Spray gun conversion adapter, spray gun, and conversion method

Abstract

An adapter (2) for converting a manually triggered spray gun for painting into an automatically triggerable spray gun for painting. The manually triggered spray gun includes a nozzle capable of spraying liquid paint, a sealable air duct for guiding pressurized air towards the nozzle to atomize the paint, and a gun body (180) having an opposing surface for sealing the air duct. The adapter (2) includes connection means (200) for attaching the adapter (2) to the gun body (180), energy supply connectors (210, 220) for the adapter to receive mechanical or electrical energy, a poppet actuator (230) that can be automatically actuated using the mechanical or electrical energy received through the energy supply connectors (210, 220), and a poppet (301) connected to the poppet actuator (230) and movable between a closed position and an open position by actuating the poppet actuator (230). After attaching the adapter (2) to the gun body (180), in the closed position, the poppet (301) cooperates with the opposing surface to block the entry of pressurized air into the air duct, and in the open position, the poppet allows the entry of pressurized air into the air duct by cooperating with the opposing surface. The poppet (301) has a sealing surface for making a sealing contact with the opposing surface of the air duct when in the closed position, thereby blocking the entry of pressurized air into the air duct.

Description

[Technical Field]

[0001] The present disclosure relates to paint spray guns and adapters and methods for converting a manual trigger spray gun into an automatic trigger spray gun. Summary of the Invention

[0002] Paint spray guns generally fall into two distinct categories: manual and automatic. Manual spray guns are typically operated by a trained operator, while automatic spray guns are used in conjunction with some form of automation or robot. For example, European Patent Application EP 1243341 A1 is directed to an automatic spray gun that is attached to a robot for painting automobile bodies.

[0003] While these two types of spray guns may share parts such as nozzles and air caps, there are many other differences. For example, many manual spray guns have a trigger that allows the operator to manually control the amount of paint sprayed. When the operator pulls the trigger against the force of a spring, a needle inside the gun body is retracted from the nozzle, allowing more paint to pass through the nozzle. In contrast, automatic spray guns, such as those attached to robotic arms, retract the needle using compressed air under computer control, and do not require a trigger.

[0004] As many auto repair shops transition from manual to automated painting methods, some want to use manual spray guns (i.e., manually triggered spray guns) as automatic spray guns (i.e., spray guns that can be automatically triggered) with only minor modifications. For example, this can be achieved by attaching the gun to a robotic arm and adding a means for automatically retracting and retracting the needle. Chinese utility model CN ​​215278017 U relates to a multi-function control device that converts a manual spray gun into an automatic spray gun and can synchronize and control multiple spray guns. This patent describes a device that can convert a manual spray gun into an automatic spray gun and synchronize and control multiple spray guns. Specifically, a bidirectional air cylinder is connected to the rear side of the multi-gun holder near the needle, and its piston rod is fixedly connected to the needle pick.

[0005] Precise control of the start and end of a spray operation is desirable for saving time, minimizing paint waste (e.g., overspray), reducing pressurized air usage, reducing hazards, reducing noise, and preventing environmental contamination of the spray cabin and robots that position and operate the spray gun. For precise control of an automatically triggerable spray gun converted from a manually triggered spray gun, controlling not only the start and end of paint flow through the nozzle is important, but also the flow of air used to atomize the paint as it exits the nozzle is important. Preferably, this "atomizing air" begins flowing at or slightly before the first paint exits the nozzle. Furthermore, for at least cost reasons and to avoid noise and contamination of the work surface, it is desirable for the atomizing air to cease flowing when paint is no longer exiting the nozzle. Even more desirable is the presence of a dedicated mechanism for controlling the flow of atomizing air in automatically triggerable spray guns converted from manually triggered spray guns. In certain circumstances, in an automatically triggerable spray gun converted from a manually triggered spray gun, it may be desirable to have a mechanism for controlling the atomizing air that is independent of the mechanism that controls the paint flow, i.e., the needle position.

[0006] Therefore, it would be desirable to provide an automated atomizing air control mechanism for converting a manually triggered paint spray gun into an automatically triggerable paint spray gun.

[0007] The present disclosure seeks to address some of these needs in a first aspect by providing an adapter for converting a manually triggered paint spray gun into an automatically triggerable paint spray gun, wherein the manually triggered spray gun includes a gun body having a nozzle capable of spraying liquid paint, a sealable air duct that directs pressurized air toward the nozzle to atomize the paint, and a counter surface for sealing the air duct, and the adapter includes: connecting means for attaching the adapter to the gun body; an energy supply connector through which the adapter can receive mechanical or electrical energy; a poppet actuator automatically actuable using mechanical or electrical energy received through said energy supply connector; A poppet connected to the poppet actuator, such that actuation of the poppet actuator moves the poppet between a closed position and an open position. Here, after the adapter is attached to the gun body, in the sealed position, the poppet cooperates with the opposing surface to block pressurized air from entering the air duct, and in the open position, the poppet cooperates with the opposing surface to allow pressurized air to enter the air duct, and the poppet has a sealing surface for sealingly contacting the opposing surface of the air duct when in the sealed position, thereby blocking pressurized air from entering the air duct.

[0008] The poppet is configured to seal the atomizing air duct with a sealing surface when moved to its closed position by an automatically actuated poppet actuator, and the sealing surface seals against an opposing surface within the gun body after the adapter is attached to the gun body, thereby blocking the flow of atomizing air. This allows the adapter to control the flow of atomizing air in an automatically triggerable spray gun. The poppet can be automatically moved to the closed and open positions via the automatically actuated poppet actuator, thereby allowing precise control over the start and end of spraying.

[0009] For a high degree of automation, it is desirable to avoid the manual step of an operator pulling the spray gun trigger, thereby opening the atomizing air duct, to initiate spraying. Using an adapter according to the present disclosure, this manual step can be automated by replacing the trigger with a poppet actuation mechanism operable under the control of a digital processor, such as a computer processor. For example, in an automatically triggerable spray gun system, the processor issues a digital signal that opens a solenoid valve, initiating the supply of mechanical energy, such as pressurized air, to a poppet actuator within the adapter, which moves the poppet to its open position, thereby initiating the atomizing air flow, and the spray gun begins spraying, either synchronously or following separate actuation of the paint flow. When spraying needs to be stopped, the processor issues a further digital signal that closes the solenoid valve, interrupting the flow of energy to the poppet actuator within the adapter, causing a spring to push the poppet back to its closed position and stopping the atomizing air flow. The paint flow can be stopped by the same signal or through a separate mechanism.

[0010] Under processor control, the atomizing air flow can be controlled with greater precision and more quickly than by a human operator, which can help speed up the paint spraying process, for example, if the spray gun is attached to a robot that can position the spray gun faster than a human operator.

[0011] The adapter of this patent application is advantageous in that it allows the gun body and other elements of a compatible manual-trigger spray gun to be used in both manual and automatic operation. This increases the versatility of the spray gun. Furthermore, an automotive paint shop no longer needs to own and operate two types of spray guns (manual and automatic) and only needs to own the manual type. The manual spray gun can be converted into an automatic spray gun by removing certain elements and inserting the adapter, and can be converted back into a manual spray gun by removing the adapter and reattaching certain elements.

[0012] Generally, all spray guns require the user to set the appropriate air pressure, shaping air balance, and paint flow rate for a specific painting job through multiple valve adjustments. These are commonly referred to as "spray gun settings." Each spray gun model typically has a different optimal setting for a painting job. When an operator switches from a manual to an automatic spray gun, these guns are typically different makes and models, so new optimal settings must be found for the automatic spray gun to achieve comparable spray results for comparable painting jobs. An essential advantage of using the same spray gun model for both manual and automatic use is that the optimal spray gun settings for a painting job identified in manual use can continue to be used in automatic use.

[0013] As used herein, the term "paint" refers to a coating material that can be applied to a surface using a spray gun system. Such coating materials include, but are not limited to, commonly understood "paints," primers, basecoats, lacquers, varnishes, and similar paint-like materials, as well as other materials such as adhesives, sealers, fillers, putties, powder coatings, blasting powders, abrasive slurries, mold release agents, and foundry finishes, which can be applied in atomized form.

[0014] As used herein, the terms "liquid" and "liquid paint" include liquids or liquid paints as defined above in which pigments, powders, granules or similar solid particles are suspended.

[0015] As used herein, "axial directions" refer to directions along the spray axis of a spray gun. Generally, the axial direction is also the length of the needle of the spray gun. Most needles are generally cylindrical between their respective tips and feet and are therefore axisymmetric about the needle axis. If the needle is axisymmetric, the axial direction is also the direction of the needle axis.

[0016] The axial direction of the gun body of a manually triggered or automatically triggerable spray gun refers to directions along and parallel to the spray axis of the gun body, which is defined by the center of the nozzle and the direction of the jet of atomized paint that emerges from the nozzle when the spray gun is in use.

[0017] In certain embodiments, the poppet is connected to a poppet actuator such that actuation of the poppet actuator causes the poppet to move linearly in the actuation direction between the closed and open positions. Linear movement facilitates more precise control of the poppet's position because its position need only be controlled in one spatial dimension.

[0018] Therefore, the linear direction of movement of the poppet is also referred to herein as the "actuation direction." The adapter may be attached to the gun body such that the actuation direction is the axial direction of the gun body. The poppet may have an elongated shape, the length of which defines the length of the poppet. If the poppet moves in its length direction, the actuation direction is also the length of the poppet. After the adapter is attached to the gun body, the length and actuation direction of the poppet may be the axial direction of the gun body.

[0019] As commonly understood in the art, a poppet, and also the poppet of the present adapter, is a valve component that moves relative to a seat. Such valves are often called poppet valves or mushroom valves. The poppet of the present adapter opens or closes (seals) the atomizing air duct in the gun body. It cooperates with an opposing surface within the gun body, which forms the seat or part of the seat of the valve.

[0020] In certain embodiments of the adapter, the sealing surface has a frustoconical profile. Thus, the sealing surface may be frustoconical or may include a frustoconical portion. A frustoconical shape in the sealing surface is advantageous in valves because it provides a well-defined abutment against the poppet and is easy to manufacture. It also helps improve the effectiveness of the seal in certain configurations, as the pressure differential forces the poppet deeper into its sealing position.

[0021] In other embodiments, the sealing surface is hemispherical or includes a hemispherical portion. The hemispherical portion can cooperate with a frustoconical counter surface because only a small portion of the sealing surface contacts the counter surface. This helps concentrate the sealing force in a small area, thereby increasing the sealing pressure. This also helps reduce the possibility of foreign matter (such as dirt, dried paint, or solidified oil) becoming trapped between the sealing surface and the counter surface and creating a leak path for atomized air.

[0022] The sealing surface may be the circumferential surface of the poppet, whether frustoconical or not. If the poppet is axisymmetric about the poppet axis, the sealing surface may be a circumferential surface that extends a full 360 degrees around the poppet axis, or a circumferential surface that extends a partial 360 degrees around the poppet axis.

[0023] However, the shape of the sealing surface is not particularly limited, for example, the sealing surface may be the radial surface of the poppet.

[0024] In certain embodiments, the poppet includes a portion comprising a resilient material, also referred to herein as the "resilient portion." The sealing surface may be the surface of this resilient portion. The mechanical properties of this resilient portion allow the resilient portion, and thus the sealing surface, to deform when the sealing surface sealingly contacts an opposing surface. This allows the sealing surface to conform to irregularities in the opposing surface. This helps prevent air leakage.

[0025] As used herein, the terms "hand-triggered spray gun," "manual spray gun," and "manually-operated spray gun" are used interchangeably unless otherwise specified. Also, as used herein, the terms "automatically-triggerable spray gun," "automatic spray gun," and "automatically-operated spray gun" are used interchangeably unless otherwise specified.

[0026] This disclosure relates to automatic and manual spray guns for spraying liquid paints. Accordingly, the term "spray gun" refers exclusively to liquid paint spray guns, and unless otherwise specified, these terms are used interchangeably herein.

[0027] A manual trigger paint spray gun as referred to in this specification is a paint spray gun that includes a trigger configured to be mechanically operated by a human hand, for example, by pulling or releasing it. The manual trigger spray gun includes a needle disposed within the gun body that is movable along its length so that its tip can move toward or away from a nozzle at the front of the spray gun.

[0028] Pulling the trigger also opens the atomizing air valve in the gun body, allowing pressurized air to flow through the atomizing air opening and into the air duct, toward the nozzle, atomizing the liquid paint exiting the nozzle. Manually operating the trigger in one direction, e.g., by manually pulling the trigger, causes the atomizing air valve to open the atomizing air opening and air duct, and the needle tip to move away from the nozzle, i.e., retract. This causes the nozzle opening's cross-sectional opening to expand as the needle tip retracts. Further trigger operation allows more atomizing air to flow, and more paint is sprayed through the enlarged nozzle opening. Similarly, manually operating the trigger in the opposite direction, e.g., by manually releasing the trigger, causes the atomizing air valve to close the atomizing air opening and air duct, and the needle tip to move toward the nozzle, i.e., advance. This causes the needle tip to narrow the cross-sectional opening of the nozzle opening, reducing the amount of atomizing air flowing and the amount of paint sprayed through the enlarged nozzle.

[0029] A manually triggered spray gun is known, for example, from International Patent Application Publication WO 2018 / 104870 A1.

[0030] In contrast to a manually triggered spray gun, an automatically triggered spray gun can be triggered by a technical system. In other words, the spraying of liquid paint through the nozzle of the automatically triggered spray gun and the flow of atomizing air toward the nozzle can be started and stopped by the technical system. In a manually triggered spray gun converted into an automatically triggered spray gun by attaching an adapter according to the present disclosure, the closed and open positions of the poppet (which determine the flow of atomizing air toward the nozzle) are achieved by automatically operating the poppet actuator.

[0031] Automatic actuation of the poppet actuator refers to actuation under the control of an automated technological system, as opposed to direct human control, i.e., direct manual or physical human control. The automated technological system for controlling actuation may be, for example, a computer, a digital processor, or an electrical or electronic circuit. A trigger present on a manually triggered spray gun for manually triggering the spray gun is not considered an automated technological system.

[0032] Through automatic operation, the poppet can be moved to a closed or open position, which seals or opens the air duct, resulting in the flow or non-flow of atomizing air, achieved under the control of an automated technological system and without the need for human intervention. A previously manually triggered spray gun becomes an automatically triggered spray gun after connecting an adapter. This spray gun can be used in automated spray systems, such as a spray robot equipped with a computer that coordinates the movement, attitude, and / or position of the support supporting the spray gun, e.g., a robotic arm, with the position of the poppet within the spray gun and the atomizing air flow rate at any given time. The position of the needle of an automatically triggered spray gun, and therefore the paint spray rate, can also be automatically controlled and coordinated with the movement, attitude, and / or position of the robotic arm supporting the spray gun.

[0033] As used herein, the term "robot" refers to any type of industrial machine, especially one that can be programmable by a computer and automatically perform a complex series of operations. Existing paint spray robots, such as those offered by Germany's Durr (durr.com), are rarely modified to operate previously manually triggered spray guns. However, many multipurpose industrial robots, such as those offered by Kuka (kuka.com), Fanuc (fanuc.eu), Yaskawa (yaskawa.com), ABB Robotics (new.abb.com), or Mitsubishi Electric (mitsubishielectric.com), can generally be utilized to support automatically triggerable paint spray guns such as those described herein.

[0034] A manual trigger spray gun includes at least a gun body having a nozzle, a sealable air duct for conducting atomizing air, and a counter surface for sealing the air duct. The nozzle may be included in a nozzle assembly, which may further include a paint inlet port for supplying liquid paint to the nozzle through the nozzle assembly. The paint inlet port may include a fluid connector for connecting the nozzle assembly to an external paint reservoir, such as a remote paint barrel via a paint hose, or to a paint cup attached directly to the nozzle assembly. The paint inlet port may include a fluid connector for directly connecting the nozzle assembly to a paint cup directly connected to the fluid inlet port of the nozzle assembly. A direct connection refers to a connection without any intervening tubes or hoses. If the paint cup's spout is mechanically connected to the fluid connector so that paint can flow from the paint cup through the spout into the paint inlet port, and then through the rest of the nozzle assembly to the nozzle, this is considered a direct connection because no intermediate tubes or hoses are involved. A connection in which a portion of the paint cup is in surface contact with a portion of the fluid connector is also generally considered a direct connection.

[0035] Thus, in certain embodiments of an automatically triggerable paint spray gun converted from a manually triggered spray gun by attaching an adapter according to the present disclosure, the gun body further includes a nozzle assembly including a nozzle, the nozzle assembly further including a liquid inlet portion for supplying liquid paint to the nozzle, the liquid inlet portion including an inlet connector for directly connecting a paint cup to the liquid inlet portion, and optionally, the automatically triggerable paint spray gun further includes a paint cup for containing liquid paint, the paint cup being directly connected to the liquid inlet portion via the inlet connector.

[0036] An auto-triggerable spray gun equipped with a direct paint cup connection can be beneficial in situations where various types of paint are expected to be sprayed, each type of paint being sprayed in small amounts. In such cases, changing from one paint cup to another can be quicker than disconnecting the spray gun from one remote paint barrel and reconnecting it to another remote paint barrel. Furthermore, the paint cup can be replaced with less labor and solvent than would be required to connect to a remote paint reservoir and clean out the hose. Therefore, an auto-triggerable spray gun equipped with a direct paint cup connection can contribute to cost and waste reduction.

[0037] The gun body may further include a gun handle portion which, prior to conversion, may facilitate handling of the spray gun by a human operator, for example, by its ergonomic shape.

[0038] Like most spray guns, the gun body includes a pressurized air channel for directing external pressurized air into the gun body, some of which is directed into an air duct that directs atomizing air toward the nozzle for atomizing the liquid paint exiting the nozzle.

[0039] The gun body, with or without a gun handle, may further include an air cap. The air cap may be operable to direct atomizing air toward the liquid paint stream exiting the nozzle. When present, the air cap may be attached to the nozzle assembly. The air cap may include one or more shaping air outlets for directing pressurized air toward the liquid paint stream as it exits the nozzle, assisting in atomizing the liquid paint and shaping the liquid paint jet into a spray pattern for the desired application. The air cap may include one or more air horns, each of which may include one or more of the shaping air outlets.

[0040] In certain embodiments, the gun body of the manual trigger spray gun is formed by a nozzle assembly including a liquid paint inlet and a nozzle, while in other embodiments, the gun body of the manual trigger spray gun includes a nozzle assembly including a liquid paint inlet and a nozzle, and a gun handle portion having a gun handle.

[0041] A manually triggered paint spray gun before conversion to an automatically triggerable paint spray gun may include a needle for controlling the amount of liquid paint sprayed. The needle may be at least partially disposed within the gun body of the manually triggered paint spray gun. The needle may be retractable from the gun nozzle to allow more liquid paint to be sprayed through the nozzle. The needle may also be advanceable toward the nozzle to allow less liquid paint to be sprayed through the nozzle.

[0042] The term "needle" as used herein refers to an elongated, thin, straight, rigid element having a needle tip at one end and a needle foot at the opposite end. In use, the needle tip is positioned near the nozzle and is suitably shaped to block the nozzle when the needle is fully advanced toward the nozzle and to gradually open the nozzle as the needle is gradually retracted from the nozzle. The elongated shape of the needle defines the axis of the needle, or synonymously, the needle axis. As used herein, "needle axis" refers to a line that passes through the needle tip and extends along the length of the needle. A needle may be axisymmetric about its needle axis.

[0043] The needle foot is included at one end of the needle, i.e., the end opposite the needle tip. In certain embodiments, the needle foot has a cylindrical shape. The axis of the cylinder is the axis of the needle. A cylindrical needle foot includes a front surface, i.e., the face of the needle foot whose surface normal is oriented parallel to the needle axis. The needle foot may also have other shapes, such as a hemispherical or concave shape.

[0044] In certain embodiments, the needle foot may have a nailhead shape, in which the radial extent of the needle foot is greater than the radial extent of the needle, or, if the needle is cylindrical, the diameter of the needle foot is greater than the diameter of the needle.

[0045] A manually triggered paint spray gun, before being converted into an automatically triggerable paint spray gun, includes a nozzle similar to the nozzle described in WO 2018 / 104870 A1. As used herein, the term "nozzle" refers to the opening in the front of the paint spray gun through which liquid paint is ejected.

[0046] The nozzle of an automatic or manual trigger paint spray gun can be gradually opened or closed by positioning the needle relative to the nozzle. When the needle advances toward the nozzle, the needle tip partially or completely obstructs the nozzle, thereby spraying less or no paint at all. When the needle retracts from the nozzle, the needle tip obstructs the nozzle less or not at all, thereby spraying more paint through the nozzle.

[0047] The adapter includes connecting means for attaching the adapter to the spray gun body.

[0048] The connecting means may be or include, for example, a thread that may engage, for example, a matching thread or bolt on the spray gun body, or a separate bolt or threaded pin for attaching the adapter to the gun body, which provides a particularly secure attachment of the adapter to the spray gun body and thereby helps to maintain a fixed spatial relationship between the two.

[0049] The connection means may be or include, for example, a press fit or an interference fit. Such a press fit or interference fit may be provided on an insert in the adapter, which may be part of the adapter designed to be inserted, for example, axially, into the spray gun body. The press fit or interference fit engages with a matching receptacle on the spray gun body to securely attach the adapter to the gun body.

[0050] The connecting means may be or include other suitable means for attaching the adapter to the gun body, such as, for example, a clip, a latch, a screw, a pin, a bayonet, a cap nut, a coupling ring, or any other suitable element.

[0051] The energy supply connector of an adapter according to the present disclosure facilitates the supply of external energy to the adapter and the spray gun body, particularly to cause the poppet actuator to move the poppet between a closed position and an open position.

[0052] In certain embodiments, the energy supply connector is a pressurized air connector. The supply of pressurized air or other pressurized gas is the supply of mechanical energy. The pressurized air can be used, for example, in combination with a piston, to move the poppet. The pressurized air can automatically actuate a poppet actuator to move the poppet. Automatic actuation can be achieved, for example, by adjusting the pressure of the pressurized air under computer control. Automatic actuation can also be achieved by switching the pressurized air pressure on or off, for example, via a computer-controlled solenoid valve.

[0053] Thus, in certain embodiments of the adapter, the poppet actuator may include a piston connected to the poppet and movable relative to the energy supply connector using mechanical or electrical energy received through the energy supply connector, such that movement of the piston moves the poppet between a sealed position and an open position. Mechanisms including pistons are commercially available and available at a reasonable cost.

[0054] As used herein, a piston is not limited to an element that slides back and forth within a cylindrical chamber. Rather, it refers to any element that is moved linearly by energy received through an energy supply connector. An element that moves linearly within a solenoid, thereby moving a poppet, or an element that is moved linearly by mechanical gears driven by an electric motor are both examples of pistons.

[0055] In certain other embodiments, the energy supply connector is an electrical connector, which facilitates the external supply of electrical energy to the adapter described herein. The supply of power, voltage, or current is the supply of electrical energy to the adapter. The electrical energy can be used, for example, in combination with a motor, pump, or solenoid included in the adapter, to move the poppet to a closed or open position. The power can automatically activate a poppet actuator to move the poppet. Automatic activation can be achieved, for example, by operating a motor connected to the poppet for a predetermined period of time under computer control. Automatic activation can also be achieved by switching power on or off, for example, via a computer-controlled relay or computer-controlled switch, to switch the relay to a different position. Automatic activation can also be achieved, for example, by increasing or decreasing the voltage or current driving a pump under the control of a computer or analog electronic or electrical circuitry, which generates a pressure differential that moves the poppet. Automatic actuation can also be achieved, for example, by increasing or decreasing the voltage or current under the control of a computer or analog electronic or electrical circuitry to drive an electromagnet or solenoid, which in turn moves the poppet.

[0056] Operation under the control of the technical system refers, for example, to the supply of mechanical or electrical energy being under the control of the technical system. In certain embodiments, the technical system can switch on or off external power supplied via the energy supply connector, with the presence or absence of power causing the poppet to move to a closed or open position. In other embodiments, the technical system can increase or decrease the voltage or current of external power supplied via the energy supply connector, with the increase or decrease in the voltage or current of the power causing the poppet to move. In other embodiments, the technical system can increase or decrease the pressure of external pressurized air supplied via the energy supply connector, with the increase or decrease in the pressure of the pressurized air causing the poppet to move. In other embodiments, the technical system can switch on or off the pressure of external pressurized air supplied via the energy supply connector, with the presence or absence of pressurized air causing the poppet to move.

[0057] Alternatively, operating under the control of a technical system may refer to, for example, a constant supply of mechanical or electrical energy, and the use of that energy in the adapter to move the poppet being under the control of the technical system. In certain embodiments, the technical system may activate a switch in the adapter to connect the motor, pump, or solenoid to a constantly externally supplied power via an energy supply connector, thereby moving the poppet. The technical system may appropriately adjust the way in which the motor, pump, or solenoid is connected to the power, for example, so that the entire externally supplied voltage or current is supplied to the motor, pump, or solenoid, thereby moving the poppet to an open or closed position. Alternatively, the technical system may adjust the way in which the motor, pump, or solenoid is connected to the power, for example, so that only a portion of the externally supplied voltage or current is supplied to the motor, pump, or solenoid, thereby moving the poppet back and forth by a predetermined amount, and accordingly, causing the air duct to be partially or completely sealed. Alternatively, the technical system may adjust the way the motor, pump or solenoid is connected to power, for example so that an externally supplied voltage or current is supplied to the motor, pump or solenoid only at intervals of a predetermined length and frequency, which may cause the poppet to move in steps.

[0058] The technical system may be included in a control system of the robot or automated spray system. The technical system may be controlled by a robot control system for controlling the robot or automated spray system. The technical system may be located within an adapter according to the present disclosure. Alternatively, it may be located external to and / or remote from the adapter.

[0059] The poppet actuator of the adapter according to the present disclosure uses energy supplied through the energy supply connector to move the poppet attached thereto. The poppet actuator is automatically actuated, and actuation of the poppet moves the poppet between a closed position and an open position. Thus, the poppet actuator is operable to move the poppet to a closed position and / or to move the poppet to an open position. The poppet actuator may be operable to move the poppet between a closed position and an open position.

[0060] In certain embodiments, the poppet actuator may be automatically actuated using mechanical or electrical energy received through the energy supply connector to move the poppet to the sealed position and tension a resilient element, such as a spring, that may be operable to move the poppet from the sealed position to the open position when no energy is supplied through the energy supply connector.

[0061] In certain embodiments, the poppet actuator may be automatically actuated using mechanical or electrical energy received through the energy supply connector to move the poppet to the open position and tension a resilient element, e.g., a spring. The tensioned resilient element may be operable to move the poppet from the open position to the closed position when no energy is supplied, e.g., through the energy supply connector.

[0062] In certain embodiments, the poppet actuator is automatically actuable using mechanical or electrical energy received through the energy supply connector and is operable to linearly move the poppet between the closed and open positions along an actuation direction.

[0063] In certain embodiments, the poppet actuator is a pneumatic poppet actuator, where mechanical energy in the form of pressurized air supplied to the poppet actuator via an energy supply connector is used to move the poppet. Movement of the poppet actuator moves the poppet, thereby closing (sealing) or opening an air duct through which the pressurized air is directed toward the nozzle.

[0064] In certain embodiments, the poppet actuator is an electric poppet actuator, where electrical energy in the form of voltage and / or current supplied to the poppet actuator via an energy supply connector is used to move the poppet between a closed position and an open position. The poppet actuator may include, for example, an electromagnet that moves to a position when energized and returns to its original position (often against a spring load) when power is removed. Movement of the electromagnet is translated into actuation of the poppet actuator, which moves the poppet.

[0065] The poppet actuator may include, for example, an electric pump. The electric pump may create a constant pressure differential in a gas or liquid. This pressure differential moves a piston or other movable element to a certain position while the pump is operating. When the pump is stopped, the element returns to its original position, for example against a spring load. The pressure differential created by the pump is thus translated into movement of the movable element, which is translated into movement of the poppet actuator and, further, into movement of the poppet.

[0066] In addition to these examples, any known mechanism for driving the movement of a piston or other movable element with mechanical or electrical energy supplied through an energy supply connector and translating it into actuation of a poppet actuator and movement of the poppet may be used.

[0067] In the manual trigger and automatic trigger spray guns described herein, a stream of pressurized air is discharged from the nozzle assembly near the nozzle to atomize the liquid paint exiting the nozzle. This "atomizing air" stream creates a jet of small paint particles. For a clear start of spray action, it is desirable for the atomizing air to begin flowing before the paint begins to flow. This sequence is often referred to as "first air." In a manual trigger spray gun, first air is achieved by squeezing the trigger a short distance, allowing only atomizing air to flow without paint flowing. Further squeezing of the trigger retracts the needle from the nozzle, thereby initiating paint flow. Further squeezing of the trigger opens the nozzle further, thereby increasing the paint flow rate.

[0068] In an automatically triggerable spray gun that has been upgraded from a manually triggered spray gun by installing an adapter according to the present disclosure, first air can be achieved by coordinating the movement of the poppet from the closed position to the open position with the retraction of the needle from the nozzle and the associated initiation of paint flow, preferably such that the needle begins to retract from the nozzle after the poppet has moved from the closed position and some atomizing air has begun to flow through the air duct toward the nozzle.

[0069] The needle may have its own independent needle actuator. Alternatively, the needle may be mechanically connected to the poppet so that movement of the poppet causes movement of the needle relative to the nozzle. The connection between the poppet and the needle avoids the need for a separate mechanism for advancing or retracting the needle independently of the poppet.

[0070] Thus, in certain embodiments of an adapter according to the present disclosure, the adapter may further include a needle positionable within the gun body with its tip positioned adjacent the nozzle, such that, in use, retracting the needle from the nozzle increases the amount of paint sprayed through the nozzle and advancing the needle toward the nozzle decreases the amount of paint sprayed through the nozzle, and further, the needle is mechanically connected to a poppet such that movement of the poppet between an open position and a closed position moves the needle.

[0071] Once the adapter is properly connected to the gun body, the poppet moves from its closed position to its open position, which moves the needle away from the nozzle, opening the nozzle and allowing paint to flow through it. Similarly, the poppet moves from its open position to its closed position, which moves the needle toward the nozzle until the tip of the needle blocks the nozzle opening, closing the nozzle and stopping paint from flowing through it.

[0072] The needle may be connected to the poppet by a design in which the foot of the needle is attached to the poppet, either by direct contact with the poppet or via an intermediate element. The sealing surface may be concentrically disposed around the portion of the poppet that contacts the needle or the intermediate element. The diameter of the needle is selected to ensure a sufficient amount of air can flow between the sealing surface and the opposing surface into the air duct.

[0073] It is often desirable to have a small initial retraction of the poppet by the poppet actuator to allow only atomizing air to flow, but not paint. Only after further retraction of the poppet does both atomizing air and paint flow be permitted. Such a mechanism is called "first air." The presence of a spring in the poppet facilitates the implementation of a simple and reliable "first air" mechanism: if the adapter includes a needle connected to the poppet as described above, the poppet may include a spring to exert an axial force on the needle to keep it urged forward (i.e., toward the nozzle when the adapter is connected to the gun body). This ensures that the tip of the needle remains blocking the nozzle even when the poppet is slightly retracted from its sealed position. This slight retraction of the poppet partially opens the atomization air duct in the gun body, so that the paint is still blocked but atomization air can flow. Further retraction of the poppet retracts the needle from the nozzle, opening it and allowing paint to flow through it.

[0074] Thus, in certain embodiments, the adapter may further include a resilient spring, the needle being elongated to define a needle length, the spring being disposed between a support portion of the poppet and a portion of the needle and configured to enable spring-biased movement of the needle relative to the poppet in the needle length direction.

[0075] In certain embodiments, an adapter according to the present disclosure may include an elongated insert configured to be inserted along its length into the gun body of a manual trigger paint spray gun. In certain embodiments, the adapter may include a cylindrical insert configured to be inserted along its axis of symmetry into the gun body of a manual trigger paint spray gun. In other embodiments, the adapter may include an insert with a non-circular cross-section configured to be inserted along the axis of symmetry of the cylindrical insert into the gun body of a manual trigger paint spray gun.

[0076] Generally, the gun body may include an adapter receptacle having a cross-sectional shape corresponding to the cross-section of the insert. Such a corresponding cross-sectional shape allows the insert to be tightly inserted into the adapter receptacle, thereby improving spatial alignment between the adapter and the gun body. When the adapter includes an insert with a non-circular cross-section and the gun body includes an adapter receptacle with a corresponding non-circular cross-section, the non-circular cross-section helps prevent the adapter from rotating relative to the gun body, facilitating a more secure attachment of the adapter to the gun body.

[0077] The presence of an insert in an adapter is generally advantageous because inserting a portion of the adapter into the gun body facilitates more secure attachment of the adapter to the gun body, and may allow for a more direct or shorter connection between the poppet actuator and a poppet advantageously located within the gun body.

[0078] In general, the insertion direction of the adapter may be along the length of the elongated insert or along the axis of symmetry of the cylindrical insert of the adapter.

[0079] The gun body of a manual trigger paint spray gun may include an adapter receptacle for receiving an adapter insert. To form the adapter receptacle, certain components of the manual trigger spray gun, such as a needle adjustment spring, a needle adjustment mechanism, a needle, or a trigger, may be removed. The adapter receptacle may have an elongated shape. The length of the elongated adapter receptacle may define a length direction of the receptacle. The adapter receptacle may have a cylindrical shape. The axis of symmetry of a cylindrical adapter receptacle may define a length direction of the receptacle. The length direction of the receptacle may be parallel to or coincident with the axial direction of the spray gun body.

[0080] The adapter according to the present disclosure can be used to convert a manually triggered spray gun into an automatically triggered spray gun. Accordingly, the present disclosure also provides an automatically triggered paint spray gun, including: a gun body including a nozzle capable of spraying liquid paint, a sealable air duct for directing pressurized air toward the nozzle for atomizing the paint, and an opposing surface for sealing the air duct; An adapter as described herein that is attached to the gun body using the connection means, wherein in a closed position, a sealing surface of a poppet cooperates with the opposing surface to block pressurized air from entering the air duct, and in an open position, the sealing surface cooperates with the opposing surface to allow pressurized air to enter the air duct.

[0081] As previously mentioned, such automatically triggerable spray guns allow for more precise control of the start and end of the spray action, which can save time, minimize paint waste, minimize pressurized air usage, reduce the risk of hazards, minimize noise, and / or minimize environmental contamination (e.g., contamination of robots that position and operate the spray gun, spray cabins, etc.).

[0082] If the poppet sealing surface has a frusto-conical shape or a portion thereof, a corresponding shape on the opposing surface of the spray gun body will improve sealing performance. A corresponding shape, i.e., a shape where the opposing surface shape is the negative of the sealing surface shape, generally improves the quality of the seal and can help distribute forces acting on the seal more evenly.

[0083] Thus, in certain embodiments of automatically triggerable spray guns according to the present disclosure, the sealing surface is frusto-conical or includes a frusto-conical portion, and the opposing surface has a corresponding frusto-conical portion for sealing contact with said sealing surface to block pressurized air from entering the air duct when the poppet is in the sealing position.

[0084] In other embodiments, the sealing surface is hemispherical or includes a hemispherical portion, and the opposing surface has a corresponding hemispherical portion for sealing contact with said sealing surface to block pressurized air from entering the air duct when the poppet is in the sealing position.

[0085] The sealing performance of the atomized air duct may be improved if the sealing surface and the opposing surface have different shapes rather than corresponding shapes. In a particularly preferred embodiment, the sealing surface is hemispherical or includes a hemispherical portion, and the opposing surface has a frustoconical portion for sealing contact with the sealing surface to block pressurized air from entering the air duct when the poppet is in the sealing position. This shape combination may help reduce the likelihood that debris (such as dirt, dried paint, or solidified oil) will become trapped between the sealing surface and the opposing surface, creating a leakage path for atomized air.

[0086] An automatically triggerable spray gun converted by installing an adapter according to the present disclosure may have better lateral balance, be more compact, and have a slimmer side profile if the poppet moves parallel to the spray axis, i.e., in the front-to-back direction of the spray gun.

[0087] Thus, in certain embodiments of an automatically triggerable spray gun, the spray gun is capable of spraying a jet of atomized paint along a spray axis, the poppet is connected to a poppet actuator, actuation of the poppet actuator moves the poppet linearly along an actuation direction between a closed position and an open position, and the adapter is positioned so that the actuation direction is parallel to the spray axis.

[0088] Preferably, after conversion, the poppet is positioned in the gun body so that its length axis is collinear (coaxial) with the spray axis, which allows for a more axisymmetric design of the spray gun, which potentially allows for a shorter flow path for the pressurized air.

[0089] In certain embodiments of the converted auto-triggerable spray gun, the poppet is rotationally symmetric about a poppet axis that is parallel to the actuation direction and collinear (coaxial) with the spray axis.

[0090] When this disclosure refers to a position "behind the needle," it means a position below the needle foot when the needle tip is considered to be located above the needle foot. Also, when this disclosure refers to a position "rearward from the needle foot," it means a position when the needle tip is considered to be located in front of the needle foot, with "rearward" meaning the opposite direction from "front."

[0091] Locating the poppet actuator behind the needle can help save lateral space and minimize the lateral profile of the automatically triggerable paint spray gun. If the poppet actuator moves the poppet and the needle, this arrangement may allow for coaxial movement of the poppet and the needle. Coaxial transmission of force can allow for a simpler mechanical design.

[0092] Thus, in certain embodiments of an automatically triggerable paint spray gun that has been upgraded from a manually triggered spray gun by attaching an adapter according to the present disclosure, the spray gun further comprises a needle, the needle being elongated to define a needle length, the needle extending rearward in the needle length direction from a tip end to a needle foot, the needle being positioned within the gun body such that the tip end is located near the nozzle, in use, retracting the needle from the nozzle increases the amount of paint sprayed through the nozzle, and advancing the needle towards the nozzle decreases the amount of paint sprayed through the nozzle, and a poppet actuator is positioned rearward of the needle foot in the needle length direction.

[0093] A manually triggered paint spray gun can be converted into an automatically triggerable paint spray gun by attaching an adapter according to the present disclosure, which conversion may include, potentially among other steps, removing an existing atomizing air valve that was operated by manually operating a trigger and replacing it with an automatically triggerable poppet included in the adapter of the present disclosure, and attaching the adapter to the gun body so that when the poppet is in an open position, it allows pressurized air to flow into the air duct and when the poppet is in a closed position, it blocks pressurized air from flowing into the air duct.

[0094] This process may also include removing any manual triggers that are no longer needed.

[0095] Accordingly, the present disclosure also provides a method for converting a manually triggered paint spray gun into an automatically triggerable paint spray gun, the method including: To provide a manual trigger paint spray gun comprising: a) a gun body including a nozzle capable of spraying liquid paint, a sealable air duct that directs pressurized air toward the nozzle for atomizing the paint, an opposing surface for sealing the air duct, and an atomizing air valve that cooperates with the opposing surface to open or close the air duct; b) a trigger mechanically connected to the atomizing air valve and configured to open the air duct when manually pulled; providing an adapter as described herein; removing said atomization air valve; The adapter is attached to the gun body using a connecting means, whereby the sealing surface of the poppet cooperates with the opposing surface in the closed position to block the flow of pressurized air into the air duct, and cooperates with the opposing surface in the open position to allow the flow of pressurized air into the air duct.

[0096] The result of this method is an automatically triggerable paint spray gun in which the flow of atomizing air is automatically triggered by movement of the poppet between a closed position and an open position, the movement being automatically triggered by automatically actuating the poppet actuator with energy supplied through the energy supply connector of the adapter.

[0097] In the automatically triggerable paint spray gun obtained by the above method, the trigger has no function, so it is advantageous to remove the trigger, and the space that the trigger occupied becomes available, which can be used, for example, to attach the spray gun to a robot arm.

[0098] In certain embodiments of the above-described method, the method may further include removing the trigger from the manually triggered spray gun. Removing the trigger may be performed, for example, before attaching the adapter to the gun body. Removing the trigger may also be performed, for example, before or after removing the atomizing air valve.

[0099] After conversion, atomizing air triggering in the automatically triggerable spray gun is controlled solely by the adapter and its poppet actuator, and the needle adjustment control knob is no longer needed. Removing the needle adjustment control knob is advantageous because it potentially frees up the passageway formerly occupied by the needle adjustment control knob, which now leads into the gun body, into which the adapter's insert can be inserted.

[0100] Thus, in certain embodiments of the above-described method, providing the manual trigger paint spray gun may further include: c) providing a manually triggered paint spray gun with a control knob for adjusting the needle; And the method may further include removing a needle adjustment control knob from the manual trigger spray gun.

[0101] Inserting the adapter into the gun body can be advantageous because an adapter inserted into the gun body generally attaches more securely to the gun body, and inserting it into the gun body toward the opposite side of the air duct can help shorten the distance between the poppet and poppet actuator, resulting in a shorter, and therefore more reliable and less costly, connection between these two elements.

[0102] Thus, in certain embodiments of the above-described methods, attaching the adapter to the gun body may include inserting a portion of the adapter, for example an insert portion of the adapter, into the gun body.

[0103] The present invention will now be described in more detail by way of example of specific embodiments with reference to the following drawings, in which like reference numerals refer to like elements, and in which: [Brief explanation of the drawings]

[0104] [Figure 1] FIG. 1 is a perspective view of a manual trigger paint spray gun before conversion.

[0105] [Figure 2] FIG. 2 is a perspective exploded view of certain elements of the spray gun of FIG.

[0106] [Figure 3] 3 is a perspective view of the gun body of the spray gun of FIG. 1. FIG.

[0107] [Figure 4] FIG. 4 is a cross-sectional view of the gun body of FIG.

[0108] [Figure 5] 5 is a cross-sectional view of the gun body of FIG. 3 and a poppet of an adapter according to the present disclosure in an open position.

[0109] [Figure 6] 6 is a cross-sectional view of the gun body of FIG. 3 and the poppet of FIG. 5 in a closed position.

[0110] [Figure 7] FIG. 7 is a perspective view of a first adapter according to the present disclosure.

[0111] [Figure 8] FIG. 8 is a perspective view of a second adapter according to the present disclosure.

[0112] [Figure 9] 9 is a cross-sectional view of the poppet of the second adapter of FIG. 8. FIG.

[0113] [Figure 10] 10 is a perspective view of the gun body of FIG. 3 and the second adapter of FIG. 8 before the adapter is attached to the gun body.

[0114] [Figure 11] 11 is a cross-sectional view of an automatically triggerable paint spray gun obtained by attaching the second adapter of FIG. 8 to the gun body of FIG. 3. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0115] 1 is a perspective view of an exemplary manually triggered paint spray gun 10 before being converted to an automatically triggerable spray gun using an adapter according to the present disclosure. The paint spray gun 10 includes a gun handle 50, a trigger 30, an air connection 40 for an external pressurized air source, a needle 20 (not shown in FIG. 1), a needle adjustment control knob 60, a shaping air control knob 70, a spray gun nozzle assembly 80, and an air cap 90. The nozzle assembly 80 includes a nozzle 130 through which liquid paint is discharged from the spray gun 10 and a liquid paint connector 100 at the end of a liquid supply 110 through which liquid paint is supplied to the spray gun 10 from an external paint reservoir 120, i.e., a paint cup 120 attached directly to the nozzle assembly 80 via the liquid paint connector 100.

[0116] A human operator can hold the spray gun 10 by the gun handle portion 50 and manually pull the trigger 30 to retract the needle 20 within the spray gun 10 from the nozzle 130, allowing pressurized air and paint to be expelled from the spray gun 10 at the nozzle 130 in a direction generally along the spray axis 140.

[0117] The spray axis 140 is oriented along the length of the needle 20, as will be apparent from the description of Figure 2. The length of the needle 20 is also the direction of movement of the needle 20 when it is advanced or retracted using the trigger 30. The spray axis 140 defines an axial direction 142 and an orthogonal radial direction 144.

[0118] When trigger 30 is pulled, needle 20 is withdrawn from nozzle 130, thereby allowing liquid paint to pass through nozzle 130. Simultaneously, pulling trigger 30 activates pressurized air supplied through air connection 40 to assist in passing the liquid paint through nozzle 130. Some of the air is used to atomize the liquid paint ("atomizing air"), and some of the air ("shaping air") is used to form a jet of paint particles (e.g., via air cap 90). The maximum travel of needle 20 and the overall air flow rate through spray gun 10 are adjusted via needle adjustment control knob 60.

[0119] Shaping air control knob 70 adjusts the amount of shaping air discharged through an air cap 90 attached to the front of nozzle assembly 80. Air cap 90 advantageously directs pressurized air toward the atomized liquid paint jet, for example, via shaping air outlets 150 located on two opposing air horns 160. As paint exits nozzle 130, atomizing air discharged from air cap 90 assists in atomizing the liquid paint and shaping the paint jet into the desired spray pattern. A central air outlet (not shown in FIG. 1 ) is located within or near air cap 90 and directs atomizing air around nozzle 130 to draw liquid paint from nozzle 130 and atomize it, producing a fine mist of droplets.

[0120] 1 into an automatically triggerable spray gun by attaching an adapter according to the present disclosure to the gun body, certain components of the manual trigger spray gun 10, such as the trigger 30 and the needle adjustment control knob 60, are removed from the manual trigger spray gun 10. The portion of the manual trigger spray gun 10 that remains after these components are removed is referred to as the "gun body" and is illustrated in FIG.

[0121] Figure 2 shows in more detail, in a perspective exploded view, the needle 20, nozzle assembly 80, and air cap 90 of the manual trigger paint spray gun 10 of Figure 1. The air cap 90 is attached to the nozzle assembly 80. In the assembled state, the nozzle 130 is surrounded by a central air outlet 170 of the air cap 90. Atomizing air discharged from the central air outlet 170 atomizes the liquid paint discharged through the nozzle 130.

[0122] Liquid paint connector 100 is designed to mate with a corresponding connector on a liquid paint reservoir 120, such as the gravity-fed spray gun paint cup 120 shown in Figure 1. Liquid paint from reservoir 120 flows through liquid supply 110 to nozzle 130, where the paint is atomized and sprayed.

[0123] The needle 20 extends along a needle length 430 and includes a needle tip 22 at its forward end and a needle foot 25 at its opposite end. In this embodiment, the needle foot 25 has a larger diameter than the remainder of the needle 20. In other embodiments, the needle foot may be the same diameter as the remainder of the needle. As is typical, the needle 20 is oriented with its length 430 parallel to the spray axis 140 and extends through the gun handle 50 and nozzle assembly 80 to the nozzle 130. When the needle 20 is retracted, i.e., moved rearward away from the nozzle 130, the nozzle 130 opens, liquid paint is expelled through the nozzle 130, and pressurized air is expelled through the central air outlet 170 (to atomize the liquid paint) and the shaping air outlet 150 (to shape the spray pattern), creating a shaped jet of paint particles. When trigger 30 (shown in FIG. 1) is not depressed and is fully advanced, i.e., moving forward toward nozzle 130, the air duct (not shown in FIGS. 1 and 2) that directs pressurized air toward nozzle 130 is blocked, thereby preventing atomizing air from flowing through central air outlet 170. In this position of trigger 30, tip 22 of needle 20 blocks nozzle 130, thereby stopping paint flow.

[0124] Figure 3 shows a side view of the gun body 180 of the manual trigger spray gun 10 of Figure 1. The needle 20, trigger 30, needle adjustment control knob 60, atomization air valve (not shown), and other elements have been removed from the manual trigger spray gun 10 shown in Figure 1. The portion of the manual trigger spray gun 10 that remains after these elements have been removed forms the gun body 180.

[0125] In the preferred embodiment shown in Figure 3, the gun body 180 includes the nozzle assembly 80 with the nozzle 130 (not shown in Figure 3), the air cap 90, the gun handle 50, the shaping air control knob 70, the fluid supply 110, the fluid paint connector 100, and the external paint reservoir 120. The needle 20 is removed and therefore not included in the gun body 180.

[0126] In the embodiment of FIG. 3, the gun body 180 includes the nozzle assembly 80 and the air cap 90, but does not include the trigger 30. In other embodiments, the gun body may include fewer elements than the gun body 180 of FIG. 3. The gun body may include a liquid supply 110 and may not include the gun handle 50. In a minimum configuration, the gun body includes a nozzle assembly 80 having a nozzle 130 for spraying a supply of liquid paint. In a minimum configuration, the nozzle assembly 80 may include a liquid supply 110 with a liquid paint connector 100 for connecting to an external paint reservoir 120 from which liquid paint can be supplied to the nozzle assembly 80. In a minimum configuration, the nozzle assembly 80 may include a liquid supply 110 with a liquid paint connector 100 for connecting directly to an external paint cup 120 from which liquid paint can be supplied to the nozzle assembly 80, without the use of hoses or tubing.

[0127] The threaded holes 190 in the gun body 180 are for receiving screws for attaching an adapter according to the present disclosure to the gun body 180. The threaded holes 190 may already be present in the gun body 180 prior to conversion to an auto-triggerable spray gun, or may be newly created in preparation for the conversion.

[0128] Figure 4 is a cross-sectional view of the gun body 180 of Figure 3 after removal of the needle 20, trigger 30, needle adjustment control knob 60, air valve, and other components, but before installation of an adapter according to the present disclosure. Pressurized air enters through air channel 45 and is divided into atomizing air and shaping air. The shaping air passes through valve 75, which can be shut off by shaping air control knob 70, and is directed through shaping air duct 77 to shaping air outlet 150 in air cap 90. Not all portions of the shaping air duct are visible in Figure 4.

[0129] Atomizing air flows through atomizing air opening 85, which may be blocked or sealed by poppet 300 of an adapter according to the present disclosure (described below), and into atomizing air duct 87. Atomizing air duct 87 directs the atomizing air to nozzle 130, through atomizing air passages 169 in air cap 90 and central air outlet 170 located near nozzle 130, and out through air cap 90 to atomize the liquid paint.

[0130] An elongated space 410 within the gun body 180 was occupied by the needle 20 of the manually triggered spray gun 10, but this space was freed by removing the needle 20 in preparation for conversion to an automatically triggerable spray gun 15.

[0131] Rearward of the atomizing air opening 85 (i.e., away from the nozzle 130), the gun body 180 defines an adapter receptacle 400 that can receive a portion of the first adapter 1 of FIG. 7 or the second adapter 2 of FIG. 8. Part of this space was previously occupied by the needle adjustment control knob 60, spring, and part of the original needle of the manually triggered spray gun 10. These components were removed in preparation for converting the manually triggered spray gun 10 into an automatically triggerable spray gun 15.

[0132] Figure 5 is a cross-sectional view of the atomizing air opening 85 of the gun body 180 of Figure 4 and a poppet 300 of an adapter 1 according to the present disclosure. The poppet 300 is rotationally symmetrical and has a frustoconical sealing surface 370 surrounding its front surface 380. The poppet 300 is shown in an open position, allowing atomizing air supplied from the air channel 45 to pass between the sealing surface 370 and a corresponding opposing surface 390 of the atomizing air duct 87 of the gun body 180 and into the atomizing air duct 87.

[0133] Figure 6 is a further cross-sectional view of the atomizing air opening 85 and poppet 300 of the gun body 180 of Figures 4 and 5, showing the poppet 300 in a sealed position. In this position, the sealing surface 370 of the poppet 300 is in intimate contact with the opposing surface 390. In this position, atomizing air supplied from the air channel 45 is prevented from flowing between the sealing surface 370 and the opposing surface 390 and into the atomizing air duct 87.

[0134] Figure 7 is a perspective view of a first adapter 1 according to the present disclosure. The adapter 1 has an elongated shape and includes radial threads 200 for attaching the adapter 1 to the gun body 180 of Figures 3 and 4. A screw can be pushed through the threaded hole 190 in the gun body 180 shown in Figure 3 to engage the threads 200 and attach the adapter 1 to the gun body 180. The threads 200 are a connecting means 200 for attaching the adapter 1 to the gun body 180.

[0135] The adapter 1 further comprises a first energy supply connector 210 and a second energy supply connector 220 for connecting the adapter 1 to a source of mechanical energy. In the embodiment of Figure 7, the energy supply connectors 210, 220 are pressurized air connectors 210, 220 for connecting the adapter 1 to a source of pressurized air. The pressurized air supply is a mechanical energy supply.

[0136] The adapter 1 further includes a poppet actuator 230 that is automatically operable to move the poppet 300 between a closed position and an open position along an actuation direction 420 relative to the energy supply connectors 210, 220. The poppet actuator 230 moves the poppet 300 using mechanical energy received through the energy supply connectors 210, 220. The actuation direction 420 is oriented parallel to the length of the elongated adapter 1. As shown in FIG. 11 , in the closed position after the adapter 1 is attached to the gun body 180, the frustoconical sealing surface 370 cooperates with the opposing surface 390 of the air duct 87 to seal the air duct 87 and prevent pressurized air from entering the air duct 87, as shown in FIG. 6 .

[0137] The closed position of the poppet 300 is the forward position of the poppet 300 in which the poppet actuator 230 pushes the poppet 300 away from the energy supply connectors 210, 220 along the actuation direction 420. The open position of the poppet 300 is the retracted position of the poppet 300 in which the poppet actuator 230 retracts the poppet 300 toward the energy supply connectors 210, 220 along the actuation direction 420.

[0138] To convert the manually triggered spray gun 10 of FIG. 1 into the automatically triggerable spray gun 15 of FIG. 11, the insert portion 245 of the adapter 1 is inserted into the adapter receiving portion 400 of the gun body 180 of FIG. 4 up to the shoulder 240.

[0139] When the adapter 1 is attached to the gun body 180, the first adapter 1 enables automatic control of atomizing air in an automatically triggerable spray gun 15. A separate mechanism is required to automatically control the position of the needle 20 relative to the nozzle 130, thereby regulating the amount of paint sprayed through the nozzle 130. However, in one embodiment, the adapter includes a needle that is connected to a poppet 300 and configured to advance and retract as the poppet actuator 230 moves the poppet 300 between its closed and open positions.

[0140] Figure 8 shows such an embodiment of an adapter according to the present disclosure. This second adapter 2 is shown in perspective view. The second adapter 2 is identical to the first adapter 1 of Figure 7, except for the addition of an additional needle 21, which is attached to a second, slightly different poppet 301.

[0141] The second poppet 301 of the second adapter 2 includes a frustoconical sealing surface 370, similar to the first poppet 300 of the first adapter 1 of Figure 7. The poppet 301 is a two-part poppet 301, including a recess and a spring (not shown) for providing a spring bias to the needle 21. The second poppet 301 is shown in cross section in Figure 9.

[0142] To improve sealing performance, sealing surface 370 is a surface of a resilient material that is slightly deformable when pressed against opposing surface 390, thereby conforming to any irregularities in opposing surface 390 and helping to prevent leakage.

[0143] FIG. 9 is a cross-sectional view of the second poppet 301 and needle 21 of the second adapter 2 of FIG. 8. The needle 21 is in contact with the second poppet 301 and is connected to the substantially rotationally symmetric poppet 301. This connection is made via the nail-head-shaped foot 25 of the needle 21, which is received in a cylindrical recess 320 in the poppet 301. A spring 330 is also disposed within the recess 320. In addition to the frustoconical sealing surface 370, the poppet 301 has an elongated, rotationally symmetric tubular forward extension 315 that defines a tubular passage 310 for receiving a portion of the needle 21 adjacent the needle foot 25. The needle 21 is longitudinally movable within the poppet 301.

[0144] The outer surface of the tubular forward extension 315 may make sealing contact with a corresponding surface of the gun body 180 when the poppet 301 is in the retracted position. In some embodiments, an actual seal may be provided within the gun body 180.

[0145] The second poppet 301 has a locking thread 340 at its rear end that engages with a corresponding thread on the front end of the elongated rearward extension member 290. The stainless steel rearward extension member 290 connects the poppet 301 to the poppet actuator 230 (the poppet actuator 230 is not shown in FIG. 9 ). The locking thread 340 is located within a cylindrical recess 320 in the poppet 301. The rearward extension member 290 and the poppet 301 are rigidly connected via the locking thread 340, and a spring 330 is positioned under slight compression between the support portion 295 of the rearward extension member 290 and the needle foot 25, biasing the needle foot 25 away from the support portion 295. The needle foot 25 is securely connected to the poppet actuator 230 because the rearward extension member 290 and the poppet 301 are securely connected to the poppet actuator 230.

[0146] In another embodiment, not shown in FIG. 9, the connection between poppet 301 and rearward extension member 290 includes a sealing surface to prevent pressurized air from entering recess 320 and escaping through passage 310.

[0147] The second poppet 301 has a shoulder 350 between the passage 310 and the recess 320 that can abut against the nail-head-shaped needle foot 25, thereby retracting the needle foot 25 rearward and retracting the needle 21.

[0148] The closed position of the second poppet 301 is a forward position of the poppet 301 in which the poppet actuator 230 pushes the poppet 301 away from the energy supply connectors 210, 220 via the rear extension member 290. The open position of the poppet 301 is a retracted position of the poppet 301 in which the poppet actuator 230 pulls the poppet 301 back towards the energy supply connectors 210, 220 via the rear extension member 290.

[0149] 4-6, after adapter 2 is attached to gun body 180, when poppet 301 is in the sealing position such that needle 21 is fully advanced toward nozzle 130, blocking nozzle 130, sealing surface 370 of poppet 301 makes sealing contact with opposing surface 390 within gun body 180, sealing atomizing air duct 87. This sealing surface 370 blocks pressurized air from flowing toward or through air cap 90 when needle 21 is fully advanced.

[0150] In the second poppet 301, the sealing surface 370 is also a surface of a resilient material that can deform slightly when pressed against the opposing surface 390. This helps prevent leakage by conforming to any irregularities in the opposing surface 390 when the poppet 301 is in the sealing position.

[0151] Similarly, when the poppet 301 is in the fully open position, thereby causing the needle 21 to be fully retracted from the nozzle 130 and the nozzle 130 to be open, the sealing surface 370 of the poppet 301 is not in contact with the opposing surface 390 in the gun body 180, and therefore atomizing air can flow between the sealing surface 370 and the opposing surface 390 into the atomizing air duct 87 and out the central air outlet 170 in the air cap 90. The poppet 301, in cooperation with the opposing surface 390, thereby permits pressurized air to enter the air duct 87. Thus, moving the poppet 301 to the open position has the dual effect of initiating the flow of atomizing air into the air duct 87 and retracting the needle 21, thereby initiating paint flow through the nozzle 130.

[0152] Poppet 301 is a separate, independent part that is shaped to fit over a compatible needle 21 from the top, with foot 25 of the needle 21 received within recess 320.

[0153] The spring 330 allows the needle foot 25 to move axially within the recess 320 against the spring force. Before the second adapter 2 is attached to the gun body 180, the spring 330 pushes the needle 21 fully forward, away from the rearward extension 290, until the needle foot 25 contacts the shoulder 350 of the poppet 301. This arrangement is shown in FIG.

[0154] When the second adapter 2 is inserted into and attached to the gun body 180, the nozzle 130 contacts the needle tip 22 and pushes the needle tip 22 backward against the force of the spring 330. As a result, the needle foot 25 no longer abuts against the shoulder 350 of the poppet 301. The needle tip 22 still blocks the nozzle 130, and the sealing surface 370 of the poppet 301 still contacts the opposing surface 390 of the gun body 180, closing the air duct 87, so atomizing air does not flow and paint is not sprayed.

[0155] When the poppet actuator 230 automatically retracts the poppet 301 slightly from its closed position, the sealing surface 370 of the poppet 301 opens the air duct 87 in the gun body 180, allowing pressurized air to enter the automatically triggerable paint spray gun 15 through the air connection 40, the air opening 85, the atomizing air duct 87, the nozzle assembly 80, into the air cap 90, and through the central air outlet 170. However, the tip 22 of the needle 21 continues to be pressed against the nozzle 130 by the slightly expanded spring 330, blocking the flow of paint. Therefore, when the poppet 301 initially retracts slightly, atomizing air begins to flow, but paint is not yet sprayed. This clears the atomizing air path of the automatically triggerable paint spray gun 15, ensuring sufficient atomizing air to atomize the paint and preventing large droplets of non-atomized paint from adhering to the workpiece.

[0156] As poppet 301 is further retracted toward its fully open position, shoulder 350 of poppet 301 again abuts needle foot 25. Thus, needle 21 is retracted from nozzle 130 approximately the same distance as poppet 301 was further retracted. This causes needle tip 22 to retract from nozzle 130, clearing the way for a constant flow of liquid paint to be sprayed from paint reservoir 120 into nozzle assembly 80 and through nozzle 130. Atomizing air and paint flow together.

[0157] 10 shows a perspective view of the gun body 180 of FIG. 3 and the second adapter 2 of FIG. 9 before the front of the adapter 2 is inserted into the gun body 180. The insertion direction is an axial direction 142 that is parallel to the actuation direction 420, parallel to the length direction 430 of the needle 21, and parallel to the spray axis 140.

[0158] Figure 11 shows, in a schematic cross-sectional view, the second adapter 2 of Figure 8 inserted into the gun body 180 of Figure 3. The insertion portion 245 is fully inserted into the adapter receptacle 400, the adapter 2 is attached to the gun body 180 with the shoulder 240 abutting the edge of the adapter receptacle 400, and the tip 22 of the needle 21 closing the nozzle 130. By inserting the adapter 2 into the adapter receptacle 400 and then attaching it to the gun body 180, the conversion of the previously manually triggered spray gun 10 into an automatically triggerable spray gun 15 is essentially complete.

[0159] As can be seen in FIG. 11 , in this embodiment, the poppet actuator 230 includes a piston 260 that is movable back and forth along the actuation direction 420 of the poppet 301 (which is parallel to the spray axis 140). The piston 260 is moved within a cylinder 270 by pressurized air supplied to both sides of the piston 260 through the energy supply connectors 210, 220. When the air pressure of the pressurized air supply connected to the first supply connector 210 is higher than the air pressure of the pressurized air supply connected to the second supply connector 220, the piston 260 moves rearward, i.e., away from the nozzle 130, to a retracted position, thereby moving the poppet 301 to an open position. Similarly, when the air pressure of the pressurized air supply connected to the second supply connector 220 is higher than the air pressure of the pressurized air supply connected to the first supply connector 210, the piston 260 moves forward, i.e., toward the nozzle 130, to an advanced position, thereby moving the poppet 301 to a sealing position. Depending on the precise control of the pressurized air, piston 260 can also assume intermediate positions by moving it via a pressure differential and holding it at a desired intermediate position by applying equal air pressure to both sides of piston 260. Figure 11 shows piston 260 in its fully extended position.

[0160] The desired air pressure at the first and second air supply connectors 210, 220 can be obtained automatically by opening or closing (partially or fully) one or more automated, digitally controlled valves connected within the respective pressurized air supply hoses, or alternatively, by operating an automated, digitally controlled air pump that supplies pressurized air at the desired pressure level to the first and second air supply connectors 210, 220. This allows the piston 260 to move back and forth in an automatic, digitally controlled manner.

[0161] The piston 260 of the poppet actuator 230 is mechanically connected to the foot 25 of the needle 21 via a rearward extension 290 that extends along the spray axis 140. When the piston 260 moves to its fully retracted position, it pulls the poppet 301 and needle foot 25 together via the rearward extension 290, thereby retracting the needle 21 from the nozzle 130. This causes the maximum amount of paint to be sprayed through the nozzle 130 during use. Similarly, when the piston 260 moves to its fully forward position, it pushes the poppet 301 and needle foot 25 together via the rearward extension 290, thereby advancing the needle 21 toward the nozzle 130, causing the needle tip 22 to block the nozzle 130. This results in paint no longer being sprayed through the nozzle 130. Intermediate positions of the piston 260 correspond to partial blockage of the nozzle 130 by the needle tip 22 and intermediate amounts of paint being sprayed through the nozzle 130. By automatically operating the piston 260 of the poppet actuator 230, the needle 21 is automatically retracted or advanced, thereby automatically adjusting the amount of paint sprayed.

Claims

1. An adapter (1, 2) for converting a manually triggered paint spray gun (10) into an automatically triggered paint spray gun (15), wherein the manually triggered spray gun (10) comprises a gun body (180) having a nozzle (130) capable of spraying liquid paint, a sealable air duct (87) for directing pressurized air toward the nozzle (130) for atomizing the paint, and an opposing surface (390) for sealing the air duct (87); The adapter (1) a connecting means (200) for attaching the adapter (1, 2) to the gun body (180); an energy supply connector (210, 220) for receiving mechanical or electrical energy from the adapter; a poppet actuator (230) that is automatically actuable using mechanical or electrical energy received through the energy supply connectors (210, 220); a poppet (300, 301) connected to the poppet actuator (230) and movable between a closed position and an open position by actuation of the poppet actuator (230); Equipped with After the adapter (1, 2) is attached to the gun body (180), the poppets (300, 301) cooperate with the opposing surface (390) to block the flow of pressurized air into the air duct (87) in the closed position, and the poppets (300, 301) cooperate with the opposing surface (390) to allow the flow of pressurized air into the air duct (87) in the open position; The poppets (300, 301) have a sealing surface (370) that comes into close contact with the opposing surface (390) of the air duct (87) when in the sealed position, thereby blocking the inflow of pressurized air into the air duct (87).

2. 2. The adapter (1, 2) of claim 1, wherein the poppet (300, 301) is connected to the poppet actuator (230) and configured such that actuation of the poppet actuator (230) causes the poppet (300, 301) to move linearly along an actuation direction (420) between the closed position and the open position.

3. 3. An adapter (1, 2) according to claim 1 or 2, wherein the sealing surface (370) is frustoconical or includes a frustoconical portion, or is hemispherical or includes a hemispherical portion.

4. the adapter (2) further comprises a needle (21), the needle (21) being positionable within the gun body (180), the tip (22) of the needle (21) being positioned near the nozzle (130), and configured such that, in use, retracting the needle (21) from the nozzle (130) increases the amount of paint sprayed through the nozzle (130), and advancing the needle (21) toward the nozzle (130) decreases the amount of paint sprayed through the nozzle (130); The adapter (2) according to any one of claims 1 to 3, wherein the needle (21) is mechanically connected to the poppet (301), and the needle (21) moves as the poppet (301) moves between the open position and the closed position.

5. The adapter (2) further comprises a resilient spring (330); 5. The adapter (2) of claim 4, wherein the needle (21) is elongated to define a needle length direction (430), and the spring (330) is disposed between a support portion (295) of the poppet (301) and a portion (25) of the needle (21) to enable spring-biased movement of the needle (21) relative to the poppet (301) in the needle length direction (430).

6. 6. The adapter (1, 2) of claim 1, wherein the poppet actuator (230) includes a piston (260), the piston (260) is connected to the poppet (300, 301), and is movable relative to the energy supply connector (210, 220) using mechanical or electrical energy received through the energy supply connector (210, 220), and movement of the piston (260) moves the poppet (300, 301) between the closed position and the open position.

7. An automatically triggerable paint spray gun (15), a gun body (180) having a nozzle (130) capable of spraying liquid paint, a sealable air duct (87) for directing pressurized air toward the nozzle (130) for atomizing the paint, and an opposing surface (390) for sealing the air duct (87); an automatically triggerable painting spray gun (15) in which the adapter (1, 2) according to any one of claims 1 to 6 is attached to the gun body (180) using the connection means (200), and in the closed position, the sealing surface (370) of the poppet (300, 301) cooperates with the opposing surface (390) to block the flow of pressurized air into the air duct (87), and in the open position, the sealing surface (370) cooperates with the opposing surface (390) to allow the flow of pressurized air into the air duct (87).

8. 8. The automatically triggerable paint spray gun (15) of claim 7, wherein the sealing surface (370) is hemispherical or includes a hemispherical portion, and the opposing surface (390) has a frustoconical portion configured to be in intimate contact with the sealing surface (370) to block the flow of pressurized air into the air duct (87) when the poppet (300, 301) is in the sealing position.

9. the spray gun (15) is capable of spraying a jet of atomized paint along a spray axis (140); 9. The automatically triggerable paint spray gun (15) of claim 7 or 8, wherein the poppet (300, 301) is connected to the poppet actuator (230), and actuation of the poppet actuator (230) causes the poppet (300, 301) to move linearly along an actuation direction (420) between the closed position and the open position, and the adapter (1, 2) is positioned such that the actuation direction (420) is parallel to the spray axis (140).

10. 10. The automatically triggerable paint spray gun (15) of claim 9, wherein the poppet (300, 301) is rotationally symmetric about a poppet axis, the poppet axis is parallel to the actuation direction (420), and the poppet axis is collinear with the spray axis (140).

11. the gun body (180) further comprises a nozzle assembly (80) comprising the nozzle (130); the nozzle assembly (80) further comprising a liquid inlet (110) for supplying liquid paint to the nozzle (130); the liquid inlet portion (110) comprises an inlet connector (100) for directly connecting a paint cup (120) to the liquid inlet portion (110); 11. The automatically triggerable paint spray gun (15) of any one of claims 7 to 10, optionally further comprising a paint cup (120) for containing liquid paint, the paint cup (120) being directly connected to the liquid inlet portion (110) via the inlet connector (100).

12. The spray gun (15) further comprises a needle (21); The needle (21) is formed to be elongated so as to define a needle length direction (430), and the needle (21) extends rearward along the needle length direction (430) from a tip end (22) toward a needle foot (25) at a rear end, The needle (21) is disposed in the gun body (180) such that the tip (22) is disposed near the nozzle (130), and in use, by retracting the needle (21) from the nozzle (130), the amount of paint sprayed through the nozzle (130) increases, and by advancing the needle (21) toward the nozzle (130), the amount of paint sprayed through the nozzle (130) decreases; The automatically triggerable paint spray gun (15) according to any one of claims 7 to 11, wherein the poppet actuator (230) is positioned rearward of the needle foot (25) in the needle length direction (430).

13. 1. A method for converting a manually triggered paint spray gun (10) into an automatically triggerable paint spray gun (15), the method comprising: To provide a manual trigger type paint spray gun (10), the manual trigger type paint spray gun (10) comprising: a) a gun body (180) including a nozzle (130) capable of spraying liquid paint, a sealable air duct (87) for directing pressurized air toward the nozzle (130) to atomize the paint, an opposing surface (390) for sealing the air duct (87), and an atomization air valve that cooperates with the opposing surface (390) to open or close the air duct (87); b) a trigger (30) mechanically connected to the atomizing air valve, which is manually pulled to open the air duct (87); providing a manually triggered paint spray gun (10) having: Providing an adapter (1, 2) according to any one of claims 1 to 6; removing the atomization air valve; attaching the adapter (1, 2) to the gun body (180) using the connecting means (200), so that in the closed position, the sealing surface (370) of the poppet (300, 301) cooperates with the opposing surface (390) to block the inflow of pressurized air into the air duct (87), and in the open position, the sealing surface (370) cooperates with the opposing surface (390) to allow the inflow of pressurized air into the air duct (87); A method comprising:

14. The method of claim 13, further comprising removing the trigger (30) from the manually triggered paint spray gun (10).

15. 15. The method according to claim 13 or 14, wherein attaching the adapter (1, 2) to the gun body (180) comprises inserting a portion of the adapter (1, 2), for example an insert portion (245) of the adapter (1, 2), into the gun body (180).

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