Fluid sprayer

Abstract

The fluid sprayer includes a body having a front surface, a rear surface, and a body axis extending from the front surface to the rear surface. The body includes a first fluid outlet disposed on the front surface of the body, a first fluid inlet, and a first fluid passage connecting the first fluid inlet to the first fluid outlet. The first fluid outlet defines an arcuate slit. The body further includes a second fluid outlet disposed on the front surface of the body, a second fluid inlet, and a second fluid passage connecting the second fluid inlet to the second fluid outlet. A shelf having a suction surface protrudes from the front surface of the body. The second fluid outlet is located between the first fluid outlet and the shelf. The sprayer can be used in devices and methods utilizing spray fluids.

Description

[Technical Field]

[0001] The present invention relates to a sprayer that converts a fluid into a fine droplet spray or mist. The invention also relates to devices including such a sprayer and methods of use. The sprayer can dispense a variety of fluids, including disinfectants, chemical reagents, and various coatings. [Background technology]

[0002] Atomizers are devices that convert fluids into a fine spray or mist of droplets. The size and shape of the atomizer can depend on the desired application and / or delivery system. Long-standing applications have included the delivery of liquid hydrocarbon feedstocks in fluid catalytic cracking processes, the delivery of chemical pesticides, and the application of surface coatings.

[0003] Sprayers are currently utilized in handheld liquid spray guns that can be used, for example, in vehicle repair body shops to apply liquid coating media such as primer, paint, and / or clearcoat to vehicle parts. Typically, spray guns are made of solid metal or plastic and include a platform and a spray head assembly. The spray head assembly includes a nozzle for supplying the liquid, one or more atomizing air outlets for atomizing the liquid as it exits the nozzle, and two or more shaping air outlets for shaping the atomized liquid into a desired spray pattern. The spray gun includes a series of internal passages that distribute air from an air supply manifold in the platform to the atomizing air outlet(s) and shaping air outlet(s) in the spray head assembly. Atomization of fluids by this technique is sometimes referred to as air atomization, air atomization, air-assisted, or air-blast atomization; an exemplary spray gun using such technology is disclosed, for example, in WO 2018 / 104870 and shown in FIG. 1 . Spray guns are specialized tools that can be expensive to manufacture and time-consuming to maintain. Users typically undergo specialized training to learn how to manually adjust complex combinations of atomizing air outlets and shaping air outlets to obtain a desired spray pattern. Summary of the Invention

[0004] The present disclosure provides a sprayer that atomizes and shapes fluids using a simplified yet elegant design. The sprayer of the present disclosure allows users to efficiently create a flat, fan-shaped pattern of spray fluid for use in a variety of applications, including applying liquid coating media such as primers, paints, and / or clear coats to vehicle parts. The fluid sprayer of the present disclosure can reduce air consumption, reduce noise generation, reduce power consumption, and / or increase coating transfer efficiency when compared to current handheld liquid spray guns. While the sprayer of the present disclosure is designed to address some of the shortcomings associated with current handheld liquid spray guns, as discussed above, it should be understood that the sprayer disclosed herein can be readily configured for other devices and / or applications requiring atomization of a fluid.

[0005] In one embodiment, the present disclosure provides a sprayer comprising a body including a front surface, a rear surface, and a body axis extending from the front surface to the rear surface. The body comprises a first fluid outlet disposed on the front surface of the body, a first fluid inlet, and a first fluid passage connecting the first fluid inlet to the first fluid outlet. The first fluid outlet defines an arcuate slit. The body further comprises a second fluid outlet disposed on the front surface of the body, a second fluid inlet, and a second fluid passage connecting the second fluid inlet to the second fluid outlet. A shelf protrudes from the front surface of the body. The second fluid outlet is located between the first fluid outlet and the shelf.

[0006] In another embodiment, the present disclosure provides a spraying device comprising a sprayer, a first fluid source fluidly connected to the first fluid inlet, and a second fluid source fluidly connected to the second fluid inlet.

[0007] In a further embodiment, the present disclosure provides a method of using a spray device, the method including: positioning the sprayer in front of a substrate; supplying a first fluid through a first fluid outlet; supplying a second fluid through a second fluid outlet; atomizing at least a portion of the second fluid to generate a flat fan-shaped pattern of sprayed fluid; and coating the substrate with the sprayed fluid.

[0008] In yet a further embodiment, the present disclosure provides a method for generating a flat fan spray using a spray device, the method including: supplying a gas from a first fluid outlet; creating a negative pressure on a shelf adjacent to a second fluid outlet; and supplying and atomizing a fluid from the second fluid outlet.

[0009] The terms "comprise" and variations thereof do not have a limiting meaning where these terms appear in the specification and claims. Such terms are understood to imply the inclusion of a described step or element, or group of steps or elements, but not the exclusion of any other step or element, or group of steps or elements. The term "consisting of" is limited to what follows the phrase "consisting of." Thus, the phrase "consisting of" indicates that the listed elements are necessary or mandatory, and that no other elements may be present. "Consisting essentially of" means including all elements listed before the phrase, and is limited to other elements that do not interfere with or contribute to the action or function specified in this disclosure for those listed elements. Thus, the phrase "consisting essentially of" indicates that the listed elements are necessary or mandatory, but that other elements are optional and may or may not be present depending on whether they materially affect the action or function of the listed elements.

[0010] In this application, terms such as "a," "an," and "the" are not intended to refer only to a singular entity, but include general classes, specific examples of which may be used for illustration. The terms "a," "an," and "the" are used interchangeably with the phrases "at least one" and "one or more." The phrases "at least one of" and "including at least one of" following a list refer to any one of the items in the list, and any combination of two or more items in the list.

[0011] The term "or" is generally used in its ordinary sense, including "and / or," unless the context clearly dictates otherwise.

[0012] The term "and / or" means one or all of the listed elements or a combination of any two or more of the listed elements.

[0013] Further herein, the recitations of numerical ranges by endpoints include all numbers subsumed within that range, and the endpoints thereof (eg, 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc.).

[0014] References throughout this specification to "some embodiments" mean that a particular feature, configuration, composition, or characteristic described in connection with an embodiment is included in at least one embodiment of the present disclosure. Thus, the appearances of such phrases in various places throughout this specification do not necessarily refer to the same embodiment of the present disclosure. Furthermore, particular features, configurations, compositions, or characteristics may be combined in any suitable manner in one or more embodiments.

[0015] The words "preferred" and "preferably" refer to embodiments of the present disclosure that may offer certain benefits, under particular circumstances, although other embodiments may be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the present disclosure.

[0016] The terms "top," "bottom," "front," and "back" are relative terms that do not imply a particular orientation in space.

[0017] The term "pressure" refers to gauge pressure (i.e., a measurement of fluid pressure relative to ambient atmospheric pressure) unless otherwise specified. Fluid pressures greater than ambient atmospheric pressure indicate positive pressures, and fluid pressures less than ambient atmospheric pressure indicate negative pressures. A negative pressure condition may also be referred to as a "vacuum," "partial vacuum," or "suction condition."

[0018] The term "hydrostatic pressure" refers to the pressure exerted by a fluid at equilibrium at a given point within the fluid due to gravity. Hydrostatic pressure increases proportionally with depth measured from the surface because increasing fluid weight exerts a downward force from above. Hydrostatic pressure can be used to describe the effect of a liquid reservoir acting as a fluid source connected to an atomizer. The height, and therefore weight, of the fluid within the reservoir provides a motive force to the fluid entering the atomizer.

[0019] The term "fluid" refers to one or more flowable materials, including, for example, a solid, liquid, gas, or combinations thereof. A fluid may be a single material or a combination of two or more materials of the same or different phases (e.g., a slurry of solvent and solid particles). In the case of liquid spray guns used for vehicle repair, fluids may include paints, primers, base coats, lacquers, varnishes, and similar paint-like materials, as well as other materials such as adhesives, sealers, fillers, putties, powder coatings, blasting powders, abrasive slurries, release agents, and foundry dressings.

[0020] The above summary of the present disclosure is not intended to describe each disclosed embodiment or every implementation of the present disclosure. The following description more particularly exemplifies exemplary embodiments. [Brief explanation of the drawings]

[0021] Throughout this specification, reference will be made to the accompanying drawings, in which like reference numerals indicate like elements.

[0022] [Figure 1] 1 is a perspective view of a current air-assisted liquid spray gun. [Figure 2] 1 is a perspective view of one embodiment of a fluid sprayer of the present application. [Figure 3] FIG. 3 is a front view of the fluid sprayer of FIG. 2. [Figure 4] FIG. 3 is a side cross-sectional view of the fluid sprayer of FIG. 2. [Figure 5]3 is a cross-sectional view of a spray device including the fluid sprayer of FIG. 2. [Figure 6] FIG. 3 is a top cross-sectional view of the fluid sprayer of FIG. 2. [Figure 7] 3 is a side cross-sectional view of the front portion of the fluid sprayer of FIG. 2. [Figure 8] 3 is a front perspective view of the fluid sprayer of FIG. 2 having a sidewall. [Figure 9] FIG. 9 is a top cross-sectional view of the fluid sprayer of FIG. 8. [Figure 10] 1 is a schematic perspective view of another embodiment of a fluid sprayer of the present application. [Figure 11] FIG. 11 is a schematic front view of the fluid sprayer of FIG. [Figure 12] FIG. 10 is a perspective view of yet another embodiment of a fluid sprayer of the present application. [Figure 13] FIG. 2 is a perspective view of another embodiment of a fluid sprayer of the present application. [Figure 14] FIG. 2 is a perspective view of another embodiment of a fluid sprayer of the present application. [Figure 15] FIG. 15 is a side cross-sectional view of the fluid sprayer of FIG. [Figure 16] FIG. 15 is a top view of the fluid sprayer of FIG. [Figure 17] FIG. 2 is a perspective view of another embodiment of a fluid sprayer of the present application. [Figure 18] FIG. 2 is a perspective view of another embodiment of a fluid sprayer of the present application.

[0023] When referring to the figures, like reference numerals (e.g., 20, 220, and 320) indicate like elements when not multiples of 100. Unless otherwise indicated, all figures and drawings in this document are not to scale and are selected for the purpose of illustrating different embodiments of the present invention. In particular, the dimensions of the various elements are described in illustrative terms only, and relationships between the dimensions of the various elements should not be inferred from the drawings unless otherwise indicated. DETAILED DESCRIPTION OF THE INVENTION

[0024] 2-4 illustrate a first embodiment of a fluid sprayer 10 of the present application. The sprayer 10 includes a body 12 having a front surface 14, a rear surface 16, and a body axis 2 extending from the front surface 14 to the rear surface 16. A first fluid passageway 18 is disposed within the body 12 and includes a first fluid outlet 20 disposed on the front surface 14 of the body 12 and a first fluid inlet 22. The first fluid outlet 20 defines an arcuate slit 23. In at least one embodiment, the term arcuate refers to a shape or wall that is arcuate in at least one dimension. The term "arcuate slit" can refer to one or more holes formed within the arcuate shape or wall. In at least one embodiment, the body axis 2 can form a plane at least parallel to the arcuate slit. The body axis 2 can intersect the arcuate slit or further bisect the arcuate slit, or can be parallel to the body axis. In at least one embodiment, the slit can be an elongated opening including multiple openings arranged to create an elongated pattern. The slits can include elliptical, rectangular, stadium, or super-elliptical shapes. The arcuate slits 23 can be defined by any curve / arch shape, including segmented curves. In at least one embodiment, the arcuate slits 23 can diverge radially from the body axis 2.

[0025] A second fluid passageway 24 is also disposed within the body 12 and includes a second fluid outlet 26 disposed on the front face 14 of the body 12 and a second fluid inlet 28 .

[0026] In at least one embodiment, a wall 25 can separate the first fluid passage 18 from the second fluid passage 24. The wall 25 can be integrally formed with the body 12 such that one side of the wall 25 is in fluid communication with the first fluid passage 18 and the other side of the wall 25 is in fluid communication with the second fluid passage 24. In at least one embodiment, edges of the wall 25 can form a portion of the first fluid outlet 20 and the second fluid outlet 26. In at least one embodiment, the wall 25 does not protrude significantly beyond the front surface 14. A shelf 29 protrudes from the front surface 14. In at least one embodiment, the shelf 29 can be configured to modify atomization and / or shaping of the fluid from the second fluid passage 24, as described herein. The second fluid outlet 26 is located between the first fluid outlet 20 and the shelf 29.

[0027] The first fluid outlet 20 generally comprises a first end 43, a second end 44, a top 40, and a bottom 42, with the top 40 and bottom 42 each extending from the first end 43 to the second end 44 of the first fluid outlet 20. The first end 43, second end 44, top 40, and bottom 42 of the first fluid outlet 20 define an arcuate slit 23 through which the first fluid can be dispensed from the sprayer 10. Corners formed at the intersections of the top 40 and bottom 42 with the first end 43 and second end 44 may be square, rounded, or a combination thereof. In a preferred embodiment, as shown in FIG. 4 , each of the corners is rounded to reduce or eliminate secondary flow that can occur at square or sharp corners. Secondary flows can create eddies and vortices that can disrupt the uniformity of the atomizing fluid spray pattern.

[0028] 2-4 are featureless, in other embodiments, one or more of the first end 43, second end 44, top 40, and bottom 42 may include one or more features (e.g., grooves, dividers, vortex generators, pillars / posts, and various textures). In one embodiment, at least one of the first end 43, second end 44, top 40, and bottom 42 of the first fluid outlet 20 includes one or more grooves.

[0029] As shown in FIG. 2 , a portion of the front surface 14 of the body 12 that includes the first fluid outlet 20 protrudes outward along the body axis 2 such that the midpoints of the top 40 and bottom 42 of the first fluid outlet 20 protrude further outward than the first end 43 and second end 44, thus forming the arcuate slit 23. While the front surface 14 of the body 12 in FIG. 2 is partially spherical (e.g., composed of two contiguous quadrants of a sphere), it should be understood that the front surface of the body can have any configuration so long as the portion that includes the first fluid outlet provides an arcuate slit. For example, in an alternative embodiment, as shown by the fluid sprayer 310 in FIG. 12 , the front surface 314 forms a portion of a cylinder, and the top 340 and bottom 342 of the first fluid outlet 320 are defined by arcs along the circumference of the cylinder. In another embodiment, the front surface of the body can be formed by one end of an oval sphere (e.g., an ellipsoid) such that the midpoints of the top and bottom of the first fluid outlet protrude further outward from the first and second ends than shown in FIG. 2. The curvature of the arcuate slit is not particularly limited and can form a circular or non-circular arc. In a preferred embodiment as shown in FIGS. 2-4, the curvature of the arcuate slit is symmetrical about a plane extending along the body axis 2 and perpendicular to the shelf 29.

[0030] In at least one embodiment, an aspect of the present disclosure is that the body 12 does not include additional valves, air horns, or needle valves, which simplifies construction, improves reliability, and allows for injection molding.

[0031] In some embodiments, regardless of curvature, the first fluid outlet 20 projects a rectangular shape onto a plane 4 substantially perpendicular to the body axis 2, as shown in FIG. 4 . As used herein, the term “substantially perpendicular” means that the plane 4 forms an angle with the body axis 2 that is at least 85 degrees and no greater than 95 degrees. As used herein, the term “rectangular shape” means a four-sided polygon having a first set of parallel sides perpendicular to a second set of parallel sides. The two sets of parallel sides may be the same length (i.e., forming a square). In preferred embodiments, one set of parallel sides is longer than the other set of parallel sides. The sides may be regular or irregular (e.g., a curved sawtooth pattern, a curved sinusoidal pattern, a discretized or stepped curve pattern, and combinations thereof), and the corners of the polygon may be square, rounded, or a combination thereof.

[0032] The first fluid outlet 20 shown in Figures 2-4 forms a single, uninterrupted slit. In other embodiments, the first fluid outlet can be divided into two or more sections to form multiple openings. The openings can be of various or uniform shapes and / or sizes. The walls that make up each section can be featureless. Alternatively, one or more of the walls that make up a section can include one or more features (e.g., grooves, pillars / posts, and various textures).

[0033] The dimensions of the first fluid outlet can vary depending on the application, but in some preferred embodiments, the first fluid outlet is longer than its height. In some embodiments, the length of the fluid outlet is at least 1.01 to 100 times greater than its height, and more specifically, 10 to 30 times greater than its height. Length, as used herein, is the arcuate length measured from the first end 43 to the second end 44 along the larger of the top 40 or bottom 42 of the first fluid outlet 20. Height, as used herein, is the average distance between the top 40 and bottom 42 of the first fluid outlet 20.

[0034] The first fluid outlet 20 is fluidly connected to a first fluid inlet 22 by a first fluid passage 18. The first fluid inlet 22 is disposed on a surface of the body 12 and connects, either directly or indirectly, to a first fluid source. The location of the first fluid inlet 22 is not particularly limited, but is generally located so that the fluid source does not interfere with atomization and delivery of the fluid. In one embodiment, as shown in FIG. 4 , the first fluid inlet 22 is located on the rear surface 16 of the body 12. In an alternative embodiment, the first fluid inlet is located on the front surface 14 of the body 12. In yet another embodiment, the first fluid inlet is located on portions of both the front surface 14 and the rear surface 16 of the body 12.

[0035] The shape of the first fluid inlet 22 is not particularly limited. However, the portion of the body including the first fluid inlet 22 is typically configured to be attached, either directly or indirectly, to an external first fluid source. In at least one embodiment, a connection mechanism 17 can be located adjacent the rear face 16. The connection mechanism 17 can be configured to releasably attach the body 12 to a fluid actuator (e.g., a spray gun or the first fluid actuator 106 of FIG. 5). As shown, the connection mechanism 17 is a twist-lock fitting; however, other configurations are possible, such as threaded, bayonet-style, push-fit, snap-lock, quick-connect, compression fit, hose barb, ultrasonic welding, spin welding, overmolding, or crimp-style connections. For example, FIG. 12 shows connection mechanism 317, which is a push-fit with an external ledge. FIG. 13 shows connection mechanism 417, which is an internal threaded connection. FIG. 14 shows connection mechanism 517, and FIG. 17 shows connection mechanism 617, which are external threaded connections. In the exemplary embodiment of FIG. 4, the first fluid inlet 22 comprises a tab 38 configured to mate with a complementary attachment means, such as a slot in the housing of the first fluid source or a slot in a conduit (e.g., tubing) used to supply the first fluid from the first fluid source.

[0036] The first fluid passage 18 fluidly connects the first fluid inlet 22 with the first fluid outlet 20. The first fluid passage 18 can take any suitable shape or path within the body. In some embodiments, at least a portion of the first fluid passage is a cylindrical cavity having a constant cross-sectional area throughout. In alternative embodiments, at least a portion of the first fluid passage is a cylindrical cavity in which the cross-sectional area of ​​the first fluid passage changes from the first fluid inlet to the first fluid outlet. In a preferred embodiment, as shown in FIG. 4 , at least a portion of the first fluid passage 18 is a cylindrical cavity in which the cross-sectional area decreases from the first fluid inlet 22 to the first fluid outlet 20, thus reducing the pressure and increasing the velocity at which the first fluid exits the first fluid outlet 20.

[0037] The second fluid outlet 26 is disposed on the front surface 14 of the body 12 between the first fluid outlet 20 and the shelf 29. The second fluid outlet 26 includes a top 49, a bottom 50, a first end 51, and a second end 52, which together define the opening 27. The dimensions of the second fluid outlet 26 can vary depending on the application, but typically the length of the second fluid outlet 26 is less than or equal to the length of the first fluid outlet 20, as measured from the first end 51 to the second end 52 along the greater of the top 49 or bottom 50 of the second fluid outlet 26. In a preferred embodiment, the length of the second fluid outlet 26 is greater than the average distance between the top 49 and the bottom 50 of the second fluid outlet 26. However, the shape of the second fluid outlet 26 is not particularly limited. 2-4, the opening 27 of the second fluid outlet 26 is an arcuate slit similar to that described with respect to the first fluid outlet 20. In alternative embodiments, the opening 27 may be a regular or irregular oval, rectangular, or semicircular shape. In some embodiments, the second fluid outlet 26 projects a rectangular shape onto a plane 4 substantially perpendicular to the body axis 2.

[0038] 2-4, the first end 51, second end 52, top 49, and bottom 50 of the second fluid outlet 26 are featureless. In other embodiments, one or more of the first end 51, second end 52, top 49, and bottom 50 include one or more features (e.g., grooves, dividers, vortex generators, pillars / posts, and various textures). In one embodiment, at least one of the first end 51, second end 52, top 49, and bottom 50 of the second fluid outlet 26 includes one or more grooves.

[0039] While the second fluid outlet 26 shown in Figures 2-4 forms a single uninterrupted slit, in other embodiments, the second fluid outlet can be divided into two or more sections to create multiple openings (e.g., the sprayer shown in Figures 10 and 11). The openings can be of various or uniform shapes and / or sizes. The walls that make up each section can be featureless. Alternatively, one or more of the walls that make up a section can include one or more features (e.g., grooves, pillars / posts, and various textures).

[0040] The second fluid outlet 26 and the first fluid outlet 20 may be flush or aligned on the front face, as shown in Figure 4. However, it should be understood that the second fluid outlet 26 may be behind or in front of the first fluid outlet 20.

[0041] The second fluid outlet 26 is fluidly connected to the second fluid inlet 28 by the second fluid passage 24. The location of the second fluid inlet 28 is not particularly limited, but the second fluid inlet 28 is generally positioned so that the second fluid source does not interfere with the atomization and delivery of fluid from the first fluid source or the front surface 14 of the body 12. In one embodiment, as shown in FIG. 4 , the second fluid inlet 28 is positioned on the front surface 14 of the body 12. In an alternative embodiment, the second fluid inlet is positioned on the rear surface 16 of the body 12. In yet other embodiments, the second fluid inlet is positioned on portions of both the front surface 14 and the rear surface 16 of the body 12.

[0042] The shape of the second fluid inlet 28 is not particularly limited. However, the portion 46 of the body 12 containing the second fluid inlet 28 is typically configured to mate, either directly or indirectly, with a second fluid source. In the embodiment shown in FIG. 4 , the second fluid inlet 28 is disposed in a tapered portion 46 of the body 12, which allows insertion of the second fluid inlet 28 into the housing of the second fluid source or into a conduit (e.g., tubing) used to deliver the second fluid from the second fluid source. A groove 48 on the tapered portion 46 can engage, for example, with a flange on the housing or conduit to secure the sprayer 10 to the second fluid source. The tapered portion 46 is only one exemplary means for connecting the sprayer 10 to the second fluid source. The body containing the second fluid inlet 28 can be readily configured for other known attachment means, including threading, snap-fitting, press-fitting, quick-disconnecting, compression fitting, hose barbing, ultrasonic welding, spin welding, and overmolding.

[0043] The second fluid passage 24 fluidly connects the second fluid inlet 28 to the second fluid outlet 26. The second fluid passage 24 can take any suitable shape or path within the body 12. In some embodiments, as shown in FIG. 4 , at least a portion of the second fluid passage 24 is a cylindrical cavity having a constant cross-sectional area throughout. In alternative embodiments, at least a portion of the second fluid passage 24 is a cylindrical cavity in which the cross-sectional area of ​​the second fluid passage 24 changes from the second fluid inlet 28 to the second fluid outlet 26. In some embodiments, at least a portion of the second fluid passage 24 is a cylindrical cavity in which the cross-sectional area decreases from the second fluid inlet 28 to the second fluid outlet 26, thus reducing the pressure and increasing the velocity at which the second fluid exits the second fluid outlet 26.

[0044] Shelf 29 projects from front face 14 of body 12 and includes a fixed end 32 adjacent front face 14 and an opposite free end 34. Shelf 29 may be integrally formed with body 12, as shown in Figure 4. Alternatively, shelf 29 may be formed separately and attached to body 12 by any suitable technique, including welding, snap-fitting, press-fitting, heat staking, and overmolding.

[0045] The shape of the shelf 29 is preferably designed so that the fluid travels the same distance across the shelf 29 regardless of where it exits the second fluid outlet 26, thus providing a uniform fluid flow. While not a required feature, such a configuration provides a more uniform pattern of sprayed fluid. In one embodiment, as shown in FIGS. 2-4 , the free end 34 of the shelf 29 forms an arcuate edge 31 that extends around the front surface 14 of the body 12 and generally follows the shape of the arcuate slit 23 of the first fluid outlet 20. In an alternative embodiment, as shown in the embodiment of FIG. 12 , the shelf 329 can form a polygonal shape, such as a triangle.

[0046] The shelf 29 has a suction surface 30 on the side facing the fluid outlets 20, 26. The suction surface 30 may be featureless (e.g., smooth), textured (e.g., three-dimensional structures), or a combination thereof. In some embodiments, at least a portion of the suction surface 30 includes three-dimensional structures such as dimples, grooves or channels, pillars or posts, vortex generators, tetrahedrons, and combinations thereof. The three-dimensional structures may be arranged randomly or in a regular pattern. In some embodiments, the three-dimensional structures may be arranged randomly on at least one portion of the suction surface and in a regular pattern on at least one other portion of the suction surface. Texturing can induce additional shear forces and three-dimensionality in the flow adjacent to the textured surface. Because this interaction between the surface and the adjacent fluid is known to exist, it can be used to increase turbulent fluid flow during operation. Benefits of turbulent mixing can include, but are not limited to, improved droplet dispersion, finer atomization, and divergence of the mixed-phase velocity field.

[0047] The suction surface may be parallel to or at an angle to the body axis 2. Referring to FIG. 4, the suction surface axis 58 extends from the midpoint of the fixed end 32 to the midpoint of the free end 34 opposite the shelf 29. In some embodiments, the suction surface axis 58 and the body axis 2 form an angle that is typically in the range of -20 to 20 degrees. In preferred embodiments, the suction surface axis 58 is substantially parallel to the body axis 2. As used herein, the term "substantially parallel" means that the angle formed between the two axes 58 and 2 is in the range of -10 to 10 degrees.

[0048] 2-4, the suction surface 30 is planar. However, in alternative embodiments, the suction surface is not planar. For example, the suction surface can have a convex, concave, or wavy configuration.

[0049] The fixed end 32 of the suction surface 30 can be positioned any suitable distance from the first fluid outlet 20, depending on the size and application of the fluid sprayer. In some embodiments, the distance between the suction surface 30 and the bottom 50 of the second fluid outlet 26, measured in a direction perpendicular to the body axis, is equal to or less than the distance between the bottom 42 of the first fluid outlet 20 and the top 49 of the second fluid outlet 26. In more particular embodiments, the distance between the suction surface 30 and the bottom 50 of the second fluid outlet 26, measured in a direction perpendicular to the body axis, is less than the distance between the bottom 42 of the first fluid outlet 20 and the top 49 of the second fluid outlet 26. In some coating applications, the distance 68 between the bottom 42 of the first fluid outlet 20 and the suction surface 30, measured in a direction perpendicular to the body axis 2, is greater than 0 mm and equal to or less than 30 mm. In one or more embodiments, this distance 68 is at least 0.5 mm and equal to or less than 2 mm.

[0050] The shelf length can have a significant effect on vacuum pressure and a lesser effect on atomization. In at least one embodiment, the dimensions of the shelf 29 are not particularly limited and vary depending on the size of the sprayer and the particular application. In some coating applications, the shelf 20 has a length 60 ranging from 0.5 to 50 mm, as measured from the midpoint of the fixed end 32 to the midpoint of the opposite free end 34. In at least one embodiment, the height difference (distance 68) from the suction surface 30 to the first fluid outlet bottom ledge on the shelf 25 can define a region / boundary where the second fluid is under strong negative pressure. In at least one embodiment, the body 12 can function with a ratio of length 60 to distance 68 of at least 1. The ratio of length 60 to distance 68 can range from 1 to 6, inclusive, such as 3 to 5.

[0051] 8 and 9 show the sprayer 10 of FIGS. 2-4 with two optional walls 70, 72 that can be used to adjust the spray angle 82 of the spray fluid as it exits the spray device. The sprayer 110 includes a first wall 70 positioned on a shelf 29 adjacent the first end 43 of the fluid outlet 20 and a second wall 72 positioned on the shelf 29 adjacent the second end 44 of the first fluid outlet 20. In some embodiments, the first wall 70 and the second wall 72 each form an angle 78, 80, respectively, with the body axis 2 that is at least 5, 10, 20, 30, 50, or 70 degrees and is equal to or less than 90, 80, or 70 degrees. In some embodiments, the first wall 70 and the second wall 72 each form an angle 78, 80, respectively, with the body axis 2 that is in the range of 5 to 90 degrees. The walls 70, 72 can be positioned to produce a spray angle 82 that is greater than 0, 40, 60, 100, or 140 degrees and less than or equal to 180, 160, or 140 degrees. In some embodiments, the spray angle 82 ranges from greater than 0 degrees to less than or equal to 180 degrees. In at least one embodiment, the spray angle 82 ranges from less than or equal to 0 degrees to less than or equal to 270 degrees.

[0052] The walls 70, 72 can be integrally formed with the sprayer body 12. Alternatively, the walls 70, 72 may be formed separately and attached to the body 12 by any suitable technique, including welding, snap-fitting, press-fitting, heat staking, and overmolding. In some embodiments, the spray angle is set for a particular sprayer during manufacturing, thus requiring multiple sprayers with different wall angles to cover a range of spray angles and patterns. In a preferred embodiment, the sprayer walls 70, 72 are adjustable so that a single device can accommodate a range of spray angles and patterns. For example, the walls 70, 72 may be movable such that adjusting the wall 70 results in movement of the wall 72 so that the angle is maintained without the need to also adjust the wall 72.

[0053] While the walls 70, 72 in Figures 8 and 9 are featureless, in other embodiments, the walls 70, 72 may include one or more features (e.g., grooves, dividers, pillars / posts, and various textures). In some embodiments, the walls are flat. In other embodiments, the walls are slightly curved outward from the body axis 2 to increase the spread of the spray fluid.

[0054] The atomizers of the present application can be assembled from two or more parts or integrally formed from a single material using a number of known techniques, including injection molding, compression molding, machining, 3D printing, forging, casting, and combinations thereof. Any suitable material(s) may be used to fabricate the atomizer, for example, thermoplastics such as polypropylene, nylon, polytetrafluoroethylene, or acetal, metals such as brass and stainless steel, ceramics such as aluminum oxide, and combinations thereof.

[0055] Figure 5 illustrates a spray device 100 using the sprayer shown in Figures 2-4. In addition to the sprayer 10 described above, the device 100 includes a first fluid source 102 having a first fluid 64 and a second fluid source 104 having a second fluid 66. Using the attachment mechanism described above, the first fluid source 102 is fluidly connected to the first fluid inlet 22 and the second fluid source 104 is fluidly connected to the second fluid inlet 28. The attachment is preferably releasable, but in some embodiments may be permanent.

[0056] The first fluid source 102 and the second fluid source 104 may comprise any suitable container, reservoir, or housing that can be attached directly or indirectly (e.g., via conduits) to the first fluid inlet 22 and the second fluid inlet 28, respectively, of the sprayer 10. The first fluid source 102 and the second fluid source 104 may each be reusable or disposable, and may be pre-filled with fluid or refillable on-site.

[0057] In some embodiments, at least one of the first fluid source 102 and the second fluid source 104 is pressurized. In some embodiments, the first fluid source 102 is pressurized. In some embodiments, the second fluid source 104 is not pressurized. In other embodiments, the second fluid source 104 is not pressurized by means other than hydrostatic pressure (e.g., the second fluid source 104 is positioned vertically above the sprayer).

[0058] In some embodiments, the first fluid 64 is a gas (e.g., air, nitrogen, oxygen, and steam). In some embodiments, the second fluid 66 is a liquid (e.g., paint, lacquer, stain, varnish, and water). In a preferred embodiment, the first fluid 64 is a gas, more specifically a pressurized gas, and the second fluid 66 is a liquid.

[0059] The spray device may optionally include one or more actuators for managing the flow of fluid within the device. As shown in FIG. 5, a first fluid actuator 106 manages the flow of fluid 64 from a first fluid source 102 to a first fluid inlet 22. Similarly, a second fluid actuator 108 manages the flow of fluid 66 from a second fluid source 104 to a second fluid inlet 28. The first fluid actuator 106 and the second fluid actuator 108 may be of the same type or different types. Exemplary actuators include hand triggers, needle valves, ball valves, poppet valves, cross-slit valves, dome valves, duckbill valves, umbrella valves, and combinations thereof.

[0060] The spray device of the present application can be used in a variety of applications involving atomization of fluids. In one embodiment, the spray device is used to coat a substrate. The sprayer 10 is positioned in front of a substrate (not shown). A first fluid 64 is directed through a first fluid outlet 20, and a second fluid 66 is directed through a second fluid outlet 26. At least a portion of the second fluid 66 is atomized by the first fluid 64 to produce a flat fan-shaped pattern of atomized fluid. The substrate is then coated with the atomized fluid.

[0061] Spray devices can be used, for example, in vehicle repair body shops to apply liquid coating media, such as primers, paints, and / or clear coats, to vehicle parts. In such applications, the first fluid is typically a gas, such as pressurized air. The second fluid is typically a liquid, which may, but need not, be pressurized. In some embodiments, the second fluid is not pressurized by means other than hydrostatic pressure.

[0062] Atomization devices and the atomizers contained therein are sometimes designed to utilize the Coanda effect. This effect is illustrated in Figures 6 and 7, where a first fluid 64 is a pressurized gas and a second fluid 66 is a liquid. When the pressurized gas is released through the first fluid outlet 20, it deflects toward the suction surface 30, creating a low-pressure zone 62 adjacent to the second fluid outlet 26. The low-pressure zone 62 draws, or helps draw, liquid through the second fluid outlet 26 and into the low-pressure zone 62 and the path of the pressurized gas. The shear force of the pressurized gas on the liquid results in atomization of the liquid.

[0063] While the low pressure zone 62 is often sufficient to draw the second fluid 66 through the second fluid outlet 26, it should be understood that the second fluid 66 may be supplied while under hydrostatic pressure and / or pressurized by an external air source. For example, in some embodiments, the second fluid source 104 may be elevated above the sprayer 10 during operation. In such cases, the supply of liquid from the second fluid outlet is affected by both the Coanda effect and hydrostatic pressure resulting from the location of the second fluid source 104 above the sprayer 10. In other embodiments, the liquid may be pressurized by, for example, a pump or an external air source.

[0064] Shaping of the atomized fluid is aided by the arcuate slits 23 in the first fluid outlet 20, which spread the atomized liquid into a flat fan-shaped pattern, as shown in Figure 6. The size of the flat fan-shaped pattern, represented by the length of the arc 82, is affected by the dimensions of the first fluid outlet 20, the dimensions of the second fluid outlet 26, and / or the position of the optional first wall 70 and second wall 72, as shown in Figure 9.

[0065] Because the functions of shaping and atomization are combined in one air stream, the atomizer of the present disclosure is much simpler than conventional air atomization, air spray, air-assisted, or air-blast atomization methods that require the coordination of multiple air streams. Furthermore, there is no need for one or more separate streams of pressurized air to shape the atomizer fluid, thus reducing pressurized air consumption by up to half.

[0066] Other variations of the presently disclosed sprayer are within the scope of the present application. For example, Figures 10 and 11 show another embodiment of the fluid sprayer of the present application. The sprayer 210 includes many of the same features already described above with respect to the sprayer 10 of Figures 2-4, including a body 212, a first fluid outlet 220 and a second fluid outlet 226 disposed on a front surface 214 of the body 212, and a shelf 229 projecting from the front surface 214. The first fluid outlet 220 defines an arcuate slit 223. The second fluid outlet 226 is located between the first fluid outlet 220 and the shelf 229. The sprayer 210 also includes a first fluid inlet 222 and a second fluid inlet 228. The connection mechanism 217 can be proximate or adjacent to the first fluid inlet 222. In at least one embodiment, a portion of the front surface 214 can be semi-hemispherical or dome-shaped.

[0067] Atomizer 210 differs from atomizer 10 in the overall shape of body 212, and more specifically, in the structure of second fluid outlet 226. As shown in Figures 10 and 11, second fluid outlet 226 is divided into a plurality of openings 207. All of the openings are the same shape and size, although it should be understood that the openings may vary in shape and / or size.

[0068] 13 shows sprayer 410. Sprayer 410 may be configured similarly to sprayer 110, except that first fluid outlet 420 and second fluid outlet 426 are separated by wall 425 and have a scalloped portion formed therein. Scalloped may refer to one of a continuous series of circular segments or angular protrusions forming a boundary.

[0069] The sprayer 410 can have a body 412 having a front surface 414, a rear surface, and a body axis 2 extending from the front surface 14 to the rear surface. A first fluid passage is disposed within the body 12 and includes a first fluid outlet 420 disposed on the front surface 14 of the body 12 and a first fluid inlet. The first fluid outlet 420 defines an arcuate slit. The first fluid outlet 420 can have a top 440 (defined by a portion of a hemisphere) and a bottom 442 (defined by a wall 425).

[0070] The second fluid outlet 426 can have a top 428 and a bottom 450. The top 428 can be defined by a wall 425. The bottom 450 can be defined by a shelf 429 and a suction surface 430. The top 428 and / or the bottom 442 can have a recess 403 that can be configured to modify the exit rate of the first fluid and / or the second fluid. In at least one embodiment, a protruding portion of the top 428 can abut or contact the bottom 450, and the shelf 429 forms an opening 405 formed in the recess. Similar to the sprayer 110, the sprayer 410 can also include a first wall 470 and a second wall 472, which may be adjustable by a user to adjust the resulting pattern of the deposited fluid.

[0071] 14-16 show a sprayer 510 similar to sprayer 110, except that sprayer 510 can include air adjustment mechanisms 533, 535 on a suction surface 530 of shelf 529. For example, sprayer 510 can have a body 512 having a front surface 514 and a rear surface 516. Body 512 can have a connection mechanism 517 formed proximate the rear surface.

[0072] A first fluid passageway 518 and a second fluid passageway 524 can be formed from the body 512. A wall 525 can separate the first fluid passageway 518 and the second fluid passageway 524. A first fluid outlet 520 can be formed from the front face 514 and can be fluidly coupled to the first fluid passageway 518. A second fluid outlet 526 can be fluidly coupled to the second fluid passageway 524. The body 512 can also include a shelf extending beyond the front face 514. In at least one embodiment, the shelf can have a connecting portion 537 connecting the shelf 529 to the body 512. For example, the connecting portion 537 is angled from the shelf 529 such that an opening is formed between the wall 525 and an outer surface of the body 512 (proximate the inlet).

[0073] Air conditioning features 533, 535 may be raised protrusions from the surface of shelf 529. In at least one embodiment, air conditioning features 533, 535 may be continuous along part or all of the shelf. In at least one embodiment, air conditioning features 533, 535 may extend along part or all of the arch between two walls 570, 575. In at least one embodiment, air conditioning features 533, 535 may be flush with wall 525 or slightly below the height of wall 525. Air conditioning features 533, 535 may be configured to generate flow-excited Helmholtz resonances in one or both of the combined fluid mixtures. It is believed that Helmholtz resonances can alter the atomization and mixing process between the first and second fluids. As shown, air conditioning feature 533 is a larger raised arch and air conditioning feature 535 is a smaller raised arch.

[0074] FIG. 17 illustrates sprayer 610 having a body 612. Sprayer 610 is similar to sprayer 510, except for air conditioning mechanism 633. As shown, air conditioning mechanism 633 is a plurality of raised dimples that extend beyond suction surface 630 of shelf 629. In at least one embodiment, air conditioning mechanism 633 may be recessed dimples. Air conditioning mechanisms 633 may be arranged in one or two rows and may be aligned at least in part radially based on the flow of the first and second fluids.

[0075] 18 shows sprayer 710 having a body 712. Sprayer 710 is similar to sprayer 510, except that air conditioning features 733, 735 on suction surface 730 of shelf 729 can further have channels or troughs 735 formed therein. For example, air conditioning feature 735 can be arch-shaped, except that multiple channels 737 can be formed therein. Air conditioning feature 733 can also be arch-shaped following the same contour as air conditioning feature 735 and can have multiple channels 739 formed therein. In at least one embodiment, channel 737 is not aligned with channel 739.

[0076] Accordingly, the present disclosure provides, among other things, a nebulizer, a system including such a nebulizer, and a method of utilizing such a nebulizer. Various features and advantages of the present disclosure are set forth in the following claims. In addition to the embodiments, the following aspects will be noted. (Appendix 1) a body including a front surface, a rear surface, and a body axis extending from the front surface to the rear surface; a first fluid outlet disposed on the front surface of the body, the first fluid outlet defining an arcuate slit; a first fluid inlet; and a first fluid passageway connecting the first fluid inlet to the first fluid outlet; a second fluid outlet disposed on the front surface of the body; a second fluid inlet; and a second fluid passage connecting the second fluid inlet to the second fluid outlet. a shelf projecting from the front surface of the body; Equipped with the second fluid outlet is located between the first fluid outlet and the shelf. Main body, A sprayer comprising: (Appendix 2) 2. The sprayer of claim 1, wherein the first fluid outlet comprises a first end, a second end, a top, and a bottom that together define the arcuate slit. (Appendix 3) 3. The sprayer of claim 2, further comprising a first wall and a second wall disposed on the shelf, the first wall adjacent to the first end of the first fluid outlet, and the second wall adjacent to the second end of the first fluid outlet. (Appendix 4) 4. The sprayer of claim 3, wherein the first wall and the second wall each form an angle with the body axis in the range of 5 to 90 degrees. (Appendix 5) 5. The sprayer of any one of claims 2 to 4, wherein at least one of the top, bottom, first end, and second end of the first fluid outlet or the second fluid outlet comprises a groove. (Appendix 6) 6. The sprayer of claim 5, wherein the groove is scalloped. (Appendix 7) 7. The sprayer of any one of claims 1 to 6, wherein the first fluid outlet is divided into two or more sections. (Appendix 8) 8. The sprayer of any one of claims 1 to 7, wherein the second fluid outlet is divided into two or more sections. (Appendix 9) 9. The sprayer of any one of claims 1 to 8, wherein the shelf has a fixed end adjacent the front surface of the body and an opposite free end, the shelf further comprising a suction surface and a suction surface axis extending from a midpoint of the fixed end of the shelf to a midpoint of the free end, the suction surface axis and the body axis forming an angle in the range of -20 to 20 degrees. (Appendix 10) 10. The sprayer of claim 9, wherein the distance between the suction surface and the bottom of the second fluid outlet is less than or equal to the distance between the bottom of the first fluid outlet and the top of the second fluid outlet, when measured in a direction perpendicular to the body axis. (Appendix 11) 11. The sprayer of claim 9 or 10, wherein at least a portion of the suction surface comprises a textured surface. (Appendix 12) 12. The atomizer of claim 11, wherein the textured surface is configured to generate a Helmholtz resonance in at least one of the first fluid or the second fluid. (Appendix 13) A nebulizer according to any one of claims 1 to 12; a first fluid source fluidly connected to the first fluid inlet; a second fluid source fluidly connected to the second fluid inlet; A spray device comprising: (Appendix 14) 14. The spray device of claim 13, wherein the first fluid source comprises a gas and the second fluid source comprises a liquid. (Appendix 15) 15. The spray device of claim 13 or 14, wherein the first fluid source is pressurized. (Appendix 16) 16. The spray device of any one of clauses 13 to 15, wherein the second fluid source is not pressurized by means other than hydrostatic pressure. (Appendix 17) 14. A method of using the spray device of claim 13, comprising: placing the sprayer in front of a substrate; supplying a first fluid through the first fluid outlet; supplying a second fluid through the second fluid outlet; atomizing at least a portion of the second fluid to produce a flat fan-shaped pattern of atomized fluid; coating the substrate with the sprayed fluid; A method comprising: (Appendix 18) 18. The method of claim 17, wherein the first fluid is pressurized and the second fluid is not pressurized by means other than hydrostatic pressure. (Appendix 19) 19. The method of claim 17 or 18, wherein the first fluid is a gas and the second fluid is a liquid. (Appendix 20) 14. A method of producing a flat fan spray using the device of claim 13, comprising: supplying a gas from the first fluid outlet; creating a negative pressure on the shelf adjacent to the second fluid outlet; supplying a fluid from the second fluid outlet for atomization; A method comprising:

Claims

1. a body including a front surface, a rear surface, and a body axis extending from the front surface to the rear surface; a first fluid outlet disposed on the front surface of the body, the first fluid outlet defining an arcuate slit; a first fluid inlet; and a first fluid passageway connecting the first fluid inlet to the first fluid outlet; a second fluid outlet disposed on the front surface of the body; a second fluid inlet; and a second fluid passage connecting the second fluid inlet to the second fluid outlet. a shelf projecting from the front surface of the body; Equipped with the second fluid outlet is located between the first fluid outlet and the shelf. Main body, A sprayer comprising:

2. 10. The atomizer of claim 1, wherein the first fluid outlet comprises a first end, a second end, a top, and a bottom that together define the arcuate slit.

3. 3. The sprayer of claim 2, further comprising a first wall and a second wall disposed on the shelf, the first wall adjacent the first end of the first fluid outlet and the second wall adjacent the second end of the first fluid outlet.

4. The atomizer of claim 3, wherein the first wall and the second wall each form an angle with the body axis in the range of 5 to 90 degrees.

5. 5. The sprayer of claim 2, wherein at least one of the top, the bottom, the first end, and the second end of the first fluid outlet or the second fluid outlet comprises a groove.

6. 6. The atomizer of claim 5, wherein the groove is scalloped.

7. 7. The sprayer of claim 1, wherein the shelf has a fixed end adjacent the front surface of the body and an opposite free end, the shelf further comprising a suction surface and a suction surface axis extending from a midpoint of the fixed end of the shelf to a midpoint of the free end, the suction surface axis and the body axis forming an angle in the range of -20 to 20 degrees.

8. 8. The sprayer of claim 7, wherein the distance between the suction surface and the bottom of the second fluid outlet is less than or equal to the distance between the bottom of the first fluid outlet and the top of the second fluid outlet, as measured in a direction perpendicular to the body axis.

9. 9. The sprayer of claim 7 or 8, wherein at least a portion of the suction surface comprises a textured surface.

10. 10. The atomizer of claim 9, wherein the textured surface is configured to generate a Helmholtz resonance of at least one of the first fluid or the second fluid.

11. A sprayer according to any one of claims 1 to 10; a first fluid source fluidly connected to the first fluid inlet; a second fluid source fluidly connected to the second fluid inlet; A spray device comprising:

12. 12. The atomizing device of claim 11, wherein the first fluid source comprises a gas and the second fluid source comprises a liquid.

13. 13. A spray device according to claim 11 or 12, wherein the first fluid source is pressurized.

14. 14. A spray device according to any one of claims 11 to 13, wherein the second fluid source is not pressurised by means other than hydrostatic pressure.

15. 12. A method of using the spray device of claim 11, comprising: placing the sprayer in front of a substrate; supplying a first fluid through the first fluid outlet; supplying a second fluid through the second fluid outlet; atomizing at least a portion of the second fluid to produce a flat fan-shaped pattern of atomized fluid; coating the substrate with the sprayed fluid; A method comprising:

16. 12. A method of producing a flat fan spray using the device of claim 11, comprising: supplying a gas from the first fluid outlet; creating a negative pressure on the shelf adjacent to the second fluid outlet; supplying a fluid from the second fluid outlet for atomization; A method comprising:

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