. A body fastener 212 extends through the valve body 60 and interfaces with the body spacer 210. The body fastener 212 secures the body spacer 210 relative to the valve body 60 and maintains the orientation between the outlet ports and the supply channels 134a, 134b. In the illustrated example, body fastener 212 is secured to valve body 60 and includes a post that extends through valve disc 60 and interfaces with body spacer 210. For example, body fastener 212 may be connected to valve disc 60 by a threaded interface, among other options. In the illustrated example, outer body 62 extends over and covers body fastener 212.

[0191] The seal bodies 76a, 76b form seats for the flow valves 58a, 58b, against which movable components (e.g., valve members 88a, 88b) of the flow valves 58a, 58b move relatively to open and close flow paths through the flow valves 58a, 58b. In the illustrated example, the gas control body 208 forms a gas seat with which the valve members 88a, 88b interface to block gas flow into the mixing chamber cavity 68. In the illustrated example, the material control body 206 forms a material seat with which the valve members 88a, 88b interface to block component material flow into the mixing chamber cavity 68. In the illustrated example, the valve members 88a, 88b maintain sealing engagement with the seal bodies 76a, 76b during operation when the flow valves 58a, 58b are in each of the first open state, the second open state, and the closed state. In the first open state, valve members 88a, 88b are disengaged from gas control body 208 and are sealingly engaged with material control body 206. In the second open state, valve members 88a, 88b are disengaged from material control body 206 and are sealingly engaged with gas control body 208. In the closed state, valve members 88a, 88b are sealingly engaged with gas control body 208 and material control body 206. It is understood that valve members 88a, 88b are considered to be sealingly engaged when directly engaged with seal bodies 76a, 76b or when engaged with a separate seal (e.g., an O-ring) supported by flow head 98 or by seal bodies 76a, 76b.

[0192] The retainers 78a, 78b are attached to the valve body 60. The retainers 78a, 78b are attached to the valve bores 66a, 66b, respectively. For example, each retainer 78a, 78b may be attached to the valve body 60 via a threaded interface, among other options. The retainers 78a, 78b are configured to retain the seal bodies 76a, 76b within the valve bores 66a, 66b, respectively. A shaft seal 136 is supported by the retainers 78a, 78b. The shaft seal 136 is configured to engage and seal with the outer surfaces of the valve members 88a, 88b.

[0193] The valve assembly 64 is configured to control the flow of the component materials and compressed gas into the mixing chamber 110. The valve assembly 64 is formed by valve members 88a, 88b attached to the coupler 90. In the illustrated example, each valve member 88a, 88b is formed as a shuttle configured to shift axially along a valve axis VA. Each valve member 88a, 88b is elongated along its respective valve axis VA. The valve members 88a, 88b are configured to slide relative to the seal bodies 76a, 76b along their respective valve axes VA to position the flow valves 58a, 58b in various operating states. The valve members 88a, 88b form movable valve components of the flow valves 58a, 58b. Movement of the valve member 88a (e.g., parallel to the spray axis SA) opens and closes the flow valve 58a. Movement of the valve member 88b (e.g., parallel to the spray axis SA) opens and closes the flow valve 58a.

[0194] Each valve member 88a, 88b extends into, but does not pass through, the valve bores 66a, 66b. The valve members 88a, 88b are at least partially disposed within the respective valve bores 66a, 66b. In the illustrated example, the valve members 88a, 88b protrude from the valve bores 66a, 66b in the second axial direction AD2. The valve members 88a, 88b extend into the body chamber 86. The valve members 88a, 88b extend to and are attached to the coupler 90. In the illustrated example, the valve members 88a, 88b protrude axially outward beyond the second body end 96 during at least some phases of operation of the cartridge 14. In the illustrated example, the valve members 88a, 88b protrude axially outward beyond the second body end 96 at least when the flow valves 58a, 58b, respectively, are in their first open states.

[0195] The valve members 88a, 88b are connected to a coupler 90 for simultaneous actuation along a valve axis VA. The coupler 90 is coaxially disposed with the mixing chamber cavity 110 on the spray axis SA. The valve members 88a, 88b interface with the coupler 90 at locations radially offset from the spray axis SA. The coupler 90 is configured to receive a drive input along the spray axis SA (in either the axial direction AD1 or AD2) and transmit the drive input radially outward to the valve members 88a, 88b, displacing the valve members 88a, 88b axially along their respective valve axes VA. The valve members 88a, 88b are secured to the coupler 90 for simultaneous actuation such that the flow valves 58a, 58b can be simultaneously actuated between states and remain in the same respective state. For example, the flow valves 58a, 58b can simultaneously be in a first open state, a second open state, or a closed state.

[0196] The cartridge 14 offers significant advantages. The cartridge 14 is attachable to and detachable from the actuator assembly 12 of the sprayer 10 as a single module. The cartridge 14 includes the static components of the flow valves 58a, 58b and the movable valve components of the flow valves 58a, 58b. The static components (e.g., seal bodies 76a, 76b) and the movable valve components (e.g., valve members 88a, 88b) are configured to be attached to and removed from the actuator assembly 12 as part of the cartridge 14. The cartridge 14 itself does not include a drive component that provides the mechanical force to actuate the flow valves 58a, 58b. The cartridge 14 does not include a driver similar to the drive piston 46. Instead, mechanical force is input to the cartridge 14 at the coupler 90 and transmitted to the valve members 88a, 88b. The cartridge 14 does not support the trigger 24. Cartridge 14 does not include a valve that redirects compressed gas to a different flow path, like gas valve 44; instead, flow valves 58a, 58b can turn the flow of compressed gas on and off to mixing chamber cavity 68. The components and compressed gas flow through cartridge 14 in a single direction toward mixing chamber cavity 68. Valve body 60 opens in second axial direction AD2 to facilitate attachment of cartridge 14 to actuator assembly 12 at static interface 126 and dynamic interface 128.

[0197] The removable cartridge 14, as a single unit, controls the flow of the components and allows for the removal and installation of the portion of the sprayer 10 where the components mix to form multiple components. The cartridge 14 is removable from the actuator assembly 12, which directs the flow of compressed gas, and from the manifold 18, which directs the flow of the components. The cartridge 14 isolates any potential cross-flow to locations within the cartridge 14, preventing cross-contamination. The cartridge 14 also includes various check valves (e.g., inlet checks 150a, 150b (FIG. 4B) and gas checks 80a (FIG. 6B), 80b) to prevent backflow. Such valves isolate any potential cross-flow into the cartridge 14. In the event of such undesired curing within the cartridge 14, the cartridge 14 can be removed and replaced with a new cartridge 14, reducing downtime and providing cost savings. A user can simply replace the cartridge 14 while utilizing the same manifold 18 and actuator assembly 12.

[0198] Figure 8A is an isometric view of cartridge 14 from the rear of cartridge 14. Figure 8B is an enlarged isometric view of cartridge 14 from the rear of cartridge 14 with gas stem 82 removed for clarity. Figure 8C is an enlarged isometric view of a portion of actuator assembly 12. Figures 8A-8C will be described together with continued reference to Figures 1A-7C.

[0199] The actuator assembly 12 and cartridge 14 of the sprayer 10 are shown. The gun body 30 and drive piston 46 of the actuator assembly 12 are shown. The housing 32, housing mount 56, receiver 132, and body slot 178 of the gun body 30 are shown. The valve disc 60, outer body 62, valve assembly 64, cartridge inlets 148a, 148b, body mount 84, and protrusion 130 of the cartridge 14 are shown. The valve members 88a, 88b, coupler 90, and valve mount 92 of the valve assembly 64 are shown.

[0200] The cartridge 14 is attachable to and detachable from the actuator assembly 12 as a single module. The cartridge 14 is configured to attach to the actuator assembly 12 via a static interface 126 (best seen in FIGS. 2A and 2B ) and a dynamic interface 128 (best seen in FIGS. 2A and 2B ). The static interface 126 remains fixed and reinforces the components when coupled. The static interface 126 secures the valve body 60 to the gun body 30 so that the cartridge 14 is supported by the gun body 30. The dynamic interface 128 allows for the transfer of mechanical motion between the actuator assembly 12 and the cartridge 14, such as opening and closing the flow valves 58 a, 58 b. Both the static interface 126 and the dynamic interface 128 can be formed and broken to connect and remove the cartridge 14 from the actuator assembly 12. The static interface 126 and the dynamic interface 128 can be formed simultaneously during installation of the cartridge 14 and broken simultaneously during removal of the cartridge 14. In the illustrated example, the static interface 126 and the dynamic interface 128 are positioned coaxially with the cartridge 14 attached to the actuator assembly 12 on the atomizing axis SA.

[0201] The static interface 126 is formed by a protrusion 130 of the valve disc 60 that interfaces with a receiver of the gun body 30. In the illustrated example, the protrusion 130 includes the body mount 84 of the valve disc 60 and is part of the cartridge 14. The protrusion 130 can be formed as a cylindrical protrusion, among other options. In the illustrated example, the receiver 132 is formed by the housing mount 56 and is part of the gun body 30. However, it is understood that in alternative examples, the protrusion 130 of the cartridge 14 can be configured to receive the receiver 132 of the gun body 30, such that the cartridge 14 can be considered to include a receiver and the gun body 30 can be considered to include a protrusion. In such examples, a portion of the gun body 30 can extend into the protrusion 130 of the cartridge 14 such that it is at least partially disposed within the valve disc 60.

[0202] The body mount 84 is formed by a series of cartridge tabs 216 that protrude radially outward from the valve body 60. The cartridge tabs 216 are arranged around the spray axis SA. In the illustrated example, the cartridge tabs 216 are evenly spaced around the spray axis SA. The cartridge tabs 216 include alignment cartridge tabs 216a and mount cartridge tabs 216b. The circumferential width CW1 of the alignment cartridge tabs 216a is different from the circumferential width CW2 of the mount cartridge tabs 216b. In the illustrated example, the circumferential width CW1 of the alignment cartridge tabs 216a is narrower than the circumferential width CW2 of the mount cartridge tabs 216b. The circumferential width is measured along the radial outer surface of the cartridge tabs 216, between the circumferential edges of the cartridge tabs 216. The varying circumferential widths of the alignment cartridge tab 216a and the mount cartridge tab 216b, in the illustrated example, provide a keyed interface between the body mount 84 and the housing mount 56 that allows the cartridge 14 to be mounted in a single orientation relative to the gun body 30. The cartridge tab 216, in the illustrated example, is formed on the second body end 96 of the valve body 60.

[0203] The housing mount 56 is configured to interface with the body mount 84 to form the static interface 126. In the illustrated example, the housing mount 56 is formed by a series of body notches 218 and body tabs 220 extending about the spray axis SA. The body notches 218 extend radially outward such that the body tabs 220 are formed between circumferentially adjacent ones of the body notches 218. Each body tab 220 extends only partially about the spray axis SA. Each body notch 218 extends only partially about the spray axis SA. The body notches 218 include aligned body notches 218a and mount body notches 218b. The aligned body notches 218a have a circumferential width CW3 that is different from the circumferential width CW4 of the mount body notches 218b. In the illustrated example, the aligned body notches 218a have a circumferential width CW3 that is narrower than the circumferential width CW4 of the mount body notches 218b. The circumferential width is taken along the radially outer surface of the body notch 218, between the circumferential edges of the body notch 218. The varying circumferential widths of the alignment body notch 218a and the mount body notch 218b provide a keyed interface between the body mount 84 and the housing mount 56 that allows the cartridge 14 to be attached to the gun body 30 in a single orientation, in the illustrated example. The body notch 218 and body tab 220 are formed at the distal end of the gun body 30 in the first axial direction AD1, in the illustrated example.

[0204] While the alignment cartridge tabs 216a are described as having a narrower width than the mount cartridge tabs 216b, it is understood that not all examples are so limited. For example, the cartridge 14 may include alignment cartridge tabs 216a having a greater circumferential width than the mount cartridge tabs 216b. In such examples, the alignment body notches 218a have a correspondingly greater circumferential width than the mount body notches 218b.

[0205] During installation, the alignment cartridge tab 216a is axially aligned with the alignment body notch 218a. The circumferential width CW2 of the mount cartridge tab 216b is greater than the circumferential width CW3 of the alignment body notch 218a so that the mount cartridge tab 216b cannot pass through the alignment body notch 218a during installation. When the mount cartridge tab 216b is aligned with the alignment body notch 218a during installation, the body tab 220 bracketing the alignment body notch 218a prevents the mount cartridge tab 216b from passing through the alignment body notch 218a, preventing installation of the cartridge 14 in such an orientation.

[0206] When the aligned cartridge tab 216a is axially aligned with the aligned body notch 218a, the cartridge 14 is shifted in the second axial direction AD2 so that the cartridge tab 216 passes through the body notch 218. Thus, the cartridge tab 216 is disposed within a receiving chamber 222 formed within the gun body 30. The receiving chamber 222 opens in the first axial direction AD1 toward the mixing chamber 110. The mixing chamber 110 does not extend into the receiving chamber 222 and does not radially overlap any portion of the gun body 30.

[0207] When the cartridge tab 216 passes through the body notch 218, the protrusion 130 radially overlaps the receiver 132. The valve element 60 is positioned within the gun body 30 so as to radially overlap the gun body 30. The cartridge 14 can be rotated relative to the gun body 30 (or the gun body 30 can be rotated relative to the cartridge 14), for example, along the spray axis SA, to disalign the cartridge tab 216 and the body notch 218 and lock the cartridge 14 to the gun body 30. Relative rotation between the cartridge 14 and the gun body 30 positions the cartridge tab 216 to axially overlap the body tab 220. The body tab 220, which axially overlaps the cartridge tab 216, prevents axial movement of the cartridge tab 216, and therefore the cartridge 14, in the first axial direction AD1.

[0208] To remove the cartridge 14, the cartridge 14 is rotated, for example, on the spray axis SA to realign the cartridge tab 216 with the body notch 218 before the body mount 84 can move from the receiving chamber 222. For example, the cartridge 14 can be rotated in a rotational direction opposite to that used to install the cartridge 14, so that the aligned cartridge tab 216a realigns with the aligned body notch 218a, and the cartridge 14 can be pulled in the first axial direction AD1 to break the static interface 126 and remove the cartridge 14 from the gun body 30. It will be understood that various other locking mechanisms are possible for the static connection between the cartridge 14 and the gun body 30. While the cartridge 14 is not threaded into the gun body 30 in this embodiment, but rather is attached to the gun body 30 only by a partial rotation, such as a quarter turn, and not a full or even half turn, not all embodiments are so limited.

[0209] Dynamic interface 128 includes valve mount 92 interfacing with drive mount 54. This interface may also be in the form of a protrusion and receiver, as previously described, with or without tabs and grooves. In the illustrated example, valve assembly 64 forms the receiver, and drive piston 46 forms a protrusion that extends into the receiver of valve assembly 64. However, it will be understood that in various other examples, drive piston 46 can receive a portion of valve assembly 64 such that valve assembly 64 extends into drive piston 46 to form dynamic interface 128.

[0210] The drive mount 54 is supported by the drive piston 46. The drive mount 54 may be integrally formed with the drive piston 46, such as the piston shaft 50, or may be formed separately from and connected to the drive piston 46.

[0211] A valve mount 92 is formed on the valve assembly 64. In the illustrated example, the valve mount 92 is formed on the coupler 90. In the illustrated example, the valve mount 92 is disposed coaxially with the body mount 84 on the spray axis SA.

[0212] In the illustrated example, the drive mount 54 includes a drive tab 224, a groove 226, and a drive brace 228. The drive tab 224 protrudes radially outward from the piston shaft 50. In the illustrated example, the drive mount 54 includes a series of drive tabs 224 protruding radially outward. The drive tabs 224 are arranged annularly around the spray axis SA. The drive brace 228 is spaced from the drive tab 224 in the second axial direction AD2. The drive brace 228 is formed as a surface facing the first axial direction AD1. The groove 226 is axially disposed between the drive tab 224 and the drive brace 228.

[0213] In the illustrated example, the valve mount 92 includes valve notches 230 and valve tabs 232. The valve notches 230 are arranged annularly about the spray axis SA and are distributed between the valve tabs 232. The valve tabs 232 are disposed between adjacent valve notches 230. The valve notches 230 are sized to allow the drive tabs 224 to pass axially through the valve notches 230 during installation and removal of the cartridge 14 onto the gun body 30. In the illustrated example, the valve mount 92 is disposed about an opening 198 that extends axially completely through the coupler 90. However, it will be understood that not all embodiments are so limited. For example, the opening 198 can be open in the second axial direction AD2 and closed in the first axial direction AD1, such as in an embodiment in which each gas channel 74a, 74b receives compressed gas from the body chamber 86, or in an embodiment including a single gas channel that receives compressed gas from the body chamber 86.

[0214] In the illustrated example, valve notch 230 is oriented in the same radial direction as cartridge tab 216. Similarly, drive tab 224 is oriented in the same radial direction as body notch 218. Such radial orientation of the interface components facilitates the simultaneous formation and breaking of static interface 126 and dynamic interface 128 during installation and removal of cartridge 14 from actuator assembly 12.

[0215] During installation, axially orienting the aligned cartridge tab 216a with the aligned body notch 218a also axially aligns the valve notch 230 with the drive tab 224. The drive tab 224 passes through the valve notch 230 as the cartridge tab 216 passes through the housing body notch 218. Relative rotation between the cartridge 14 and the gun body 30 also causes relative rotation between the valve assembly 64 and the drive piston 46. Such relative rotation shifts the valve notch 230 relative to the drive tab 224, causing it to become misaligned with the drive tab 224. Relative rotation between the cartridge 14 and the drive piston 46 positions the drive tab 224 to axially overlap the valve tab 232, which also axially overlaps the drive brace 228. The valve tab 232 is at least partially disposed within the groove 226 and is axially bracketed between the drive tab 224 and the drive brace 228.

[0216] When dynamic interface 128 is engaged, drive mount 54 can linearly displace coupler 90 via valve mount 92. For example, drive tab 224 can apply a force to valve tab 232 in a second axial direction AD2 to displace valve assembly 64 in the second axial direction AD2, while drive brace 228 can apply a force to valve tab 232 in a first axial direction AD1 to displace valve assembly 64 in the first axial direction AD2.

[0217] Movement of the drive piston 46 in a first axial direction AD1 (downstream direction) displaces the coupler 90 in the first axial direction AD1, which applies a driving force to the valve members 88a, 88b, displacing them in the first axial direction AD1. Displacing the valve members 88a, 88b in the first axial direction AD1 actuates the flow valves 58a, 58b to their respective second open states, fluidly connecting the flow chambers 70a, 70b to the mixing chamber 110 and allowing the flow of components A and B into the mixing chamber 110 while simultaneously closing the flow of compressed gas to the mixing chamber 110. Movement of the drive piston 46 in a second axial direction AD2 (upstream direction) displaces the coupler 90 in the second axial direction AD2, which applies a driving force to the valve members 88a, 88b, displacing them in the second axial direction AD2. Displacing the valve members 88a, 88b in the second axial direction AD2 returns the flow valves 58a, 58b to their respective first open conditions, fluidly connecting the gas chambers 72a, 72b to the mixing chamber 110 and resuming the flow of purge gas while blocking the flow of components A and B to the mixing chamber 110. Drive mechanical motion is transmitted from the drive piston 46 through the coupler 90 to the valve members 88a, 88b.

[0218] It should be noted that in some embodiments, the linear motion generated in actuator assembly 12 and then conveyed into cartridge 14 via dynamic interface 128 may be generated electrically (e.g., by a solenoid or other electrical actuator), hydraulically by a liquid under pressure, or mechanically through the pulling and release of a trigger (e.g., a trigger that mechanically displaces drive mount 54 in a first axial direction AD1 and a spring that mechanically displaces drive mount 54 in a second axial direction AD2) instead of or in addition to pneumatic actuation. Various other types of dynamic and static interfaces are possible for securing cartridge 14 and transmitting mechanical motion to open and close flow valves 58 a, 58 b.

[0219] In the illustrated example, the protrusions and receivers forming the static interface 126 and the dynamic interface 128 are arranged in an opposite configuration. The static interface 126 is disposed within a portion of the actuator assembly 12 and is formed between a portion of the cartridge 14 received thereby. In the illustrated example, a portion of the valve disc 60 extends into a portion of the gun body 30 and interfaces therewith to form a static interface. The dynamic interface 128 is disposed within a portion of the cartridge 14 and is formed between a portion of the cartridge assembly 12 received thereby. In the illustrated example, a portion of the drive piston 46 extends into a portion of the valve assembly 64 and interfaces therewith. However, it will be understood that not all embodiments are so limited. In some examples, the protrusions can be formed on both the cartridge 14 and the receiver, both formed on the actuator assembly 12, such that a portion of the cartridge 14 is received in a portion of the actuator assembly 12 to form both the static interface 126 and the dynamic interface. In some examples, a receiver can be formed on both the cartridge 14 and a protrusion, both formed on the actuator assembly 12, such that a portion of the actuator assembly 12 is received in a portion of the cartridge 14 to form both a static interface 126 and a dynamic interface 128. In some examples, a portion of the actuator assembly 12 extends into a portion of the cartridge 14 to form a static interface 126, while a portion of the cartridge 14 extends into a portion of the actuator assembly 12 to form a dynamic interface 128.

[0220] In the illustrated example, the valve assembly 64 is keyed to the valve disc 60. More specifically, the coupler 90 is keyed to the valve disc 60. The valve assembly 64 can be considered to form the dynamic component of the cartridge 14, while the valve disc 60 and other portions of the cartridge 14 form one or more static components of the cartridge 14. The dynamic valve assembly 64 is keyed to the valve disc 60. In the illustrated example, the coupler 90 is keyed to the valve disc 60. Specifically, the radially outer surface of the coupler 90 is non-circular to mate with the non-circular radially inner surface of the protrusion 130 of the valve disc 60, which defines the body chamber 86. In the illustrated example, the outer surface of the coupler 90 is curved with flat portions, and the inner surface defining the body chamber 86 is similarly curved with flat portions. The flat portions may overlap radially and interface to prevent relative rotation. In the illustrated example, the exterior of coupler 90 and the interior surface of valve body 60 that defines body chamber 86 are D-shaped. It is understood that coupler 90 and body chamber 86 can be any desired interface shape that prevents relative rotation, such as hexagonal, square, triangular, trapezoidal, elliptical, among other options.

[0221] The keyed interface rotatably locks the valve assembly 64 relative to the valve body 60, providing for simultaneous rotation. Such a keyed interface can protect the valve members 88a, 88b and other portions of the flow valves 58a, 58b from damage that may be caused by relative rotation. The valve members 88a, 88b extend into the valve bores 66a, 66b and are secured to the coupler 90. If the valve assembly 64 is in the incorrect axial position, such that the valve tab 232 is circumferentially aligned with the drive tab 224 when the cartridge 14 is rotated relative to the gun body 30 to form the static interface 126 connection, such rotation could exert torque on the valve members 88a, 88b, bending or otherwise deforming them. The keyed interface prevents rotation of the valve body 60 relative to the valve assembly 64 about the spray axis SA.

[0222] Rotationally locking the valve assembly 64 relative to the valve disc 60 facilitates simultaneous formation of the static interface 126 and dynamic interface 128 connections. During installation, the cartridge 14 is aligned with the receiving chamber 222 of the gun body 30. In the illustrated example, both the static interface 126 and the dynamic interface 128 are formed by relative rotation between the cartridge 14 and the actuator assembly 12. If the valve disc 60 is able to rotate relative to the valve assembly 64, a connection may not be formed at the dynamic interface 128, and / or the dynamic interface 128 may remain connected when the static interface 126 is broken. In the illustrated example, the valve disc 60 can apply a torque to the coupler 90 as the valve disc 60 rotates to form or break the static interface 126. Preventing relative rotation facilitates simultaneous formation and breaking of the static interface 126 and the dynamic interface 128.

[0223] As described above, the manifold 18 can be attached to the cartridge 14 and can lock the cartridge 14 onto the gun body 30 to prevent relative rotation therebetween. FIG. 8C shows a body slot 178 formed on the underside of the gun body 30. In the illustrated example, the body slot 178 is formed in the housing 32. The body slot 178 is formed on the underside of the housing 32. The body slot 178 is formed on the same side of the housing 32 from which the handle 34 protrudes. The body slot 178 is configured to receive a manifold brace 172 protruding from the manifold body 166. The manifold brace 172 is disposed within the body slot 178 and prevents the manifold 18 from moving circumferentially relative to the gun body 30 about the spray axis SA. With the manifold 18 secured to the cartridge 14 (e.g., by fasteners 20), the cartridge 14 is also prevented from rotating about the spray axis SA due to the rotational locking interface between the manifold 18 and the gun body 30. The connection interface between the actuator assembly 12 and the cartridge 14 provides significant advantages. The cartridge 14 is installable with less than a full relative rotation between the cartridge 14 and the actuator assembly 12. The cartridge 14 is not threaded into the gun body 30, which requires multiple full rotations to form the static interface 126. Such a threaded interface can lead to misalignment when forming the dynamic interface 128, increasing the complexity of the sprayer 10 and the connection of the cartridge 14. The static interface 126 and the dynamic interface 128 can be considered to form a dual protrusion-receptor connection.

[0224] The dynamic interface 128 connection and the static interface 126 connection are configured to be formed simultaneously. Both connections are formed by relative axial movement between the cartridge 14 and the actuator assembly 12 and relative rotational movement between the cartridge 14 and the actuator assembly 12. Both connections are broken by relative rotational movement between the cartridge 14 and the actuator assembly 12 and relative axial movement between the cartridge 14 and the actuator assembly 12. Simultaneous formation of the dynamic and static connections allows for quick, efficient, and easy installation and removal of the cartridge 14. A user can easily remove the cartridge 14 and install the same or a different cartridge 14 into the actuator assembly 12, while minimizing downtime and providing a more efficient spraying operation.

[0225] Figure 9 is an exploded view of the valve assembly 64 showing the interface between the valve members 88a, 88b and the coupler 90. Figure 9 will be described with continued reference to Figures 1A-8C. The valve assembly 64 includes valve members 88a, 88b, a coupler 90, and a valve mount 92. The coupler 90 includes mounting slots 234a, 234b. Each mounting slot 234a, 234b includes a receiving opening 236 and a retention slot 238. Each valve member 88 includes a flow head 98, a flow neck 100, a valve member body 102, a mount neck 104, a mount head 106, and a tail 108.

[0226] Valve assembly 64 forms a dynamic component of cartridge 14 that is configured to move relative to valve body 60 during operation. Valve assembly 64 controls flow valves 58a, 58b between respective first open, second open, and closed states.

[0227] The coupler 90 is configured to interface with a drive component (e.g., drive piston 46) of the actuator assembly 12 to receive a mechanical input that displaces the coupler 90 along an axis (e.g., spray axis SA). A valve mount 92 is formed by the coupler 90. The valve mount 92 is disposed about an opening 198 through the coupler 90. Mounting slots 234a, 234b are formed in a coupler body 233 of the coupler 90. In the illustrated example, the mounting slots 234a, 234b extend completely through the coupler body 233 and are open in the first axial direction AD1 and the second axial direction AD2. In the illustrated example, each mounting slot 234a, 234b extends through a first surface of the coupler body 233 oriented in the axial direction AD1 and a second surface of the coupler body 233 oriented in the second axial direction AD2. Each mounting slot 234 a, 234 b includes a receiving opening 236 and a retention slot 238 extending from the receiving opening 236. The receiving openings 236 are wider than the retention slots 238. The wider receiving openings 236 facilitate passage of the valve members 88 a, 88 b through the mounting slots 234 a, 234 b and alignment for mounting onto the coupler 90. The narrower retention slots 238 connect the valve members 88 a, 88 b to the coupler 90 and enable the coupler 90 to apply a driving force to the valve members 88 a, 88 b to displace the valve members 88 a, 88 b in either of the axial directions AD1, AD2.

[0228] The flow head 98 is configured to interface with the seal bodies 76 a, 76 b (e.g., directly with the seal bodies 76 a, 76 b or indirectly via a seal disposed between the flow head 98 and the seal bodies 76 a, 76 b) to control the flow of the component materials and compressed gas into the mixing chamber 110. A flow neck 100 extends between and connects the flow head 98 and a member body 102. The flow neck 100 has a smaller diameter than the flow head 98. The member body 102 extends axially between the flow neck 100 and a mounting neck 104. The member body 102, in the illustrated example, has a larger diameter than the flow neck 100. The mounting neck 104 extends axially between the member body 102 and a mounting head 106. The mounting neck 104 is configured to extend axially through the coupler 90. The mount neck 104 is configured to be positioned within the mount slots 234a, 234b to mount the valve members 88a, 88b to the coupler 90. The mount head 106 is positioned at the axial end of the mount neck 104 opposite the member body 102. In the illustrated example, the valve members 88a, 88b include a tail 108 extending axially from the mount head 106. The tail 108 protrudes axially away from the mount neck 104 and is positioned axially opposite the mount head 106 from the mount neck 104. The tail 108 is configured to provide a tool interface to facilitate removal of the valve assembly 64 from the cartridge 14, for example, for cleaning or replacement.

[0229] The mount neck 104 has a smaller diameter than the member body 102 and the mount head 106. The larger diameter of the valve member body 102 and the mount head 106 relative to the mount neck 104 facilitates the coupler 90 transmitting a driving force to the valve members 88a, 88b to displace the valve members 88a, 88b in either the first axial direction AD1 or the second axial direction AD2. The coupler 90 applies an axial driving force to the member body 102 to displace the valve members 88a, 88b in the first axial direction AD1. The coupler 90 applies an axial driving force to the mount head 106 to displace the valve members 88a, 88b in the second axial direction.

[0230] To assemble the valve members 88a, 88b to the coupler 90, the valve members 88a, 88b pass through the receiving openings 236 so that the mount necks 104 are positioned within the receiving openings 236 and aligned with the retention slots 238. The valve members 88a, 88b are then shifted relative to the coupler 90 (or the coupler 90 is shifted relative to the valve members 88a, 88b) so that the mount necks 104 are positioned within the retention slots 238. With the mount necks 104 positioned within the retention slots 238, the mount head 106 and valve member body 102 axially overlap the body of the coupler 90. The coupler 90 can then apply an axial driving force to the member body 102 to displace the valve members 88a, 88b in a first axial direction AD1 and an axial driving force to the mount head 106 to displace the valve member 88 in a second axial direction AD2.

[0231] FIG. 10A is an isometric view of coupler 90′. FIG. 10B is an elevational view of the rear side of coupler 90′. FIGS. 10A and 10B will be discussed together with continued reference to FIGS. 1A-9. Coupler 90′ is substantially similar to coupler 90, except that coupler 90′ includes rotation locks 240. The rotation locks 240 protrude from a face of coupler 90′ oriented in the second axial direction AD2. Each rotation lock 240 is formed as an individual protrusion extending in the second axial direction AD2. The rotation locks 240 are circumferentially disposed between valve notches 230 of coupler 90′. At least a portion of each rotation lock 240 extends from a valve tab 232. The rotation locks 240 can be considered to axially overlap the valve tabs 232.

[0232] The rotation lock 240 is configured to ensure the formation of the dynamic interface 128 when forming the static interface 126 between the cartridge 14 and the actuator assembly 12. For example, the valve assembly 64 may be fully displaced in the first axial direction AD1 when attempting to attach the cartridge 14 to the actuator assembly 12. However, the drive piston 46 is displaced in the second axial direction AD2 so that the sprayer 10 is intended to be in a non-spraying state upon initial attachment. The forward valve assembly 64 and the rearward drive piston 46 can form an axial gap between the valve mount 92 and the drive mount 54 such that the static interface 126 can be formed but the dynamic interface 128 cannot be formed. In such an example, initiating the flow of the multiple component materials into the cartridge 14 causes the multiple component materials to flow into the mixing chamber 110 and mix therein, but the flow of the components cannot be shut off without the dynamic connection being formed.

[0233] The rotation lock 240 extends from the coupler 90′ and is configured to extend circumferentially into the gap between the drive tabs 224 when the valve assembly 64 is forward and the drive piston 46 is rearward during installation. The rotation lock 240, which circumferentially overlaps the drive tabs 224, prevents the cartridge 14 from rotating on the spray axis SA to form a static connection. Such rotational resistance signals to a user that the valve assembly 64 needs to be displaced in the second axial direction AD2 (e.g., by grasping the tail 108 with a tool such as pliers or by grasping the coupler 90′ through the opening 198, among other options). The rotation lock 240 does not prevent rotation of the cartridge 14 when the drive mount 54 and the valve mount 92 are aligned to form the dynamic interface 128. While the coupler 90′ is shown including the rotation lock 240, it is understood that not all examples are so limited. For example, the cartridge 14 and actuator assembly 12 can be sized so that the drive tabs 224 circumferentially overlap the valve tabs 232 when the valve assembly 64 is fully forward and the drive piston 46 is fully rearward; this interface also prevents the formation of the static interface 126 when the drive mount 54 and the valve mount 92 are not aligned to form the dynamic interface 128.

[0234] Figure 11A is a partial cross-sectional view taken along line 11-11 of Figure 1A, showing shutoff 22 in an unlocked state. Figure 11B is a partial cross-sectional view similar to Figure 11A, but showing shutoff 22 in a locked state.

[0235] 1A-10B. The gun body 30, shutoff 22, drive piston 46, and injection piston 48 of the sprayer 10 are shown. The shutoff 22 includes a knob 42, a converter 112, a connector 114, a shutoff fastener 142, and a spring 242. The converter 112 includes a positioner 118 and a converter body 116. The converter body 116 includes a locking slot 244. The connector 114 includes a connector shaft 120 and a connector head 122.

[0236] The shutoff 22 is connected to the drive piston 46 and configured to control the operability of the drive piston 46, thereby controlling whether the sprayer 10 can be actuated to a spraying state. The shutoff 22 is connected to the valve assembly 64 via the drive piston 46. The shutoff 22 is supported by the gun body 30. The shutoff 22 is configured to actuate the valve assembly 64 in a second axial direction AD2, in which the shutoff 22 moves away from the spray orifice 28 of the mixing chamber 110. The shutoff 22 can actuate the valve assembly 64 in the second axial direction AD2 to place each of the flow valves 58a, 58b in a respective first open state, in which the flow of components A and B to the mixing chamber 110 is blocked and the sprayer 10 does not emit the multiple component materials.

[0237] Knob 42 is disposed on the exterior of gun body 30 and is accessible from the exterior of sprayer 10. Knob 42 is accessible by a user to actuate shutoff 22 between a locked state and an unlocked state. Knob 42 is configured to rotate on spray axis SA to actuate shutoff 22 between a locked state and an unlocked state.

[0238] A spring 242 is disposed between the knob 42 and the gun body 30. The spring 242 is configured to bias the knob 42 in the second axial direction AD2, away from the gun body 30. The spring 242 can urge the positioner 118 into a detent 246 in a locking slot 244 of the converter 112 to maintain the shutoff 22 in a locked condition, as described in more detail below.

[0239] The connector 114 is connected to the drive piston 46. In the illustrated example, the connector head 122 is at least partially disposed within the piston head 52 of the drive piston 46. The connector 114 is held within a cavity in the piston head 52 by a retainer 248. The retainer 248 is attached to the drive piston 46 and configured to prevent the connector 114 from moving in the second axial direction AD2 relative to the drive piston 46. The retainer 248 may be formed as a full ring extending completely around the spray axis SA, or may be formed as one or more partial rings extending partially around the spray axis SA. The connector shaft 120 extends in the second axial direction AD2 away from the drive piston 46. The connector shaft 120 extends within the converter body 116 and radially overlaps a portion of the converter body 116.

[0240] The converter 112 is operably connected to the connector 114 and the knob 42. The converter 112 is operably connected to the connector 114 such that the converter 112 can axially displace the connector 114 in a second axial direction AD2 along the spray axis SA. The converter 112 is further operably connected to the connector 114 such that the converter 112 can prevent the connector 114, and therefore the drive piston 46, from shifting in the first axial direction AD1. When the shutoff 22 is in the unlocked state (FIG. 11A), the connector 114 can move axially relative to the converter body 116. When the shutoff 22 is in the locked state (FIG. 11B), the connector 114 is held in a fixed position along the spray axis SA to prevent the sprayer 10 from being actuated to the spraying state.

[0241] Converter 112 is configured to convert a rotational input from knob 42 into a linear input to connector 114. Converter 112 is configured to convert the rotational input from knob 42 into axial movement of connector 114 along spray axis SA to actuate drive piston 46 from a forward position associated with a spraying state of sprayer 10 to a rearward position associated with a non-spraying state of sprayer 10.

[0242] The positioner 118 is supported by the connector 114. In the illustrated example, the positioner 118 is supported by the connector shaft 120. In the illustrated example, the positioner 118 extends through the connector shaft 120. The positioner 118 extends radially outward from the connector shaft 120. The positioner 118 is configured to interface with the converter body 116. In the illustrated example, the positioner 118 extends into a locking slot 244 formed in the converter body 116. The positioner 118 forms a linear displacer for the converter 112.

[0243] The converter body 116 is connected to the knob 42 by a shutoff fastener 142. The shutoff fastener 142 secures the converter 112 and the knob 42 together. The converter body 116 is connected to the knob 42 for simultaneous rotation such that rotating the knob 42 causes rotation of the converter body 116. In the illustrated example, the converter body 116 is disposed coaxially with the atomizing axis SA and is configured to rotate on the atomizing axis SA. The converter body 116 forms the rotational input of the converter 112.

[0244] The locking slots 244 are formed in the converter body 116. In the illustrated example, each locking slot 244 extends completely through the converter body 116 between the radially outer surface of the converter body 116 and the radially inner surface of the converter body 116. In the illustrated example, the locking slots 244 extend spirally around the spray axis SA. The locking slots 244 extend between a free end 250 and a locking end 252. The free end 250 has a greater axial length than the locking end 252. When the positioner 118 is positioned at the free end 250, it is able to move axially relative to the converter body 116, and when the positioner 118 is positioned at the locking end 252, it is restricted from moving axially.

[0245] The locking slot 244 includes an angled surface 254 configured to interface with the positioner 118 to axially displace the positioner 118. The angled surface 254 applies a driving force to the positioner 118 to displace the positioner 118 in the second axial direction AD2.

[0246] The positioner 118 may include a pin, knob, or other protrusion that interfaces with a helical structure (e.g., locking slot 244) on the converter body 116. The helical locking slot 244 may, among other options, wrap partially or completely around an axis. In the illustrated example, the locking slot 244 does not extend completely around the spray axis SA. The positioner 118 may be fixed so that it can only translate linearly along the spray axis SA, such that an interface with the rotating helical structure of the converter body 116 causes the pin, knob, or other protrusion that forms the positioner 118 to move linearly along the axis. In the illustrated example, the positioner 118 is connected to the connector 114; however, it is understood that the positioner 118 may be directly or indirectly connected to the drive piston 46, which in turn is indirectly connected to the valve members 88a, 88b via the coupler 90.

[0247] The shutoff 22 is actuable between a locked state and an unlocked state. To actuate the shutoff 22 from the unlocked state to the locked state, the knob 42 is rotated in a first rotational direction (e.g., one of clockwise and counterclockwise) on the spray axis SA. Rotating the knob 42 rotates the converter body 116 in the same rotational direction as the knob 42. The converter body 116 rotates relative to the positioner 118 to position the positioner 118 within the lock end 252 of the lock slot 244. With the positioner 118 in the lock end 252 of the lock slot 244, the converter body 116 prevents axial movement of the positioner 118 in the first axial direction AD1. The positioner 118 interfaces with the converter body 116 to prevent the connector 114 secured to the positioner 118 from moving in the first axial direction AD1, thereby preventing the drive piston 46, and therefore the valve assembly 64, from moving in the first axial direction AD1, thereby locking the sprayer 10 in a non-spraying state.

[0248] When shutoff 22 is locked, positioner 118 is positioned at lock end 252 of lock slot 244 and is prevented from moving in the first axial direction AD1. Positioner 118 is connected to connector 114 to prevent connector 114 from moving in the first axial direction AD1. Connector 114 is connected to drive piston 46 to prevent drive piston 46 from moving in the first axial direction AD1. Therefore, drive piston 46 is prevented from actuating valve assembly 64, and sprayer 10 is locked in a non-spraying state.

[0249] To actuate the shutoff 22 from the locked state to the unlocked state, the knob 42 is rotated in a second rotational direction (e.g., the other of clockwise and counterclockwise) on the spray axis SA. The converter body 116 rotates in the same rotational direction as the knob 42. The converter body 116 rotates relative to the positioner 118 to position the positioner 118 within the free end 250 of the locking slot 244. With the positioner 118 in the free end 250 of the locking slot 244, the converter body 116 does not prevent axial movement of the positioner 118 in the first axial direction AD1. Thus, the drive piston 46 can move in the first axial direction AD1 to actuate the valve assembly 64 and place the sprayer 10 in the spraying state.

[0250] When the shutoff 22 is in the unlocked state (FIG. 11A), the positioner 118 is disposed at the free end 250 of the locking slot 244 and is axially movable within the locking slot 244. The positioner 118 is axially movable relative to the converter body 116. When the positioner 118 is axially movable relative to the converter body 116, the connector 114 is axially movable, and the drive piston 46 is axially movable. The drive piston 46 is movable in a first axial direction AD1 along the spraying axis SA so that the sprayer 10 can be actuated from a non-spraying state to a spraying state. The drive piston 46 can also be moved in a second axial direction AD2 along the spraying axis SA so that the sprayer 10 can be actuated from a spraying state to a non-spraying state.

[0251] In the illustrated example, the mechanical motion that moves valve members 88a, 88b results from pneumatic actuation initiated by trigger 24. However, on rare occasions, while sprayer 10 is in the spraying state and spraying, air pressure (or hydraulic pressure, in examples including hydraulic actuation) may be lost, thereby preventing trigger 24 from pneumatically (or hydraulically) moving drive piston 46, necessitating a rapid manual shutoff of the flow of components A and B to stop spraying of the multi-component material. Such action is provided by shutoff 22. Shutoff 22 is attached to drive piston 46 and can displace drive piston 46 in a second axial direction AD2 to pull valve members 88a, 88b rearward to close flow valve 58a to shut off the flow of component A to mixing chamber 110 and close flow valve 58b to shut off the flow of component B to mixing chamber 110.

[0252] In the event of a loss of pneumatic (or hydraulic) flow, the knob 42 is rotated by the user. The knob 42 rotates the converter body 116. As the converter body 116 rotates on the spray axis SA, the inclined surface 254 interfaces with the positioner 118, displacing the positioner along the inclined surface 254. As the converter body 116 rotates, the positioner 118 is displaced linearly in the second axial direction AD2. The positioner 118 is driven along the inclined surface to the lock end 252 of the lock slot 244. As the positioner 118 displaces along the inclined surface 254, it moves in the second axial direction AD2.

[0253] Positioner 118 retracts connector 114 in the second axial direction AD2, which in turn retracts drive piston 46 in the second axial direction AD2. Drive piston 46 retracts valve assembly 64 in the second axial direction AD2, blocking the flow of components A and B to mixing chamber 110 and thereby blocking spraying of the multiple components. This allows shutoff 22 to actuate sprayer 10 from a spraying state to a non-spraying state in the event of a loss of pneumatic (or hydraulic) pressure.

[0254] The knob 42 is accessible by a user to activate the shutoff 22. Actuation of the knob 42 provides a mechanical input to the converter 112. In this embodiment, the converter 112 converts rotary motion into linear motion. More specifically, the knob 42 can be rotated to provide a rotational input to the converter 112. The converter 112 axially displaces the connector 114 in a second axial direction AD2 due to a connection between the positioner 118 and the connector 114. The connector 114 is attached to the drive piston 46 and can mechanically displace the drive piston 46.

[0255] Figure 12A is a first exploded view of the shutoff 22 and drive piston 46. Figure 12B is a second exploded view of the shutoff 22. Figure 13A is an isometric view of the shutoff 22 and drive piston 46 showing the shutoff 22 in an unlocked state. Figure 13B is an isometric view of the shutoff and drive piston showing the shutoff in a locked state.

[0256] 1A-11B. Shut-off 22 includes knob 42, converter 112, connector 114, shut-off fastener 142, and spring 242. Converter 112 includes positioner 118 and converter body 116. Converter body 116 includes locking slot 244, slot body 256, and mount body 258. Connector 114 includes connector shaft 120 and connector head 122.

[0257] The shutoff 22 is operable between a locked state, in which the shutoff 22 locks the sprayer 10 in a non-spraying state, and an unlocked state, in which the sprayer 10 is operable between the non-spraying state and the spraying state. The shutoff 22 can actuate the sprayer 10 from the spraying state to the non-spraying state by actuation of the shutoff 22 from the unlocked state to the locked state.

[0258] The knob 42 is configured to be disposed at least partially outside the gun body 30. The knob 42 is accessible to a user from the exterior of the sprayer 10. The knob 42 is rotatable on the spray axis SA and is configured to actuate the shutoff 22 between a locked state and an unlocked state. A spring 242 interfaces with the knob 42 and is configured to bias the knob 42 in the second axial direction AD2. The spring 242 is disposed between the knob 42 and the gun body 30. While the spring 242 is shown as a wave spring, it is understood that other spring types are possible.

[0259] The connector 114 is connected to the drive piston 46 and moves with the drive piston 46 on the spray axis SA. In the illustrated example, the connector head 122 is at least partially disposed within the piston head 52 of the drive piston 46. A retainer 248 is attached to the piston head 52 and axially overlaps the connector head 122. The retainer 248 secures the connector head 122 within a chamber formed in the piston head 52 of the drive piston 46. The retainer 248 secures the connector 114 to the drive piston 46.

[0260] The converter 112 is connected to the knob 42 and the drive piston 46. In the illustrated example, the converter 112 is indirectly connected to the drive piston 46 via a connector 114. The converter 112 can convert the rotational input from the knob 42 into linear motion of the drive piston 46 in a second axial direction AD2 axially away from the spray orifice 28 of the mixing chamber 110.

[0261] The positioner 118 is attached to the connector 114. In the illustrated example, the positioner 118 is attached to the connector shaft 120. The positioner 118 extends completely through the connector shaft 120 such that each end of the positioner 118 projects radially outward from the connector shaft 120. Each radial end of the positioner 118 extends into and is disposed within the locking slot 244.

[0262] The converter body 116 is attached to the knob 42 for coaxial rotation therewith. In the illustrated example, a mount body 258 of the converter body 116 is at least partially disposed within a knob cavity 260 formed in the knob 42. The shutoff fastener 142 is at least partially disposed within the converter body 116. The shutoff fastener 142 extends through the mount body 258 and into the knob 42. The shutoff fastener 142 may include external threads configured to interface with internal threads in the knob 42. The shutoff fastener 142 axially secures the converter body 116 and the knob 42 relative to one another.

[0263] In the illustrated example, the mount body 258 is keyed to the knob 42 to prevent relative rotation between the mount body 258 and the knob 42. The outer surface of the mount body 258 is non-circular, and the inner surface of the knob chamber 260 has a corresponding non-circular shape that interfaces with the outer surface of the mount body 258. In the illustrated example, the outer surface of the mount body 258 includes converter flats 262 that mate with corresponding knob flats 264 formed on the knob 42. However, it will be understood that the keyed interface can be of any desired configuration. For example, the exterior of the mount body 258 and the interior surfaces of the knob cavity 260 can be hexagonal, square, oval, triangular, among other non-circular options.

[0264] The slotted body 256 extends from the mount body 258 in the first axial direction AD1. The locking slot 244 is formed in the slotted body 256. In the illustrated example, the locking slot 244 extends helically around the slotted body 256. The locking slot 244 extends both axially and circumferentially around the slotted body 256. In the illustrated example, the converter body 116 includes a pair of locking slots 244 into which opposite ends of the positioner 118 extend. The dual slot configuration of the converter body 116 balances the forces applied to the positioner 118 when the shutoff 22 actuates the drive piston 46 in the second axial direction AD2, for example, in the event of a pressure loss, and when the shutoff 22 is in a locked state, holding the sprayer 10 in a non-spraying state. The interface between the converter body 116 and the positioner 118 is radially outward of the spraying axis SA, and the holding forces are balanced by the dual slot configuration.

[0265] Each locking slot 244 extends between a free end 250 and a locking end 252. The free ends 250 have a longer axial length than the locking ends 252. In the illustrated example, the free ends 250 are open in the first axial direction AD1, allowing the positioner 118 to pass into or out of the converter body 116 during assembly or disassembly of the sprayer 10. The gun body 30 is sized such that the positioner 118 remains disposed within the locking slots 244 even when the drive piston 46 is fully displaced in the first axial direction AD1 during operation of the sprayer 10.

[0266] In the illustrated example, a detent 246 is formed on the locking end 252. The detent 246 extends in the first axial direction AD1 such that a portion of the structure of the converter body 116 circumferentially overlaps the detent 246. The detent 246 is configured to receive an end of the positioner 118 when the shutoff 22 is in the locked state.

[0267] 13A and 13B illustrate the operation of the shutoff 22 between an unlocked state (FIG. 13A, showing a configuration in which the sprayer 10 is in a spraying state) and a locked state (FIG. 13). As described above, the shutoff 22 is configured to actuate the sprayer 10 from a spraying state to a non-spraying state in the event of a pressure loss, as well as to lock the sprayer 10 in a non-spraying state. The shutoff 22 can be actuated to the locked state when the sprayer 10 is in either the spraying or non-spraying state.

[0268] To actuate the sprayer 10 from the spraying state to the non-spraying state, the knob 42 is rotated, which rotates the converter body 116. The angled surface 254 of the locking slot 244 interfaces with the end of the positioner 118, linearly translating the positioner 118 in the second axial direction AD2. The angled surface 254 is curved to displace the positioner 118 as the converter body 116 rotates. The positioner 118 is connected to the connector 114, which is connected to the drive piston 46 such that the converter 112 pulls the drive piston 46 in the second axial direction AD2. The knob 42 is rotated until the positioner 118 reaches the locking end 252 of the locking slot 244. The spring 242 biases the knob 42 in the second axial direction AD2, causing the positioner 118 to enter the detent 246. When the positioner 118 is positioned in the locking end 252 of the locking slot 244, the sprayer 10 is locked in a non-spraying state. When the positioner 118 is positioned within the detent 246, the knob 42 is prevented from freely rotating about the spraying axis SA to place the shutoff 22 in an unlocked state.

[0269] To actuate the shutoff 22 to the unlocked state, the knob 42 is rotated, which rotates the converter body 116. The converter body 116 rotates relative to the positioner 118 such that the positioner 118 is disposed at the free end 250 of the locking slot 244. In the illustrated example, a detent 246 secures the shutoff 22 in the locked state. To actuate the shutoff 22 to the unlocked state, the knob 42 is depressed in the first axial direction AD1, which compresses the spring 242 and moves the converter body 116 in the first axial direction AD1 relative to the positioner 118. Thus, the positioner 118 is moved out of the detent 246 and the knob 42 can be rotated to place the shutoff 22 in the unlocked state.

[0270] The shutoff 22 offers significant advantages. The shutoff 22 is actuable between a locked state and an unlocked state by rotating the knob 42. Rotation of the knob 42 causes liner displacement of the drive piston 46 and the valve assembly 64, actuating the sprayer 10 from a spraying state to a non-spraying state. The shutoff 22 can also lock the sprayer 10 to a non-spraying state, preventing actuation of the sprayer 10 to the spraying state. The shutoff 22 provides a single mechanism that can shut off spraying and lock the sprayer 10 to prevent spraying. The shutoff 22 is easily accessible by the user to provide rapid actuation of the sprayer 10 to a non-spraying state, prevent material loss, and prevent undesired spraying in the event of a loss of pressure. The shutoff 22 interfaces with the drive piston 46 to physically lock the drive piston 46 and prevent actuation of the sprayer 10 to the spraying state. In the illustrated example, shutoff 22 can be thought of as forming a trigger lock in that it prevents triggering of sprayer 10 to the spraying state, but does not directly interface with trigger 24. Thus, although trigger 24 can still be actuated when shutoff 22 is in the locked state, such actuation will not actuate sprayer 10 to the spraying state.

[0271] While the present invention has been described with reference to exemplary embodiments, those skilled in the art will recognize that various changes can be made and equivalents can be substituted for elements without departing from the scope of the invention. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the invention without departing from its essential scope. Therefore, it is understood that the invention is not limited to the particular embodiments disclosed, but rather includes all embodiments falling within the scope of the appended claims. Also, while certain options are shown, it is understood that these options need not be present and that certain aspects can be eliminated or substituted.

Claims

1. A cartridge for use with a multi-component spray gun having a spray gun body and configured to receive first and second constituent materials that are mixed to form a multi-component material, A valve body extending between the first end of the main body and the second end of the main body, A first flow valve disposed within the valve body; A second flow valve is disposed within the valve body, A mixing chamber cavity extending along the spray axis into the first body end of the valve body and configured to receive at least a portion of the mixing chamber of the multi-component spray gun, Equipped with, The aforementioned cartridge is removable from the spray gun body as a single module. If the mixing chamber has not yet been removed from the cartridge, removing the cartridge from the spray gun body will inevitably disconnect the mixing chamber from any connection to the spray gun body.

2. The cartridge according to claim 1, wherein the mixing chamber cavity does not extend through the second end of the main body.

3. The cartridge according to claim 1, wherein the mixing chamber cavity is open on the first body end of the valve body so that the mixing chamber can be removed from the first body end of the valve body, and the mixing chamber cavity is partially or completely closed to the second body end of the valve body so that the mixing chamber cannot be moved through the second body end.

4. The cartridge according to any one of claims 1 to 3, wherein the mixing chamber is in direct contact with the cartridge and is removable so as not to come into contact with the cartridge, but the mixing chamber does not come into direct contact with the spray gun body during spraying.

5. The cartridge according to any one of claims 1 to 3, wherein the mixing chamber is received by the cartridge and is removable from the cartridge, and the mixing chamber does not come into contact with the spray gun body during spraying.

6. The valve body defines a first material passage between the first material inlet and the mixing chamber cavity, The valve body defines a second material passage between the second material inlet and the mixing chamber cavity, The first material passage and the second material passage are fluidically separated such that the first and second constituent materials flow separately into the valve body, are mixed to form the multi-component material, and exit from the first end of the body. The cartridge according to any one of claims 1 to 3.

7. The cartridge according to any one of claims 1 to 3, wherein the first end of the main body is configured to be connected to an air cap.

8. The cartridge according to claim 7, wherein the air cap holds the mixing chamber within the cartridge, and removal of the air cap from the cartridge allows removal of the mixing chamber from the cartridge from the first body end of the cartridge.

9. The cartridge according to claim 7, wherein a thread is formed on the valve body at the first end of the main body, and the thread is configured to connect the air cap to the cartridge.

10. A first valve hole extending from the second body end into the valve body along a first valve stem offset from the spray shaft, A second valve hole extending from the second body end into the valve body along a second valve shaft offset from the spray shaft, Furthermore, The first flow valve is positioned within the first valve hole. The second flow valve is positioned within the second valve hole. The cartridge according to any one of claims 1 to 3.

11. The cartridge according to claim 10, wherein the first valve hole is not open through the first end of the main body.

12. The cartridge according to claim 11, wherein the second valve hole is not open through the first end of the main body.

13. A first gas chamber is formed within the first valve opening. The first flow chamber is positioned within the first valve opening. The first gas chamber is fluidly connected to the mixing chamber bore when the first flow valve is in the first open state, so that compressed gas can flow from the first gas chamber to the mixing chamber bore. The first flow chamber is fluidly connected to the mixing chamber bore when the first flow valve is in the second open state, so that the constituent material can flow from the first flow chamber to the mixing chamber bore. The cartridge according to claim 10.

14. The cartridge according to claim 13, wherein the first gas chamber is fluidly disconnected from the mixing chamber bore when the first flow valve is in the second open state, and the first flow chamber is fluidly disconnected from the mixing chamber bore when the first flow valve is in the first open state.

15. The cartridge according to claim 10, wherein a first supply hole is formed in the valve body, extends between the first valve hole and the mixing chamber cavity, and fluidly connects them, and a second supply hole is formed inside the valve body, extends between the second valve hole and the mixing chamber cavity, and fluidly connects them.

16. A first gas passage that opens through the second end of the main body, further comprising a first gas passage in which at least a portion of the first gas passage is arranged on the spray axis, The cartridge according to any one of claims 1 to 3.

17. The cartridge according to any one of claims 1 to 3, wherein the entirety of the first flow valve and the entirety of the second flow valve are removed from the multi-component spray gun together with the cartridge.

18. A cartridge according to any one of claims 1 to 3, wherein a body joint is formed at the second body end, and the body joint is configured to interface with the spray gun body to form a static interface that supports the cartridge on the spray gun body.

19. The cartridge according to claim 18, wherein the main body mount includes at least one tab that protrudes radially outward with respect to the spray axis.

20. The cartridge according to claim 19, wherein the at least one tab is formed on the outside of the valve body.

21. A body cavity formed within the valve body and opening through the second body end, A valve assembly, at least partially located within the main body cavity, comprising a valve assembly movable along the spray axis to operate the first flow valve and the second flow valve to open and close the flow path to the mixing chamber cavity, A cartridge according to any one of claims 1 to 3, further comprising the above.

22. The cartridge according to claim 21, wherein a cavity wall is formed at the axial end of the main body cavity, and the cavity wall is positioned between the first main body end and the second main body end.

23. A body cavity formed within the valve body and opening through the second body end, A first valve hole extending into the valve body and opening into the main body cavity, A second valve hole extending into the valve body and opening into the main body cavity, A valve assembly, at least partially located within the main body cavity, which is movable along the spray axis to actuate the first flow valve and the second flow valve to open and close the flow path to the mixing chamber cavity, A first valve member, at least partially located within the first valve opening and movable along the first valve opening, A second valve member, at least partially located within the second valve opening and movable along the second valve opening, A coupler connected to the first valve member and the second valve member, and at least partially located within the main body cavity, A valve assembly comprising, The cartridge according to claim 1, comprising:

24. A first seal body disposed within the first valve hole, wherein the first flow valve has a first seal body formed between the first seal body and the first valve member, A second seal body disposed within the second valve hole, wherein the second flow valve has a second seal body formed between the second seal body and the second valve member, The cartridge according to claim 23, further comprising the following:

25. The cartridge according to claim 24, wherein the first valve member is configured to slide along the valve shaft of the first valve hole and relative to the first seal body.

26. The cartridge according to claim 25, wherein the first valve member is sealed and engaged with the first seal body, allowing the first component material to flow into the mixing chamber bore when the first flow valve is open, and preventing the first component material from flowing into the mixing chamber bore when the first flow valve is closed.

27. A multi-component spray gun configured to receive a first component material and a second component material and to output a spray of a multi-component material, The gun body and A handle protruding from the gun body, The trigger is supported by the gun body, A cartridge that can be detachably attached to the gun body, A valve body extending between a first body end and a second body end, wherein the second body end is configured to interface with the gun body for connecting the cartridge to the gun body, A first flow valve arranged within the valve body, A second flow valve is disposed within the valve body, The valve body comprises a mixing chamber cavity extending along the spray axis into the first body end of the valve body, A cartridge that can be removed from the spray gun body as a single module, A mixing chamber that can be installed in the aforementioned mixing chamber cavity, Equipped with, If the mixing chamber has not yet been removed from the cartridge, removing the cartridge from the gun body will inevitably disconnect the mixing chamber from any connection to the spray gun body, in a multi-component spray gun.

28. A cartridge for use with a multi-component spray gun having an actuator assembly including a spray gun body and a displacer, configured to receive first and second constituent materials that are mixed to form a multi-component material, A valve body extending along the axis between the first end of the main body and the second end of the main body, A mixing chamber cavity formed within the valve body, A first flow valve arranged within the valve body, A second flow valve is disposed within the valve body, A valve mount configured to interface with the actuator assembly in a dynamic interface for receiving mechanical input to actuate the first flow valve and the second flow valve, between a first state in which the flow of the first and second components into the mixing chamber cavity is closed and a second state in which the flow of the first and second components into the mixing chamber cavity is open, A body mount formed on the valve body and configured to interface with the actuator assembly in a static interface for attaching the cartridge to the spray gun body, Equipped with, The cartridge is a single unit that can be attached to and removed from the actuator assembly.

29. A cartridge for use with a multi-component sprayer having an actuator assembly including a spray gun body and a displacer, configured to receive first and second constituent materials that are mixed to form a multi-component material, A valve body extending along an axis between a first body end and a second body end, the valve body including a body mount configured to interface with the spray gun body for fixing the valve body to the spray gun body, A mixing chamber cavity formed within the valve body and opening through the first end of the main body, A valve assembly supported by the valve body, the valve assembly including a valve mount configured to be movable relative to the valve body along the axis, to open and close a passage for the first and second components to flow into the mixing chamber cavity, and to interface with the displacer for fixing the valve assembly to the displacer, Equipped with, The cartridge is a single unit that can be attached to and removed from the actuator assembly.

30. A cartridge for a multi-component sprayer having an actuator assembly including a spray gun body and a displacer, configured to receive first and second constituent materials that are mixed to form a multi-component material, A valve body extending along the axis between a first body end and a second body end, The block body and A mixing chamber cavity extending into the block body in the first axial direction along the aforementioned axis, A first valve opening extending into the block body in a second axial direction along the aforementioned axis, wherein a first flow chamber and a first gas chamber configured to receive the first constituent material are disposed within the first valve opening, and the second axial direction is opposite to that of the first valve opening, A second valve opening extending in the second axial direction within the block body, wherein a second flow chamber and a second gas chamber configured to receive the second constituent material are disposed within the second valve opening, A gas passage extending into the block body in the second axial direction, A body mount configured to interface with the spray gun body in order to fix the valve body, A valve body comprising, A valve assembly supported by the valve body, A first valve member, at least partially positioned in the first valve bore, is movable relative to the block body between a first state of the first member in which the first gas chamber is fluidly connected to the mixing chamber cavity and the first flow chamber is fluidly isolated from the mixing chamber cavity, and a second state of the first member in which the first flow chamber is fluidly connected to the mixing chamber cavity and the first gas chamber is fluidly isolated from the mixing chamber cavity. A second valve member, at least partially positioned in the second valve bore, is movable relative to the block body between a first state of the second member in which the second gas chamber is fluidly connected to the mixing chamber cavity and the second flow chamber is fluidly isolated from the mixing chamber cavity, and a second state of the second member in which the second flow chamber is fluidly connected to the mixing chamber cavity and the second gas chamber is fluidly isolated from the mixing chamber cavity. A valve mount configured to interface with the displacer in order to secure the valve assembly to the displacer, A valve assembly comprising, Equipped with, The cartridge is a single unit that can be attached to and removed from the actuator assembly.

31. A multi-component spray gun configured to receive a first component material and a second component material and to output a spray of a multi-component material, An actuator assembly including a gun body and a displacer movable along an axis relative to the gun body, A cartridge that is removablely attached to the actuator assembly by a static interface formed between the cartridge and the gun body and a dynamic interface formed between the cartridge and the displacer, wherein the dynamic interface is configured to actuate a first flow valve of the cartridge to control the flow of the first component material into a mixing chamber cavity formed within the cartridge, and the dynamic interface is configured to actuate a second flow valve of the cartridge to control the flow of the second component material into the mixing chamber cavity, Equipped with, The cartridge is a multi-component spray gun that can be mounted to and removed from the actuator assembly as a single unit.

32. A cartridge for use with a multi-component spray gun having an actuator assembly including a spray gun body and a displacer, configured to receive first and second constituent materials that are mixed to form a multi-component material, wherein the cartridge is A valve body extending along the axis between the first end of the main body and the second end of the main body, A mixing chamber cavity formed within the valve body and opening through the first end of the main body, A first valve hole is formed within the valve body and opens through the second end of the main body, A second valve hole is formed within the valve body and opens through the second end of the main body, A valve assembly supported by the valve body, A first valve member, at least partially disposed within the first valve hole, A second valve member, at least partially positioned within the second valve hole, A valve assembly comprising, A first flow valve formed in the first valve hole, wherein the first valve member forms a valve component of the first flow valve, A second flow valve formed in the second valve hole, wherein the second valve member forms a valve component of the second flow valve, Equipped with, The valve assembly is movable to operate the first flow valve and the second flow valve between a first state in which the flow of the first component material and the flow of the second component material into the mixing chamber cavity are blocked, and a second state in which the flow of the first component material and the flow of the second component material into the mixing chamber cavity are not blocked. The cartridge is a single unit that can be attached to and removed from the actuator assembly.

33. A cartridge for use with a multi-component spray gun having an actuator assembly including a spray gun body and a displacer, configured to receive first and second constituent materials that are mixed to form a multi-component material, The aforementioned cartridge is A valve body extending along the axis between the first end of the main body and the second end of the main body, A mixing chamber cavity formed within the valve body and opening through the first end of the main body, A first valve hole is formed within the valve body and opens through the second end of the main body, A second valve hole is formed within the valve body and opens through the second end of the main body, A valve assembly supported by the valve body, A coupler, at least partially disposed within the valve body, A first valve member connected to the coupler and at least partially positioned within the first valve hole, A second valve member connected to the coupler and at least partially positioned within the second valve hole, Equipped with, The coupler is configured to transmit force to the first valve member in order to displace the first valve member along the first valve hole between a first state of the first member in which the flow of the first component material into the mixing chamber cavity is blocked so as to prevent the first component material from flowing into the mixing chamber cavity, and a second state of the first member in which the flow of the first component material into the mixing chamber cavity is not blocked so as to allow the first component material to flow into the mixing chamber cavity. The coupler is configured to transmit force to the second valve member in order to displace the second valve member along the second valve hole between a first state of the second member in which the flow of the second component material into the mixing chamber cavity is blocked so as to prevent the second component material from flowing into the mixing chamber cavity, and a second state of the second member in which the flow of the second component material into the mixing chamber cavity is not blocked so as to allow the second component material to flow into the mixing chamber cavity. valve assembly and, Equipped with, The cartridge is a cartridge that can be mounted to the actuator assembly as a single unit and is removable from the actuator assembly such that the valve body and the valve assembly are mounted together and removed together.

34. A multi-component sprayer configured to receive a first component material and a second component material, and to release a spray of a multi-component material formed by combining the first component material and the second component material, The gun body and A displacer, at least partially located within the gun body, A mixing chamber configured to receive the first and second constituent materials and to release the multi-component materials, A cartridge that can be attached to and detached from the gun body and the displacer as a single unit, A valve body extending along the axis between the first end of the main body and the second end of the main body, A mixing chamber cavity formed within the valve body and opening through the first end of the main body, wherein the mixing chamber is at least partially located within the mixing chamber cavity, A first valve hole is formed within the valve body and opens through the second end of the main body, A second valve hole is formed within the valve body and opens through the second end of the main body, A valve assembly supported by the valve body, A first valve member, at least partially disposed within the first valve hole, A second valve member, at least partially positioned within the second valve hole, A valve assembly comprising, A cartridge equipped with, Equipped with, The first valve member is movable between a first state of the first member, in which the flow of the first constituent material into the mixing chamber cavity is blocked so as to prevent the first constituent material from flowing into the mixing chamber cavity, and a second state of the first member, in which the flow of the first constituent material into the mixing chamber cavity is not blocked so as to allow the first constituent material to flow into the mixing chamber cavity. A multi-component sprayer, wherein the second valve member is movable with respect to the second valve hole between a first state of the second member in which the flow of the second component material into the mixing chamber cavity is blocked so as to prevent the second component material from flowing into the mixing chamber cavity, and a second state of the second member in which the flow of the second component material into the mixing chamber cavity is not blocked so as to allow the second component material to flow into the mixing chamber cavity.

35. A multi-component sprayer configured to receive a first component material and a second component material, and to discharge a spray of a multi-component material formed by combining the first component material and the second component material, The gun body and A displacer, at least partially located within the gun body, A mixing chamber configured to receive the first and second constituent materials and to release the multi-component materials, A first flow valve configured to control the flow of the first constituent material into the mixing chamber, A second flow valve configured to control the flow of the second constituent material into the mixing chamber, A shutoff, supported by the gun body and connected to the first flow valve and the second flow valve, configured to operate the first flow valve to block the flow of the first component material into the mixing chamber, and configured to operate the second flow valve to block the flow of the second component material into the mixing chamber, A multi-component sprayer equipped with these features.

36. A multi-component sprayer configured to receive a first component material and a second component material, and to release a spray of a multi-component material formed by combining the first component material and the second component material, The gun body and A displacer, at least partially located within the gun body, A mixing chamber configured to receive the first constituent material and the second constituent material and to release the multi-component material, wherein the mixing chamber is configured to release the multi-component material from a spray orifice in a first axial direction along the spray axis, A valve assembly configured to control the flow of the first component material into the mixing chamber and the flow of the second component material into the mixing chamber, the valve assembly being connected to a displacer that operates along the spray axis, A shutoff is connected to the valve assembly and configured to actuate the valve assembly in a second axial direction opposite to the first axial direction along the spray axis in order to block the flow of the first and second constituent materials into the mixing chamber, A multi-component sprayer equipped with these features.

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