Fluid sprayer and components of the fluid sprayer

Abstract

The air-assisted airless spray gun includes a valve cartridge configured to control the flow of air or spray fluid through the spray gun. The valve cartridge includes a housing configured to interface with the spray gun body and fully support the flow-control components of the valve cartridge. The housing is secured within a bore in the spray gun body. A valve member is supported by the housing and is actuatable against a seat. A valve is formed between a sealing end of the valve member and the seat.

Description

[Technical Field]

[0001] The present disclosure relates to sprayers, and more particularly, to spray guns for sprayers. [Background technology]

[0002] This application claims priority to and benefit of U.S. Provisional Application No. 63 / 041,454, entitled "Fluid Sprayer and Components of a Fluid Sprayer," filed June 19, 2020, which claims priority to and benefit of U.S. Provisional Application No. 63 / 178,683, entitled "Fluid Sprayer and Components of a Fluid Sprayer," filed April 23, 2021, which claims priority to and benefit of U.S. Provisional Application No. 63 / 188,817, entitled "Fluid Sprayer and Components of a Fluid Sprayer," filed May 14, 2021, the disclosures of which are incorporated herein by reference in their entireties.

[0003] Spray guns can be used to spray fluids onto surfaces. For example, spray guns can be used to spray paints, lacquers, finishes, and other coatings onto furniture, cabinets, appliances, equipment, workpieces, etc. While a variety of fluids can be sprayed by the embodiments referenced herein, paint is used as an example.

[0004] Typically, paint is placed under pressure by a piston, diaphragm, or other positive displacement pump. The pump can place paint under pressure between 500 and 5,000 pounds per square inch (psi), although higher and lower pressures are possible. The pump outputs the paint under pressure through a flexible hose. A spray gun is used to dispense the paint; the gun is attached to the end of the hose opposite the pump. In this way, the spray gun does not include a pump; rather, it ejects paint that is pumped through a hose into the spray gun. The spray gun atomizes the paint under pressure into a spray fan, which applies it to the surface.

[0005] Some spray guns, which may be referred to as air-assisted airless spray guns, emit a stream of air to assist in atomizing and / or shaping the fluid spray. Such spray guns emit a fluid through a spray nozzle and an air stream adjacent to the fluid spray. Such spray guns include valves for controlling the fluid stream and multiple air streams. Summary of the Invention [Problem to be solved by the invention]

[0006] According to one aspect of the disclosure, a spray gun configured to receive a flow of fluid and air and emit a fluid spray includes a gun body having a first bore, a second bore, and a gap disposed therebetween; a fluid control cartridge having a first housing disposed within the first bore, the fluid control valve being fully contained within the first housing and configured to control spray from the spray gun; an air control cartridge having a second housing disposed within the second bore, the first air control valve being fully contained within the second housing and configured to control air flow for spraying by the spray gun; and a trigger extending into the gap and configured to actuate the fluid control valve between a closed state and an open state.

[0007] According to an additional or alternative aspect of the present disclosure, a spray gun configured to receive a flow of fluid and air and to emit a fluid spray and air includes a gun body, a first valve bore formed within the gun body, and a first flow valve cartridge disposed within the first valve bore, the first flow valve cartridge entirely containing a first flow valve configured to control downstream flow through the first flow valve cartridge.

[0008] According to another additional or alternative aspect of the present disclosure, a spray tip assembly for a spray gun includes a spray tip and a turbulator assembly positioned upstream of the spray tip.

[0009] According to yet another or alternative aspect of the present disclosure, a spray gun includes a gun body having an air valve bore, an air inlet bore in communication with the air valve bore, an auxiliary air bore extending from the air valve bore, and a fan air bore extending from the air valve bore, and an air valve assembly disposed within the air valve bore and configured to control a first air flow between the air inlet bore and the auxiliary air bore and a second air flow between the air inlet bore and the fan air bore. The air valve assembly includes a valve body disposed within the air valve bore and having an axial bore therethrough and at least one air outlet port in fluid communication with the fan air bore, a common valve member disposed at least partially within the air valve bore, a first end of the common valve member extending from the air valve bore and a second end of the common valve member disposed within the valve body, a fan valve member disposed within the air valve bore, and a stop extending into the air valve bore. The first valve is formed at least in part by the common valve member and is configured to control downstream flow to the auxiliary air bore. The second valve is formed at least in part by the common valve member and is configured to control downstream flow to the fan air bore. The stop is configured to interact with the fan valve member to limit axial displacement of the fan valve member.

[0010] According to yet another or alternative aspect of the present disclosure, a spray tip assembly includes a tip body, an air cap disposed at least partially within the tip body and at a first end of the tip body, a spray tip supported by the air cap, a first trapping member disposed in a first slot in the tip body, a second trapping member disposed in a second slot in the upper body and axially spaced from the first slot, and a collar disposed around the tip body, the collar being movable between a detached state and an attached state, the collar biasing the second trapping member downward toward an axis passing through the spray tip when the collar is attached.

[0011] According to yet another or alternative aspect of the present disclosure, an air valve cartridge for an air-assisted airless spray gun includes a cartridge body having a first end, a second end, at least one air inlet port through the cartridge body, and at least one air outlet port through the cartridge body, a first valve member disposed at least partially within the cartridge body and at least partially defining a first valve and a second valve, a second valve member disposed at least partially within the cartridge body and at least partially defining a third valve disposed downstream from the second valve, and a spring disposed within a housing to bias the first valve member toward the first end, the spring biasing the first valve and the second valve toward their respective closed states. The cartridge body, the first valve, the second valve, the spring, the first valve member, and the second valve member form a separate assembly configured to control first and second air flows downstream of the air valve cartridge.

[0012] According to yet another or alternative aspect of the present disclosure, a method of assembling a fluid conduit assembly to a spray gun includes aligning a mounting block with a mounting slot formed in a gun body of the spray gun, sliding the mounting block into the mounting slot, and inserting a valve cartridge through the mounting block to secure the mounting block within the mounting slot, the valve cartridge including a fluid valve member configured to control the spraying of spray fluid by the spray gun.

[0013] According to yet another or alternative aspect of the present disclosure, a method of assembling a spray gun includes the steps of inserting a first valve cartridge as a unit into a first cartridge bore formed in a gun body of the spray gun, the first valve cartridge including at least one first flow control valve, and securing the first body of the first valve cartridge to the gun body; inserting a second valve cartridge as a unit into a second cartridge bore formed in the gun body, the second valve cartridge including at least one first flow control valve, and securing the second body of the second valve cartridge to the gun body. [Brief explanation of the drawings]

[0014] [Figure 1A] FIG. 2 is a rear isometric view of the spray gun. [Figure 1B] FIG. 1 is a front isometric view of a spray gun. [Figure 1C] FIG. 2 is a side view of the spray gun. [Figure 2] FIG. 2 is a side view of the spray gun. [Figure 3A] FIG. 1B is an isometric exploded view of the spray gun shown in FIG. 1A. [Figure 3B] FIG. 3B is an isometric exploded cross-sectional view of the spray gun shown in FIG. 3A. [Figure 4A] FIG. 2 is an enlarged cross-sectional view of a flow control section of a spray gun. [Figure 4B]FIG. 4B is an enlarged view of detail B of FIG. 4A. [Figure 4C] FIG. 4B is an enlarged view of detail C of FIG. 4A. [Figure 4D] FIG. 4B is an enlarged view of detail D of FIG. 4A. [Figure 5A] FIG. 1 is an isometric view of a fluid valve cartridge. [Figure 5B] FIG. 2 is an exploded cross-sectional view of the fluid valve cartridge. [Figure 6A] FIG. 1 is an isometric view of an air valve cartridge. [Figure 6B] FIG. 2 is an exploded cross-sectional view of the air valve cartridge. [Figure 7] FIG. 1 is an enlarged cross-sectional view of a portion of the spray gun showing the air valve assembly. [Figure 8] FIG. 2 is an enlarged cross-sectional view showing the air valve assembly. [Figure 9] FIG. 4 is a cross-sectional view showing a fan air conditioning member. [Figure 10A] FIG. 1 is a cross-sectional view showing the quick connect air cap attached to the spray gun in a locked state. [Figure 10B] FIG. 10 is a cross-sectional view showing the quick connect air cap in an unlocked state. [Figure 11A] FIG. 11D is a cross-sectional view of the spray tip assembly taken along line AA in FIG. 11C showing the spray tip assembly attached to the gun body. [Figure 11B] FIG. 11B is a cross-sectional view of the spray tip assembly taken along line BB of FIG. 11A. [Figure 11C] FIG. 11B is a cross-sectional view of the spray tip assembly taken along line CC of FIG. 11A. [Figure 12A] FIG. 10 is a cross-sectional view of the spray tip assembly attached to the gun body with the collar in a locked position. [Figure 12B] FIG. 12B is a cross-sectional view of the spray tip assembly of FIG. 12A showing the collar in an unlocked position. [Figure 12C] FIG. 12B is a cross-sectional view of the spray tip assembly taken along line CC of FIG. 12A. [Figure 12D]FIG. 12C is a cross-sectional view of the spray tip assembly taken along line DD of FIG. 12B. [Figure 13] FIG. 12D is a cross-sectional view of a spray tip assembly similar to the view shown in FIG. 12C. [Figure 14A] FIG. 2 is a cross-sectional view of a spray tip. [Figure 14B] FIG. 1 is a rear view of the spray tip. [Figure 14C] FIG. 1 is a front view of the spray tip. [Figure 14D] FIG. 1 is a side view of a spray tip. [Figure 14E] FIG. 10 is a rear view of the turbulator assembly. [Figure 15] FIG. 1 is a rear isometric view showing various spray tips. DETAILED DESCRIPTION OF THE INVENTION

[0015] The present disclosure relates to fluid spraying. More specifically, the present disclosure relates to air-assisted airless spraying. Air-assisted airless (AA) spray guns are configured to emit a spray of spray fluid, such as paint, varnish, lacquer, fine finish, high-gloss finish, water-based coating, or solvent-based coating. Air-assisted airless spray guns can be used to apply coatings to surfaces, furniture, cabinets, appliances, equipment, and workpieces, among other options. Air-assisted airless spray guns also emit compressed air. The auxiliary air portion of the compressed air is configured to assist in atomizing the spray fluid, complete the atomization of the fan tail, and prevent undesirable tailing. The fan air portion of the compressed air is configured to form a spray pattern. The spray fluid is emitted through a spray tip, and air is emitted through an air cap surrounding the spray tip. The auxiliary air is emitted with each trigger stroke, while the fan air can be set by the user between no fan air and maximum flow rate. The spray gun is configured to spray at a fluid pressure of up to about 34.5 megapascals (MPa) (about 5000 pounds per square inch (psi)). In some examples, the spray gun is configured to spray at a fluid pressure of up to about 10 MPa (about 1500 psi). In some examples, the spray gun is configured to spray at an air pressure of up to about 0.7 MPa (about 100 psi).

[0016] Figure 1A is a rear isometric view of spray gun 10. Figure 1B is a front isometric view of spray gun 10. Figure 1C is a side view of spray gun 10. Figures 1A-1C are taken together to illustrate the gun body 12, trigger 14, air cap 16, spray tip 18, collar 20, knob 22, fluid conduit assembly 24, and trigger lock 42. Gun body 12 includes a handle 26, a front end 28, and a rear end 30. Fluid conduit assembly 24 includes a fluid conduit 32, a lower fluid coupling 34, an upper fluid coupling 36, an air coupling 38, and a connector 40.

[0017] The spray gun 10 is configured to receive spray fluid and compressed air and emit a fluid spray. The gun body 12 supports various components of the spray gun 10. The air cap 16 is configured to emit air. The spray tip 18 is oriented to emit a spray through the air cap 16. In some examples, the spray tip 18 extends through the air cap 16 to emit the spray fluid. The spray tip 18 may include a shaped orifice, such as a cat-eye configuration, configured to shape the liquid spray emitted from the spray tip 18. A collar 20 secures the air cap 16 and spray tip 18 to the gun body 12. The trigger 14 is attached to the gun body 12 and is configured to actuate both the air valve and the fluid valve, as described in more detail below. A trigger lock 42 is movable between a deployed state and a stowed state. In the deployed state, the trigger lock 42 interacts with the trigger 14 to prevent actuation of the trigger 14. In the stowed state, the trigger lock 42 is spaced from the trigger 14 so that the trigger 14 can be actuated. In the illustrated example, the trigger lock 42 is configured to be oriented horizontally in the deployed state and vertically in the stowed state. The knob 22 extends from the rear end 30 of the gun body 12 and is positioned above the handle 26. The knob 22 can interact with an air valve in the gun body to adjust the opening therethrough, as described in more detail below. The knob 22 is configured to interact with the user's hand to provide a resting spot for the hand while gripping the handle 26. The knob 22 is sized to position the user's hand in a desired position along the handle 26 for the best ergonomic grip of the trigger 14.

[0018] The fluid tube assembly 24 is attached to the gun body 12. The lower fluid coupling 34 is configured to connect to a tube to receive spray fluid. The fluid tube 32 extends between the lower fluid coupling 34 and the upper fluid coupling 36. The fluid tube 32 carries spray fluid to the upper fluid coupling 36. The upper fluid coupling 36 is connected to a block within the gun body 12, which provides spray fluid to a fluid valve within the gun body 12. The air coupling 38 is connected to the handle 26 and supplies compressed air to an air flow path through the gun body 12. A connector 40 extends between the lower fluid coupling 34 and the air coupling 38 and maintains the desired spacing between them. The connector 40 can be a strip of material, such as plastic or metal, that maintains the spacing and connection.

[0019] During operation, a user can grasp the handle 26 of the gun body 12 with one hand and operate the spray gun 10 with one hand. The user can also operate the trigger 14 with one hand and actuate the trigger 14 to initiate spraying with the spray gun. Actuating the trigger 14 opens the air and fluid valves so that the spray gun 10 emits both spray fluid and air. Releasing the trigger 14 returns the valves to a normally closed state, stopping the flow of both spray fluid and air. In the illustrated example, a tail 27 extends from the rear of the spray gun 10 and is positioned between the knob 22 and the user's hand during operation. The tail 27 interacts with the user's hand and can provide support during spraying. In some examples, the spray gun 10 does not include a tail 27.

[0020] FIG. 2 is a side view of the spray gun 10′. As shown in FIG. 2, the knob 22 is located directly above the handle 26. The body 12′ of the spray gun 10′ does not include a tail 27, allowing the knob 22 to interact with the user's hand and provide upper support. The knob 22 can be removed and replaced with other knobs 22 of various sizes to modify the spray gun 10′ to accommodate the current user. For example, a knob 22 with a larger diameter can be used to position the user's hand lower on the handle 26, while a knob 22 with a smaller diameter can be used to position the user's hand higher on the handle 26. The knob 22 facilitates a custom fit of the spray gun 10′ to the user's hand, providing an appropriately sized grip area regardless of the user's hand size. Thus, a single spray gun 10′ can be modified to comfortably fit different users' hands by replacing the knob 22 with other knobs 22 of different sizes.

[0021] Figure 3A is an isometric exploded view of the spray gun 10. Figure 3B is an isometric exploded cross-sectional view of the spray gun 10. Figures 3A and 3B are described together. The spray gun 10 includes a gun body 12, a trigger 14, an air cap 16, a spray tip 18, a collar 20, a knob 22, a fluid conduit assembly 24, a fluid valve cartridge 44, an air valve cartridge 46, a fluid valve bore 48, an air valve bore 50, an air tube 82, and an air tube cap 83. The gun body 12 includes a handle 26, a front end 28, a rear end 30, a front block 52, and a rear block 54. The gun body 12 further includes a tail section 27, a mounting slot 56, an inlet bore 58, an auxiliary air bore 60, a fan air bore 62, a supply air bore 64, a front bore 72, and a rear bore 74. The fluid conduit assembly 24 includes a fluid conduit 32, a lower fluid coupling 34, an upper fluid coupling 36, an air coupling 38, a connector 40, and a mounting block 66. The mounting block 66 includes a spray fluid inlet 68 and a mounting bore 70. The fluid valve member 76 of the fluid valve cartridge 44 is shown. The first valve member 78 and the second valve member 80 of the air valve cartridge 46 are shown.

[0022] The spray gun 10 is configured to receive separate flows of spray fluid and compressed air and to emit a spray formed by the spray fluid and assisted by the compressed air. The spray gun 10 is capable of emitting the compressed air to form a spray pattern. The handle 26 extends from a rear block 54 of the gun body 12. The rear block 54 is positioned opposite the front block 52 and is integrally formed as part of each gun body 12. The trigger 14 is positioned in the axial gap between the front block 52 and the rear block 54.

[0023] The trigger 14 is configured to interact with the fluid valve cartridge 44 and the air valve cartridge 46 to control the flow of spray fluid and compressed air downstream through the fluid valve cartridge 44 and the air valve cartridge 46, respectively. In the illustrated example, the trigger 14 is configured to actuate the fluid valve member 76 of the fluid valve cartridge 44 and the first valve member 78 of the air valve cartridge 46 from a closed state to an open state. Actuating the trigger 14 to initiate spraying shifts each of the fluid valve member 76 and the first valve member 78 to their respective open states. The rear block 54 includes only the air flow path and air control components (e.g., the air valve cartridge 46) and does not include any fluid control components. The air valve cartridge 46 is self-contained enough to include all air valve components of the spray gun 10 and to control the flow of both the downstream auxiliary air and fan air portions through the auxiliary air bore 60, the fan air bore 62, and the supply air bore 64. In the illustrated example, the rear block 54 does not include any components related to the spray fluid. The front block 52 includes both liquid and air flow paths. The front block 52 thereby includes and / or defines both hydraulic and pneumatic flow paths. The front block 52 includes only liquid control components (e.g., the fluid valve cartridge 44) and does not include air control components. The fluid valve cartridge 44 is self-contained enough to include all spray fluid valve components for the spray gun 10 and control the flow of spray fluid to the spray tip 18.

[0024] An air valve bore 50 is formed in the gun body 12. The air valve bore 50 is formed in the rear block 54 and extends completely through the rear block 54. The air valve bore 50 includes two axial openings. The first opening extends through the rear end 30 of the spray gun 10 and is the opening through which the air valve cartridge 46 is attached to and detached from the gun body 12. The second opening extends through the front of the rear block 54 and opens into a gap in which the trigger 14 is located.

[0025] The air valve cartridge 46 is mounted within the air valve bore 50 and extends through each axial end of the air valve bore 50. The air valve cartridge 46 interacts with the gun body 12 to secure the air valve cartridge 46 within the air valve bore 50. The air valve cartridge 46 is connected to the gun body 12 within the air valve bore 50. In some examples, the housing of the air valve cartridge 46 can extend from the air valve bore 50 through an opening in the rear end 30. The first valve member 78 extends through an opening in the forward inner end of the rear block 54. The first valve member 78 controls the flow of the auxiliary air portion to the auxiliary air bore 60. The first valve member 78 controls the flow of the fan air portion to the second valve member 80. The first valve member 78 can also be referred to as a common valve member because the first valve member 78 is associated with both the first valve 90 and the second valve 92. The second valve member 80 controls the flow of the fan air portion downstream of the air valve cartridge 46. The second valve member 80 may also be referred to as a fan valve member because the second valve member 80 controls the flow of the fan air portion.

[0026] The air valve cartridge 46 contains the air control components of the spray gun 10 and can be installed and removed as a single part. The air valve cartridge 46 facilitates quick and easy installation, removal, and replacement of the air control components. In addition, the cartridge 46 is inserted and removed through the rear end 30, just as all air control components are inserted and removed through the rear end 30, providing a simple, efficient, and quick service process. Replacing the fluid valve cartridge 44 replaces each of the spray gun 10's spray fluid valve components as a single unit. Replacing the air valve cartridge 46 replaces each of the spray gun 10's air valve components as a single unit. The air valve cartridge 46 can be removed and installed while the fluid valve cartridge 44 remains installed in the spray gun body 12.

[0027] The knob 22 is disposed on the end of the air valve cartridge 46 that protrudes from the rear end 30. In some examples (e.g., as shown in FIG. 2 ), a portion of the knob 22, e.g., a cylindrical wall, can protrude toward the gun body 12 and above the portion of the air valve cartridge 46 that extends from the rear end 30. The knob 22 can interact with the second valve member 80. In some examples, the knob 22 can be free-floating on the air valve cartridge 46 such that the knob 22 is movable relative to the air valve cartridge 46 and the second valve member 80. As discussed in more detail below, a tool interface can be formed on the second valve member 80. The tool interface requires an adaptable adjustment tool to adjust the position of the second valve member 80 and, therefore, the adjustment tool to adjust the flow of the fan air portion. In the illustrated example, the knob 22 is engaged with the second valve member 80 such that the knob 22 can actuate the second valve member 80 to change the size of the flow path of the fan air portion downstream of the air valve cartridge 46. Knob 22 can be grasped by a user and manipulated (e.g., rotated or pulled) to adjust the position of second valve member 80 within the housing of air valve cartridge 46. In the illustrated example, knob 22 is secured to air valve cartridge 46 by fastener 84 and is configured to rotate to adjust the position of second valve member 80 to control the flow of the fan air portion.

[0028] The fluid valve bore 48 is at least partially formed in the gun body 12. A portion of the fluid valve bore 48 is formed through the mounting block 66. A forward bore 72 and a rearward bore 74 of the fluid valve bore 48 are formed axially on opposite sides of the mounting slot 56. The forward bore 72 and the rearward bore 74 are formed in the gun body 12. The forward bore 72 and the rearward bore 74 may be coaxial with the air valve bore 50. When the mounting block 66 is inserted into the mounting slot 56, the forward bore 72 and the rearward bore 74 align with the mounting bore 70 through the mounting block 66 to form the fluid valve bore 48. The forward bore 72, the rearward bore 74, and the mounting bore 70 can be considered to be aligned on a spray axis A of the spray gun 10, from which the liquid spray is emitted. In some examples, the liquid spray is formed as a pattern shape, such as an oval, a circle, or a sector, with the spray axis A located at the center of the spray pattern. Fluid valve bore 48 includes a first opening at front end 28 of spray gun 10 and a second opening that opens through the rear of front block 52 into a gap in which trigger 14 is located. In some examples, fluid valve bore 48 and air valve bore 50 are coaxially disposed on axis A.

[0029] The fluid valve cartridge 44 is mounted within the fluid valve bore 48 and extends through the forward bore 72, the mount bore 70, and the rear bore 74. To lock the fluid valve cartridge 44 within the fluid valve bore 48, the fluid valve cartridge 44 interacts with the gun body 12. The fluid valve cartridge 44 is connected to the gun body 12 within the fluid valve bore 48. For example, the interface between the fluid valve cartridge 44 and the gun body 12 can be formed within one of the forward bore 72 and the rear bore 74. The fluid valve cartridge 44 extends through the mount bore 70 between portions of the fluid valve bore 48 formed in the gun body 12. The fluid valve cartridge 44 extends through the mount block 66 and forms a support beam that locks the mount block 66 to the gun body 12 within the mount slot 56. The fluid valve cartridge 44 retains the mount block 66 within the mount slot 56 by extending through the mount hole 70 and the gun body 12.

[0030] The fluid valve cartridge 44 contains the spray fluid control components of the spray gun 10 and can be installed and removed as a single part. The fluid valve cartridge 44 facilitates quick and easy installation, removal, and replacement of the fluid control components. Additionally, the fluid valve cartridge 44 is inserted and removed through the front end 28, just as all fluid control components are inserted and removed through the front end 28, providing a simple, efficient, and quick servicing process. The fluid valve cartridge 44 can be removed and installed while the air valve cartridge 46 remains attached to the spray gun body 12.

[0031] In the illustrated example, the housing of the fluid valve cartridge 44 is configured to extend from each axial end of the fluid valve bore 48. A fluid valve member 76 is at least partially disposed within the housing of the fluid valve cartridge 44 and extends rearward from the housing toward the air valve cartridge 46. The fluid valve member 76 is configured to interact with the first valve member 78 such that the trigger 14 can actuate both the fluid valve member 76 and the first valve member 78.

[0032] The fluid conduit assembly 24 is attached to the gun body 12 and provides a connection for both spray fluid and compressed air to enter the spray gun 10. The air fitting 38 is connected to the handle 26 and is configured to connect to a conduit to provide compressed air to the air path through the gun body 12. It will be understood that the compressed air can be supplied to the air path through the gun body 12 in any desired manner. The compressed air flows through the inlet bore 58 to the air valve bore 50 and is stopped by the air valve cartridge 46 when the air valve cartridge 46 is in the closed position.

[0033] A connector 40 is attached to the lower fluid fitting 34. An air fitting 38 extends through the connector 40 and is attached to the handle 26. The air fitting 38 and connector 40 position the lower fluid fitting 34 and the fluid conduit 32 relative to the handle 26. The connector 40 can be a strip of material between the lower fluid fitting 34 and the air fitting 38, such as metal or plastic, among other options. The lower fluid fitting 34 is configured to connect to a tube extending from the pump and receive spray fluid from the pump via the tube. The fluid conduit 32 extends between the lower fluid fitting 34 and the upper fluid fitting 36. The upper fluid fitting 36 is connected to a mounting block 66 at a spray fluid inlet 68. The fluid conduit 32 supplies spray fluid to the mounting block 66 through the spray fluid inlet 68.

[0034] The mounting block 66 is configured to slidably fit within the mounting slot 56. In the illustrated example, the mounting slot 56 includes a single opening for receiving the mounting block 66. The mounting slot 56 includes a downwardly facing opening for receiving the mounting block 66. The mounting slot 56 can be formed in any desired manner. For example, the mounting slot 56 can be cast or machined. The gun body 12 can be formed by multiple components that fit together to form the mounting slot 56, such as a clamshell configuration, among other options. In the illustrated example, the mounting block 66 is a rectangular cuboid configured to be received by the rectangular mounting slot 56. The mounting block 66 slides vertically into the mounting slot 56. The mounting block 66 slides vertically out of the mounting slot 56. The mounting block 66 can slide transversely to the spray axis A, and in some examples, can slide perpendicular to the spray axis A. Although the mounting block 66 and the mounting slot 56 are described as having a rectangular horizontal cross-section, it is understood that the mounting block 66 and the mounting slot 56 can be of any desired compatible cross-sectional shape. For example, the mounting block 66 and the mounting slot 56 can have a triangular, square, circular, or other cross-sectional shape. In some examples, the mounting block 66 and the mounting slot 56 can include an error-proof element to prevent installation of the mounting block 66 in an incorrect orientation. For example, a keying element (e.g., a pin, rail, bump, etc.) can extend from one of the outer surface of the mounting block 66 and the wall of the mounting slot 56 and be received by a keying slot or opening formed in the other of the mounting block 66 and the mounting slot 56. In some examples, the keying element can be formed by a non-uniform cross-section of the mounting block 66 and the mounting slot 56 (e.g., one side is wider than the other). The error-proof element ensures that the mounting block 66 is properly oriented to receive the fluid valve cartridge 44.

[0035] The mounting block 66 slides into the mounting slot 56 and is positioned so that the mounting bore 70 is aligned with both the forward bore 72 and the rearward bore 74 to form the fluid valve bore 48. The fluid valve cartridge 44 is inserted into the fluid valve bore 48 and extends through the forward bore 72, the mounting bore 70, and the rearward bore 74 to secure the mounting block 66 within the mounting slot 56. In some examples, the fluid valve cartridge 44 may be the only component of the spray gun 10 that secures the mounting block 66 within the mounting slot 56. Spray fluid is provided to the mounting bore 70 through the spray fluid inlet 68. The spray fluid enters the fluid valve cartridge 44 from within a fluid chamber formed in the mounting block 66 between the portion of the mounting block 66 that defines the mounting bore 70 and the housing of the fluid valve cartridge 44.

[0036] During assembly of the spray gun 10, the fluid conduit assembly 24 is installed in front of the fluid valve cartridge 44. The trigger 14 can be attached after the fluid conduit assembly 24. The fluid conduit assembly 24 is positioned adjacent to the gun body 12, and the mounting block 66 is aligned with the mounting slot 56. The mounting block 66 is slid vertically into the mounting slot 56. The air fitting 38 is inserted through the connector 40 and threaded into the handle 26. In such an example, the fluid conduit assembly 24 is connected to the gun body 12 by the air fitting 38, but the mounting block 66 is not fixed relative to the gun body 12.

[0037] The fluid valve cartridge 44 is inserted into the fluid valve bore 48 through the front end 28 and secured to the gun body 12. The fluid valve cartridge 44 extends through the forward bore 72, the mount bore 70, and the rear bore 74. The fluid valve cartridge 44 supports the mounting block 66 and secures it within the gun body 12 and the mount slot 56. The fluid valve cartridge 44 interacts with the mounting block 66 within the mounting bore 70 to form a fluid seal and define a fluid chamber. For example, an annular elastomeric sealing ring may be attached to one of the mounting block 66 and the fluid valve cartridge 44 and interact with the other of the mounting block 66 and the fluid valve cartridge 44. The fluid seal prevents spray fluid from leaking from the fluid chamber within the mounting bore 70 between the wall of the mounting bore 70 and the fluid valve cartridge 44. It will be appreciated that in some examples, the fluid valve cartridge 44 may be inserted through the fluid valve bore 48 before connecting the air fitting 38.

[0038] The air valve cartridge 46 is inserted into the air valve bore 50 through the rear end 30 of the gun body 12. The first valve member 78 protrudes into the gap between the front block 52 and the rear block 54 and interacts with the fluid valve member 76. The first valve member 78 interacts with the fluid valve member 76 such that the first valve member 78 can move the fluid valve member 76 relative to the first valve member 78 during at least a portion of the pull stroke of the trigger 14. The relative movement causes the flow path through the air valve cartridge 46 to open before the flow path through the fluid valve cartridge 44. This causes the spray gun 10 to begin emitting air before emitting spray fluid, which ensures a uniform spray pattern and prevents buildup of spray fluid on the air cap 16, preventing clogging.

[0039] The air tube 82 is inserted into the supply air bore 64. The air tube cap 83 is connected to the gun body 12 and secures the air tube 82 within the gun body 12. For example, the air tube cap 83 may include threads configured to interact with threads in the air bore 64.

[0040] During operation, the trigger 14 is actuated to open the fluid valve member 76 and the first valve member 78. Spray fluid is permitted to flow downstream from the fluid valve cartridge 44 and is emitted as a liquid spray through the spray tip 18. Compressed air flows through the air inlet bore 58 into the air valve cartridge 46. The auxiliary air portion flows downstream from the air valve cartridge 46 to the auxiliary air bore 60, through the auxiliary air bore 60, and into the supply air bore 64. The fan air portion flows downstream from the air valve cartridge 46 through the fan air bore 62 to the supply air bore 64, assuming the second valve member 80 is in an open state. While the auxiliary air portion and the fan air portion each flow into the air bore 64, the air tube 82 located within the supply air bore 64 forms a fluid barrier between the respective airflow portions. The auxiliary air portion and the fan air portion do not mix downstream of the air valve cartridge 46. In the illustrated example, the auxiliary air portion flows through the supply air bore 64 between the air tube 82 and the portion of the gun body 12 defining the supply air bore 64, while the fan air portion flows through the supply air bore 64 within the air tube 82.

[0041] The fluid conduit assembly 24 facilitates quick and easy assembly and maintenance of the spray gun 10. Assembling and maintaining the multiple components that form a fluid conduit assembly can be cumbersome. Each of the multiple components must be individually considered, tracked, and carefully joined together to prevent leaks and unwanted pressure loss. The fluid conduit assembly 24 provides a single assembly that facilitates assembly and maintenance, allowing for greater machining and manufacturing versatility in both the gun body 12 and the fluid conduit assembly 24 without compromising operational efficiency or spray quality. The self-contained valving provided by the fluid valve cartridge 44 and air valve cartridge 46 also facilitates quick and efficient maintenance and maintains isolation between air- and fluid-supply related components.

[0042] Figure 4A is an enlarged cross-sectional view of spray gun 10 showing the flow control and spray components of spray gun 10. Figure 4B is an enlarged view of detail B in Figure 4A. Figure 4C is an enlarged view of detail C in Figure 4A. Figure 4D is an enlarged view of detail D in Figure 4A. Figures 4A-4D together illustrate the gun body 12, trigger 14, air cap 16, spray tip 18, mounting collar 20, knob 22, handle 26, fluid valve cartridge 44, air valve cartridge 46, fluid valve bore 48, air valve bore 50, mounting block 66, air tube 82, and coupler 86 of spray gun 10. Gun body 12 includes mounting slot 56, inlet bore 58, auxiliary air bore 60, fan air bore 62, supply air bore 64, forward bore 72, and rear bore 74. Mounting block 66 includes spray fluid inlet 68 and mounting bore 70.

[0043] The air valve cartridge 46 includes a first valve member 78, an air cartridge body 88, a first valve 90, a second valve 92, a third valve 94, a first interface 98, and a return spring 108. The air cartridge body 88 includes an air inlet port 100 and an air outlet port 102. A first seat 104 is formed by the gun body 12, and a second seat 106 is disposed within the air cartridge body 88. The first valve member 78 includes a first valve seal 110, a second valve seal 112, a drive shaft 114, and a receiving chamber 116. The second valve member 80 includes a third valve seal 120 and a valve actuator 121. The first valve 90 is defined by the first seat 104 and the first valve seal 110. The second valve 92 is defined by a second seat 106 and a second valve seal 112. The third valve 94 is defined by a third seat 118 and a third valve seal 120.

[0044] The fluid valve cartridge 44 includes a fluid cartridge body 122, a fluid valve 124, a seal assembly 126, a second interface 128, and an actuator spring 154. The fluid cartridge body 122 includes a tip mount 130, a fluid housing 132, a spring housing 134, and a fluid inlet port 136. The fluid valve 124 includes a fluid valve member 76 and a fluid seat 138. The fluid valve member 76 includes a needle 140 and an actuator shaft 142. The needle 140 includes a fluid valve seal 144.

[0045] The gun body 12 supports the other components of the spray gun 10. The spray gun 10 receives a flow of spray fluid, such as a liquid such as paint, among other things, as well as a flow of compressed air. The spray fluid may be received through the upper fluid coupling 36 and the mounting block 66. The fluid valve cartridge 44 controls the flow of spray fluid between the mounting block 66 and the spray tip 18. The fluid valve cartridge 44 is disposed within the fluid valve bore 48.

[0046] Compressed air can be received through an air inlet bore 58 in the handle 26. The air valve cartridge 46 controls the flow of air between the air inlet bore 58 and the air cap 16. The air valve cartridge 46 controls the flow of both an auxiliary air portion (indicated by arrow AA) and a fan air portion (indicated by arrow FA) downstream of the air valve cartridge 46. While the fan air portion FA and the auxiliary air portion AA are shown flowing through first and second flow paths, respectively, it is understood that the fan air portion FA can be directed to the second flow path and the auxiliary air portion AA can be directed to the first flow path in other embodiments of the spray gun 10, depending on the internal routing configuration for delivering air downstream of the air valve cartridge 46. The inlet air flow (IF) flows through the inlet bore 58 into the air valve bore 50. Air is contained within the air valve bore 50 and the air cartridge body 88 with the air valve cartridge 46 in a closed position. The air valve cartridge 46 is disposed within the air valve bore 50. Inlet bore 58 extends through handle 26 to air valve bore 50. A fan air bore 62 and an auxiliary air bore 60 extend from air valve bore 50. Fan air bore 62 and auxiliary air bore 60 each extend to a supply air bore 64.

[0047] The supply air bore 64 extends through the gun body 12 from the rear end 30 toward the front end 28. The air tube 82 is disposed within the supply air bore 64 and divides the supply air bore 64 into two separate flow paths. A first flow path is disposed between the exterior of the air tube 82 and the interior of the supply air bore 64. The first passage is fluidly connected to the air valve bore 50 by the auxiliary air bore 60. An opening 146 is formed in the inner end of the supply air bore 64. In the illustrated example, the opening 146 is an entrance to a flow path through the gun body 12 for the auxiliary air portion to flow between the supply air bore 64 and the air cap 16. A second flow path extends through the air tube 82. The second passage is fluidly connected to the air valve bore by the fan air bore 62. The first and second flow paths are fluidly isolated from each other by the air tube 82 so that air flowing in one flow path does not mix with air flowing in the other flow path and there is no crossover between the flow paths. The fan air portion and the auxiliary air portion are fluidly isolated at a location downstream of the air valve cartridge 46. The fan air portion and the auxiliary air portion are fluidly isolated from each other at a location downstream of the first valve member 78. The fan air portion and the auxiliary air portion are fluidly isolated between the air valve cartridge 46 and the air cap 16.

[0048] The fluid valve bore 48 and the air valve bore 50 are coaxially disposed on the spray axis A. The fluid valve cartridge 44 and the air valve cartridge 46 are coaxially disposed on the spray axis A. The fluid valve member 76 and the first valve member 78 are coaxially disposed on the spray axis A. The first valve member 78 and the second valve member 80 are coaxially disposed on the spray axis A.

[0049] The fluid control components of the spray gun 10 are disposed within and supported by the front block 52, and the air control components of the spray gun 10 are disposed within and supported by the rear block 54 of the spray gun 10. The valve members and return springs of the fluid valve cartridge 44 and the air valve cartridge 46 are formed as part of the cartridges. Each of the flow control components is disposed on the same side of the trigger 14 for the spray fluid flow and the air flow, respectively. Thus, all of the spray fluid-contacting flow control components (e.g., the fluid valve member 76) are disposed on one axial side of the trigger 14. All of the air-contacting flow control components (e.g., the first valve member 78 and the second valve member 80) are disposed on one axial side of the trigger 14. In the illustrated example, all of the spray fluid flow control components are disposed on the opposite axial side of the trigger 14 from all of the air flow control components. No fluid control components are disposed within the air valve bore 50, and no air control components are disposed within the fluid valve bore 48.

[0050] The trigger 14 is attached to the gun body 12. The trigger 14 is configured to control actuation of the first valve member 78 and the fluid valve member 76. The trigger 14 is spaced from the handle 26 and disposed between the fluid cartridge body 122 and the air cartridge body 88. A portion of the fluid valve member 76 extends through the trigger 14. In the illustrated example, a portion of the actuator shaft 142 extends through the trigger 14. The coupler 86 is disposed around a portion of the fluid valve member 76 disposed on the same side of the trigger 14 as the air valve cartridge 46. The coupler 86 is attached to, and in some examples, can be connected to, an end of the first valve member 78. The coupler 86 is configured to interact with the trigger 14 and the first valve member 78 to actuate the first valve member 78 from a closed state to an open state. The coupler 86 is configured to interact with the trigger 14 and the fluid valve member 76 to actuate the fluid valve member 76 from a closed state to an open state.

[0051] As best shown in FIG. 4B , the spray tip 18 is disposed within the air cap 16. The spray tip 18 can interact with the end of the fluid valve cartridge 44 to seal the fluid flow path therebetween. In the illustrated example, the seal within the spray tip 18 interacts with a nozzle extending from the tip mount 130 of the fluid cartridge body 122. The air cap 16 is disposed around the end of the fluid valve cartridge 44. In the illustrated example, the air cap 16 axially overlaps the tip mount 130 of the fluid cartridge body 122. In the illustrated example, the air cap 16 does not axially overlap the fluid valve 124.

[0052] The collar 20 interfaces with the ends of the air cap 16 and the gun body 12. The collar 20 holds the air cap 16 in place relative to the fluid valve cartridge 44 and connects the air cap 16 to the gun body 12. In the illustrated example, the collar 20 includes a threaded interface. However, it is understood that the collar 20 can be a quick connect collar 20, as described in more detail below.

[0053] The mounting block 66 is configured to fit within the mounting slot 56. The mounting slot 56 is configured to receive the mounting block 66. The fluid valve cartridge 44 extends into and through the fluid valve bore 48. A mounting bore 70 for the fluid valve bore 48 is formed through the fluid mounting block 66. The fluid valve bore 48 includes a forward bore 72 formed in the gun body 12. Spray fluid can flow through the forward bore 72 between the spray fluid inlet 68 and the spray tip 18. The fluid valve bore 48 includes a rear bore 74 formed in the gun body 12, through which a portion of the fluid cartridge body 122 extends. The fluid valve bore 48 includes a mounting bore 70 formed through the mounting block 66. The fluid valve cartridge 44 extends through each of the forward bore 72, the mounting bore 70, and the rear bore 74.

[0054] The fluid cartridge body 122 is attached to the gun body 12 by a second interface 128. For example, the second interface 128 can be formed by interacting threads formed on the fluid cartridge body 122 and the gun body 12. In some examples, the second interface 128 is the only fixed interface between the fluid valve cartridge 44 and the gun body 12. In the illustrated example, the second interface 128 is formed within the forward bore 72. In the illustrated example, the fluid cartridge body 122 is formed by a tip mount 130, a fluid housing 132, and a spring housing 134. Both the spray fluid and air can flow through the fluid valve cartridge 44. For example, an air passage can extend through a portion of the tip mount 130 and can be spaced radially outward from the central spray fluid passage. At least a portion of each of the air and spray fluid passages can be formed within the tip mount 130.

[0055] All components of the fluid valve cartridge 44 are removable together as a single piece and do not require separate removal from the fluid valve bore 48 and the gun body 12. The various components of the fluid valve cartridge 44 are connected to one another independently of the gun body 12 and other portions of the spray gun 10. Thus, the fluid valve cartridge 44 can be installed in and removed from the spray gun 10 as a single piece. For example, the various components of the fluid valve cartridge 44 can be threaded or press-fit to hold the components together so that the components stay together regardless of the orientation of the fluid valve cartridge 44 (e.g., the components do not slide apart). In some examples, the components forming the fluid cartridge body 122 can be permanently assembled such that the fluid cartridge body 122 can be considered a single element that is insertable into and removable from the spray gun body. For example, the components can be brazed, welded, press-fit, glued, etc. The fluid valve cartridge 44 remains a unitary piece when outside the gun body 12 so that the various components of the fluid valve cartridge 44 do not freely separate.

[0056] The fluid valve cartridge 44 supports the fluid mounting block 66 within the gun body 12. The fluid valve cartridge 44 can hold the fluid mounting block 66 within the gun body 12. The fluid cartridge body 122 extends between the forward bore 72 and the rear bore 74 formed in the gun body 12 and through the mounting bore 70 of the mounting block 66. The mounting block 66 is fixed in the mounting slot 56 by the fluid valve cartridge 44, which forms a support beam between the forward bore 72 and the rear bore 74 via the mounting block 66. Both the fluid valve cartridge 44 and the mounting block 66 can be considered to be attached to the gun body 12 by a second interface 128. Therefore, the mounting block 66 is held within the gun body 12 but is not directly connected to the gun body 12.

[0057] A sealing interface between the fluid valve cartridge 44 and the fluid valve bore 48 is formed within the mounting block 66 and between the mounting block 66 and the fluid cartridge body 122. Spray fluid is supplied through a spray fluid inlet 68 formed in the mounting block 66 and flows into the interior of the mounting block 66. The spray fluid enters the fluid cartridge body 122 through a fluid inlet port 136 formed in the fluid cartridge body 122. In the illustrated example, the fluid inlet port 136 is formed within the fluid housing 132. A seal groove is formed on the fluid housing 132 to receive a sealing member, such as an elastomeric O-ring, for interacting with the mounting block 66 to seal a fluid chamber formed between the inner wall of the mounting block 66 and the outer surface of the fluid cartridge body 122.

[0058] The seal assembly 126 is disposed within the fluid housing 132. The fluid valve member 76 extends through the seal assembly 126. The seal assembly 126 is configured to prevent fluid from flowing from outside the fluid housing 132 into the spring housing 134 and may include one or more seals configured to wipe fluid from the needle 140 during actuation of the needle 140. The fluid valve member 76 extends between the trigger 14 and a fluid seat 138. The fluid valve member 76 is actuable between an open state and a closed state. In the open state, the fluid valve member 76 is spaced from the fluid seat 138 to open a flow path for spray fluid to exit the fluid valve cartridge 44 and flow to and through the spray tip 18 to generate a fluid spray. In the closed state, the fluid valve seal 144 interacts with the fluid seat 138 to close the flow path and prevent fluid from exiting the fluid valve cartridge 44.

[0059] A fluid valve seal 144 is formed at the tip of the cantilevered end of the needle 140. The fluid valve seal 144 can be formed in any desired manner, such as a ball attached to the needle 140. However, it is understood that other forms of the valve seal 144, such as a cone, are also possible. The fluid valve seal 144 can be formed from, among other materials, metal. For example, the fluid valve seal 144 can be formed from, among other materials, stainless steel. The fluid seat 138 can be formed as part of the fluid cartridge body 122 or as a separate component. The fluid valve 124 is defined by the fluid valve seal 144 and the fluid seat 138.

[0060] The needle 140 extends through a fluid chamber formed within the fluid cartridge body 122. The needle 140 extends outside the fluid chamber and interacts with an actuator shaft 142. The needle 140 is fixed to and moves with the actuator shaft 142. The actuator shaft 142 is at least partially disposed within the spring housing 134 and extends outside the spring housing 134. The actuator shaft 142 extends through the trigger 14. The actuator shaft 142 extends through an opening in the trigger 14, such as a slot, among other options. The slot is sized to allow the trigger 14 to move relative to the actuator shaft 142 without engaging the actuator shaft 142. The actuator shaft 142 extends into a receiving chamber 116 formed at the end of the first valve member 78.

[0061] An actuator spring 154 is disposed within the spring housing 134. The actuator spring 154 interacts with the actuator shaft 142 to bias the actuator shaft 142 toward the fluid housing 132, thereby biasing the fluid valve member 76 toward the closed position. The actuator spring 154 drives the fluid valve member 76 from an open state to a closed state. When the trigger 14 is released, the actuator spring 154 returns the fluid valve member 76 to the closed state to stop fluid flow downstream from the fluid valve cartridge 44. Spray fluid is prevented from flowing downstream from the fluid valve cartridge 44 with the fluid valve 124 closed.

[0062] As best seen in FIG. 4C , the air valve cartridge 46 is disposed within the air valve bore 50 of the gun body 12. The air cartridge body 88 is attached to the gun body 12 by a first interface 98. For example, the first interface 98 can be formed by interacting threads formed on the air cartridge body 88 and the gun body 12. In some examples, the first interface 98 is the only fixed interface between the air valve cartridge 46 and the gun body 12. In the illustrated example, the first interface 98 is formed within the air valve bore 50. In the illustrated example, the fan air bore 62 and the auxiliary air bore 60 are each located axially on the same side of the first interface 98. In the illustrated example, the fan air bore 62 and the auxiliary air bore 60 are axially disposed relative to the spray axis A between the first interface 98 and the second interface 128. However, it is understood that the first interface 98 can be located at various positions along the air valve bore 50. For example, first interface 98 may be formed at an axial location between where fan air bore 62 and auxiliary air bore 60 extend from air valve bore 50. In some examples, the location where fan air bore 62 and auxiliary air bore 60 intersect air valve bore 50 is located axially opposite first interface 98 from second interface 128.

[0063] All components of the air valve cartridge 46 are removable together as a single piece and do not require separate removal from the air valve bore 50 or the gun body 12. The various components of the air valve cartridge 46 are connected to one another independently of the gun body 12 and other portions of the spray gun 10. In some examples, multiple components can form the air cartridge body 88, and the components forming the air cartridge body 88 can be permanently assembled such that the air cartridge body 88 can be considered a single component. In the illustrated example, the air cartridge body 88 is formed as a single component. In examples where the air cartridge body 88 is formed from multiple components, the components can be threaded, brazed, welded, press-fit, glued, etc. to hold the components together so that they stay together regardless of the orientation of the air valve cartridge 46 (e.g., so that the components do not slide apart). In some examples, the connections can be permanent connections. The air valve cartridge 46 remains a unitary piece when outside the gun body 12 so that the various components of the air valve cartridge 46 do not freely separate.

[0064] A sealing interface is formed between the air valve cartridge 46 and the air valve bore 50. Compressed air is supplied through an inlet bore 58 formed in the handle 26 and flows into the air valve bore 50. Air can enter the air cartridge body 88 through one or more inlet ports 100. In the illustrated example, the inlet ports 100 are oriented axially toward the front end of the spray gun 10. One or more seal grooves can be formed in the air cartridge body 88 to receive seals for interaction with the gun body 12 to seal an air chamber formed between the inner wall of the air valve bore 50 and the outer surface of the air cartridge body 88. In the illustrated example, the air cartridge body 88 includes two annular seal grooves located axially on either side of an outlet port 102. The air outlet ports 102 can be generally radially positioned in some examples to provide a generally radial flow of fan air exiting the air valve cartridge 46.

[0065] The first valve member 78 is configured to control the flow of fan air and auxiliary air downstream from the inlet air chamber within the air valve cartridge 46. The second valve member 80 is configured to control the flow of fan air downstream from the air valve cartridge 46. Auxiliary air can flow downstream from the air valve cartridge 46 with the first valve member 78 in an open state and the second valve member 80 in either an open or closed state. Fan air can flow downstream from the air valve cartridge 46 with the first valve member 78 in an open state and the second valve member 80 in an open state. Thus, the fan air portion requires multiple valves to be open simultaneously, while the auxiliary air portion requires a single valve to be open.

[0066] The first valve member 78 is at least partially disposed within the air cartridge body 88 and is actuable relative to the air cartridge body 88 along the spray axis A. Actuating the first valve member 78 to an open state opens a flow path through both the first valve 90 and the second valve 92. A return spring 108 extends between the air cartridge body 88 and the first valve member 78 and interacts with both the air cartridge body 88 and the first valve member 78. The return spring 108 is configured to bias the first valve member 78 toward a closed state. In the illustrated example, the return spring 108 is disposed outside the air cartridge body 88. However, it will be understood that in other examples, the return spring 108 can be disposed wholly or partially within the air cartridge body 88.

[0067] In the illustrated example, the first valve seal 110 is formed by a portion of the first valve member 78. In the illustrated example, the second valve seal 112 is formed by a portion of the first valve member 78. The first valve seal 110 and the second valve seal 112 can be formed as enlargements of the first valve member 78 relative to the spray axis A. The first valve seal 110 and the second valve seal 112 can protrude in a generally radial direction. In the illustrated example, the first valve seal 110 is formed as a generally conical enlargement of the first valve member 78. The first valve seal 110 is configured to interact with the gun body 12 when in the closed state. In the illustrated example, a seal groove is formed in the outer surface of the first valve seal 110. The seal is disposed in the seal groove to interact with a portion of the gun body 12 and form a fluid-tight seal between the first valve seal 110 and the gun body 12. In the illustrated example, the seal is a U-cup seal. However, it is understood that other options are possible.

[0068] The second valve seal 112 is disposed at the end of the first valve member 78 opposite the first valve seal 110. The second valve seal 112 is formed as a spherical portion extending radially relative to the body of the first valve member 78. In the illustrated example, the second valve seal 112 connects the first valve member 78 to the cartridge body 88, maintaining the air valve cartridge 46 as a single assembly even when removed from the gun body 12. In the illustrated example, the maximum diameter D1 of the spherical portion forming the second valve seal 112 is larger than the diameter D2 of the cartridge body 88. The second valve seal 112 can be formed from a resilient material configured to deform and return to its nominal size and shape after deformation. For example, the second valve seal 112 (or all of the first valve member 78) can be formed from plastic, among other options. The first valve member 78 can be connected to the cartridge body 88 by inserting the second valve seal 112 into the cartridge body 88 through the port 100. The smaller diameter D2 deforms the resilient second valve seal 112 as it passes through the smaller diameter D2 portion of the cartridge body 88. The resilient second valve seal 112 returns to its nominal shape and size after passing through the diameter D1 portion of the cartridge body 88. The larger diameter portion of the cartridge body 88 retains the larger diameter portion of the second valve seal 112 within the cartridge body. Thus, the first valve member 78 can be pressed into the cartridge body 88. As shown, a seal member, such as an elastomeric O-ring, is disposed in a seal groove formed on the second valve seal 112. The seal groove has two walls on each axial side of the seal groove. In the illustrated example, one of the walls extends radially farther than the other wall. In the example shown, the wall at the rear end of the bulb, which may define the larger diameter D1, extends further from the body of the first valve member 78 than the front wall.

[0069] In the illustrated example, the return spring 108 interacts with the side of the first valve seal 110 opposite the sealing surface of the first valve seal 110. The return spring 108 is configured so that the spring force is sufficient to return the first valve member 78 to the closed position (shown in FIG. 4C ), but not sufficient to cause the second valve seal 112 to exit the cartridge body 88. It should be understood that the first valve seal 110 and the second valve seal 112 can be formed in any desired manner suitable for controlling airflow and can be formed in different manners. Each of the first valve seal 110 and the second valve seal 112 can include an inclined surface. The inclined surface can be oriented in the same axial direction. The inclined surface facilitates sealing. In the illustrated example, a seal is attached to each of the first valve seal 110 and the second valve seal 112. A seal groove can be formed in each of the first valve seal 110 and the second valve seal 112. It should be understood that in some examples, the first valve seal 110 and the second valve seal 112 may directly interact with the first seat 104 and the second seat 106, respectively, when the first valve member 78 is in the closed state. In the illustrated example, the elastomeric seal disposed on the first valve seal 110 is a U-cup seal and the elastomeric seal disposed on the second valve seal 112 is an O-ring seal, although it should be understood that other configurations are possible.

[0070] The first seat 104 is formed by the gun body 12. The first seat 104 is located at a first end of the cartridge bore 50 opposite the second valve member 80. While the first seat 104 is shown as being formed by the gun body 12, it is understood that the first seat 104 may be formed by a separate component mounted within the spray gun 10. For example, the first seat 104 may be formed by a portion of the air cartridge body 88 or another component disposed within and / or supported by the air cartridge body 88. In some examples, the first seat 104 may be formed by a component separate from the air cartridge body 88 and disposed within the cartridge bore 50. The first valve 90 is defined by a first valve seal 110 and the first seat 104. An auxiliary air outlet flow path is formed through the first valve 90 between the first valve seal 110 and the first seat 104 when the first valve 90 is in an open state. The auxiliary air outlet passage is generally axially oriented.

[0071] The first valve member 78 extends into and at least partially axially overlaps the air cartridge body 88. A second seat 106 is formed by the air cartridge body 88. In the illustrated example, a second valve seal 112 interacts with the air cartridge body 88 to control the flow of air through the second valve 92. The second valve 92 is defined by the second valve seal 112 and the second seat 106.

[0072] The drive shaft 114 is part of the first valve member 78, extending axially forward from the air valve bore 50. The drive shaft 114 extends through a throat seal 148. The throat seal 148 maintains pressurization within the air valve bore 50 downstream of the first valve seal 110. In the illustrated example, the throat seal 148 is a U-cup seal. The tip of the drive shaft 114 is disposed outside the air valve bore 50. A receiving chamber 116 is formed within the drive shaft 114.

[0073] The actuator shaft 142 extends from the spring housing 134 into the receiving chamber 116. The coupler 86 is disposed around the actuator shaft 142 and interacts with the drive shaft 114 of the first valve member 78. The coupler 86 is movable relative to the actuator shaft 142 along with the drive shaft 114. In some examples, the coupler 86 can float freely on the actuator shaft 142 between the tip of the drive shaft 114 and the trigger 14. Both the fluid valve member 76 and the first valve member 78 can float relative to the coupler 86 during at least a portion of the trigger's pull stroke. In some examples, the coupler 86 can be secured to the drive shaft 114, for example, by an interacting thread. This allows the fluid valve member 76 to float relative to the coupler 86 while the first valve member 78 is secured to the coupler 86.

[0074] The second valve member 80 is at least partially disposed within the air cartridge body 88. In the illustrated example, a third valve seal 120 is disposed within the air cartridge body 88, and a valve actuator 121 extends from the third valve seal 120. The valve actuator 121 is configured to axially shift the third valve seal 120 to move the second valve member 80 between an open state and a closed state. A third valve 94 is formed within the air cartridge body 88. In the illustrated example, a tip of the second valve member 80 forms the third valve seal 120, and the air cartridge body 88 forms a third seat 118. The third valve 94 is defined by the third valve seal 120 and the third seat 118.

[0075] The second valve member 80 is configured to interact with the third seat 118 when the second valve member 80 is in a closed state. More specifically, the third valve seal 120 is configured to interact with the air cartridge body 88 to form the third valve 94. The second valve member 80 can directly contact and interact with the air cartridge body 88 when the third valve 94 is in a closed state. Thus, the third valve 94 can be defined by a hard contact (e.g., direct contact between the air cartridge body 88 and the second valve member 80) rather than a soft seal such as an elastomeric seal. However, it will be understood that the third valve 94 can be formed in any desired manner. The third valve seal 120 is formed at the end of the second valve member 80. The third valve seal 120 can include an inclined surface (e.g., not perpendicular or parallel to the spray axis A) on the second valve member 80 to interact with the cartridge body 88 to form the third valve 94. For example, the sealing surface of the third valve seal 120 may be formed by a shoulder on the second valve member 80. In the illustrated example, the third valve seal 120 is formed by a plug attached to the valve shaft 121. The second valve member 80 is spaced from the third seat 118 when the third valve 94 is in the open position.

[0076] The second valve member 80 is supported by the air cartridge body 88 and is unaffected by the pull of the trigger 14. The second valve member 80 may, in some examples, be connected to the air cartridge body 88 by, among other options, interacting threads or the like. As described in more detail below, the third valve seal 120 includes an outer contour configured to interact with an inner contour within the air cartridge body 88 to prevent the third valve seal 120 from rotating about the axis A.

[0077] The second valve member 80 is movable relative to the gun body 12. A valve actuator 121 is connected to the third valve seal 120 and extends rearward through the air cartridge body 88. The valve actuator 121 is configured to shift the position of the third valve seal 120 to change the size of the opening through the third valve 94. In the illustrated example, the valve actuator 121 is connected to the third valve seal 120 by interacting threads. The valve actuator 121 is connected to the knob 22 by a fastener 84. A seal groove may be formed in the outer radial surface of the second valve member 80. In the illustrated example, the seal groove is formed on the valve shaft 121, and a seal, such as an elastomeric O-ring, is positioned in the seal groove to contact the inner surface of the air cartridge body 88 and prevent air from flowing around the second valve member 80 and out of the air cartridge body 88.

[0078] The interface between the second valve member 80 and the air cartridge body 88 facilitates actuation of the second valve member 80 against the third seat 118 to change the size of the opening through the third valve 94. For example, the valve actuator 121 can be rotated relative to the air valve bore 50 (e.g., in one of a clockwise and counterclockwise direction) to thread the third valve seal 120 further onto the valve actuator 121 and widen and / or open the flow path through the third valve 94 between the second valve member 80 and the third seat 118. The valve actuator 121 can be rotated in the other rotational direction (e.g., the other of the clockwise and counterclockwise directions) to axially shift the third valve seal 120, thereby narrowing and / or closing the flow path through the third valve 94. The keyed interface between the cartridge body 88 and the third valve seal 120 prevents rotation of the third valve seal 120 when the valve actuator 121 is rotated, thereby causing linear movement when the third valve seal 120 is threaded and unthreaded from the valve actuator 121.

[0079] The air outlet ports 102 extend through the air cartridge body 88 and provide a flow path for fan air to exit the air valve cartridge 46. The air outlet ports 102 are generally radially disposed such that the fan air flow exiting the air valve cartridge 46 is generally radial. In the illustrated example, the air outlet ports 102 are angled forward between an inlet formed inside the air cartridge body 88 and an outlet formed outside the air cartridge body 88. The outlets of the air outlet ports 102 are axially disposed between the first interface 98 and a seal groove formed around the air cartridge body 88. In some examples, the air valve cartridge 46 may include an annular array of air outlet ports 102.

[0080] The knob 22 is supported by the air valve cartridge 46. The knob 22 is disposed outside the gun body 12 and is accessible by the user. In the illustrated example, the knob 22 is fixedly connected to the second valve member 80 such that the position of the second valve member 80 can be adjusted by grasping and manipulating the knob 22. For example, the knob 22 can be rotated to rotate the valve actuator 121. In the illustrated example, a detent 123 interacts with a recess 125 to fix the rotational position of the knob 22, thereby fixing the size of the opening through the third valve 94. In the illustrated example, the detent 123 is fixed to the knob 22, and the recess 125 is formed on the air cartridge body 88. As described in more detail below, an array of recesses 125 can be formed on the air valve body 88 such that the knob 22 can be set to a plurality of positions associated with different sized openings through the third valve 94. In some examples, the knob 22 is freely mounted such that rotation of the knob 22 does not affect the position of the second valve member 80 .

[0081] The knob 22 projects rearward relative to the gun body 12. The knob 22 is not a permanent part of the spray gun 10 or the gun body 12. The knob 22 may not be a permanent component on the air valve cartridge 46. In some examples, the gun body 12 does not include a tail 27, and as a result, the gun body 12 does not include an integral or permanent protrusion extending rearward to interact with a user's hand. In such examples, the knob 22 may be sized to position the user's hand in an appropriate position along the handle 26 for efficient and ergonomic actuation of the trigger 14 while gripping the handle 26. In some examples, the knob 22 may be removed and replaced with a knob 22 of the same or different dimensions.

[0082] As best seen in FIG. 4D , a radial gap RG1 is disposed between the actuator shaft 142 and the wall of the receiving chamber 116. The radial gap RG1 is an annular gap extending around the actuator shaft 142 between the actuator shaft 142 and the wall of the drive shaft 114 that defines the chamber 116. The radial gap RG1 compensates for axial misalignment between the fluid valve cartridge 44 and the air valve cartridge 46. The radial gap RG1 minimizes adverse effects that may be caused by stack-up errors in the valve assembly. The fluid valve cartridge 44 and the air valve cartridge 46 are preferably coaxially aligned on the spray axis A. The flow control components of the fluid valve cartridge 44 are aligned on the fluid valve axis, which is aligned on the spray axis A by the second interface 128. The air flow control components of the air valve cartridge 46 are aligned on the air valve axis, which is aligned on the spray axis A by the first interface 98. The fluid valve axis and the air valve axis are preferably coaxially aligned by the first interface 98 and the second interface 128. The number of interfaces is limited to two. Limiting the number of interfaces facilitates alignment and prevents stackup and concentricity errors from accumulating between multiple connections. The limited number of connections and the large radial gap RG1 prevent contact between the fluid valve member 76 and the first valve member 78, which could cause wear and lead to leaks. The radial gap RG1 is sized to allow some misalignment between the fluid valve axis and the air valve axis and prevent undesired contact between the actuator shaft 142 and the drive shaft 114. The fluid valve axis and the air valve axis can be tilted slightly, for example, up to 1, 2, 3, 4, 5 degrees, or more, without undesired contact. One or both of the fluid valve axis and the air valve axis can be slightly offset transversely or axially relative to the spray axis A without undesired contact.In some examples, one or both of the fluid valve axis and the air valve axis can be tilted at up to 1, 2, 3, 4, 5, or more angles relative to the spray axis A.

[0083] An axial gap AG1 is disposed between the ring 152 and the coupler 86, and an axial gap AG2 is disposed between the tip of the actuator shaft 142 and the bottom (e.g., closed axial end) of the receiving chamber 116. The axial gap AG1 facilitates a delay between the first valve member 78 shifting to an open state and the fluid valve member 76 shifting to an open state. The first valve member 78 shifts to an open state before the fluid valve member 76. The spray gun 10 begins to discharge air before the spray gun 10 discharges spray fluid. The trigger 14 first engages the coupler 86, and the coupler 86 applies a force to the first valve member 78. As the first valve member 78 shifts open, the axial gap AG1 decreases. The trigger 14, coupler 86, and first valve member 78 shift relative to the actuator shaft 142 until the coupler 86 encounters the ring 152. Coupler 86 engages ring 152 and pulls open first valve member 78. Air flow beginning before atomizing fluid flow ensures that atomizing air is already flowing, preventing spitting and uneven patterns as atomization begins, improving atomization and preventing fluid buildup on air cap 16.

[0084] The axial gap AG2 prevents undesired contact between the bottom of the receiving chamber 116 and the actuator shaft 142 when the trigger 14 is released, shifting the fluid valve member 76 and the first valve member 78 to their respective closed states. The fluid valve member 76 is actuated to the closed state by an actuator spring 154. The first valve member 78 is actuated to the closed state by a return spring 108. The actuator spring 154 can be sized to have a higher spring constant than the return spring 108. The higher spring constant facilitates closing the fluid valve member 76 before or simultaneously with closing the first valve member 78. The first valve member 78 operates a longer axial distance between its fully closed and fully open positions than the fluid valve member 76 operates between its fully closed and fully open positions. Therefore, the fluid valve member 76 has a shorter travel distance to return to its closed position. This allows the spray gun 10 to be configured so that the flow of spray fluid stops before the flow of air. Stopping the flow of spray fluid before the air flow stops ensures that atomizing air continues to flow until the spray fluid stops, preventing tailing at the end of the spray, preventing spray fluid from accumulating on the air cap 16, and preventing clogging of any air outlet openings in the spray gun 10 (e.g., through the air cap 16).

[0085] The air valve cartridge 46 and fluid valve cartridge 44 facilitate quick and efficient operation, repair, and replacement of the flow control (air and spray fluid) components of the spray gun 10. The air valve cartridge 46 can be removed and replaced as a single component. The fluid valve cartridge 44 can be removed and replaced as a single component. Users no longer need to find and track various small, separate parts, but instead can simply remove and replace the complete cartridge assembly. The air valve cartridge 46 and fluid valve cartridge 44 thereby reduce downtime and improve spray efficiency and operation.

[0086] During disassembly, the trigger 14 can be removed from between the coupler 86 and the spring housing 134. In examples where the coupler 86 is connected to the drive shaft 114, the coupler 86 can be decoupled from the drive shaft 114. A portion 89 of the air cartridge body 88 extends from the air valve bore 50 and can be manipulated to decouple the first interface 98. In some examples, the portion 89 of the air cartridge body 88 can have contours that facilitate a tool interface or texturing that facilitates gripping, among other options. For example, the surface can be configured to be gripped by a wrench. In some examples, the air valve cartridge 46 is configured for tool-less installation and removal, allowing a user to grip and manipulate the air valve cartridge 46 by hand without using tools. For example, the surface of the portion 89 can be knurled, grooved, pebbled, or otherwise textured or contoured. Thus, the first interface 98 can be a tool-less interface.

[0087] The air cartridge body 88 is removed from the gun body 12 at the first interface 98. The air valve cartridge 46 can be pulled axially rearward from the trigger 14 to remove it from the air valve bore 50 and the gun body 12. It is understood that the air valve cartridge 46 can be removed from the air valve bore 50 and the gun body 12 while the trigger 14 and fluid valve cartridge 44 remain attached to the spray gun 10 in their operative positions. The same or a new air valve cartridge 46 can be installed in the gun body 12. The air valve cartridge 46 is inserted into the air valve bore 50 from the rear end 30 of the gun body 12. The drive shaft 114 extends out from the front end of the air valve bore 50 through a throat seal 148. The air cartridge body 88 is connected to the gun body 12 at the first interface 98. For example, the air cartridge body 88 can be rotated to engage interacting threads between the air cartridge body 88 and the gun body 12. Thus, the air flow control components of the spray gun 10 are completely removed and replaced.

[0088] The fluid valve cartridge 44 can be removed and replaced similarly to the air valve cartridge 46. The collar 20, air cap 16, and spray tip 18 are removed from the spray gun 10. The trigger 14 is disengaged or otherwise moved from the gun body 12 so that the coupler 86 can pass from the rear to the front of the trigger 14. Removing the collar 20 and air cap 16 exposes the end of the fluid valve cartridge 44. In some instances, the exposed portion of the fluid cartridge body 122, which in some instances extends from the front end of the gun body 12, can include, among other features, contours to facilitate tool interface or texturing for easy gripping. For example, the surface can be contoured to be gripped with a wrench. In some instances, the fluid valve cartridge 44 can be configured for tool-less installation and removal, allowing a user to grip and manipulate the fluid valve cartridge 44 directly by hand without the use of tools. For example, the surface can be knurled, grooved, pebbled, or otherwise contoured or textured. Thus, the second interface 128 can be a tool-less interface.

[0089] The fluid cartridge body 122 is removed from the gun body 12 at the second interface 128. The fluid valve cartridge 44 may be pulled axially forward from the trigger 14 and removed from the gun body 12 and fluid valve bore 48. The fluid valve cartridge 44 is removed through the front end 28 of the gun body 12. The same or a new fluid valve cartridge 44 may be installed in the gun body 12. Removing the fluid valve cartridge 44 disconnects the mounting block 66 so that the fluid conduit assembly may be removed and repaired and / or replaced with the fluid valve cartridge 44.

[0090] During installation, the same or a different fluid valve cartridge 44 is inserted into the fluid valve bore 48 from the front end 28 of the gun body 12. A spring housing 134 extends from the rear end of the fluid valve bore 48. An actuator shaft 142 extends from the spring housing 134 into a receiving chamber 116 formed in the drive shaft 114. The fluid cartridge body 122 is connected to the gun body 12 at the second interface 128. For example, the fluid cartridge body 122 can be rotated to engage threads interacting between the fluid cartridge body 122 and the gun body 12. The trigger 14, spray tip 18, air cap 16, and collar 20 can be reinstalled. The trigger 14 is attached to the gun body 12 so that the coupler 86 is disposed between the trigger 14 and the drive shaft 114. In some examples, the coupler 86 can be connected to the end of the drive shaft 114. Thus, the spray fluid flow control components of the spray gun 10 are completely removed and replaced, and the spray gun 10 is ready to resume operation.

[0091] During spraying, spray fluid and compressed air are supplied to the spray gun 10. The spray fluid is supplied through the fluid piping and enters the mounting block 66 through the spray fluid inlet 68. The spray fluid enters the mounting bore 70 and enters the interior of the fluid valve cartridge 44 through the fluid inlet port 136. A fluid valve seal 144 engages the fluid seat 138, preventing the spray fluid from flowing downstream from the fluid valve cartridge 44. Compressed air is supplied through the handle 26 and through the air inlet bore 58. The compressed air enters the air chamber in the air valve bore 50, and a portion of the compressed air can enter the air valve cartridge 46 through the air inlet port 100. A first valve seal 110 engages the first seat 104, preventing a portion of the auxiliary air from flowing downstream from the air valve cartridge 46. A second valve seal 112 engages the second seat 106, preventing a portion of the fan air from flowing downstream to the third valve 94. The second valve member 80 is positioned in a desired position relative to the third seat 118 to set the size of the opening through the third valve 94 and thus control the fan airflow. The third valve 94 remains open or closed regardless of the position of the trigger 14.

[0092] A user grasps the handle 26, grasps the trigger 14, and pulls the trigger 14 toward the handle 26. The trigger 14 moves relative to the actuator shaft 142 and engages the coupler 86. The coupler 86 interacts with the tip of the drive shaft 114, driving the first valve member 78 rearward relative to the gun body 12 and the air cartridge body 88. The first valve 90 and the second valve 92 shift to their respective open states. In the illustrated example, the first valve 90 and the second valve 92 shift to their respective open states simultaneously.

[0093] The auxiliary air portion of the compressed air exits the air valve cartridge 46 through the first valve 90 and flows to auxiliary air bore 60. The auxiliary air portion flows through supply air bore 64, through the gun body 12, and to the air cap 16. The auxiliary air is discharged through the air cap 16.

[0094] The fan air portion of the compressed air flows through the second valve 92 to the third valve 94. When the third valve 94 is in a closed position, the fan air portion is prevented from flowing into the fan air bore 62, and the fan air is not discharged from the spray gun. When the third valve 94 is in an open position, the fan air portion flows through the third valve 94 and exits the air cartridge body 88 through the air outlet port 102. The fan air portion flows through the fan air bore 62 and into the air tube 82 in the supply air bore 64. The fan air portion flows through the air tube 82 through a bore in the fluid cartridge body 122 and is discharged adjacent to the spray tip 18. The fan air portion controls the width of the spray fan emitted by the spray gun 10. The position of the second valve member 80 controls the size of the opening through the third valve 94, varying the spray pattern between a flat fan and a round spray depending on the fan air flow rate.

[0095] The trigger 14, coupler 86, and first valve member 78 continue to shift relative to the actuator shaft 142 until the coupler 86 engages the ring 152. The trigger 14 engages each of the first valve member 78 and the fluid valve member 76 via the coupler 86. Once the coupler 86 contacts the ring 152, further depression of the trigger 14 pulls the fluid valve member 76 rearward, opening a flow path through the fluid valve 124. With the fluid valve member 76 open, spray fluid exits the fluid valve cartridge 44 and flows to the spray tip 18. The spray tip 18 produces a fluid spray.

[0096] The user releases the trigger 14 to stop spraying. The actuator spring 154 drives the fluid valve member 76 back to the closed state. The fluid valve 124 closes, stopping the flow of spray fluid downstream of the fluid valve cartridge 44. The return spring 108 drives the first valve member 78 back to the closed state. The first valve 90 and the second valve 92 are closed. The closed first valve 90 stops the flow of auxiliary air downstream from the air valve cartridge 46. The closed second valve 92 stops the flow of fan air downstream from the air valve cartridge 46. The third valve 94 can remain open, thereby maintaining the size of the restriction through the third valve 94 and, therefore, the desired spray pattern shape for the next trigger stroke. The first valve member 78 must move a greater axial distance between the open and closed states than the fluid valve member 76 so that the spray gun 10 stops emitting spray fluid before it stops emitting air. The actuator spring 154 can also have a higher spring constant than the return spring 108 to cause the fluid valve member 76 to close more quickly than the first valve member 78. The continued flow of air after the spray fluid stops prevents the buildup of undesirable material and clogging.

[0097] The spray gun 10 offers significant advantages. The fluid valve cartridge 44 houses the spray gun's 10 spray fluid control components, while the air valve cartridge 46 houses the spray gun's 10 air control components. The fluid valve cartridge 44 and the air valve cartridge 46 can each be individually removed and replaced as a single unit, simplifying and speeding replacement and maintenance. The first interface 98 is a single interface that holds each of the air valve cartridge 46 components in place and aligns them during operation. The second interface 128 is a single interface that holds each of the fluid valve cartridge 44 components in place and aligns them during operation. These single interfaces prevent the accumulation of alignment errors during assembly and minimize the opportunity for misalignment. The complete fluid valve cartridge 44 and / or air valve cartridge 46 can be stored as a single unit separate from the spray gun 10 and replaced as a single unit when needed.

[0098] The air valve cartridge 46 is a single unit that contains the valve functions for controlling both auxiliary and fan air flow. Combining the valves into one unit facilitates servicing and provides improved aesthetics. The gun body 12 is configured for a more ergonomic and aesthetically pleasing appearance because only a single air valve bore is required. Combining the auxiliary and fan air valves into a single assembly provides improved reliability and ease of repair and assembly. Combining the air and fan air valves into a single assembly further reduces part count, facilitating component tracking and management, reducing downtime and part count, thereby reducing costs associated with downtime and increasing user reliability. The single assembly further simplifies installation of the air valve components and prevents mis-installation of the air valve components in the incorrect part or orientation of the spray gun 10.

[0099] FIG. 5A is an isometric view of the fluid valve cartridge 44. FIG. 5B is an exploded view of the fluid valve cartridge 44. FIGS. 5A and 5B are described together. The fluid valve cartridge 44 includes a fluid valve member 76, a coupler 86, a fluid cartridge body 122, a fluid valve 124, a seal assembly 126, a fluid valve connector 129, and an actuator spring 154. The fluid cartridge body 122 includes a tip mount 130, a fluid housing 132, a spring housing 134, and a fluid inlet port 136. The fluid valve 124 includes a fluid valve member 76 and a fluid seat 138. The fluid valve member 76 includes a needle 140 and an actuator shaft 142. The needle 140 includes a fluid valve seal 144. A ring 152 is disposed on the actuator shaft 142.

[0100] The tip mount 130 is connected to a first end of the fluid housing 132, and the spring housing 134 is connected to a second end of the fluid housing 132 to form the fluid cartridge body 122. A portion of the tip mount 130 extends into the fluid housing 132. Seal grooves 159a and 159b are disposed on the exterior of the tip mount 130. The seal groove 159a includes a seal 161, such as an O-ring, configured to interface with the air cap 16. The seal groove 159b includes a seal 163, such as an O-ring, configured to interface with the gun body 12. In the illustrated example, both seal grooves 159a and 159b are disposed on the same side of the fluid valve connector 129. The fluid valve connector 129 forms part of the second interface 128. The nozzle 164 extends from the front end of the tip mount 130 and is configured to interface with the spray tip 18. The nozzle 164 is a protrusion at least partially disposed within a cylindrical region defined by the housing formed by the tip mount 130. A fan air opening 166 extends through the tip mount 130, providing a path for fan air to flow through the tip mount 130. The outer surface of the tip mount 130 can be configured to interface with a tool, such as a wrench, to facilitate connection and disconnection between the second interface 128 and the gun body 12. The first seal 156 is disposed between the tip mount 130 and the fluid housing 132. Seal grooves 158a, 158b are formed on the exterior of the fluid housing 132 and are located axially on opposite sides of the fluid inlet port 136. In the illustrated example, both seal grooves 158a, 158b are located on the same axial side of the fluid valve connector 129. The seal grooves 158a, 158b are located on the opposite axial side of the fluid valve connector 129 from the seal grooves 159a, 159b. A second seal 160 is disposed in seal groove 158 a, and a third seal 162 is disposed in seal groove 158 b. A fluid valve connector 129 is formed on the exterior of fluid housing 132 between seal groove 158 a and tip mount 130. In the illustrated example, fluid valve connector 129 is formed on the exterior of fluid housing 132 and includes threads configured to interact with threads in a bore of gun body 12.Although the fluid cartridge body 122 is described as including seal grooves 158a, 158b, it is understood that one or both of the seal grooves 158a, 158b can be formed in the mounting block 66 such that the seal is mounted within the mounting block 66 and not on the fluid cartridge body 122.

[0101] A fluid seat 138 is disposed within the tip mount 130. A seat retainer 139 secures the fluid seat 138 within the tip mount 130. The seat retainer 139 can be connected to the tip mount 130 in any desired manner, such as by interfacing threads. The seal assembly 126 is disposed within the fluid housing 132 at an end of the fluid housing 132 opposite the tip mount 130. The needle 140 extends through the seal assembly 126 and interacts with an actuator shaft 142. As shown, the seal assembly 126 can include multiple seals assembled together. A fluid valve seal 144 is disposed at the tip of the needle 140 and is configured to interact with the fluid valve 124 and the fluid seat 138 in the closed state. For example, the fluid valve seal 144 can be retained on the needle 140 by a needle cap 141, among other options. The actuator shaft 142 is at least partially disposed within the spring housing 134. An actuator spring 154 is disposed within the spring housing 134 and interacts with the actuator shaft 142. The coupler 86 is disposed around the portion of the actuator shaft 142 that extends outside the spring housing 134. A ring 152 is mounted on the actuator shaft 142 and retains the coupler 86 on the actuator shaft 142.

[0102] FIG. 6A is an isometric view of the air valve cartridge 46. FIG. 6B is an isometric, exploded cross-sectional view of the air valve cartridge 46. FIGS. 6A and 6B are described together. The air valve cartridge 46 includes a first valve member 78, a second valve member 80, an air cartridge body 88, a first valve 90, a second valve 92, a third valve 94, a seat fitting 96, and an air valve connector 99. The air cartridge body 88 includes a first end 91, a second end 93, an air inlet port 100, an air outlet port 102, and air seal grooves 168a, 168b. The first valve 90 is defined by a first valve seal 110 and a first seat 104. The second valve 92 is defined by a second valve seal 112 and a second seat 106. The first valve member 78 includes a first valve seal 110, a second valve seal 112, a drive shaft 114, and a receiving chamber 116. The third valve 94 is defined by a third valve seal 120 and a third seat 118. The second valve member 80 includes a third valve seal 120 and a valve actuator 121.

[0103] An air inlet port 100 extends axially into the end of the air cartridge body 88. An air outlet port 102 extends through the air cartridge body 88. An air seal groove 168a is axially disposed between the air inlet port 100 and the air outlet port 102. An air seal groove 168b is disposed between the air outlet port 102 and the first interface 98. Seals 170, 172 are configured to be disposed in the seal grooves 168a, 168b, respectively. While the seal grooves 168a, 168b are described as being formed on the air cartridge body 88, it will be understood that one or more of the seal grooves 168a, 168b can be formed in the air valve bore 50 of the gun body 12, with the seals 170, 172 attached to the gun body 12.

[0104] A seal 182 is mounted on the first valve seal 110 and is configured to interact with the gun body 12 to close the first valve 90. A second seal 188 is mounted on the second valve seal 112 and is configured to interact with the air cartridge body 88 to close the second valve 92.

[0105] An air valve connector 99 is formed on the exterior of the air cartridge body 88. The air valve connector 99 forms part of the first interface 98 and is configured to attach the air valve cartridge 46 to the gun body 12. The air valve connector 99 is formed axially between the second end 93 of the air cartridge body 88 and the opening of the air outlet port 102 outside the air cartridge body 88. The air valve connector 99 is formed by threading on the exterior of the air cartridge body 88, although it will be understood that other configurations are possible. The exterior surface of the second end 93 of the air cartridge body 88 may be configured to interface with a tool, such as a wrench, to facilitate connection and disconnection of the second interface 128 within the gun body 12. In the illustrated example, the detent 123 is connected to the knob 22, and recesses 125 are formed in the second end 93 of the air cartridge body 88. In the illustrated example, an array of recesses 125 is formed in the second end 93. Detent 123 interacts with recess 125 to maintain the position of knob 22 relative to air cartridge body 88. Detent 123 interacting with recess 125 prevents inadvertent rotation of knob 22, which sets the size of the opening through third valve 94.

[0106] The first valve member 78 is at least partially disposed within the air cartridge body 88. The return spring 108 extends between the first end 91 of the air cartridge body 88 and the first valve seal 110, biasing the first valve member 78 toward a closed state. The first valve member 78 is at least partially disposed within the air cartridge body 88 and is movable relative to the air cartridge body 88. The first valve seal 110 is formed by an angled protrusion 180 and a seal 182. The back side of the protrusion 180 interacts with the return spring 108. The portion of the protrusion 180 that interacts with the return spring 108 may also define a seal groove 184. The seal 182 is mounted within the seal groove 184 formed on the protrusion 180. The first valve seal 110 is configured to engage with the first seat 104 when the first valve 90 is closed. The second valve seal 112 is formed by a tapered portion 186 of the spherical portion 187 and a seal 188. The seal 188 is mounted in a seal groove 190 formed between two axially aligned surfaces of the spherical portion 187, which are each tapered to define a radial protrusion of the spherical portion 187. The second valve seal 112 is configured to engage a second seat 106 formed in the air cartridge body 88 when the second valve 92 is in a closed state. In the illustrated example, the seal 182 is a cup seal and the seal 184 is a ring seal, although it is understood that other seal options are possible. While the first valve seal 110 and the second valve seal 112 are shown as including tapered portions, it is understood that other configurations are possible.

[0107] The second valve member 80 is at least partially disposed in the second end 93 of the air cartridge body 88. The second valve member 80 is configured to interact with a portion of the air cartridge body 88 that defines the third valve 118 when the third valve 94 is in the closed state, and is configured to be spaced apart from the portion of the air cartridge body 88 that defines the third valve 118 when the third valve 94 is in the open state. A seal groove 174 is formed on the second valve member 80, and a seal 176 is disposed in the seal groove 174 and configured to interact with the interior of the air cartridge body 88. The seal 176 prevents air from leaking around the second valve member 80. In the illustrated example, the seal groove 174 is formed in the valve actuator 121. A clip 178 can be inserted into the second end of the air cartridge body 88 to prevent the second valve member 80 from moving out of the air cartridge body 88.

[0108] In the illustrated example, second valve seal 112 is formed on plug 113. Protrusion 115 extends radially relative to the body of plug 113. Chamber 95 is formed within air valve body 88, is non-circular, and is configured to interact with plug 113 to prevent plug 113 from rotating within air valve body 88. More specifically, protrusion 115 is contoured to interact with the contour of chamber 95. Valve actuator 121 includes external threads configured to interact with threads formed within the bore of plug 113.

[0109] The knob 22 is connected to the second valve member 80. The knob 22 is configured to actuate the second valve member 80 to control the size of the opening through the third valve 94. In the illustrated example, the knob 22 is connected to the valve actuator 121 by a fastener 84. The fastener 84 secures the knob 22 to the valve actuator 121 such that rotating the knob 22 rotates the valve actuator 121. A detent 123 is supported by the knob 22 and configured to interact with a recess 125. The detent 123 interacting with the recess 125 secures the position of the knob 22, and therefore the position of the second valve member 80. The detent 123 moving out of and back into the recess can provide feedback (e.g., vibration) to the user to indicate a change in the position of the second valve member 80.

[0110] The second valve member 80 is actuable between a closed state and an open state. The open state includes multiple open positions. The second valve member 80 can be maintained in a desired open position during operation. The knob 22 is rotated, thereby causing rotation of the valve actuator 121. Rotating the valve actuator 121 causes the plug 113 to shift axially along the valve actuator 121 relative to the air cartridge body 88 due to the contoured interface between the chamber 95 and the protrusion 115, preventing rotation of the plug 113.

[0111] 7 is an enlarged cross-sectional view of a portion of gun body 12 showing air valve assembly 46'. Air valve assembly 46' is substantially similar to air valve assembly 46 (best seen in FIGS. 4C, 6A, and 6B).

[0112] The air valve cartridge 46' includes a first valve member 78', an air cartridge body 88', a first valve 90', a second valve 92', a third valve 94', a seat fitting 96, a first interface 98, and a return spring 108. The air cartridge body 88' includes an air inlet port 100 and an air outlet port 102. A first seat 104' and a second seat 106' are disposed within the air cartridge body 88'. The first valve member 78' includes a first valve seal 110', a second valve seal 112', a drive shaft 114, and a receiving chamber 116. The second valve member 80' includes a third valve seal 120'. The first valve 90' ​​is defined by the first seat 104' and the first valve seal 110'. The second valve 92' is defined by a second seat 106' and a second valve seal 112'. The third valve 94' is defined by a third seat 118' and a third valve seal 120'.

[0113] The air valve cartridge 46' is disposed within the air valve bore 50 of the gun body 12. The air cartridge body 88' is attached to the gun body 12 by a first interface 98. For example, the first interface 98 may be formed by interacting threads formed on the air cartridge body 88' and the gun body 12. The first interface 98 may be the only fixed interface between the air valve cartridge 46' and the gun body 12.

[0114] All components of the air valve cartridge 46' are removed together as a single piece and do not require separate removal from the air valve bore 50 or the gun body 12. The various components of the air valve cartridge 46' are connected to one another independently of the gun body 12 and other parts of the spray gun 10. The air valve cartridge 46' remains a unitary piece when outside of the gun body 12 so that the various components of the air valve cartridge 46' are not free to separate.

[0115] A sealing interface is formed between the air valve cartridge 46' and the air valve bore 50. Compressed air is supplied through an inlet bore 58 formed in the handle 26 and enters the interior of the air valve bore 50. The air enters the air cartridge body 88' through air inlet ports 100. The air cartridge body 88' may include an annular array of air inlet ports 100. Seal grooves are formed on the air cartridge body 88' to receive seals that interact with the gun body 12 to seal the air chamber formed between the inner wall of the air valve bore 50 and the outer surface of the air cartridge body 88'. In the illustrated example, air seal groove 168a is located between the air inlet port 100 and the first end of the air cartridge body 88'. Air seal groove 168b is located between the air inlet port 100 and the air outlet port 102. Seal 170 is attached to air seal groove 168a, and seal 172 is attached to air seal groove 168b. The air inlet port 100 is oriented generally radially to allow inlet air to flow generally radially into the air valve cartridge 46′. The air outlet port 102 is positioned generally radially to allow fan air exiting the air valve cartridge 46′ to flow generally radially. The air inlet port 100 is disposed between two annular seals around the air cartridge body 88′. One of the seals 170 is disposed axially between the air inlet port 100 and the air outlet port 102. Another of the seals 172 is disposed proximate the end of the air cartridge body 88′ disposed within the air valve bore 50. The air inlet port 100 is disposed axially between the axial outlet of the auxiliary air section and the radial air outlet port 102 of the fan air section.

[0116] The first valve member 78' is configured to control the flow of fan air and auxiliary air downstream from the inlet air chamber within the air valve cartridge 46'. The second valve member 80' is configured to control the flow of fan air downstream from the air valve cartridge 46'. Auxiliary air can flow downstream from the air valve cartridge 46' with the first valve member 78' in an open state and the second valve member 80' in either an open or closed state. Fan air can flow downstream from the air valve cartridge 46' with the first valve member 78' in an open state and the second valve member 80' in an open state. Thus, the fan air portion requires multiple valves to be open simultaneously, while the auxiliary air portion requires a single valve to be open.

[0117] The first valve member 78′ is disposed within the air cartridge body 88′ and is actuable relative to the air cartridge body 88′ along the spray axis A. The first valve member 78′, actuated to an open state, opens a flow path through both the first valve 90′ and the second valve 92′. A return spring 108 is disposed within the air cartridge body 88′ and interacts with the first valve member 78′. The return spring 108 is configured to bias the first valve member 78′ toward a closed state.

[0118] In the illustrated example, the first valve seal 110' is formed by a portion of the first valve member 78'. In the illustrated example, the second valve seal 112' is formed by a portion of the first valve member 78'. The first valve seal 110' and the second valve seal 112' may be formed as enlargements formed on the first valve member 78'. The first valve seal 110' and the second valve seal 112' may protrude in a generally radial direction. In the illustrated example, the first valve seal 110' is formed as a generally conical protrusion 180 on the first valve member 78', and the second valve seal 112' is similarly formed as a generally conical protrusion 186 on the first valve member 78'.

[0119] In the illustrated example, the return spring 108 interacts with the side of the first valve seal 110′ opposite the sealing surface of the first valve seal 110′. It is understood that the first valve seal 110′ and the second valve seal 112′ can be formed in any desired manner suitable for controlling airflow and can be formed in different manners. Each of the first valve seal 110′ and the second valve seal 112′ can include an inclined surface. The inclined surfaces can be oriented in the same axial direction. The inclined surfaces facilitate sealing. In the illustrated example, a seal is attached to each of the first valve seal 110′ and the second valve seal 112′. A seal groove can be formed in each of the first valve seal 110′ and the second valve seal 112′. It should be appreciated that in some examples, the first valve seal 110' and the second valve seal 112' may directly interact with the first seat 104' and the second seat 106', respectively, when the first valve member 78' is in the closed state.

[0120] The first seat 104' is formed by the air cartridge body 88'. The first seat 104' is disposed at the first end 91 of the second valve member 80' opposite the air cartridge body 88'. While the first seat 104' is shown as being formed by the air cartridge body 88', it is understood that the first seat 104' may be formed by a separate component mounted within the air cartridge body 88'. The first valve 90' ​​is defined by the first valve seal 110' and the first seat 104'. An auxiliary air outlet flow path is formed through the first valve 90' ​​between the first valve seal 110' and the first seat 104' when the first valve 90' ​​is open. The auxiliary air outlet flow path is axially oriented.

[0121] The seat fitting 96 is disposed within the air cartridge body 88'. The first valve member 78' extends into and overlaps the seat fitting 96 along the spray axis A. A second seat 106' is formed by the seat fitting 96. In the illustrated example, a second valve seal 112' interacts with the seat fitting 96 to control the flow of air through the second valve 92'. The second valve 92' is defined by the second valve seal 112' and the second seat 106'.

[0122] A drive shaft 114 is part of the first valve member 78' that extends axially forward from the air valve bore 50. The drive shaft 114 extends through a throat seal 148. A receiving chamber 116 is formed within the drive shaft 114. An actuator shaft 142 exits the spring housing 134 and extends into the receiving chamber 116. The coupler 86 is disposed around the actuator shaft 142 and interacts with the drive shaft 114 of the first valve member 78'.

[0123] The second valve member 80' is at least partially disposed within the air cartridge body 88'. The third valve 94' is disposed within the air cartridge body 88'. In the illustrated example, the tip of the second valve member 80' forms a third valve seal 120', and the seat fitting 96 forms a third seat 118'. The third valve 94' is defined by the third valve seal 120' and the third seat 118'.

[0124] The second valve member 80' is configured to interact with the third seat 118' when the second valve member 80' is in a closed state. The second valve member 80' can directly contact and interact with the seat fitting 96 when the third valve 94' is in a closed state. A third valve seal 120' is formed on the second valve member 80'. The third valve seal 120' can be formed by an inclined surface on the second valve member 80' (e.g., not perpendicular or parallel to the spray axis A). For example, the third valve seal 120' can be formed by a shoulder on the second valve member 80'. The second valve member 80' is spaced from the third seat 118' when the third valve 94' is in an open state.

[0125] In the illustrated example, the second valve member 80' is attached to the air cartridge body 88' and is unaffected when the trigger 14 is pulled. The second valve member 80' can be connected to the air cartridge body 88' by, among other options, interacting threads. The second valve member 80' is movable relative to the gun body 12. A seal groove 174 is formed in the outer radial surface of the second valve member 80'. A seal 176 is disposed within the seal groove 174 and interacts with the inner surface of the air cartridge body 88' to prevent air flow around the second valve member 80'.

[0126] The interface between the second valve member 80′ and the air cartridge body 88′ facilitates actuation of the second valve member 80′ against the third seat 118′. For example, the second valve member 80′ can be rotated (e.g., in one of a clockwise and counterclockwise direction) relative to the air valve bore 50 to unscrew the second valve member 80′ and widen and / or open the flow path through the third valve 94′ between the second valve member 80′ and the third seat 118′. The second valve member 80′ can be rotated in the other rotational direction (e.g., the other of the clockwise and counterclockwise directions) to narrow and / or close the flow path through the third valve 94′.

[0127] The air outlet ports 102 extend through the air cartridge body 88′ and provide a flow path for fan air to exit the air valve cartridge 46′. The air outlet ports 102 are generally radially disposed such that the fan air flow exiting the air valve cartridge 46′ is generally radial. The air outlet ports 102 are axially disposed between the first interface 98 and a mid-seal of the seals about the air cartridge body 88′. The air valve cartridge 46′ may include an annular array of air outlet ports 102.

[0128] The knob 22' is supported by the air valve cartridge 46'. The knob 22' is positioned outside the gun body 12 and is accessible by the user. The knob 22' covers the end of the air cartridge body 88' that extends outside the gun body 12. In some examples, the knob 22' can be fixedly connected to the second valve member 80' so that the position of the second valve member 80' can be adjusted by grasping and manipulating the knob 22'. In some examples, the knob 22' is freely mounted so that rotation of the knob 22' does not affect the position of the second valve member 80'. A tool interface 150 forms part of the third valve 94'. The tool interface 150 is configured to interface with a compatible adjustment tool to manipulate the position of the second valve member 80' relative to the third seat 118', thereby varying the fan air flow. For example, the tool interface 150 can be an opening configured to receive a flat-head, cross-head, star-shaped, hexagonal, square, or other shaped screwdriver. A driver head can be inserted into tool interface 150 and manipulated, such as by rotation, to adjust the position of second valve member 80′ and therefore the opening through third valve 94′. In some examples, tool interface 150 can be a protrusion instead of a recess and received by a driver, such as a socket.

[0129] In some examples, the knob 22′ can be removed from the air valve cartridge 46′ to access the tool interface 150. The knob 22′ can surround the tool interface 150 when the knob 22′ is installed on the spray gun 10. In some examples, the knob 22′ can include a central opening through which an adjustment tool can be inserted to interact with the tool interface 150. This allows the second valve member 80′ to be adjusted while the knob 22′ is attached around but not secured to the second valve member 80′. The tool interface 150 allows the fan air opening to be set so that it can only be adjusted using the appropriate adjustment tool. The tool interface 150 prevents undesired adjustments to the fan air flow. The tool interface 150 thereby ensures consistent quality, uniform spray and finish, even when different operators utilize the same spray gun 10.

[0130] The knob 22' projects rearward relative to the gun body 12. The knob 22' extends beyond the rear edge of the handle 26. The knob 22' is sized and positioned so that it rests on the user's hand in the space between the thumb and index finger. The gun body 12 does not include an integral or permanent protrusion extending rearward to interact with the user's hand. The knob 22' is sized to position the user's hand in the appropriate position along the handle 26 for efficient and ergonomic actuation of the trigger 14 while gripping the handle 26. The knob 22' prevents the handle 26 from slipping downward in the operator's hand during operation. The knob 22' is not a permanent part of the spray gun 10 or the gun body 12. The knob 22' need not be a permanent component on the air valve cartridge 46'. In some examples, the knob 22' can be removed and replaced with a knob 22' of the same or different dimensions. In some examples, the spray gun 10 can include multiple knobs of different dimensions that can be interchanged on the spray gun 10 to accommodate different hand sizes among users. For example, a knob 22' with a larger diameter can be installed for users with smaller hands, and a knob 22' with a smaller diameter can be installed for users with larger hands. The removable knobs 22' make it easy to modify the spray gun 10 based on the actual operator, facilitating a more comfortable, ergonomic, and efficient spraying experience.

[0131] The knob 22' supports the operator's hand and is formed separately from the gun body 12. The knob 22' provides a large, ergonomic, and comfortable resting place for the operator's hand, which may also be integrated with the fan air controls. The air valve cartridge 46' may be configured to accept a number of different knobs 22 to customize the spray gun 10 for the user. This allows the spray gun 10 to be customized without requiring new molding. In some examples, the gun body 12 does not include a molded extension below the knob 22'; instead, the knob 22' is configured to interact directly with the user's hand.

[0132] 8 is an enlarged cross-sectional view of a portion of the gun body 12 showing the air valve assembly 192. The air valve assembly 192 is configured to control the flow of auxiliary and fan air portions downstream of the air valve bore 50. The air valve assembly 192 includes the return spring 108, an air housing 194, a first air valve 196, a second air valve 198, a common valve member 200, a fan valve member 202, a fan stop 204, and a fan control spring 206. The air housing 194 includes the air outlet port 102. The common valve member 200 includes an auxiliary control shaft 208 and a fan control shaft 210. The auxiliary control shaft 208 includes an end shaft 212, an auxiliary transition section 214, a connecting shaft 216, and a control seal groove 234. A control seal 236 is shown. The fan control shaft 210 includes an inner end 218, a control end 220, a control body 222, and a fan transition section 222. The fan valve member 202 includes a first end 228, a second end 230, a valve body 232, and a fan seal groove 246. A fan seal 248 is shown. The fan stop 204 includes a stop shaft 238 and a setting knob 240.

[0133] The air valve assembly 192 provides a dynamic, variable fan airflow based on the degree of actuation of the trigger 14. The greater the degree of actuation of the trigger 14 (e.g., the further the trigger 14 is depressed toward the handle 26), the greater the downstream flow of fan air. The air housing 194 is connected to the gun body 12 within the air valve bore 50. In some examples, the air housing 194 forms a cartridge body that at least partially contains the common valve member 200. For example, the air housing 194 can extend around the common valve member 200 to secure it within the air housing 194, and the air housing 194 can form a seat for the first air valve 196. Thus, the air valve assembly 192 can be integrated into or formed as a valve cartridge, similar to the air valve cartridge 46 (best seen in FIGS. 4C, 6A, and 6B) and the air valve cartridge 46' (FIG. 7).

[0134] A common valve member 200 is disposed at least partially within the air valve bore 50. The common valve member 200 is configured to control the flow of auxiliary air and fan air downstream from the air valve assembly 192.

[0135] A fan control shaft 210 is connected to the auxiliary control shaft 208. A return spring 108 is disposed around the fan control shaft 210 and extends between a flange at the inner end 218 and the air housing 194. The return spring 108 is configured to bias the common valve member 200 toward a closed state. The return spring 108 drives the common valve member 200 toward a closed state upon release of the trigger 14. The return spring 108 biases each of the first air valve 196 and the second air valve 198 toward their respective closed states.

[0136] The auxiliary control shaft 208 is disposed at the inner end of the air valve bore 50 and extends from the air valve bore 50 into the gap between the forward block 52 and the aft block 54. The end shaft 212 extends from the air valve bore 50 into the gap between the forward block 52 and the aft block 54. The trigger 14 is disposed in the gap. A receiving chamber 116 is formed in the end shaft 212. An auxiliary transition section 214 extends from the end of the end shaft 212 opposite the receiving chamber 116. In the illustrated example, the auxiliary transition section 214 has a sloped outer surface that increases the diameter of the auxiliary control shaft 208 between the end shaft 212 and the connecting shaft 216. The connecting shaft 216 extends from the auxiliary transition section 214 and is secured to an inner end 218 of the fan control shaft.

[0137] The first air valve seal 242 is formed on the auxiliary transition portion 214. The first air valve 196 is defined by the first air valve seal 242 and a first seat 250. The first air valve seal 242 interacts with the first seat 250 when the first air valve 196 is in a closed state. In the illustrated example, a control seal groove 234 is formed on the auxiliary transition portion 214, and the control seal 236 is disposed within the control seal groove 234. While the control seal 236 is shown as a cup seal, it may be of any suitable configuration for sealing an air flow path. In some examples, the auxiliary transition portion 214 can seal directly with the first seat 250. In the illustrated example, the first air valve seal 242 and the first seat 250 each include an inclined surface. The inclined surfaces are disposed opposite one another. The first seat 250 is shown to be formed by a portion of the gun body 12. However, it will be appreciated that the first seat 250 may be formed by the air housing 194 in instances where the air housing 194 forms a cartridge body similar to the first valve 90 .

[0138] The inner end 218 is connected to the connecting shaft 216 of the auxiliary control shaft 208. The inner end 218 can be snap-locked onto the auxiliary control shaft 208, among other options. A control body 222 extends between the inner end 218 of the fan control shaft 210 and a fan transition portion 224. The control body 222 includes a fan inlet opening 226, such as a window or notch, that allows a portion of the fan air to enter the interior of the control body 222 from the air valve bore 50, or from the interior of the cartridge in examples where the air housing 194 forms the cartridge body of the air valve assembly 192. The fan transition portion 224 is formed on the inner surface of the fan control shaft 210. In the illustrated example, the fan transition portion 224 is a sloped surface extending between the control body 222 and the control end 220. The control end 220 has a reduced diameter relative to the control body 222. The control end 220 extends into the air housing 194. A dynamic seal is formed between the fan control shaft 210 and the air housing 194. The fan control shaft 210 is capable of shifting axially relative to the air housing 194.

[0139] The fan valve member 202 is at least partially disposed within the fan control shaft 210. The fan control spring 206 is disposed within the fan control shaft 210 and extends between the fan valve member 202 and the auxiliary control shaft 208. The fan control spring 206 is configured to bias the fan valve member 202 toward the control end 220 of the fan control shaft 210 to maintain the second valve 198 in a closed state. The fan control spring 206 interacts with the second end 230 of the fan valve member 202. The first end 228 of the fan valve member 202 is oriented toward the control end 220. The first end 228 can extend through an axial opening in the control end 220. A fan seal 248 is disposed within a fan seal groove 246 formed in the valve body 232. The fan seal 248 interacts with the fan control shaft 210 when the second valve 198 is in a closed state. In the illustrated example, fan seal 248 forms second air valve seal 244, and fan control shaft 210 forms second seat 252. First valve 196 is defined between second air valve seal 244 and second seat 252. Valve body 232 has a first diameter on the side of fan seal groove 246 adjacent first end 228 and a second diameter on the side of fan seal groove 246 adjacent second end 230. The second diameter is larger than the first diameter.

[0140] The fan stop 204 is configured to interact with the fan valve member 202 to open the second air valve 198. The fan stop 204 is attached to the air housing 194. The fan stop 204 extends through a fan air chamber defined by the air housing 194. A stop shaft 238 is disposed within the air housing 194. The stop shaft 238 defines a limit to the rearward axial movement of the fan valve member 202. A setting knob 240 is disposed outside the air housing 194 and the air valve bore 50. In the illustrated example, the setting knob 240 and the stop shaft 238 are integrally formed. The relative axial position of the stop shaft 238 can be set by manipulating the setting knob 240. For example, the fan stop 204 can be threadably connected to the air housing 194 such that rotating the setting knob 240 moves the stop shaft 238 toward and away from the fan valve member 202. It is understood that in some examples, the fan stop 204 can include a tool interface 150 such that an adjustment tool is required to adjust the position of the fan stop 204. In some examples, the setting knob 240 can be configured similarly to the knob 22.

[0141] During operation, a user can set the fan stop 204 to a desired position. For example, a user can adjust the fan stop 204 to retract the stop shaft 238 so that the fan valve member 202 does not contact the fan stop 204 with the trigger 14 fully depressed. Such a setting prevents any fan air from flowing downstream from the air valve assembly 192. The second air valve 198 remains closed. A user can adjust the fan stop 204 to a fully forward position so that the fan valve member 202 contacts the stop shaft 238 upon or shortly after actuation of the trigger 14. Such a setting can provide for simultaneous or near-simultaneous flow of auxiliary air and fan air. A user can adjust the fan stop 204 to an intermediate position so that the fan valve member 202 contacts the stop shaft 238 after the trigger 14 is partially actuated. The spray gun 10 can thereby emit auxiliary air but not fan air during a portion of the pull stroke of the trigger 14, and then emit both auxiliary air and fan air during another, later portion of the pull stroke of the trigger 14. This may be desirable when a user does not require fan air during some spraying operations, but does require fan air during other spraying operations. The user does not have to manually adjust a fan air valve, but instead can vary the fan air based on the degree of actuation of the trigger 14.

[0142] For the purposes of the following discussion, it is assumed that the fan stop 204 is in the actuated position, such that the fan stop 204 contacts the fan valve member 202, opening the second air valve 198 and allowing fan airflow during at least a portion of the actuation range of the trigger 14. The trigger 14 is actuated, driving the common valve member 200 rearward within the air valve bore 50. The first air valve 196 opens, allowing auxiliary air portion AA to flow downstream from the air valve assembly 192 to assist the air bore 60. The return spring 108 compresses between the inner end 218 and the air housing 194.

[0143] A fan control shaft 210 is secured to and moves rearwardly on an auxiliary control shaft 208. A fan control spring 206 maintains the fan valve member 202 in sealing engagement with the fan control shaft 210 as the common valve member 200 moves rearward. The auxiliary control shaft 208, fan control shaft 210, fan control spring 206, and fan valve member 202 are secured together and move as a unit.

[0144] The fan valve member 202 moves with the common valve member 200 until it encounters a fan stop 204. The fan stop 204 is a hard stop that prevents the fan valve member 202 from shifting axially rearward within the air valve bore 50. The trigger 14 continues to be depressed, maintaining the position of the fan valve member 202. The fan control spring 206 compresses between the fan valve member 202 and the auxiliary control shaft 208 as the common valve member 200 moves rearward. The auxiliary control shaft 208 and the fan control shaft 210 shift relative to the fan valve member 202. The sealed interface between the fan valve member 202 and the fan control shaft 210 disengages to open a flow path through the second air valve 198. A fan air portion FA flows through an opening in the second air valve 198 into a chamber within the air housing 194 and exits the air housing 194 through the air outlet port 102 into the fan air bore 62.

[0145] As the trigger 14 continues to be depressed, the fan control shaft 210 shifts further axially rearward relative to the fan valve member 202. The fan transition portion 224 and the valve body 232 each include various diameters (e.g., each surface includes a complementary slope). The size of the opening through the second air valve 198 increases as the fan control shaft 210 shifts rearward relative to the fan valve member 202. The size of the restriction through the second air valve 198 decreases as the fan control shaft 210 shifts rearward relative to the fan valve member 202. Thus, the volume of fan air that can pass through the second air valve 198 increases as the fan control shaft 210 shifts rearward relative to the fan valve member 202. The user can release the trigger 14 to reduce or stop the fan airflow.

[0146] In the illustrated example, the sloped interface between the fan control shaft 210 and the fan valve member 202 provides a continuously variable opening that allows for a range of fan airflow. The fan airflow through the second air valve 198 is continuously variable depending on the position of the trigger 14. In some examples, the air valve assembly 192 can be configured to provide graduated variations in fan airflow. For example, the fan control shaft 210 can include a fan transition portion 224 having a first cylindrical portion with a first inner diameter and a second cylindrical portion with a second inner diameter that is larger than the first inner diameter. A first opening having a first area is formed between the fan valve member 202 and the first cylindrical portion. A second opening having a second area that is larger than the first area is formed between the fan valve member 202 and the second cylindrical portion. The fan air flows at a first flow rate through the first opening and at a second flow rate that is larger than the first flow rate through the second opening. In operation, the air valve assembly 192 provides fan air at a first flow rate for a first portion of the trigger stroke and at a second flow rate for a second portion of the trigger stroke. Although the air valve assembly 192 is described as having first and second stepped sections, it is understood that the air valve assembly 192 can include any desired number of stepped sections, such as three, four, five, or more, having different flow areas, to provide any desired number of variable flow rates.

[0147] The air valve assembly 192 provides variable fan airflow based on the degree of actuation of the trigger 14. The fan airflow is typically set by setting the size of an opening through the valve that controls the fan airflow. That opening is maintained throughout the spray. If the user stops spraying and a different fan airflow is desired, they manually adjust the opening by manipulating the fan valve. The air valve assembly 192 provides variable opening based on the degree of actuation of the trigger 14. The flow of the fan air portion is controlled by the actuation of the trigger 14. This allows the user to dynamically adjust the width of the fan air, and therefore the spray pattern emitted by the spray gun 10, by simply depressing or releasing the trigger 14. The spray pattern can be dynamically adjusted by the feathering trigger. The user can apply spray fluid to both wide and narrow items without changing spray tips or adjusting the fan air valve. It will be appreciated that the air valve assembly 192 and feathered fan airflow may be integrated with the air valve cartridge 46 to provide a variable dynamic fan airflow in conjunction with and through the air valve cartridge.

[0148] FIG. 9 is a cross-sectional view illustrating a second valve member 80 having an integrally formed tool interface 150. The tool interface 150 is formed in the second valve member 80 and configured to receive a tool head. For example, the tool interface 150 can be an opening configured to receive a flat-head, cross-head, star-shaped, hexagonal, square, or other shaped driver. The driver head can be inserted into the tool interface 150 and manipulated, such as by rotation, to adjust the position of the second valve member 80 and, therefore, the fan air openings around the second valve member 80. While the tool interface 150 is described as accepting a tool head, it will be understood that the tool interface 150 can have any desired configuration suitable for being manipulated by a tool. For example, the tool interface 150 can be a hexagonal protrusion configured to be received by a socket.

[0149] The knob 22 is positioned around the end of the air housing 254, as are the housing 194 and cartridge body 88. The integrated tool interface 150 can be utilized on any manually set second valve member 80 to adjust the fan air portion, preventing undesired adjustments by requiring an adjustment tool. The knob 22 can be freely mounted on the housing 254 so that the operating knob 22 does not change the position of the second valve member 80. This allows the knob 22 to be rotatable and movable relative to the housing 254. A user can access the second valve member 80 by removing the knob 22 or through a central opening formed in the knob 22 with an adjustment tool. The valve member 256 controls the flow of both the auxiliary air portion and the fan air portion downstream of the air valve assembly 258. The valve assembly 258 includes a dynamic valve member and a static valve member. The static valve member can be adjusted and set with an adjustment tool via the tool interface 150.

[0150] Figure 10A is a cross-sectional view of spray tip assembly 254, showing the spray tip assembly attached to gun body 12 with collar 20' in a locked position. Figure 10B is a cross-sectional view of spray tip assembly 254 removed from gun body 12 with collar 20' in an unlocked position. Figures 10A and 10B are described together. Spray tip assembly 254 includes air cap 16, spray tip 18, collar 20', tip body 256, tip guard 258, front detent 260, rear detent 262, and locking piston 264. Locking piston 264 includes a head 266 and a piston spring 268.

[0151] Tip body 256 supports the other components of spray tip assembly 254. Air cap 16 is disposed within tip body 256. Spray tip 18 is disposed within air cap 16. Locking piston 264 is disposed within tip body 256 and is retained within tip body 256 by front detent 260. Front detent 260 may also be referred to as a catch. Piston spring 268 is disposed between head 266 and air cap 16 and is configured to bias locking piston 264 away from air cap 16 toward the position shown in FIG. 10B. Tip guard 258 is attached to tip body 256 and extends away from tip body 256.

[0152] The front detent 260 is disposed in a front opening formed in the tip body 256. The front detent 260 is engaged by the head 266 with the collar 20' in a disengaged state, the spray tip assembly 254 removed from the gun body 12, and the front detent 260. A shoulder 270 on the head 266 engages the front detent 260 and pushes the front detent 260 through the spray tip assembly 254 and away from the central axis CA-CA. The central axis CA-CA may be coaxial with the spray axis A. The front detent 260 is biased into a homing groove 276 formed in the collar 20'. The front detent 260, disposed within the homing groove 276, locks the collar 20' in the disengaged position. The lip 272 engages the front detent 260 to limit axial displacement of the head 266. The locking piston 264 prevents the user from actuating the collar 20 ′ from the unlocked state to the locked state unless the spray tip assembly 254 is attached to the gun body 12 .

[0153] The front detent 260 is also configured to engage the head 266 when the spray tip assembly 254 is installed on the gun body 12 and the collar 20′ is in the locked position (FIG. 10A). A flat 278 on the collar 20′ presses the front detent 260 downward, causing the front detent 260 to move into a receiving groove 274 on the head 266. The receiving groove 274 aligns with the front detent 260 when the locking piston 264 is in the installed position. The receiving groove 274 allows the front detent 260 to move downward toward the central axis CA-CA to lock the position of the head 266 and prevent the head 266 from moving relative to the front detent 260. The front detent 260 can be formed in any manner suitable for engaging, positioning, and being actuated by the locking piston 264. The front detent 260 can be a dowel rod or a ball bearing, among other options. For example, the front detent 260 may be metal, ceramic, or another rigid material.

[0154] The rear detent 262 is disposed in a rear opening formed in the tip body 256. The rear detent 262 is configured to engage with a mounting groove 280 formed in the gun body 12 when the spray tip assembly 254 is attached to the gun body 12. The rear detent 262 may also be referred to as a catch. The rear detent 262 can float within its respective opening when the spray tip assembly 254 is removed and the collar 20′ is in an unlocked state. A retention groove 282 is formed in the collar 20′ to allow the rear detent 262 to displace radially outward when the collar 20′ is attached to and removed from the gun body 12. The retention groove 282 prevents the rear detent 262 from disengaging from the tip body 256. The rear detent 262 can be formed in any manner suitable for engaging the gun body 12 to secure the spray tip assembly 254 to the gun body 12. The rear detent 262 can be a dowel rod or a ball bearing, among other options. For example, the rear detent 262 may be metal, ceramic, or another hard material.

[0155] The collar 20' is disposed on the tip body 256 and is movable between a locked state (FIG. 10A) and an unlocked state (FIG. 10B). The collar 20' includes a homing groove 276 and a retention groove 282 that align with the front detent 260 and the rear detent 262, respectively, when the collar 20' is in the unlocked state. The grooves allow the front detent 260 and the rear detent 262 to move radially, allowing an object to pass beneath the front detent 260 and the rear detent 262. The front detent 260 is also driven into engagement with the homing groove 276 by the lock piston 264 when the lock piston 264 is in the release position (FIG. 10B). The front detent 260 is maintained within the homing groove 276, preventing the collar 20' from being actuated to the locked state unless installed on the gun body 12. The collar 20' also includes a flat 278 adjacent the groove. The flats 278 are aligned with the front detents 260 and rear detents 262 in the locked position of the collar 20'. The flats 278 drive the front detents 260 and rear detents 262 radially inward, locking the detents in their biased positions. The collar 20' engages the rear detents 262 within the mounting groove 280 to secure the spray tip assembly 254 to the gun body 12.

[0156] During operation, the spray tip assembly 254 is first removed from the gun body 12. The spray tip assembly 254 is positioned relative to the gun body 12 and shifted so that the end of the gun body extends into the tip body 256. The spray tip assembly 254 is shifted from the position shown in FIG. 10B to the position shown in FIG. 10A. The tip mount 130 is shown in FIG. 10A. During installation, the spray tip 18 fully engages with the tip mount 130 to provide a fluid seal and ensure a high-quality spray. The nozzle 164 engages with the spray tip 18 to form a fluid seal therebetween. When the spray tip assembly 254 is inserted, the end of the gun body 12 encounters the locking piston 264. The gun body 12 prevents the locking piston 264 from moving further, and the piston spring 268 compresses between the locking piston 264 and the air cap 16. The locking piston 264 continues to displace until the spray tip assembly 254 is fully inserted. When the spray tip assembly 254 is fully inserted, the front detent 260 aligns with and drops into the receiving groove 274 and out of the homing groove 276 in the collar 20'. With the front detent 260 removed from the homing groove 276, the collar 20' can be actuated from an unlocked state to a locked state relative to the tip body 256.

[0157] The collar 20' is shifted from the unlocked position shown in FIG. 10B to the locked position shown in FIG. 10A. For example, the collar 20' can slide axially relative to the tip body 256. In some examples, the collar 20' can rotate relative to the tip body 256 between the unlocked and locked states. It should be understood that the collar 20' can be actuated between states in any manner suitable for engaging and biasing the front detent 260 and the rear detent 262. With the collar 20' in the locked state, the collar 20' engages two seals 284 between the collar 20' and the tip body 256 to prevent airflow leakage therebetween. The seals 284 can also help maintain the collar 20' in the locked state.

[0158] A flat 278 formed on the collar 20' engages the rear detent 262, locking the rear detent 262 into a mounting groove 280 on the gun body 12. The flat 278 engages the front detent 260, locking the front detent to the locking piston 264. With the collar 20' in the locked state, the spray tip assembly 254 is mounted and locked to the gun body 12. The spray tip assembly 254 remains locked onto the gun body 12 until the collar 20' is again transitioned to the unlocked state. The spray tip assembly 254 can be removed by simply actuating the collar 20' from the locked state to the unlocked state and pulling the spray tip assembly 254 axially away from the gun body 12. The piston spring 268 returns the locking piston 264 to the position shown in FIG. 10B, and the locking piston 264 drives the front detent 260 into engagement with the collar groove, placing the locking collar 20' in the unlocked state.

[0159] The spray tip assembly 254 is a quick-connect assembly that facilitates quick and easy installation and removal of the spray tip assembly 254 from the gun body 12. The spray tip assembly 254 facilitates quick and easy installation, removal, and replacement of the air cap 16 and spray tip 18. In some examples, the quick-connect configuration can be retrofitted to existing spray guns. For example, a gun body configured to accept a threaded collar can instead have a quick-connect mount threaded onto the end of the gun body. The quick-connect mount can include internal threads for attachment to the gun body and an external mounting groove 280 for receiving the rear detent 262. Spray guns that require threading for spray tip attachment can thereby be modified to accept the quick-connect spray tip assembly 254. The tip body 256 can be configured with various diameters to connect to threaded gun bodies and facilitate modifications.

[0160] The spray tip assembly 254 offers significant advantages. The quick-connect spray tip assembly 254 allows the user to quickly and efficiently change spray tips during operation, increasing spray efficiency and reducing downtime. The operator simply connects and disconnects the collar 20' between locked and unlocked positions to install and remove the spray tip assembly 254. The operator does not need to screw the collar in or out, which requires a cumbersome rotational motion relative to the gun body 12, and the single-motion connection and disconnection provides improved ergonomics and faster connection and disconnection times. Additionally, each of the components of the spray tip assembly 254 is provided as a cartridge that can be installed and removed as a single piece. Therefore, the spray tip assembly 254 can be considered a spray tip cartridge.

[0161] Figure 11A is a cross-sectional view of the spray tip assembly 254' taken along line AA in Figure 11C, showing the spray tip assembly 254' mounted to the gun body 12. Figure 11B is a cross-sectional view of the spray tip assembly 254' taken along line BB in Figure 11A. Figure 11C is a cross-sectional view of the spray tip assembly 254' taken along line CC in Figure 11A. Figures 11A-11C are described together. The spray tip assembly 254' includes an air cap 16, a collar 20', a tip body 256', a tip lock 259, and a detent 261. The collar 20' includes a recess 263 and a detent flat 278. The gun body 12 includes a mounting groove 280 and a locking interface 281.

[0162] The tip body 256′ supports the other components of the spray tip assembly 254′. The air cap 16 is disposed within the tip body 256′. The air cap 16 is connected to the tip body 256′. A spray tip similar to the spray tip 18 is disposed within the air cap 16, but the spray tip is not shown in FIGS. 11A-11C for ease of illustration. The collar 20′ is disposed around and supported by the tip body 256′. In the illustrated example, the collar 20″ includes a main collar body 267 and a support ring 269 connected to the main collar body 267. The support ring 269 extends radially inward to cover the rear axial end of the tip body 256′. The support ring 269 secures the tip body 256′ within the collar 20″. The collar 20″ is rotatable around the tip body 256′. The collar 20″ is rotatable relative to the air cap 16. Collar 20" is rotatable about central axis CA-CA. Collar 20" is rotatable between an unlocked state and a locked state (shown in FIGS. 11A and 11C), as described in more detail below.

[0163] The tip lock 259 is secured to the tip body 256′ and protrudes radially inward relative to the inner radial surface of the tip body 256′. The tip lock 259 may be formed separately from the tip body 256′ or may be integral with the tip body 256′. The tip lock 259 is configured to interact with a locking interface 281 formed on the gun body 12. Because the tip lock 259 prevents the tip body 256′ from rotating relative to the gun body 12, the tip lock 259 may also be referred to as a rotation lock. The locking interface 281 may be a flat portion of the gun body 12. In some examples, the locking interface 281 may be referred to as an anti-rotation flat. The tip lock 259 interacting with the locking interface 281 secures the tip body 256′, and thus the air cap 16 and spray tip, relative to the gun body 12 and central axis CA-CA. The interface between the tip body 256′ and the gun body 12 thereby prevents rotation of the air cap 16 and spray tip relative to the central axis CA-CA. As shown, the gun body 12 includes a plurality of locking interfaces 281 disposed around the end of the gun body 12 to which the spray tip assembly 254′ is attached. The array of locking interfaces 281 facilitates mounting of the spray tip assembly 254′ in different orientations so that the spray tip 18 can be mounted in different orientations to change the direction of the spray fan emitted by the spray gun 10. While the keyed interface between the tip body 256′ and the gun body 12 is described as being formed by planar portions of the tip body 256′ and the gun body 12, it will be understood that the keyed interface can be formed in any manner suitable for preventing relative rotation between the tip body 256′ and the gun body 12. For example, the tip body 256′ can include one or more protrusions or recesses that interact with corresponding recesses or protrusions on the gun body 12.

[0164] The detents 261 are supported by the tip body 256′. The detents 261 are positioned in openings 265 formed in the tip body 256′. The detents 261 may also be referred to as catches. When the collar 20″ is in the unlocked state, the detents 261 can float within their respective openings 265 and are forced radially inward to remain in place with the collar 20″ in the locked state. When the spray tip assembly 254′ is attached to the gun body 12, the detents 261 align with the mounting grooves 280. When the collar 20″ is in the unlocked state, the detents 261 are radially aligned with the recesses 263 such that the detents 261 can move radially into the recesses 263. When the collar 20″ is in the locked state, the detents 261 are radially aligned with the detent flats 278, which bias the detents radially inward. Although the detents 261 are shown as balls, it is understood that the detents 261 can be formed as dowel rods, ball bearings, collets, etc. The detents 261 can be metal, ceramic, or another hard material. It is understood that the spray tip assembly 254' can include any desired number of detents 261.

[0165] The spray tip assembly 254′ is attached to the spray gun 10 by axially moving the spray tip assembly 254′ onto the gun body 12. The detents 261 are initially aligned with the recesses 263 so that the detents 261 can be pushed radially outward into the recesses 263 by the gun body 12 when the spray tip assembly 254′ is placed on the gun body 12. Once the spray tip assembly 254′ is placed on the gun body 12, the tip lock 259 interacts with the locking interface 281. The collar 20″ is rotated about the central axis CA-CA toward the locked state such that the detent flats 278 press the detents 261 radially inward into the mounting grooves 280. The interface between the tip lock 259 and the locking interface 281 prevents the tip body 254′ and air cap 16 from rotating with the collar 20′ about the central axis CA-CA. When the collar 20" is in the locked state (as shown in FIG. 11C), the detents 261 are disposed within the mounting groove 280 and are prevented from moving radially outward by the collar 20". The detents 261 secure the spray tip assembly 254" to the gun body 12, preventing it from being pulled axially away from the gun body 12. To remove the spray tip assembly 254', the collar 20" is rotated to the unlocked state so that the recesses 263 are radially aligned with the detents 261. The spray tip assembly 254' can then be pulled axially away from the gun body 12. As shown, the front wall of the mounting groove 280 is sloped. The sloped wall helps push the detents radially outward when the spray tip assembly 254' is removed from the gun body 12, facilitating easy and quick removal of the spray tip assembly 254'.

[0166] The spray tip assembly 254' is a quick-connect assembly that facilitates quick and easy installation and removal of the spray tip assembly 254' from the gun body 12. The spray tip assembly 254' facilitates quick and easy installation, removal, and replacement of the air cap 16 and spray tip 18. In some examples, the quick-connect configuration can be retrofitted to an existing spray gun. For example, a gun body configured to accept a threaded collar can instead have a quick-connect mount threaded onto the end of the gun body. The quick-connect mount can include internal threads for attachment to the gun body, as well as an external mounting groove 280 and locking interface 281. Spray guns that require threads for spray tip attachment can thereby be modified to accept the quick-connect spray tip assembly 254'.

[0167] The spray tip assembly 254' offers significant advantages. The quick-connect spray tip assembly 254' allows users to quickly and efficiently change spray tips during operation, increasing spray efficiency and reducing downtime. The operator simply connects and disconnects the collar 20 between locked and unlocked states to install and remove the spray tip assembly 254'. The operator does not need to screw or loosen the collar, which requires a cumbersome rotational motion relative to the gun body 12. Connecting and disconnecting in one motion improves ergonomics and provides faster connection and disconnection times. The collar 20'' is rotated less than one full revolution between locked and unlocked states, as opposed to a threaded connection that may require multiple full revolutions. Additionally, each of the components of the spray tip assembly 254' is provided as a cartridge that can be installed and removed as a single piece. Therefore, the spray tip assembly 254' can be thought of as a spray tip cartridge.

[0168] Figure 12A is a cross-sectional view of the spray tip assembly 254' attached to the gun body 12 with the collar 20' in a locked position. Figure 12B is a cross-sectional view of the spray tip assembly 254' positioned on the gun body 12 with the collar 20' in an unlocked position. Figure 12C is a cross-sectional view taken along line CC of Figure 12A. Figure 12D is a cross-sectional view taken along line DD of Figure 12B. Figures 12A-12D are described together. The spray tip assembly 254' includes the air cap 16, the spray tip 18, the collar 20', a tip body 256', a detent 261', and a spring 271. The collar 20' includes detent slots 273. Each detent slot 273 includes a first portion 275, a second portion 277, and a homing protrusion 279. The tip body 256' includes a retention slot 283 and a tip lock 259. Each detent 261' includes a retention flange 285, a locking flange 287, and a spring groove 289. The gun body 12 includes a mounting groove 280 and a locking interface 281.

[0169] The tip body 256′ supports the other components of the spray tip assembly 254′. The air cap 16 is disposed within the tip body 256′. The air cap 16 is connected to the tip body 256′. The spray tip 18 is disposed within the air cap 16 and configured to emit a fluid spray. A collar 20″ is disposed around and supported by the tip body 256′. In the illustrated example, the collar 20″ includes a main collar body 267 and a support ring 269 connected to the main collar body 267. The support ring 269 extends radially inward to at least partially surround the rear end of the spray tip assembly 254′. The collar 20′ is rotatable around the tip body 256′. The collar 20″ is rotatable relative to the air cap 16. The collar 20″ is rotatable about a central axis CA-CA, which may be coaxial with the spray axis A. The collar 20″ is rotatable between an unlocked state and a locked state, as described in more detail below.

[0170] The tip lock 259 is formed on the tip body 256′ and is configured to interact with a lock interface 281 on the gun body 12. Because the tip lock 259 prevents the tip body 256′ from rotating relative to the gun body 12, the tip lock 259 may also be referred to as a rotation lock. In the illustrated example, the tip body 256′ has a generally cylindrical interior, and the tip lock 259 is formed as a flat portion on the cylindrical interior. The lock interface 281 is formed as a flat surface on the gun body 12. The lock interface 281 may also be referred to as an anti-rotation flat. The tip lock 259 interacts with the lock interface 281 to prevent the tip body 256′ from rotating about the central axis CA-CA. Although the key interface between the tip body 256′ and the gun body 12 is described as being formed by flat portions of the tip body 256′ and the gun body 12, it is understood that the key interface may be formed in any manner suitable for preventing relative rotation between the tip body 256′ and the gun body 12. For example, the tip body 256 ′ can include one or more protrusions or recesses that interact with corresponding recesses or protrusions on the gun body 12 .

[0171] The detents 261′ are radially disposed between the collar 20′ and the tip body 256′. The detents 261′ may also be referred to as catches or collets. In the illustrated example, the detents 261′ extend at least partially around the circumference of the tip body 256′. Each detent 261′ has a retention flange 285 that interacts with the tip body 256′. The retention flanges 285 interact with the tip body 256′ within retention slots 283. The retention slots 283 are recesses formed in the tip body 256′. The retention flanges 285 are configured to be disposed within the retention slots 283 in each of the locked and unlocked states of the collar 20′. The retention flanges 285 thereby retain the detents 261′ with the collar 20′ on the tip body 256′ in each of the locked and unlocked states. The detent 261' can also help retain the collar 20' on the tip body 256' by the interface between the retention flange 285 and the retention slot 283, where the detent 261' interacts with the collar 20' to prevent the collar 20' from moving axially.

[0172] A locking flange 287 is disposed on the axial end of the detent 261' opposite the retaining flange 285. When the spray tip assembly 254' is disposed on the gun body 12, the locking flange 287 is aligned with the mounting groove 280. When the collar 20'' is in the locked state, the locking flange 287 extends into and is retained within the mounting groove 280. The locking flange 287, disposed within the mounting groove 280, secures the spray tip assembly 254' to the gun body 12 and prevents axial displacement of the spray tip assembly 254' from the gun body 12.

[0173] The springs 271 are radially disposed between the detents 261′ and the tip body 256′. The springs 271 are configured to interact with the detents 261′ and urge the detents 261′ radially away from the gun body 12 and toward the collar 20′. The springs 271 are disposed within the spring grooves 289 of each detent 261′. The springs 271 are compressed between the detents 261′ and the tip body 256′ when the collar 20′ is in the locked state. The springs 271 urge the detents 261′ away from the tip body 256′, thereby removing the locking flange 287 from the mounting groove 280 when the collar 20′ is in the unlocked state. In the illustrated example, the springs 271 extend only partially around the circumference of the tip body 256′. The springs 271 are arcuate and extend less than 360° around the tip body 256′.

[0174] The detents 261′ interact with detent slots 273 formed in the collar 20″. In the illustrated example, the collar 20″ includes the same number of detent slots 273 as there are detents 261′. The detent slots 273 are elongated in the circumferential direction in the illustrated example. In the illustrated example, each detent slot 273 is separated from an adjacent detent slot 273, such that each detent 261′ is associated with its own dedicated detent slot 273. A blocker is disposed at each circumferential end of each detent slot 273 to prevent the detent 261′ from passing between the detent slots 273. Each detent slot 273 includes a first portion 275, which may also be referred to as a recess, that receives the detent 261′ when the collar 20′ is in the unlocked state, and a second portion 277 that receives the detent 261′ when the collar 20′ is in the locked state. The second portion 277 can be referred to as being formed by a homing surface of the collar 20′. More specifically, a homing slot 291 of the second portion 277 receives the detent 261′ in a locked position on the collar 20′. The inner radial surface of the second portion 277 is radially closer to the axis CA-CA than the inner radial surface of the first portion 275, such that the second portion 277 biases the detent 261′ radially inward to position the locking flange 287 within the mounting groove 280. A homing protrusion 279 is formed on the collar 20′ and extends radially inward from the detent slot 273. The homing protrusion 279 is formed on the second portion 277 and extends radially inward relative to the inner radial surface of the second portion 277. The homing protrusion 279 partially defines the homing slot 291 of the second portion 277.

[0175] The spray tip assembly 254' is attached to the spray gun 10 by moving the spray tip assembly 254' axially onto the gun body 12. The collar 20' is initially in an unlocked state such that the spring 271 biases the detents 261' radially outward into the first portions 275 of the detent slots 273. Once the detents 261' are biased into the first portions 275, the spray tip assembly 254' is shifted axially onto the gun body 12 such that the tip lock 259 interacts with the lock interface 281.

[0176] Once the spray tip assembly 254'' is placed on the gun body 12, the collar 20'' is rotated relative to the gun body 12 and about axis CA-CA to a locked state. For example, a user can grasp the collar 20' with one hand and rotate the collar 20' relative to the gun body 12. The interface between the tip lock 259 and the lock interface 281 prevents the tip body 256', and therefore the air cap 16 and spray tip 18, from rotating about axis CA-CA while the collar 20' is rotated between the locked and unlocked states. The detents 261' pass from the first portion 275 of the detent slot 273 to the second portion 277 of the detent slot 273 and are pushed radially inward by the collar 20'. As the collar 20'' further rotates, the detents 261' strike the homing protrusions 279, which cause the detents 261' to be pushed further radially inward. The detent 261′ passes over the homing protrusion 279 and enters the homing slot 291. The spring 271 urges the detent 261′ radially outward into the homing slot 291, causing the detent 261′ to seat within the homing slot 291. The securing flange 287 is thus disposed within the mounting groove 280 to secure the spray tip assembly 254′ to the gun body 12.

[0177] As the detent 261′ passes over the homing protrusion 279 and enters the homing slot 291, it can provide feedback to the user that the collar 20″ is locked. For example, the spring 271 urging the detent 261′ into the homing slot 291 can cause vibration feedback that the user feels in their hand as they grasp and manipulate the collar 20′. The spring 271 urging the detent 261′ into the homing slot 291 can cause audible feedback, such as a click, that confirms to the user that the collar 20″ is locked.

[0178] With the collar 20' in the locked position, the spray tip assembly 254' is secured to the gun body 12 and positioned for spraying. To remove the spray tip assembly 254', the collar 20' is rotated from the locked position to the unlocked position. The detent 261' enters the first portion 275 of the detent slot 273, and the spring 271 biases the detent 261' toward the first portion 275, away from the gun body 12. This disengages the locking flange 287 from the mounting groove 280, allowing the spray tip assembly 254' to be pulled axially away from the gun body 12.

[0179] The spray tip assembly 254' is a quick connect assembly that facilitates quick and easy installation and removal of the spray tip assembly 254' from the gun body 12. The spray tip assembly 254' facilitates quick and easy installation, removal, and replacement of the air cap 16 and spray tip 18. In some examples, the quick connect configuration can be retrofitted to existing spray guns, similar to the spray tip assembly 254' described above.

[0180] The spray tip assembly 254' offers significant advantages. The quick-connect spray tip assembly 254' allows users to quickly and efficiently change spray tips during operation, increasing spray efficiency and reducing downtime. The operator simply connects and disconnects the collar 20 between its locked and unlocked states to install and remove the spray tip assembly 254'. The operator does not need to screw the collar in or out, which requires a cumbersome rotational motion relative to the gun body 12. Connecting and disconnecting in one motion improves ergonomics and provides faster connection and disconnection times. The collar 20'' is rotated less than one full revolution between its locked and unlocked states, as opposed to a threaded connection that may require multiple full revolutions. In some examples, the collar 20'' can be rotated only one-quarter of a revolution between its locked and unlocked states. In some examples, the collar 20'' can be rotated one-third of a revolution between its locked and unlocked states. The detents 261' extend at least partially around the gun body 12 so that the detents 261' do not apply a point load to the gun body 12. The detents 261', spreading the load over a portion of the gun body 12, prevent pitting and other contact damage to the gun body 12, which may be formed from a metal such as aluminum. Additionally, each of the components of the spray tip assembly 254'' is provided as a cartridge that can be installed and removed as a single piece. Thus, the spray tip assembly 254'' can be considered a spray tip cartridge.

[0181] FIG. 13 is a cross-sectional view of spray tip assembly 254'". Spray tip assembly 254'" is substantially similar to spray tip assembly 254, spray tip assembly 254', and spray tip assembly 254". Spray tip assembly 254 is a quick-connect spray tip assembly 254" that facilitates quick and easy installation and removal of spray tip 18 and air cap 16 from spray gun 10. Spray tip assembly 254" is substantially similar to spray tip assemblies 254" and 254' in that collar 20" of spray tip assembly 254" rotates between a locked state and an unlocked state. Spray tip assembly 254" includes a detent slot 273 that interacts with detent 261. Detent 261 is supported by tip body 256'. Collar 20" is rotatable relative to tip body 256' and interacts with detent 261. The first portion 275 is radially aligned with the detent 261 in the unlocked state of the spray tip assembly 254′ and functions to allow the detent 261 to move radially away from and over the gun body 12. The homing slot 291 is radially aligned with and interacts with the detent 261 in the locked state of the spray tip assembly 254′ to secure the spray tip assembly 254′ to the gun body 12.

[0182] As detent 261 passes over homing protrusion 279 and into homing slot 291, it can provide feedback to the user that collar 20' is locked. For example, detent 261 can jump into homing slot 291, causing vibration feedback that can be felt by the user's hand as they grasp and manipulate collar 20'. As detent 261 jumps into homing slot 291, audible feedback, such as a click, can be generated to confirm to the user that collar 20' is locked.

[0183] Figure 14A is a cross-sectional view of spray tip 18. Figure 14B is a rear view of spray tip 18. Figure 14C is a front view of spray tip 18. Figure 14D is a side view of spray tip 18. Figure 14E is a rear view of turbulator assembly 286. Figures 14A-14E will be discussed together. Spray tip 18 includes turbulator assembly 286, orifice 288, tip housing 290, tip 292, retaining ring 294, gasket 296, tip seal 298, and positioning tab 300. Turbulator assembly 286 includes turbulators 302 and support ring 304.

[0184] The spray tip 18 receives a stream of spray fluid and emits the spray fluid as a spray. Turbulence upstream of the spray orifice 288 is desirable to enhance atomization of the fluid as it exits the spray tip 18. A tip 292 is disposed within the tip housing 290. The tip 292 is formed from a hardened material. In some examples, the spray tip 18 is formed from carbide. It should be understood that the tip 292 can be formed from other suitable hard materials, such as metals and ceramics, among other options. A turbulator assembly 286 is disposed adjacent to the tip 292. The turbulator assembly 286 is disposed immediately upstream of the tip 292. The spray fluid flows through the turbulator assembly 286, enters the tip 292, and is emitted through the orifice 288. A support ring 304 is disposed within the tip housing 290 adjacent to the tip 292. The turbulators 302 are supported by the support ring 304. In some examples, each end of the turbulator 302 is supported by a support ring 304. The support ring 304 may be formed by, among other options, a gasket that seals against the tip 292. The turbulator 302 extends through a tip axis TP-TP, which may be coaxial with the central axis CA-CA and the spray axis A, such that the turbulator 302 extends through a central flow axis that passes through the spray tip 18.

[0185] A retaining ring 294 is disposed adjacent to the turbulator assembly 286 and retains the turbulator assembly 286 within the tip housing 290. A gasket 296 is disposed within the tip housing 290 and is configured to form a sealed interface with a nozzle, such as the nozzle 164, extending from the spray gun 10. For example, the gasket 296 can seal against a portion of the fluid valve cartridge 44, such as against a portion of the fluid cartridge body 122. In one example, the gasket 296 can seal against the nozzle 164 extending from the tip mount 130 of the fluid cartridge body 122. A tip seal 298 is disposed around the inlet end of the spray tip 18 and the tip housing 290. The tip seal 298 is configured to interact with the air cap 16 and help retain the spray tip 18 within the air cap 16. A positioning tab 300 locks the orientation of the spray tip 18 relative to the air cap 16.

[0186] The turbulator assembly 286 is disposed within the flow path through the spray tip 18. Some examples of the spray tip 18 do not include a pre-orifice element upstream of the tip 292. The pre-orifice element has a pre-orifice with a narrowing diameter, followed by a chamber with an enlarged diameter, which then narrows and continues through the tip 292 to the orifice 288. The pre-orifice is formed by openings aligned on the axis TP-TP. The turbulators 302 extend through the axis TP-TP such that the flow aligned on the axis TP-TP encounters an obstacle formed by the turbulators 302. The turbulators 302 interrupt the relatively laminar flow and create turbulence in the flow. The turbulence improves atomization of the spray fluid when the spray fluid is driven through the orifice 288 at a lower pressure. This allows relatively thin spray liquids, such as varnishes, lacquers, fine or high-gloss finishes, thin water-based paints, solvent-based materials, and the like, to be sprayed with spray tips 18 having a relatively large diameter opening upstream of the orifice 288, such as spray tips 18 that do not include a pre-orifice component. For example, some spray tips 18 may include relatively large orifices 288 having diameters up to about 1.016 millimeters (mm) (about 0.040 inches). Some spray tips 18 may include relatively large orifices 288 having diameters of at least about 0.508 mm (at least about 0.020 inches). It will be appreciated that the turbulators 302 provide improved spray and benefit for tip orifices across a range of sizes. In some examples, spray tips 18 include orifices 288 larger than about 0.051 mm (about 0.002 inches). In some examples, the spray tip 18 includes an orifice of about 0.002 inches to about 0.015 inches.

[0187] During operation, spray fluid flows through the spray tip 18 from the upstream end to the orifice 288. The spray fluid encounters a turbulator 302 just upstream of the portion of the flow path defined by the tip 292. The turbulator 302 provides a flow obstacle that reduces the flow area and generates turbulence downstream of the turbulator 302. The turbulated flow is received by the tip 292 just downstream of the turbulator assembly 286, flows through the tip 292, and is discharged through the orifice 288. The turbulator 302 is positioned at the upstream end of the tip 292 so that the turbulent flow is generated as close as possible to the orifice 288. Turbulent flow has better spray characteristics and exhibits better atomization than laminar flow.

[0188] The turbulators 302 extend through the axis TP-TP through the spray tip 18 and are positioned within the flow path through the spray tip 18. A relatively large orifice can be utilized to prevent clogging of the spray fluid, but this results in an undesirably high flow rate. Users can reduce the flow rate, but this results in a corresponding pressure drop. Lower pressures can adversely affect spray quality. The turbulators 302 provide a flow restriction, adding turbulence to the fluid flow to improve atomization of the spray fluid at the lower pressures required to reduce the flow rate. The turbulators 302 also facilitate atomization of spray fluids, particularly thin spray fluids, such as varnishes, lacquers, fine or high-gloss finishes, thin water-based paints, solvent-based materials, and the like.

[0189] The turbulators 302 alter the flow and induce turbulence, providing better spray characteristics. The spray gun 10 emits a high-quality spray of a relatively low-viscosity fluid. The spray gun 10 can produce the desired atomization with a tip 292 having a relatively large orifice, which is beneficial at relatively low flow rates and pressures to prevent clogging. In some examples, the spray gun 10 can apply spray fluid at flow rates between about 50 cubic centimeters per minute (about 3.05 cubic inches per minute) and about 500 cubic centimeters per minute (about 30.5 cubic inches per minute). The turbulators 302 facilitate spraying at pressures 25% lower, and in some cases 10-20% lower, than spray tips without the turbulators 302. This allows users to apply materials without replacing the spray tip 18 on the spray gun 10.

[0190] FIG. 15 is a rear view of spray tips 18a-18c. Spray tip 18a includes turbulator 302a. Spray tip 18b includes turbulator 302b. Spray tip 18c includes turbulator 302c. Each turbulator 302a-302c (collectively "turbulators 302" herein) is disposed within an axial flow path along axis TP (FIG. 14A) through its respective spray tip 18a-18c (collectively "spray tip 18" herein). The turbulators 302 are disposed within the flow path, and specifically on axis TP, to generate turbulence in the spray fluid flowing through the spray tip 18. The turbulators 302 pass completely through the flow path. The turbulators 302 intersect axis TP. The ends of the turbulators 302 can connect 180 degrees apart on either side of the orifice 288. The turbulators 302a are shaped as a cross disposed within the flow path. The arms of turbulator 302a may be spaced approximately 90 degrees apart, although other angles are possible. Turbulator 302b includes an expanding portion 306. The expanding portion may include a center point located on axis TP. Turbulator 302b includes ends spaced approximately 180 degrees apart around orifice 288. Turbulator 302c is generally uniform between its first and second ends. The ends of turbulator 302c are spaced approximately 180 degrees apart around orifice 288. While turbulators 302a, 302b, and 302c are shown, it will be understood that other variations of turbulators 302 may be included within spray tip 18 to generate turbulence.

[0191] While the present invention has been described with reference to exemplary embodiments, those skilled in the art will recognize that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from essential scope thereof. Therefore, it is not intended that the invention be limited to the particular embodiments disclosed, but rather that the invention will include all embodiments falling within the scope of the appended claims.

Claims

1. 1. A spray gun configured to receive a fluid and air stream and emit a fluid spray and air, comprising: a gun body having a first bore opening at a front end of the gun body, a second bore opening at a rear end of the gun body, and a gap disposed therebetween, the first bore and the second bore being coaxially disposed on a spray axis; a spray fluid control cartridge having a first housing disposed within the first bore, a spray fluid control valve entirely contained within the first housing, the spray fluid control cartridge configured to control the spray of spray fluid from the spray gun, the spray fluid control cartridge configured to be attachable to and detachable from the gun body as a single unit; an air control cartridge having a second housing disposed within the second bore, a first valve member at least partially contained within the second housing, the first valve member configured to control air flow for spraying by the spray gun, the air control cartridge configured to be attachable to and detachable from the gun body as a single unit; a trigger extending into the gap and configured to actuate the spray fluid control valve between a closed state and an open state; Equipped with A spray gun wherein the spray fluid control valve and a first valve member are coaxially disposed.

2. The spray gun of claim 1 , wherein the air control cartridge includes a second valve member.

3. The spray gun of claim 2 , wherein the first valve member is configured to be actuated by the trigger.

4. 4. A spray gun according to claim 2 or 3, wherein the second valve member is set independently of the trigger and is not affected by the depression of the trigger.

5. 4. The spray gun of claim 3, wherein a first valve stem of the first valve member interacts with the second valve stem of the spray fluid control valve such that the trigger actuates the second valve stem to the open state by the first valve stem.

6. 6. The spray gun of claim 5, wherein the second valve stem extends within the first valve stem, and a coupler is disposed about the second valve stem, the coupler being configured to interact with the trigger, the first valve stem, and the second valve stem to actuate the first valve stem and the second valve stem to their respective open states.

7. 7. The spray gun of claim 6, wherein a gap is formed between the coupler and a protrusion disposed on the second valve stem, the gap being positioned such that the first valve stem shifts axially a first distance before the coupler engages the protrusion to actuate the second valve stem.

8. 4. The spray gun of claim 3, wherein a knob is supported by the second valve member.

9. The spray gun of claim 8 , wherein the knob is rotatable relative to the valve member.

10. 9. The spray gun of claim 8, wherein the knob is secured to the second valve member such that the knob can actuate the second valve member between an open position and a closed position.

11. 1. A spray gun configured to receive a stream of spray fluid and air and to emit a fluid spray and air, comprising: The gun body and a first valve bore formed in the gun body; a second valve bore formed in the gun body; a first flow valve cartridge disposed in the first valve bore, the first flow valve cartridge entirely containing a first flow valve configured to control downstream flow through the first flow valve cartridge; a second flow valve cartridge disposed in the second valve bore, the second flow valve cartridge entirely containing a second flow valve configured to control downstream flow through the second flow valve cartridge; Equipped with the first flow valve cartridge is positioned to control the flow of spray fluid between the spray fluid inlet and the spray tip; the second flow valve cartridge is positioned to control a first flow of air between the air inlet bore and the air cap and a second flow of air between the air inlet bore and the air cap; A spray gun, wherein the first flow valve cartridge and the second flow valve cartridge are each configured to be attachable to and detachable from the gun body as a single unit.

12. further comprising a fluid conduit assembly configured to provide spray fluid to the gun body; the fluid conduit assembly includes a mount block having a mount bore extending therethrough; The spray gun of claim 11 , wherein the gun body includes a mounting slot configured to receive the mounting block, and the mounting bore forms a portion of the first valve bore.

13. further comprising a forward bore formed within the gun body and a rearward bore formed within the gun body and axially aligned with the forward bore; The spray gun of claim 12 , wherein the forward bore, the mount bore, and the rearward bore form the first valve bore.

14. 14. The spray gun of claim 11, wherein the first flow valve cartridge is secured to the gun body by a first interface formed between a first cartridge body of the first flow valve cartridge and the gun body.

15. 12. The spray gun of claim 11, wherein the first flow valve cartridge includes a first cartridge body, a first valve member at least partially disposed within the first cartridge body, and an actuator spring interacts with the first valve member to bias the first valve member toward a closed position.

16. The spray gun of claim 15, wherein the actuator spring is located in a portion of the first cartridge housing that protrudes from the gun body.

17. 12. The spray gun of claim 11, wherein the first flow valve cartridge includes a first cartridge body, a first valve member at least partially disposed within the first cartridge body, and a second valve member at least partially disposed within the first cartridge body.

18. 18. The spray gun of claim 17, wherein the first flow valve cartridge includes a first valve associated with the first valve member, a second valve associated with the first valve member, and a third valve associated with the second valve member.

19. 20. The spray gun of claim 18, wherein the second valve is located upstream of the third valve.

20. 20. The spray gun of claim 18, wherein the first valve member is operably associated with a trigger of the spray gun such that the trigger can actuate the first valve member to shift the first valve and the second valve from their respective closed states to their respective open states.

21. 20. The spray gun of claim 18, wherein the second valve is formed in the first cartridge body and the third valve is formed in the first cartridge body.

22. 22. The spray gun of claim 21, wherein the first valve is formed between the first valve member and one of the gun body and the first cartridge body.

23. 12. The spray gun of claim 11, wherein the first valve bore is formed in a front block of the gun body, the second valve bore is formed in a rear block of the gun body, and a trigger is located in a gap disposed between the front block and the rear block.

24. 12. The spray gun of claim 11, wherein the first flow valve cartridge is secured to the gun body at a first interface within the first valve bore and the second flow control cartridge is secured to the gun body at a second interface within the second valve bore.

25. A spray gun configured to receive a stream of spray fluid and air and emit a fluid spray and air, comprising: The gun body and a first valve bore formed in the gun body; a first flow valve cartridge disposed in the first valve bore, the first flow valve cartridge entirely containing a first flow valve configured to control downstream flow through the first flow valve cartridge; Equipped with The gun body, an air inlet bore extending into the first valve bore; an air supply bore extending through the gun body; a first air bore extending between the first valve bore and the supply air bore; a second air bore extending between the first valve bore and the supply air bore; Equipped with an air tube disposed within the supply air bore, the air tube dividing the supply air bore into a first portion in fluid communication with the first air bore and a second portion in fluid communication with the second air bore.

26. 26. The spray gun of claim 25, wherein the first portion is fluidly isolated from the second air bore and the second portion is fluidly isolated from the first air bore.

27. 26. The spray gun of claim 25, further comprising at least one opening formed in an end of the supply air bore, the at least one opening providing an exit from the first portion.

28. 26. The spray gun of claim 25, wherein the first flow valve cartridge includes a first valve seal associated with a first valve and a second valve seal associated with a second valve, the first valve configured to control the flow of an auxiliary air portion from the first valve bore to the first air bore, and the second valve configured to control the flow of a fan air portion.

29. 30. The spray gun of claim 28, further comprising a second valve member at least partially disposed within a first cartridge body of the first flow valve cartridge, the second valve member associated with a third valve disposed downstream of the second valve.

30. 30. The spray gun of any one of claims 28 and 29, wherein the first valve seal and the second valve seal are connected for simultaneous operation between their respective open and closed conditions.

31. 30. The spray gun of claim 28, wherein the auxiliary air portion is fluidly isolated from the fan air portion within the supply air bore.

32. A spray gun configured to receive a stream of spray fluid and air and emit a fluid spray and air, comprising: The gun body and a first valve bore formed in the gun body; a first flow valve cartridge disposed in the first valve bore, the first flow valve cartridge entirely containing a first flow valve configured to control downstream flow through the first flow valve cartridge; Equipped with The first flow valve cartridge comprises: a first cartridge body; a first valve member at least partially disposed within the first cartridge body; a second valve member at least partially disposed within the first cartridge body; The spray gun, wherein the first cartridge body extends from a rear end of the gun body and a knob is disposed around a portion of the second valve member.

33. 33. The spray gun of claim 32, wherein the spray gun includes a plurality of knobs having a plurality of diameters, each of the plurality of knobs being attachable to the first flow valve cartridge.

34. 33. The spray gun of claim 32, wherein the knob is located above a handle of the spray gun.

35. 35. The spray gun of claim 34, wherein the spray gun does not include a protrusion below the knob.

36. A spray gun according to any one of claims 32 to 35, wherein the knob is configured to interact with a user's hand.

37. A spray gun according to any one of claims 32 to 35, wherein the knob is fixed to the second valve member such that the knob can actuate the second valve member within the first cartridge body.

38. 36. A spray gun according to any one of claims 32 to 35, wherein the knob is freely supported by and decoupled from the second valve member such that the knob can move relative to the second valve member while the second valve member is stationary.

39. 39. The spray gun of claim 38, wherein the knob is decoupled from the second valve member such that the knob cannot actuate the second valve member.

40. 36. The spray gun of any one of claims 32 to 35, wherein a tool interface is formed on an end of the second valve member, the tool interface configured to interact with an adjustment tool to actuate the second valve member.

41. 1. A spray tip assembly for a spray gun, the spray tip assembly comprising: The spray tip and a turbulator assembly disposed upstream of the spray tip.

42. 42. The spray tip of claim 41, wherein the turbulator assembly includes turbulators extending through a central axis and through an orifice of the spray tip.

43. the spray tip assembly a tip body supporting the spray tip and defining a spray bore; a gasket disposed within the spray bore configured to interact with a portion of the spray gun; 43. The spray tip of claim 42, wherein the turbulator assembly is disposed within the spray bore axially between the spray tip and the gasket.

44. 44. The spray tip of claim 43, wherein the turbulator assembly includes a second gasket positioned adjacent the spray tip and supporting the turbulators.

45. A spray gun, a gun body having an air valve bore extending along a bore axis, an air inlet bore communicating with said air valve bore, an auxiliary air bore extending from said air valve bore, and a fan air bore extending from said air valve bore; an air valve assembly disposed within the air valve bore and configured to control a first air flow between the air inlet bore and the auxiliary air bore and a second air flow between the air inlet bore and the fan air bore; the air valve assembly comprising: a valve body disposed within the air valve bore and having an axial bore therethrough and at least one air outlet port, the at least one air outlet port being in fluid communication with the fan air bore; a common valve member disposed at least partially within the air valve bore, wherein a first end of the common valve member extends from the air valve bore and a second end of the common valve member is disposed within the valve body; a fan valve member disposed within the air valve bore, the fan valve member being formed separately from the common valve member and spaced apart from the common valve member along the bore axis; Equipped with a first valve formed at least in part by the common valve member and configured to control downstream flow to the auxiliary air bore; a second valve at least partially formed by the common valve member and configured to control downstream flow to the fan air bore; the fan valve member is disposed downstream of the second valve; Spray gun.

46. 46. ​​The spray gun of claim 45, further comprising a stop extending into the air valve bore and configured to interact with the fan valve member to limit axial displacement of the fan valve member.

47. 47. The spray gun of claim 46, wherein the stop includes a shaft and a knob, the shaft configured to interact with the fan valve member.

48. 46. ​​The spray gun of claim 45, wherein the fan valve member is disposed within the common valve member, and a fan valve spring is disposed within the common valve member and biases the fan valve member toward the second end of the common valve member.

49. 49. The spray gun of claim 48, wherein the second valve is formed between the common valve member and the fan valve member.

50. 46. ​​The spray gun of claim 45, wherein the second valve is configured such that a flow opening through the second valve expands as the common valve member shifts rearward relative to the fan valve member.

51. 46. ​​The spray gun of claim 45, wherein a trigger of the spray gun is configured to actuate the common valve member.

52. 46. ​​The spray gun of claim 45, wherein the size of the opening through the second valve varies based on the degree of actuation of a trigger of the spray gun.

53. A tip body, an air cap disposed at least partially within the tip body and at a first end of the tip body; a spray tip supported by the air cap; a first capture member disposed in a first slot in the tip body; a second capture member disposed within a second slot in the tip body, the second slot being axially spaced from the first slot; a collar disposed about the tip body, the collar being movable between a detached state and an attached state, the collar biasing the second capture member downwardly toward an axis passing through the spray tip in the attached state; A spray tip assembly comprising:

54. 54. The spray tip assembly of claim 53, wherein a first groove formed on the collar is aligned with the first capture member, a second groove formed on the collar is aligned with the second capture member when the collar is removed, a first flat portion formed on the collar is aligned with the first capture member, and a second flat portion formed on the collar is aligned with the second capture member when the collar is attached.

55. 54. The spray tip assembly of claim 53, further comprising:

54. The spray tip assembly of claim 53, comprising a locking piston disposed within the tip body, the locking piston configured to bias the first capture member into the first groove when the collar is removed.

56. 56. The spray tip assembly of claim 55, wherein the locking piston includes a piston head and a piston spring, the piston spring being disposed between the piston head and the air cap.

57. 1. A spray tip assembly comprising: A tip body, an air cap disposed at least partially within the tip body and at a first end of the tip body; a spray tip supported by the air cap and having an axis passing through the spray tip; a collar disposed about the tip body; at least one fastener disposed at least partially within the collar; Equipped with the collar is configured to rotate about the shaft and relative to the tip body between a locked state and an unlocked state, the collar biasing the catch radially inward toward the shaft in the locked state. Spray tip assembly.

58. 58. The spray tip assembly of claim 57, wherein the collar includes at least one recess formed on an inner radial surface of the collar, the collar includes at least one homing surface formed on the inner radial surface of the collar, the at least one recess radially aligned with the at least one fastener in an unlocked state of the collar, and the at least one homing surface radially aligned with the at least one fastener in a locked state of the collar.

59. 59. The spray tip assembly of claim 58, wherein the collar includes a circumferentially elongated detent slot, the circumferentially elongated detent slot including each of the at least one recess and the at least one homing surface, and the at least one fastener is disposed within the circumferentially elongated detent slot when the collar is in each of the locked and unlocked states.

60. 60. The spray tip assembly of claim 59, wherein the at least one fastener comprises a plurality of fasteners and the collar comprises a plurality of the circumferentially elongated detent slots.

61. 60. The spray tip assembly of claim 59, wherein the circumferentially elongated detent slot extends radially inward and includes a homing protrusion formed on the homing surface.

62. 58. The spray tip assembly of claim 57, further comprising a spring interacting with the at least one fastener to bias the at least one fastener radially outward and away from the axis.

63. 58. The spray tip assembly of claim 57, wherein the collar is configured to rotate between the locked and unlocked states in less than one revolution.

64. 64. The spray tip assembly of claim 63, wherein the collar is configured to rotate a quarter turn between the locked and unlocked states.

65. An air valve cartridge for a spray gun, comprising: a cartridge body having a first end, a second end, at least one air inlet port therethrough, and at least one air outlet port therethrough; a first valve member at least partially disposed within the cartridge body, the first valve member having a first radial protrusion and a second radial protrusion; a second valve member at least partially disposed within the cartridge body; a spring positioned to interact with the cartridge body and the first valve member to bias the first valve member away from the second end; Equipped with an air valve cartridge, wherein the cartridge body, the spring, the first valve member, and the second valve member form separate assemblies configured to control a first air flow and a second air flow downstream from the air valve cartridge.

66. 66. The air valve cartridge of claim 65, wherein the first valve member is slidable relative to the cartridge body.

67. 66. The air valve cartridge of claim 65, wherein a second protrusion is configured to interact with the cartridge body to define a first valve, and the second valve member at least partially defines a second valve within the cartridge body, the second valve being positioned downstream of the first valve.

68. 1. A method of assembling a fluid conduit assembly to a spray gun, comprising: aligning a mounting block with a mounting slot formed in a gun body of the spray gun; Sliding the mounting block into the mounting slot; a fluid valve member configured to control the spray of spray fluid by the gun through the mounting block to secure the mounting block within the mounting slot; A method comprising:

69. 69. The method of claim 68, further comprising the step of inserting an air fitting into the handle of the spray gun.

70. 70. The method of claim 69, wherein the air fitting is inserted through a connector, the connector extending between the air fitting and a lower fluid fitting, and a fluid conduit extending between the mounting block and the lower fluid fitting.

71. 1. A method of assembling a spray gun, comprising: inserting a first valve cartridge as a unit into a first cartridge bore formed in a gun body of the spray gun, the first valve cartridge moving in a first direction along an axis into the first cartridge bore, the first valve cartridge including at least one first flow control valve; securing a first body of the first valve cartridge to the gun body; inserting a second valve cartridge as a unit into a second cartridge bore formed in a gun body of the spray gun, the second valve cartridge moving in a second axial direction into the second cartridge bore opposite the first direction, the second valve cartridge including at least one second flow control valve; securing a second body of the second valve cartridge to the gun body; A method comprising:

72. 72. The method of claim 71, further comprising the step of securing the trigger to a gun body such that a coupler of the first valve cartridge is disposed between the trigger and a valve member of the second valve cartridge.

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