Fluid sprayer

Abstract

A fluid sprayer includes a pump module configured to put a spray fluid under pressure and pump the spray fluid to a spray gun for emission onto a target substrate. The pump module includes a motor that generates a rotational output, a drive that converts the rotational output to a linear reciprocating motion, and a pump that receives the linear reciprocating motion and moves the spray fluid. A recirculation valve is configured to direct pumped fluid not emitted through the spray gun back to a reservoir of the spray fluid.

Description

[0001] FLUID SPRAYER

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

[0003] This application claims the priority to U.S. Provisional Application No. 63 / 664,525 filed June 26, 2024 and entitled “PAINT SPRAYER,” and claims priority to U.S. Provisional Application No. 63 / 717,684 filed November 7, 2024 and entitled “PAINT SPRAYER,” and claims priority to U.S. Provisional Application No. 63 / 775,596 filed March 21, 2025 and entitled “PAINT SPRAYER,” and claims priority to U.S. Provisional Application No. 63 / 800,656 filed May 6, 2025 and entitled “PAINT SPRAYER,” the disclosures of which are hereby incorporated by reference in their entireties.

[0004] BACKGROUND

[0005] This disclosure relates to fluid sprayers. More particularly, this disclosure relates to a fluid sprayers for spraying of paints and other coatings.

[0006] Fluid sprayers are configured to output a spray of paint or other coating material. Fluid sprayers include a pump that puts the spray fluid under pressure and outputs the pressurized spray fluid to a nozzle. The nozzle is configured to atomize the flow of spray fluid for application on the target surface.

[0007] SUMMARY

[0008] According to an aspect of the disclosure, a fluid sprayer for spraying a spray fluid configured to coat a surface includes an electric motor, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion on a motor axis; a drive which converts the rotational motion output by the electric motor into linear reciprocating motion; a pump, the pump receiving the linear reciprocating motion from the drive to linearly reciprocate a piston to pump the spray fluid; a spray nozzle which atomizes the spray fluid output by the pump; a trigger; and a spray valve that receives the spray fluid output by the pump and allows the spray fluid to flow to the spray nozzle when the trigger is in an actuated state and which blocks the spray fluid from flowing to the spray nozzle when the trigger is in a non-actuated state. The electric motor operates to cause the piston pump to continuously pump the spray fluid with the trigger both in the actuated state and the non-actuated state.

[0009] According to an additional or alternative aspect of the disclosure, a fluid sprayer for spraying a spray fluid configured to coat a surface includes an electric motor, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion on a motor axis; a drive which converts the rotational motion output by the electric motor into linear reciprocating motion; a pump, the pump receiving the linear reciprocating motion from the drive to linearly reciprocate a piston to pump the spray fluid; a spray nozzle which atomizes the spray fluid output by the pump; a trigger; a spray valve that receives the spray fluid output by the pump and allows the spray fluid to flow to the spray nozzle when the trigger is in an actuated state and which blocks the spray fluid from flowing to the spray nozzle when the trigger is in a non-actuated state; a power supply that provides electrical power to the electric motor; and a power switch actuatable between an ON state in which the electrical power is provided to the electric motor to cause the stator to rotate the rotor and an OFF state in which the electrical power is not provided to the electric motor. The electric motor operates to cause the pump to continuously pump the spray fluid with the power switch in the ON state.

[0010] According to another additional or alternative aspect of the disclosure, a pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface includes an electric motor, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion on a motor axis; a drive which converts the rotational motion output by the electric motor into linear reciprocating motion; a pump, the pump receiving the linear reciprocating motion from the drive to linearly reciprocate a piston to pump the spray fluid; a spray passage extending downstream from the pump to an outlet orifice; and a recirculation valve connected to spray passage at a location upstream of the outlet orifice, the recirculation valve configured to open at a threshold pressure of the spray fluid. The electric motor operates to cause the piston to continuously reciprocate to pump the spray fluid with the pump module in an ON state. The recirculation valve is configured to open based on a fluid pressure downstream of the pump reaching the threshold pressure to provide a return flow of the spray fluid output from the pump to a reservoir of the spray fluid.

[0011] According to yet another additional or alternative aspect of the disclosure, a pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface includes a primary housing; an electric motor disposed in the primary housing, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion on a motor axis; a drive housing connected to the primary housing; a drive disposed in the drive housing, the drive configured to convert the rotational motion output by the electric motor into linear reciprocating motion; a pump, the pump receiving the linear reciprocating motion from the drive to linearly reciprocate a piston to pump the spray fluid; and a stand connected to the primary housing, the stand configured to support the primary housing on a support surface. The electric motor, the drive, and the pump are indirectly connected to the stand by the primary housing.

[0012] According to yet another additional or alternative aspect of the disclosure, a pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface includes a primary housing; an electric motor disposed in the primary housing, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion on a motor axis; a drive housing directly connected to the primary housing; a drive disposed in the drive housing, the drive configured to convert the rotational motion output by the electric motor into linear reciprocating motion; and a pump, the pump receiving the linear reciprocating motion from the drive to linearly reciprocate a piston within a fluid manifold to pump the spray fluid. The fluid manifold is directly connected to the drive housing.

[0013] According to yet another additional or alternative aspect of the disclosure, a pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface includes a primary housing; an electric motor disposed in the primary housing, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion on a motor axis; a drive disposed in the primary housing, the drive configured to convert the rotational motion output by the electric motor into linear reciprocating motion; a pump disposed at least partially within the primary housing, the pump receiving the linear reciprocating motion from the drive to linearly reciprocate a piston to pump the spray fluid; and a stand connected to the primary housing, the stand configured to support the primary housing on a support surface, wherein the stand is snap fit to the primary housing.

[0014] According to yet another additional or alternative aspect of the disclosure, a pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface includes an electric motor, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion on a motor axis; a drive connected to the electric motor, the drive configured to convert the rotational motion output by the electric motor into linear reciprocating motion; and a pump connected to the drive, the pump receiving the linear reciprocating motion from the drive to linearly reciprocate a piston to pump the spray fluid. The piston is connected to the drive on a top side of the drive.

[0015] According to yet another additional or alternative aspect of the disclosure, a pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface includes an electric motor, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion on a motor axis; a drive which converts the rotational motion output by the electric motor into linear reciprocating motion; a pump, the pump receiving the linear reciprocating motion from the drive to linearly reciprocate a piston on a pump axis to pump the spray fluid; a spray passage extending downstream from the pump to an outlet orifice; an outlet check valve disposed downstream of the pump; a return passage that routes the spray fluid output by the pump back to the reservoir, the return passage fluidly connected to the spray passage at a branch orifice; and a recirculation valve within the return passage, the recirculation valve configured to open at a threshold pressure of the spray fluid. The branch orifice opens into the spray passage at a location that radially overlaps with the outlet check valve.

[0016] According to yet another additional or alternative aspect of the disclosure, a pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface includes an electric motor, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion on a motor axis; a drive which converts the rotational motion output by the electric motor into linear reciprocating motion; a pump, the pump receiving the linear reciprocating motion from the drive to linearly reciprocate a piston on a pump axis to pump the spray fluid; a spray passage extending downstream from the pump to an outlet orifice; and a recirculation valve connected to spray passage at a location upstream of the outlet orifice, the recirculation valve configured to open at a threshold pressure of the spray fluid. The recirculation valve includes a spring biasing the recirculation valve to a closed state; a lever accessible from an exterior of the pump module, the lever configured to actuate the recirculation valve to an open state and hold the recirculation valve in the open state; and a collar configured to rotate to change a compression of the spring to thereby change the threshold pressure. The lever is connected to the collar such that the lever rotates with the collar.

[0017] According to yet another additional or alternative aspect of the disclosure, a pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface includes a primary housing having a front end, a rear end, a top side, a bottom side, a first lateral side, a second lateral side, at least one rear vent opening through the rear end, and at least one lateral vent opening through at least one of the first lateral side and the second lateral side; an electric motor disposed within the housing, the electric motor comprising a rotor configured to rotate on a motor axis and a stator, the electric motor configured to output rotational motion, the electric motor at least partially disposed in a motor housing; a drive at least partially disposed within the primary housing, the drive configured to convert rotational motion output by the electric motor into linear reciprocating motion, the drive supported by a drive housing; a pump, the pump receiving linear reciprocating motion from the drive to linearly reciprocate a piston along a pump axis to pump the spray fluid; and an upper baffle extending between the first lateral side and the second lateral side and extending towards the bottom side from the top side, wherein the upper baffle is disposed between the rear end and an air intake of the electric motor.

[0018] According to yet another additional or alternative aspect of the disclosure, a pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface includes a primary housing having a front end, a rear end, a top side, a bottom side, a first lateral side, a second lateral side, at least one rear vent opening through the rear end, and at least one lateral vent opening through at least one of the first lateral side and the second lateral side; an electric motor disposed within the primary housing, the electric motor comprising a rotor configured to rotate on a motor axis and a stator, the electric motor configured to output rotational motion, the electric motor at least partially disposed in a motor housing; a drive at least partially disposed within the primary housing, the drive configured to convert rotational motion output by the electric motor into linear reciprocating motion, the drive supported by a drive housing; and a pump, the pump receiving linear reciprocating motion from the drive to linearly reciprocate a piston along a pump axis to pump the spray fluid. A cooling air pathway extends through the rear end, through the motor housing, through the drive housing, and out from the drive housing into an exhaust chamber in the housing.

[0019] According to yet another additional or alternative aspect of the disclosure, a pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface includes a primary housing having a front end, a rear end, a top side, a bottom side, a first lateral side, a second lateral side, at least one rear vent opening through the rear end, and at least one lateral vent opening through at least one of the first lateral side and the second lateral side; an electric motor disposed within the primary housing, the electric motor comprising a rotor configured to rotate on a motor axis and a stator, the electric motor configured to output rotational motion, the electric motor at least partially disposed in a motor housing; a drive at least partially disposed within the primary housing, the drive configured to convert rotational motion output by the electric motor into linear reciprocating motion, the drive supported by a drive housing; and a pump, the pump receiving linear reciprocating motion from the drive to linearly reciprocate a piston along a pump axis to pump the spray fluid. The primary housing includes an intake chamber, a motor chamber within the motor housing, and a drive chamber within the drive housing. A cooling air pathway extends from the intake chamber, through the motor chamber, and into the drive chamber. According to yet another additional or alternative aspect of the disclosure, a pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface includes a primary housing having a front end, a rear end, a top side, a bottom side, a first lateral side, a second lateral side; an electric motor disposed within the primary housing, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion; a drive disposed at least partially within the primary housing, the drive configured to convert rotational motion output by the electric motor into linear reciprocating motion; a pump, the pump receiving linear reciprocating motion from the drive to linearly reciprocate a piston along a pump axis to pump the spray fluid; an inlet passage that routes the spray fluid from a reservoir to the piston pump; a return passage that routes the spray fluid output by the pump back to the reservoir; an inlet hose fluidly connected to the inlet passage and extending downward from an inlet of the piston pump; a return hose fluidly connected to the return passage; and a holder mountable to a projection of the housing, wherein holder holds the return hose.

[0020] According to yet another additional or alternative aspect of the disclosure, a spray gun for spraying a spray fluid includes a gun body; a spray tip including a spray nozzle; a spray valve displaceable between an open state and a closed state, the spray valve allowing flow of spray fluid to the spray tip in the open state and blocked flow of the spray fluid to the spray tip in the closed state; and a handle piece depending from the gun body, the handle piece including a handle and a fitting, the fitting configured to attach to a supply hose which provides spray fluid to the spray gun, wherein the handle piece, including the fitting and the handle, is monolithic.

[0021] According to yet another additional or alternative aspect of the disclosure, a spray gun valve assembly includes a valve housing assembly, the valve housing assembly comprising a valve housing, a seat ring piece located within the valve housing, and a ball located within the valve housing, the ball and the seat ring piece configured so that the ball engages the seat ring piece to block passage of spray fluid and further so that the ball disengaging from the seat ring piece permits passage of spray fluid; a sealing piece, the sealing piece comprising an internal channel extending along a spray axis and through which spray fluid flows after having passed by the ball and the seat ring piece when disengaged; and a sealing ring that seals with the sealing piece, the sealing ring disposed on a radial exterior of the sealing piece.

[0022] According to yet another additional or alternative aspect of the disclosure, a spray gun valve assembly for a spray gun includes a valve housing having a seat ring piece located within the valve housing and a ball configured to engage the seat ring piece to place a spray valve in a closed state and the ball configured to disengage from the seat ring piece to place the spray valve in an open state; a tip housing; a sealing piece at least partially disposed in the tip housing, the sealing piece including an internal channel extending along a spray axis and through which spray fluid flows after having passed by the ball and the seat ring piece; and a spring biasing the sealing piece away from the valve housing and into the tip housing.

[0023] According to yet another additional or alternative aspect of the disclosure, a spray gun valve assembly for a spray gun includes a valve housing having a seat ring piece located within the valve housing and a ball configured to engage the seat ring piece to place a spray valve in a closed state and the ball configured to disengage from the seat ring piece to place the spray valve in an open state; a tip housing having a tip receiver configured to receive a barrel of a spray tip and having a receiving aperture open into the tip receiver; and a sealing piece at least partially disposed in the tip housing, the sealing piece including an internal channel extending along a spray axis and through which spray fluid flows after having passed by the ball and the seat ring piece. The sealing piece includes a seal head having a saddle face, the seal head disposed within the receiving aperture and the saddle face configured to engage the barrel to seal with the barrel; a sealing piece body; and a neck extending between and connecting the sealing piece body and the seal head, the neck configured to flex to allow pivoting of the seal head for aligning the saddle face and the barrel.

[0024] According to yet another additional or alternative aspect of the disclosure, a spray gun valve assembly for a spray gun includes a valve housing having a seat ring piece located within the valve housing and a ball configured to engage the seat ring piece to place a spray valve in a closed state and the ball configured to disengage from the seat ring piece to place the spray valve in an open state; a tip housing having a tip receiver configured to receive a barrel of a spray tip and having a receiving aperture open into the tip receiver; and a sealing piece at least partially disposed in the tip housing, the sealing piece including an internal channel extending along a spray axis and through which spray fluid flows after having passed by the ball and the seat ring piece. The sealing piece includes a seal head having a saddle face, the seal head disposed within the receiving aperture and the saddle face configured to engage the barrel to seal with the barrel. The sealing piece is keyed to the tip housing to prevent relative rotation between the sealing piece and the tip housing on the spray axis. According to yet another additional or alternative aspect of the disclosure, a spray gun valve assembly for a spray gun, includes a valve housing having a seat ring piece located within the valve housing and a ball configured to engage the seat ring piece to place a spray valve in a closed state and the ball configured to disengage from the seat ring piece to place the spray valve in an open state; a tip housing having a tip receiver configured to receive a barrel of a spray tip and having a receiving aperture open into the tip receiver; a sealing piece at least partially disposed in the tip housing, the sealing piece including an internal channel extending along a spray axis and through which spray fluid flows after having passed by the ball and the seat ring piece; and a sealing ring disposed on the sealing piece and forming a radial seal between the sealing piece and the valve housing.

[0025] According to yet another additional or alternative aspect of the disclosure, a spray gun valve assembly for a spray gun includes a valve housing having a seat ring piece located within the valve housing and a ball configured to engage the seat ring piece to place a spray valve in a closed state and the ball configured to disengage from the seat ring piece to place the spray valve in an open state; a tip housing having a tip receiver configured to receive a barrel of a spray tip and having a receiving aperture open into the tip receiver; a sealing piece at least partially disposed in the tip housing, the sealing piece including an internal channel extending along a spray axis and through which spray fluid flows after having passed by the ball and the seat ring piece; and a sealing ring disposed on the sealing piece, wherein an upstream side of the sealing ring is directly exposed to the spray fluid downstream of the seat ring piece.

[0026] According to yet another additional or alternative aspect of the disclosure, a tip assembly for a spray gun includes a tip housing having a tip receiver configured to receive a spray tip; a tip guard connected to the tip housing; a tip retainer within which the tip housing is at least partially disposed; a sealing piece disposed within the tip housing; and a tip spring retaining the sealing piece within the tip housing.

[0027] BRIEF DESCRIPTION OF THE DRAWINGS

[0028] FIG. 1A is an isometric view of a fluid sprayer.

[0029] FIG. IB is a side elevational view of a pump module of the fluid sprayer.

[0030] FIG. 1C is an isometric view of the pump module with a primary housing removed to expose other components of the fluid sprayer.

[0031] FIG. 2 is a cross-sectional view taken along line 2-2 in FIG. 3A.

[0032] FIG. 3A is a cross-sectional view taken along line A-A in FIG. 2.

[0033] FIG. 3B is a cross-sectional view taken along line B-B in FIG. 3A. FIG. 4 is a schematic diagram of a fluid sprayer.

[0034] FIG. 5A is a first isometric view of a fluid sprayer.

[0035] FIG. 5B is a second isometric view of the fluid sprayer.

[0036] FIG. 5C is an isometric view of the fluid sprayer showing a holder dismounted.

[0037] FIG. 6A is an isometric cutaway view showing an interior of the fluid sprayer.

[0038] FIG. 6B is an isometric cross-sectional view taken along line B-B in FIG. 6A.

[0039] FIG. 6C is a cross-sectional view of the fluid sprayer similar to FIG. 6B showing the piston at an end of a suction stroke.

[0040] FIG. 6D is a cross-sectional view of the fluid sprayer similar to FIG. 6B showing the piston at an end of a pumping stroke.

[0041] FIG. 7A is a cross-sectional view taken along line A- A in FIG. 7B.

[0042] FIG. 7B is a cross-sectional view taken along line B-B in FIG. 7A.

[0043] FIG. 8A is an enlarged isometric view of a portion of the fluid sprayer showing a collar in a first position.

[0044] FIG. 8B is an enlarged isometric view of the portion of the fluid sprayer showing the collar in a second position.

[0045] FIG. 8C is an enlarged isometric view of the portion of the fluid sprayer showing the collar in a third position.

[0046] FIG. 8D is an enlarged isometric view of the portion of the fluid sprayer showing a lever actuated to place a recirculation valve in an open state.

[0047] FIG. 9A is an isometric view showing the motor exploded away from the drive.

[0048] FIG. 9B is an isometric view showing the fluid manifold exploded away from the drive.

[0049] FIG. 10 is an isometric cutaway view of a portion of the fluid sprayer illustrating interior components within the primary housing.

[0050] FIG. 11 is an enlarged cross-sectional view taken along line 11-11 in FIG. 10.

[0051] FIG. 12 is a cross-sectional view taken along line 12-12 in FIG. 6D.

[0052] FIG. 13A is a cutaway view showing flow of cooling air within a fluid sprayer.

[0053] FIG. 13B is a cross-sectional view showing a portion of the fluid sprayer.

[0054] FIG. 14 is an isometric view showing a portion of a fluid sprayer with a stand exploded away from a primary housing.

[0055] FIG. 15 A is an isometric view of a spray gun. FIG. 15B is a cross-sectional view of the spray gun taken along line B-B in FIG.

[0056] 15A.

[0057] FIG. 15C is an enlarged detail view of detail C in FIG. 15B.

[0058] FIG. 16A is a cross-sectional view of another example of a spray gun showing the spray gun in a non-spray state.

[0059] FIG. 16B is a cross-sectional view of the spray gun showing the spray gun in a spray state.

[0060] FIG. 16C is an enlarged view of detail C in FIG. 16B.

[0061] FIG. 16D is a partially exploded view of the spray gun.

[0062] FIG. 16E is an isometric partially exploded view of the spray gun.

[0063] FIG. 17A is an isometric cross-sectional view showing a tip retainer and tip housing dismounted from a spray gun.

[0064] FIG. 17B is a cross-sectional view taken along line B-B in FIG. 17A.

[0065] FIG. 18 is an isometric view showing a sealing piece removed from a tip housing and flipped to an opposite orientation from when inserted into the tip housing.

[0066] FIG. 19 A is a plan view showing the sealing piece exploded away from the tip housing.

[0067] FIG. 19B is an isometric view showing the sealing piece exploded away from the tip housing.

[0068] FIG. 20A is an isometric view of a spray gun showing the spray tip in a first orientation.

[0069] FIG. 20B is an isometric view of the spray gun showing the spray tip in a second orientation.

[0070] DETAILED DESCRIPTION

[0071] The present disclosure concerns fluid sprayers for outputting a spray of spray fluid. Fluid sprayers according to aspects of the disclosure can be used to spray a variety of fluids. Paint will be used herein as the main example of a type of fluid that can be sprayed, but it will be understood that the teachings of the present disclosure can relate to spraying of other types of fluids, such as lacquers, stains, finishes, coatings, textures, and adhesives, among others.

[0072] Fluid sprayers according to aspects of the present disclosure include a pump that is driven by an electric motor. The pump can be a piston pump. A drive can convert a rotational output from the motor into a linear reciprocating input to the pump to cause reciprocation of a piston of the pump. The pump can be operated regardless of actuation of a trigger of a spray gun. As such, the pump can be configured to continuously pump fluid so long as the fluid sprayer is switched to an ON state, regardless of whether the spray fluid is actually being sprayed or not.

[0073] The fluid sprayer can include a recirculation valve that provides a return flow of spray fluid, such as when the trigger is not actuated. The recirculation valve can route the return flow of the spray fluid back to a reservoir from which the spray fluid is drawn into the pump.

[0074] According to some examples of the disclosure, the recirculation valve can provide pressure control for operation of the pump. The recirculation valve can be set to open at a threshold pressure. In some examples, the threshold pressure is adjustable, such as by adjusting the tension on a spring maintaining the recirculation valve in a closed state. Changing the threshold pressure adjusts the fluid pressure required to open the recirculation valve, thereby adjusting the fluid pressure that can flow downstream to the spray gun. Increasing the threshold pressure increases the fluid pressure that can be output to the spray gun. Decreasing the threshold pressure decreases the fluid pressure that can be output to the spray gun.

[0075] According to some examples of the disclosure, the fluid sprayer includes a primary housing that at least partially encloses other components of the fluid sprayer. The primary housing can support the motor, the drive, and the pump. The primary housing can provide a structural connection between a stand of the paint sprayer and the moving components of the paint sprayer (e.g., motor, drive, pump). The stand extend from the primary housing and is configured to support the paint sprayer on a support surface, such as the ground. The stand can connect directly to the primary housing. The primary housing can provide the connection between the stand and the moving components of the sprayer. The stand can include one or more legs that connect to the primary housing.

[0076] In some examples of the disclosure, the motor is disposed in and supported by a motor housing. The drive can be disposed in and supported by a drive housing. According to some examples, one or both of the drive housing and the motor housing can be connected to the primary housing. According to some examples, the motor housing can be connected to the primary housing through the drive housing. For example, the motor housing can be directly connected to the drive housing while the drive housing is directly connected to the primary housing. According to some aspects of the disclosure, the pump can include a pump body. The pump body can connect to the drive housing and be supported by the drive housing. In some examples, the pump body can directly interface with the primary housing.

[0077] Sprayers according to aspects of the disclosure can include legs that snap fit to the primary housing. In some examples, the legs can shift linearly relative to the primary housing to connect to the primary housing.

[0078] Sprayers according to some aspects of the disclosure include a piston pump that has a single piston. The single piston is configured to linearly reciprocate to pump the spray fluid. The drive that converts the rotational output from the motor to the linear input to the piston of the pump can be configured as a wobble drive, among other options.

[0079] According to various aspects of the disclosure, the motor can include a pinion that interfaces with a gear of the wobble drive on a top side of the gear. The piston of the pump can interface with an angled ring of the wobble drive that rocks to output the reciprocating motion on a top side of the angled ring. Both the motor and the piston can interface with a top side of the drive.

[0080] Pumps according to aspects of the disclosure include an outlet valve disposed downstream of the piston of the pump. The outlet valve can be configured as a ball valve, among other options. A valve spring can bias the outlet valve towards a closed state. The pressure generated by the pump causes the outlet valve to open to allow flow downstream from the pump for spraying. A side channel branches from the flowpath downstream of the pump piston to provide flow to the recirculation valve. The side channel opens into the flowpath downstream of the pump at a location that overlaps with structure of the outlet valve. For example, the intersection between the side channel and the flowpath can be at a location that directly overlaps with one or more of a cage of the outlet valve, a spring of the outlet valve, a ball of the outlet valve, etc.

[0081] Sprayers according to aspects of the disclosure include a pressure control that can set the fluid pressure provided to the spray gun. The pressure control can be formed by the recirculation valve, among other options. The recirculation valve can also form a priming valve, in which the recirculation valve in put in an open state during priming and is returned to the normally closed state for spray operations. A prime lever can be connected to the recirculation valve to allow the user to actuate the recirculation valve open for priming and closed for spraying. A knob is actuatable to change the threshold pressure of the recirculation valve. The prime lever can interface with the knob such that moving the knob also moves the prime lever. For example, rotating the knob can also rotate the prime lever.

[0082] Spray guns according to aspects of the disclosure include a tip housing that can hold a spray tip. The spray tip can, in some examples, be rotatable between a spray state and a de-clog state. The spray tip includes a nozzle that is configured to atomize the spray fluid. The tip housing is mounted to a valve housing of the spray gun, the valve housing contains a spray valve that is opened to cause spraying and closed to stop spraying. The spray valve can be actuated by a trigger, such as a manual pull trigger. The tip housing can be mounted to the valve housing by a retainer. The retainer can be configured to maintain connection with the valve housing throughout the life of the spray gun, such that the retainer can be considered to be permanently connected, such as by interfaced threading and adhesive. The tip housing is rotatable relative to the valve housing, such as to change an orientation of the spray pattern. For example, the tip housing can be rotated to change a spray fan orientation between vertical and horizontal. The tip housing is rotatable relative to the tip housing without any manipulation or movement of the retainer holding the tip housing on the valve housing.

[0083] A sealing piece is disposed between the valve housing and a barrel of the spray tip to seal with the barrel of the spray tip. The sealing piece can be biased into contact with the barrel of the spray tip by a spring. The spring can be a wave spring, among other options.

[0084] According to aspects of the disclosure, the sealing piece can include a seal head that engages with the tip barrel. The seal head can be formed as a saddle seal and can, in some examples, be referred to as a saddle head. A neck can extend between a body of the sealing piece and the seal head. The neck can allow the seal head to flex to form and / or maintain mating engagement with the barrel of the spray tip. The neck can allow the seal head to gimbal to maintain engagement with the barrel.

[0085] Spray guns according to aspects of the disclosure include a saddle seal that mates with a barrel of a spray tip to form a seal with the barrel. The saddle seal includes a curved seal face that engages with a curved exterior surface of the barrel. The saddle seal can be keyed to a tip housing. Keying the saddle seal to the tip housing maintains a set orientation of the seal face relative to the bore that the barrel is insertable into, thereby maintaining an orientation of the saddle seal relative to the barrel.

[0086] Spray guns according to various aspects of the disclosure include a seal ring disposed fluidly between the spray tip and an outlet of the valve housing. The seal ring is exposed to the flow of spray fluid between the valve housing and the spray tip. The seal ring is smaller than a valve seat of the spray valve.

[0087] Sprayers according to various aspects of the disclosure include a holder that supports a return hose that provides a return flow of the spray fluid to the reservoir. The holder can connect to a housing of the sprayer, such as the primary housing, to be supported by the housing. In some examples, the holder includes a clip that connects the holder to mount of the housing. The sprayer can be configured such that the holder remains mounted to the housing during spray operations.

[0088] According to some aspects of the disclosure, the holder that holds the return hose is mounted to the housing and positioned to return the return flow of spray fluid to the reservoir during spray operations. An inlet hose of the sprayer extends into the reservoir to draw the spray fluid from the reservoir during spray operations. The holder is configured such that the return flow is provided to the reservoir at a location vertically spaced from an intake through which the spray fluid is drawn into the inlet hose.

[0089] Sprayers according to various aspects of the disclosure provide active cooling for the motor and the drive of the sprayer. The motor includes a fan that is configured to blow cooling air across the motor and the drive. The drive housing can include one or more inlet openings through which the cooling air is received and can include one or more exhaust openings through which the cooling air is exhausted.

[0090] The sprayer can be configured to filter liquid particles (e.g., overspray) from the cooling air at locations upstream of the motor. According to some examples, the sprayer includes a serpentine cooling flowpath between vent openings through which the cooling is air drawn into a primary housing of the fluid sprayer and an air inlet of the motor. The cooling air flowing through the serpentine passage can impinge on one or more baffles that define the serpentine passage. The impingement can cause the liquid particles to adhere to the baffles, thus removing such particles from the airflow to the motor.

[0091] Sprayers according to aspects of the disclosure can be configured to have multiple flow stages for the cooling air flow through the sprayer. The sprayer can include a filter stage in which the liquid particles are filtered from the cooling air upstream of the motor. The sprayer can include a funnel stage in which the cooling air is funneled through the motor housing and to the drive housing. The sprayer can include an exhaust phase in which the cooling air is exhausted from the drive housing back into the primary housing of the sprayer and then out from the primary housing. Sprayers according to aspects of the disclosure can include one or more walls that divide the interior of the primary housing of the sprayer. The walls can divide the interior of the housing into various chambers for the cooling air. One wall can extend around the motor housing to prevent the cooling air from flowing around the motor housing. A pair of walls can be disposed on opposite sides of an exhaust opening through the drive housing to define an exhaust chamber into which the cooling air is exhausted from the drive housing.

[0092] Spray guns according to various aspects of the disclosure include a handle configured to be grasped by a hand of the user. The spray gun includes a fitting disposed at a lower end of the handle, the fitting configured to connect to a hose that conveys the spray fluid to the spray gun. The handle and the fitting can be contiguous. The handle and fitting can be monolithically formed.

[0093] Components can be considered to radially overlap when those components are disposed at common axial locations along an axis. A radial line extending from the axis will extend through each of the radially overlapping components. Components can be considered to axially overlap when those components are disposed at common radial and circumferential locations relative to an axis such that an axial line parallel to the axis extends through the axially overlapping components. Components can be considered to circumferentially overlap when aligned about the axis, such that a circle centered on the axis passes through the circumferentially overlapping components. Components can be considered to tangentially overlap when aligned tangentially about an axis, such that a tangent line to a circle centered on the axis passes through the tangentially overlapping components.

[0094] FIG. 1A is an isometric view of fluid sprayer 10. FIG. IB is a side elevational view of pump module 12 of fluid sprayer 10. FIG. 1C is an isometric view of pump module 12 with a primary housing 18 removed to expose other components of fluid sprayer 10. Fluid sprayer 10 includes pump module 12, spray gun 14, and supply hose 16. The pump module 12 includes primary housing 18, motor 20, drive 22, pump 24, recirculation valve 26, outlet fitting 28, stand 30, inlet hose 32, return hose 34, and power switch 36. Spray gun 14 includes handle 38, spray tip 40, spray nozzle 42, trigger 44, and spray valve 46.

[0095] Fluid sprayer 10 is configured to draw spray fluid, such as paint among other options, from reservoir 48 and to output the spray fluid as a fluid spray. The fluid sprayer 10 is configured to receive spray fluid from the reservoir 48 and output the paint through spray nozzle 42. The pump module 12 draws the spray fluid from reservoir 48 and outputs the spray fluid to spray gun 14 through supply hose 16. The reservoir 48 is shown to be a paint can, which can be a one gallon can intended to hold and transport one gallon of paint. Such a gallon paint can may hold no more than 1.5 gallons (when filled beyond its intended fill volume). The paint can may be metal or plastic.

[0096] The spray nozzle 42 is part of the spray tip 40. The spray tip 40 can be rotatable, such as to reverse flow through the spray tip 40 for clog removal. The spray nozzle 42 can be integrated into a barrel of the rotatable spray tip 40. The spray tip 40 can be rotated to reverse the direction of flow of paint through the spray nozzle 42 to unclog the spray nozzle 42 in the event of formation of a clog in the spray nozzle 42. For example, the spray tip 40 can be rotated between a spray state, in which the spray nozzle 42 is oriented outward away from the spray gun 14, and a de-clog state, in which the spray nozzle 42 is oriented inward towards the spray gun 14 to allow reverse flow through the spray nozzle 42 relative to the spray state.

[0097] The rotatable spray tip 40 is insertable into spray gun 14. The rotatable spray tip 40 can be replaced with a variety of other rotatable spray tips, typically of different sizes which produce different spray patterns. The different spray tips 40 can have spray nozzles 42 of different sizes for shapes to produce the different spray patterns. The spray gun 14 receives the spray fluid through a supply hose 16. The supply hose 16 can be a single segment of a hose or can be multiple hose segments serially connected to each other by fittings. The supply hose 16 connects to an outlet fitting 28. The outlet fitting 28 is part of pump module 12.

[0098] Spray gun 14 is configured to output an atomized spray of the spray fluid. Trigger 44 is operatively connected to spray valve 46 such that trigger 44 can actuate spray valve 46. Pulling, or otherwise actuating, the trigger 44 causes the spray valve 46 to open, allowing flow of the spray fluid past spray valve 46 and through spray nozzle 42. Releasing the trigger 44 causes the spray valve 46 to close, stopping further flow of the spray fluid to the spray nozzle 42 and stopping the emission of the fluid spray.

[0099] The pump module 12 includes primary housing 18. The primary housing 18 can partially or entirely hold various components of the fluid sprayer 10, such as pump 24, drive 22, and / or motor 20, amongst others. The primary housing 18 can be considered to form a shroud that at least partially encloses various other components of fluid sprayer 10. In some examples, the primary housing 18 can hold and support the various moving components of pump module 12, such as motor 20, pump 24, and drive 22.

[0100] These components and / or the primary housing 18 can be supported by a stand 30. The stand 30 is shown with four legs 50, however various other examples may have only two legs 50 and / or one or more wheels to aid with transport. The stand 30 is configured to interface with a support surface (e.g., the floor or ground) to support the pump module 12 on the support surface. As discussed in more detail below, the stand 30 can connect directly to the primary housing 18. In this way, other components of pump module 12 can be connected to the stand 30 via the primary housing 18.

[0101] Spray fluid is transported from the reservoir 48 to the pump module 12 via the inlet hose 32. As shown, the inlet hose 32 extends directly downward into the reservoir 48 without having to bend. In particular, the paint is pulled upwards through the inlet hose 32 via suction generated by pump 24. A return hose 34 extends downward into the reservoir 48, in this example. The return hose 34 dispenses spray fluid back into the reservoir 48 during priming and / or non-spray periods (e.g., whenever the fluid sprayer 10 is powered and the trigger 44 of the spray gun 14 is not actuated). In some examples, the return hose 34 can dispense paint back into the reservoir 48 during spray operations, such as a part of a pressure control of the fluid sprayer 10.

[0102] The fluid sprayer 10 includes power switch 36. The power switch 36 can be a mechanical switch with a rocker or other type mechanism to toggle between an ON state and an OFF state. As further discussed herein, actuation of the power switch 36 to the ON state turns on the fluid sprayer 10 and causes the pump 24 to pump continuously until the power switch 36 is turned to an OFF state. It will be understood that a painter will not be painting for the entire time that the power switch 36 is in the ON state; however, so long as the trigger 44 of the spray gun 14 is not actuated such that the spray gun 14 is not spraying (i.e., the spray valve 46 is closed), then the spray fluid that is continuously pumped from the reservoir 48 up the inlet hose 32 is returned back to the reservoir 48 via the return hose 34. In this way, the spray fluid is pumped continuously and recirculated back to the reservoir 48 until such time as the trigger 44 of the spray gun 14 is actuated and the paint goes through the supply hose 16 and out of the spray nozzle 42. Actuation of the power switch 36 to an OFF state stops the pumping and stops the recirculation of the paint.

[0103] Recirculation valve 26 is configured to route spray fluid back to the reservoir 48 during operation of fluid sprayer 10. The recirculation valve 26 can direct spray fluid down through the return hose 34 and back to the reservoir 48 and such spray fluid can once again be sucked up through the inlet hose 32. In this way, the spray fluid can be recycled from the reservoir 48, up the inlet hose 32 into the pump 24, and then down the return hose 34 as directed by the recirculation valve 26, continuously until the trigger 44 of the spray gun 14 is actuated which causes the spray fluid to be directed out of the outlet fitting 28, through the supply hose 16 to the spray gun 14 to be atomized by the spray nozzle 42. As such, the operation of fluid sprayer 10 is to continuously pump and recycle spray fluid until it is sprayed.

[0104] Motor 20 of fluid sprayer 10 is disposed within the primary housing 18. Motor 20 is configured as an electric motor 20. Motor 20 includes pinion 52 which conveys rotational motion output by the motor 20. The motor 20 includes a rotor 54 that is rotated by a stator 56. The stator 56 can electromagnetically drive rotation of the rotor 54 on a motor axis MA. The electric motor 20 can be a radial flux motor, among other options. The motor 20 can include an outer electromagnetic stator 56 and an inner rotor 54 with rotor magnetics (e.g., permanent magnets, electromagnets, or other material that can be moved by a magnetic field) that is rotated by the stator 56.

[0105] Drive 22 is at least partially disposed within primary housing 18. Drive 22 is connected to the motor 20 to receive the rotational output from the motor 20. Drive 22 is configured to convert rotational motion output by the electric motor 20 into linear reciprocating motion provided to pump 24 to cause pumping by pump 24.

[0106] Pump 24 is at least partially disposed within primary housing 18. Pump 24 can include a fluid manifold 58 and a piston 60. The fluid manifold 58 forms a pump body of the pump 24. The piston 60 is operated by the drive 22 to linearly reciprocate at least partially within the fluid manifold 58 to cyclically increase and decrease the space within a pumping chamber of the pump 24.. The drive 22 is connected to the piston 60 by connector 62 to convey the linear reciprocating motion. The connector 62 is a projection which extends into a socket in the piston 60, though it is understood that in various examples the piston 60 can include a projection that extends into a socket of the drive 22, among other options.

[0107] In the example shown, the drive 22 is configured as a wobble drive. It is understood, however, that drive 22 can be of any configuration suitable for converting a rotational input into a linear output. In the example shown, the drive 22 includes an eccentric 64 that conveys, at least in part, rotational motion to linear reciprocating motion. The eccentric 64 in this particular version of the drive 22 is a wobble eccentric that causes the connector 62 to move back and forth as eccentric 64 wobbles as it rotates. The eccentric 64 rotates with gear 66, the gear 66 interfacing with the pinion 52 of the electric motor 20. At least one drive bearing 68 supports the drive 22.

[0108] As shown, the inlet hose 32 can extend straight upwards into a fluid manifold 58. The inlet hose 32 can extend straight upwards without bending. A vertical space between the top rim of the reservoir 48 and the fluid manifold 58 is less than 3 / 4 of the height of the reservoir 48. More specifically, the space between the top rim of the reservoir 48 and the fluid manifold 58 is less than half of the height of the reservoir 48. The space between the top rim of the reservoir 48 and the piston 60 (shown in FIG. 1C) is less than 3 / 4 of the height of the reservoir 48. More specifically, the space between the top rim of the reservoir 48 and the piston 60 is less than half of the height of the reservoir 48. As such, the pump 24 is positioned close, and directly over, the opening of the reservoir 48, which minimizes the flow path of recycled paint. In various examples, the outlet fitting 28 that conveys spray fluid from the pump module 12 can be disposed directly over the reservoir 48, which can assist in cleaning and assembly / disassembly as any dripping fluid, such as when supply hose 16 is disconnected, can fall directly into the reservoir 48.

[0109] In the example shown, the power switch 36 is positioned directly over the recirculation valve 26. Such positioning consolidates controls to one side of the fluid sprayer 10. In particular, the operator will operate the power switch 36 and the lever 70 of the recirculation valve 26, which as shown are located in a directly under / over relationship. This can assist with operation without having the user move around the fluid sprayer 10. Also, the power switch 36 being located above the fluid manifold 58, including the recirculation valve 26, avoids the risk of any leakage from the fluid manifold 58 leaking paint onto the power switch 36 had the power switch 36 instead been below the fluid manifold 58.

[0110] FIG. 2 is a cross-sectional view of pump 24. Pump 24 includes fluid manifold 58, piston 60, outlet fitting 28, inlet fitting 72, inlet check valve 74, outlet check valve 76, piston seal 78, and seal retainer 80. Fluid manifold 58 includes manifold body 82 and has inlet passage 84, spray passage 86, drain passages 88, and pumping chamber 90. Inlet check valve 74 includes inlet seat 92, inlet ball 94, and inlet spring 96. Outlet check valve 76 includes outlet seat 98, outlet ball 104, outlet spring 100, and outlet cage 102.

[0111] Pump 24 is configured to draw spray fluid from the reservoir 48, put the spray fluid under pressure, and drive the spray fluid downstream. As discussed above, the spray fluid can be output as a fluid spray from the spray gun 14 when a spray valve of the spray gun 14 is opened. The spray fluid can be returned to the reservoir 48 when the spray valve of the spray gun 14 is closed.

[0112] Fluid manifold 58 defines various fluid passages for flow of the paint. Fluid manifold 58 can be a single piece of metal or may be formed from multiple different pieces. The fluid manifold 58 forms a pump body of the pump, within which the piston 60 extends and reciprocates, in the example shown. The fluid manifold 58 includes a manifold body 82 which is a single piece of metal with various passages formed therein. An inlet fitting 72 is connected to the manifold body 82 of the fluid manifold 58. In the example shown, the inlet fitting 72 is connected to the manifold body 82 by interfaced threading. The inlet fitting 72 includes a lower end which can connect with the inlet hose 32. In particular, the inlet hose 32 can fit over the lower end of the inlet fitting 72, though it is understood that not all examples are so limited.

[0113] The fluid manifold 58 includes an inlet passage 84. The inlet passage 84 can extend from an inlet orifice 106 to the pumping chamber 90. The inlet passage 84 extends through inlet check valve 74. The inlet check valve 74, in this example, is formed as a ball check that is normally closed. It is understood, however, that not all examples are so limited. Inlet ball 94 engages with inlet seat 92 to place the inlet check valve 74 in a closed state. The inlet ball 94 is urged against the inlet seat 92 by inlet spring 96 to place the inlet check valve 74 in the normally closed state. Inlet check valve 74 allows spray fluid to flow upwards past the inlet check valve 74 due to suction created by the piston 60 moving rearward to expand the volume within the pumping chamber 90. The inlet check valve 74 closes when the piston 60 strokes forward to decrease the volume within the pumping chamber 90 forcing the paint out of the pumping chamber 90. The inlet spring 96 can assist in closing of the inlet check valve 74. The inlet check valve 74 being in the closed state prevents retrograde flow of the spray fluid from the pumping chamber 90 downward along the inlet passage 84 back towards the reservoir 48.

[0114] Leaking spray fluid can be returned to the reservoir 48 via drain passages 88, such as when the spray fluid leaks between the piston 60 and the cylinder defining the pumping chamber 90. Such leaking spray fluid can flow or drip along the drain passages 88 back to the reservoir 48, but it is noted that the spray fluid does not drain back under higher flow and pressure from the piston 60, rather it is a leak return. It is noted that one drain passage 88 is included forward of piston seal 78 and another drain passage 88 is located rearward of the piston seal 78 in this example.

[0115] Seal retainer 80 is connected to manifold body 82. Seal retainer 80 holds piston seal 78 within manifold body 82. Seal retainer 80 can compress piston seal 78 in various examples. In the example shown, the seal retainer 80 is connected to the manifold body 82 by interfaced threading. The piston 60 extends entirely through seal retainer 80. The piston 60 reciprocates within the seal retainer 80. The seal retainer 80 can help retain the piston seal 78 within the manifold body 82 to help prevent flow of paint rearward beyond the piston seal 78. The piston seal 78 forms a dynamic seal that engages with the moving piston 60 to prevent leakage of spray fluid rearward between the piston 60 and the manifold body 82.

[0116] Spray fluid is forced downstream from the pumping chamber 90 as the piston 60 moves forward to decrease the volume within the pumping chamber 90 and is pushed along spray passage 86. Spray passage 86 extends from the pumping chamber 90 to an outlet orifice 108 of the outlet fitting 28. Spray fluid traveling along the spray passage 86 flows through the outlet check valve 76. Outlet check valve 76 is configured to open to allow flow of paint downstream past outlet check valve 76 and is configured to close to prevent retrograde flow through outlet check valve 76 towards pumping chamber 90.

[0117] In the example shown, outlet check valve 76 is formed as a ball check valve, though it is understood that not all examples are so limited. In this example, outlet check valve 76 includes outlet ball 104 that is urged by outlet spring 100 to engage and seal with outlet seat 98. Outlet check valve 76 is normally closed. Outlet spring 100 can bias the outlet check valve 76 to the normally closed state. Outlet check valve 76 prevents retrograde flow of spray fluid that has exited the pumping chamber 90 while permitting the spray fluid to flow downstream along the spray passage 86. This is called the spray passage 86 because, so long as the trigger 44 of the spray gun 14 is actuated to open the spray valve 46 within the spray gun 14, the spray fluid primarily or entirely flows along the spray passage 86 and out of the outlet orifice 108 to the supply hose 16. Outlet check valve 76 allows spray fluid to flow downstream past the outlet check valve 76 due to pressure created by the piston 60 moving forward to decrease the volume within the pumping chamber 90. The outlet check valve 76 closes when the piston 60 strokes rearward to increase the volume within the pumping chamber 90 such as due to suction created by such movement of the piston 60. The outlet spring 100 can assist in closing of the outlet check valve 76.

[0118] Outlet cage 102 at least partially contains each of the outlet spring 100 and the outlet ball 104. Outlet cage 102 includes side apertures which allow spray fluid to flow through the sides of the outlet cage 102 and downstream past the outlet cage 102.

[0119] During operation, the piston 60 is reciprocated through respective suction and pumping strokes to pump the spray fluid. The piston 60 moves through pump cycles to pump the spray fluid, each pump cycle including a pumping stroke and a suction stroke. The piston 60 is configured to reciprocate on pump axis PA. The piston 60 is driven in axial direction ADI through a pumping stroke to decrease the volume of pumping chamber 90 and drive the spray fluid downstream past outlet check valve 76. The piston 60 is driven in axial direction AD2 through a suction stroke to increase the volume of pumping chamber 90 and pull spray fluid downstream through inlet check valve 74 and into pumping chamber 90. In various examples, pump 24 is a single piston pump in that piston 60 is the only piston of the pump 24.

[0120] FIG. 3A is a cross-sectional view taken along line A-A in FIG. 2. FIG. 3B is a cross-sectional view taken along line B-B in FIG. 3A. Recirculation valve 26 is shown. Stem 110, ball 112, seat 114, housing 116, retainer 118, spring 120, lever 70, and cap 122 of recirculation valve 26 are shown.

[0121] Return passage 124 branches from the spray passage 86. The return passage 124 is configured to divert flow of paint back to the reservoir 48. Recirculation valve 26 is disposed along the return passage 124. Ball 112 is configured to engage with seat 114 to place recirculation valve 26 in a closed state. Ball 112 can disengage from seat 114 to open recirculation valve 26. The ball 112 is held by a stem 110 in the example shown. The stem 110 can take the form of an elongate rod. The recirculation valve 26 is urged towards a normally closed state by spring 120. In the example shown, the spring 120 urges the ball 112 against the seat 114 such that recirculation valve 26 is normally closed. It is noted that, in this example, the spring 120 does not directly engage the ball 112; instead, the spring 120 pushes off of a retainer 118 and engages a stem flange 126 of the stem 110 to bias the stem 110, and thus the ball 112, towards the seat 114.

[0122] Recirculation valve 26 is at least partially disposed within the fluid manifold 58. A side projection 128 of the manifold body 82 at least partially contains the recirculation valve 26. The side projection 128 can be cylindrical, among other options. Housing 116 and retainer 118 are at least partially disposed within fluid manifold 58. In the example shown, housing 116 is connected to manifold body 82 by interfaced threading. In the example shown, retainer 118 is connected to manifold body 82 by interfaced threading. In this example, the retainer 118 is directly connected to the manifold body 82, though it is understood that not all examples are so limited. For example, retainer 118 can be directly connected to housing 116 such that retainer 118 is indirectly connected to manifold body 82.

[0123] The ball 112 and seat 114 of the recirculation valve 26 are held within the housing 116. At least one seal ring 130 interfaces with housing 116 to prevent leakage of paint around housing 116. A stem seal 132 engages with the stem 110 to prevent leakage of paint between stem 110 and housing 116. The stem seal 132 can move with the stem 110 as the recirculation valve 26 is actuated open and closed. Stem 110 extends out of fluid manifold 58 such that recirculation valve 26 is accessible from the exterior of fluid sprayer 10. In the example shown, stem 110 extends through retainer 118 and cap 122. Retainer 118 is connected to manifold body 82. Spring 120 interfaces with retainer 118 and with stem 110. In the example shown, the spring 120 interfaces with stem flange 126 of stem 110. The spring 120 interfaces with stem 110 to bias recirculation valve 26 towards the closed state. Spring 120 is at least partially disposed within retainer 118 in the example shown.

[0124] In the example shown, the retainer 118 is movable relative to manifold body 82 to adjust a tension on the spring 120. For example, the retainer 118 can be rotated relative to the manifold body 82 to thread the retainer 118 further into the manifold body 82 and towards seat 114 or further out of manifold body 82 and away from seat 114. The spring 120 can set a threshold pressure for opening of the recirculation valve 26. Further compressing the spring 120 increases the threshold pressure while reducing the compression of the spring 120 decreases the threshold pressure.

[0125] Cap 122 interfaces with retainer 118. In the example shown, the cap 122 is keyed to the retainer 118 such that cap 122 and retainer 118 rotate together. The cap 122 can be rotated to rotate the retainer 118 and thereby adjust the compression of the spring and the threshold pressure. The threshold pressure can also be referred to as a crack pressure as the threshold pressure is the pressure at which the recirculation valve 26 opens.

[0126] Lever 70 is mounted on the stem 110. The lever 70 can be rotated such that a cam of the lever 70 engages the cap 122 to pull the stem 110 outward, resulting in the ball 112 disengaging from the seat 114. Such use of the lever 70 to disengage the ball 112 from the seat 114 converts the recirculation valve 26 for priming of the pump 24. During priming of the pump 24, the trigger 44 of the spray gun 14 would not be actuated such that spray fluid does not readily flow along the spray passage 86. However, opening of the recirculation valve 26 allows the spray fluid to flow through the branch orifice 134 and along the return passage 124, ultimately through the return hose 34 and back into the reservoir 48. This allows for recycling of the paint during priming of the pump 24.

[0127] Branch orifice 134 opens into the spray passage 86 at a location downstream of the pumping chamber 90. The branch orifice 134 provides an opening for spray fluid to flow into the return passage 124. The return passage 124 provides the return flow of spray fluid for the reservoir 48. The return passage 124 is shown from the branch orifice 134 through the seat 114 and through a side passage 136. The side passage 136 is disposed downstream of the seat 114 of the recirculation valve 26. The side passage 136 directs the spray fluid passing through the recirculation valve 26 back toward the reservoir 48 via return hose 34.

[0128] The return hose 34 can connect with the return fitting 138 that is connected to the manifold body 82. The spray fluid can take this route when the recirculation valve 26 is manually opened for priming, and additionally or alternatively in a recirculation mode during spray operations.

[0129] In the example shown, the branch orifice 134 is aligned with structure of the outlet check valve 76. The branch orifice 134 radially overlaps with structure of the outlet check valve 76 relative to the pump axis PA. The branch orifice 134 is fluidly connected to the spray passage 86 at a location downstream of the outlet seat 98 of the outlet check valve 76. The branch orifice 134 opens into the spray passage 86 at a location intermediate with the outlet check valve 76, such that the branch orifice 134 is disposed upstream of a downstream end of the structure of the outlet check valve 76.

[0130] In the example shown, the branch orifice 134 opens into the spray passage 86 at a location that radially overlaps with the outlet spring 100 of the outlet check valve 76 along the pump axis PA. In the example shown, the branch orifice 134 opens into the spray passage 86 at a location that radially overlaps with the outlet cage 102 of the outlet check valve 76. In various examples, the branch orifice 134 can radially overlap with the outlet ball 104 of the outlet check valve 76 during at least a portion of the period of operation. In some examples, the branch orifice 134 can radially overlap with the outlet ball 104 with outlet check valve 76 in an open state. In some examples, the branch orifice 134 can radially overlap with the outlet ball 104 with outlet check valve 76 in both an open state and a closed state. In some examples, the outlet ball 104 does not radially overlap with the outlet ball 104 but does radially overlap with other structure of outlet check valve 76.

[0131] The branch orifice 134 opening into the spray passage 86 at a location radially overlapping with structure of the outlet check valve 76 provides for a compact configuration of fluid sprayer 10.

[0132] During operation, the recirculation valve 26 can operate in a priming mode and a recirculation mode. During priming, the lever 70 is actuated and the recirculation valve 26 is placed in an open state. With the recirculation valve 26 in the open state, the spray fluid output by pump 24 can freely flow through recirculation valve 26 to return hose 34 and back to the reservoir 48. Such operation can prime the pump 24 with spray fluid for spray operations. The recirculation valve 26 is placed back in the normally closed state for spray operations. During spray operation, the recirculation valve 26 is biased towards the closed state by spring 120. The spring 120 maintains the recirculation valve 26 in a normally closed state. The recirculation valve 26 is configured to open based on a threshold fluid pressure. As discussed above, the cap 122 can be rotated to adjust the compression of the spring 120 and thereby adjust the threshold fluid pressure.

[0133] The piston 60 is reciprocated on the pump axis PA to pump the spray fluid. As discussed above, fluid sprayer 10 can be configured such that pump 24 is continuously operated when the fluid sprayer 10 is in an ON state. The pump 24 outputs the spray fluid into the spray passage 86, however, the flow to spray gun 14 is deadheaded and blocked when the spray valve 46 of spray gun 14 is closed. In such a state, the pump 24 continues to operate and pump spray fluid through outlet check valve 76. The recirculation valve 26 opens when the pressure reaches the threshold pressure. The fluid pressure acts on the ball 112 and can overcome the spring force applied by spring 120 to cause the recirculation valve 26 to open. The spray fluid can flow through the recirculation valve 26 and back to the reservoir 48. Such a configuration allows the pump 24 to continuously operate and pump the spray fluid while maintaining the fluid pressure in spray passage 86 and downstream to spray gun 14 at a desired pressure level for spraying.

[0134] Further, the recirculation valve 26 can open while the spray valve 46 of the spray gun 14 is open such that the spray gun 14 is outputting a spray of the spray fluid. The recirculation valve 26 can open to vent excess pressure generated by pump 24, thereby controlling the fluid pressure provided downstream to spray gun 14. As such, a user can set a desired pressure for the spray fluid emitted by spray gun 14 by setting the compression of the spring 120, thereby setting the threshold pressure. Excess fluid pressure is vented by the recirculation valve 26 to maintain the output at spray gun 14 at a desired pressure level for spraying.

[0135] FIG. 4 is a schematic diagram of fluid sprayer 10. In particular, the schematic view represents the fluid sprayer 10 as having a circuit section 140 and a fluid section 142. Electrical power is supplied to the circuit section 140 via electrical power input 144, and the components of the circuit section 140 convert that electrical power into mechanical motion which is delivered to the fluid section 142, which fluid section 142 converts the mechanical motion to output of spray fluid under pressure by the pump 24.

[0136] The electrical power input 144 can be a cord which plugs into a standard electrical socket (e.g., three prong plug), such as a wall socket or an extension cord that connects with the wall socket, an electric generator, or other source of electrical power. In some examples, the electric power input 144 can be a battery. Two lines are shown in the circuit section 140 representing respective positive and negative lines and terminals of a circuit, forming electrical wiring 146.

[0137] The circuit section 140 includes power switch 36. The power switch 36 can be a mechanical rocker as previously mentioned, amongst other options. Actuating the power switch 36 to an ON position completes the circuit and directs electrical power from the electrical power input 144 to the electric motor 20 to operate electric motor 20. With power switch 36 in an ON position the fluid sprayer 10 is in an ON state. Actuating the power switch 36 to an OFF position interrupts the circuit and prevents electrical power from the electrical power input 144 from reaching the electric motor 20 such that the electric motor 20 does not operate. With power switch in an OFF position the paint sprayer is in an OFF state.

[0138] In the example shown, the circuit section 140 includes fuse 148. Fuse 148 can be any type of fuse that can be tripped by high current to interrupt the flow of electricity. It is noted that the fuse 148 may not be present in some embodiments.

[0139] Assuming that the power switch 36 is in the ON position and the fuse 148 (if present in the embodiment) is not tripped, then electrical power from the electrical power input 144 flows through the electric motor 20 and operates the electric motor 20 to cause the electric motor 20 to output rotational motion to the drive 22. The drive 22 converts the rotational motion to a linear reciprocating motion that operates the pump 24 to intake spray fluid from the reservoir 48 and output the spray fluid through outlet check valve 76.

[0140] In the example shown, electric motor 20 includes thermal fuse 150, which can be a mechanical or electrical thermal protection feature whereby excessive heat rise causes the electric motor 20 to cease operating. It is understood, however, that not all examples are so limited. But absent such excessive heat rise, such as during normal operating conditions, the electric motor 20 operates to rotate its rotor so long as electric power is supplied to the electric motor 20.

[0141] It is noted that the circuit section 140 does not include a controller, such as an integrated circuit, programmable circuit, chip, or other logic circuitry. Circuit section 140 does not include a pressure transducer or a flow transducer or any other sensor that is responsive to a parameter of the spray fluid such as pressure or flow. The fluid spray 10 in various examples does not include a pressure sensor or a flow sensor. The fluid sprayer 10 in various examples does not include a control board such as for controlling a parameter of the spray fluid (e.g., pressure, flow, etc.). As such, the operation of the electric motor 20 is not influenced by the pressure or flow of the spray fluid or any other fluid parameter. Also, the operation of the electric motor 20 is not responsive to whether or not the trigger 44 of the spray gun 14 is actuated (i.e. is in a pulled or released state). As such, electric motor 20 operates in an always on manner so long as the power switch 36 is in the ON state.

[0142] A typical paint sprayer is responsive to some parameter that determines whether or not its motor is an on state or an off state. For example, many paint sprayers include a pressure transducer which turns off the electric motor when the pressure of the paint reaches a threshold amount (typically indicating that the trigger is not actuated at that moment such that the motor does not need to operate). Various other paint sprayers turn the electric motor on and off responsive to whether or not the trigger 44 is pulled, such as with a sensor that indicates whether the trigger 44 is pulled and electronically sends to the controller an indication which causes the controller to power up and / or otherwise operate the electric motor to start and stop when the trigger 44 is pulled and released respectively. In each of these cases, the electric motor may be starting and stopping repeatedly when the power switch remains in the ON position.

[0143] Various fluid sprayers 10 according to the current disclosure do not include a fluid transducer and do not include a trigger switch. Instead, the electric motor 20 is always operating to output the rotational motion and power pumping by pump 24 so long as the power switch 36 is in the ON position. The electric motor 20 is continuously operating such that the rotor 54 of the electric motor 20 is continuously spinning to provide the rotational output whenever the fluid sprayer 10 is in the ON state. Electric motor 20 continues to operate the drive 22 and the pump 24 even when the trigger 44 of the spray gun 14 is not pulled due to the user not spraying at that moment. This allows simplification of the fluid sprayer 10 and elimination of various components, which can themselves be failure points and which also provide increased cost and complexity.

[0144] Spray operations can be considered to occur while the fluid sprayer 10 is in the ON state, regardless of whether spray fluid is being actively emitted from the spray gun 14 (e.g., regardless of whether the spray valve 46 is open or closed). When the user is actively spraying, the user actuates the trigger 44 of the spray gun 14. The spray valve 46 of the spray gun 14 is moved to an open state when the trigger 44 is actuated. The spray valve 46 can be a ball-and-seat valve in which the trigger 44 mechanically moves the ball off of the seat upon actuation of the trigger 44 to open the spray valve 46, and a spring returns the ball to seal with the seat upon release of the trigger 44 to close the spray valve 46. In some examples, the spray valve 46 can be an electric valve in which a solenoid moves the ball off of the seat.

[0145] The spray valve 46 being in the open state allows spray fluid to flow through the spray gun 14 and be sprayed out of the spray nozzle 42. Release of the trigger 44 causes the spray valve 46 to close, blocking the flow of spray fluid through the spray gun 14 and ceasing spraying from the spray nozzle 42. When the spray valve 46 is open and spray fluid is allowed to flow out of the spray nozzle 42, this reduces the pressure of the spray fluid downstream of the pump 24, in particular the hydraulic pressure applied to the recirculation valve 26 by the spray fluid. Closure of the spray valve 46 increases the pressure of the spray fluid downstream of the pump 24, including the hydraulic pressure applied to the recirculation valve 26 by the spray fluid. This difference in pressure is enough to overcome the spring 120 of the recirculation valve 26 such that the ball 112 lifts off of the seat 114 to open the recirculation valve 26 to allow spray fluid to flow along the return passage 124.

[0146] The electric motor 20 continues to operate the drive 22 and the pump 24 while the spray valve 46 remains closed. The spray fluid continues to flow along the return passage 124 to the reservoir 48. This recirculation of the spray fluid through the pump 24, the recirculation valve 26, and the reservoir 48 continues until the spray valve 46 is again opened upon actuation of the trigger 44 (or upon depowering of the sprayer 10 by the power switch 36 being moved to an OFF position to place the fluid sprayer 10 in an OFF state).

[0147] Reopening of the spray valve 46 lowers the pressure of the spray fluid downstream of the pump 24, and in particular the hydraulic pressure that the spray fluid exerts on the recirculation valve 26. Such lower pressure allows the spring 120 to close the recirculation valve 26 by the ball 112 being pressed against the seat 114. In some examples, a small amount of recirculation may occur despite the spray valve 46 being opened, such as if a particularly small spray nozzle 42 is used so that the pressure downstream of the pump 24 stays high enough to overcome the spring 120 to even a small enough degree to lift the ball 112 at least partially off of the seat 114. As such, the state of the recirculation valve 26 operates responsively, although indirectly, to the state of the spray valve 46.

[0148] Generally, when the spray valve 46 is opened due to actuation of the trigger 44, the recirculation valve 26 is closed, but when the spray valve 46 is closed due to release of the trigger 44, then the recirculation valve 26 is open. By this arrangement, the electric motor 20 is allowed to continuously run as the spray fluid flow is transitioned alternatively between spraying and recirculation responsive to the state of the trigger 44, which permits simplification of the fluid sprayer 10 by not having electrical components responsive to a fluid parameter and / or actuation of the trigger 44. It is expected that the user will pull the trigger 44 to open the spray valve 46 tens, hundreds, or more times during the course of a project, during which time the power switch 36 will remain in the ON position and the electric motor 20 will continuously run. The electric motor 20 will not turn off every time the user releases the trigger 44 between spraying many swaths of paint on the target surface. Such a configuration that allows the motor 20 to continuously spin can decrease wear that is typically generated due to many starts and stops of the motor 20.

[0149] The continuous operation of motor 20 and pumping by pump 24 provides significant advantages. A large amount of the heat generated by a motor 20 is generated due to start and stop of the motor 20. The motor 20 running continuously when fluid sprayer 10 is in the ON state reduces heating of motor 20 as the motor 20 is not subjected to start and stop. Further, the motor 20 can continuously generate a flow of cooling air, as discussed further herein.

[0150] Fluid sprayer 10 is of a simpler and less costly configuration in that fluid sprayer 10 does not include sensors and controllers for start and stop of motor 20. Instead, the motor 20 is operated and the pump 24 pumps whenever the fluid sprayer 10 is in the ON state. The recirculation valve 26 provides a mechanical pressure control that allows for continuous flow of spray fluid output by pump 24 regardless of whether spray valve 46 is open.

[0151] FIG. 5A is a first isometric view of fluid sprayer 10. FIG. 5B is a second isometric view of fluid sprayer 10. FIG. 5C is an isometric view of fluid sprayer 10 showing holder 152 dismounted from primary housing 18 and mounted to reservoir 48. The return hose 34 is omitted in FIG. 5C for clarity. FIGS. 5A-5C are discussed together.

[0152] The holder 152 of fluid sprayer 10 that return hose 34 is connected to is shown in FIGS. 5A-5C. The front end 154, rear end 156, top side 158, bottom side 160, and lateral sides 162 of the primary housing 18 of the pump module 12 are shown. Front end 154 is a longitudinally forward end of the pump module 12. Rear end 156 is a longitudinally rearward and of the pump module 12. Top side 158 is oriented vertically upwards. Bottom side 160 is oriented vertically downwards.

[0153] The return hose 34 connects to holder 152. The holder 152 can be considered to attach to return hose 34. Return hose 34 is fluidly connected to the return passage 124 of the fluid sprayer 10 to receive spray fluid that passes through the recirculation valve 26. The return hose 34 can connect to the return fitting 138. The return hose 34 can be connected to the fluid manifold 58 by the return fitting 138.

[0154] Return hose 34 is typically placed in the reservoir 48 during spraying so that spray fluid that is pumped but not sprayed and is instead routed through the recirculation valve 26 is returned back to the reservoir 48 to be once again sucked in through the inlet hose 32 to be pumped again and either sprayed or returned to the reservoir 48 via the return hose 34. While the return hose 34 routes to the reservoir 48, the holder 152 allows return hose 34 to be mounted on the side of the reservoir 48, as shown in FIG. 5C, or to be mounted directly to the pump module 12, as shown in FIGS. 5A and 5B.

[0155] In the example shown, the holder 152 is configured to mount directly to the primary housing 18. The holder 152 is further configured to mount directly to a paint can or other type of container forming the reservoir 48. In the example shown, the holder 152 includes hook 164. The hook 164 is disposed at a mount end 166 of the holder 152. The hook 164 is disposed at an end of the holder 152 opposite an output end 168 at which the spray fluid is output from the return hose 34 and back into the reservoir 48.

[0156] Hook 164 can wrap around the lip of a paint can or other type of container forming the reservoir 48 to hold the return hose 34 within the reservoir 48. The user can grasp the hook 164 to remove the holder 152 as well as the return hose 34 connected to the holder 152 to a waste bucket during priming, flushing, and / or cleaning, or may stow the holder 152 by attaching the hook 164 to a mount 170 on the body of the fluid sprayer 10.

[0157] In the example shown, the hook 164 clamp leg 165 that extends back towards the holder body 176. The clamp leg 165 and holder body 176 define a narrow opening that allows the holder 152 to snap fit onto various structure, such as the lip of a paint can or the mount 170 itself.

[0158] In this particular example, the holder 152 is mounted to mount 170 of the primary housing 18, though it is understood that the mount 170 may be part of other components of pump module 12 in various other examples. The mount 170 is a projection extending from the body of the fluid sprayer 10. The mount 170 can be formed as a portion of the primary housing 18. The mount 170 can be formed monolithically with other portions of the primary housing 18, though it is understood that not all examples are so limited. The projection can be partially cylindrical, as shown. The projection can include one or more upward projecting tabs to help retain the holder 152 on the pump module 12.

[0159] In the example shown, the holder 152 is mounted on a lateral side 162 of the primary housing 18. The mount 170 extends laterally outward from the lateral side of the primary housing 18. In this example, the mount 170 is formed on an opposite lateral side 162 of the primary housing 18 from the lever 70 of the recirculation valve 26 and the power switch 36. Such a configuration prevents the holder 152 or return hose 34 from interfering with access to the power switch 36 and / or the recirculation valve 26. This allows for easier use by the user. The return hose 34 being routed on an opposite lateral side 162 from the power switch 36 also maintains the return flow of the spray fluid at a location away from the electrical components of the power switch 36.

[0160] In some examples, the mount 170 can include one or flats 172 on the exterior surface of the mount 170. The flats 172 of the mount 170 can interface with corresponding flats

[0161] 173 on the holder 152. In the example shown, the flats 173 are formed on the hook 164 of the holder 152. The interfacing between the flats 172 of the mount 170 and the flats 173 of the holder 152 can inhibit rotation of the holder 152 relative to the mount 170. Such interfacing can maintain the holder 152, and thus the return hose 34, oriented into the reservoir 48 while liquid spray fluid is output through the return hose 34 and back into the reservoir 48. In the example shown, mount 170 includes hook retainer 175 that prevents holder 152 from sliding laterally off of mount 170.

[0162] The holder 152 can be considered to be keyed to the mount 170 in various examples. The keying of the holder 152 to the mount 170 can be formed by the interfacing flat surfaces of the mount 170 and the holder 152. Such keying inhibits rotation of the holder 152 on the mount 170. Inhibiting such rotation maintains the return hose 34 oriented into the reservoir 48 while resisting the rotational forces that can be generated by the return flow of spray fluid through the return hose 34 and into the reservoir 48.

[0163] The holder 152 includes one or more clips 174. The clips 174 can wrap partially or fully around the return hose 34. In this particular example, the clips 174 wrap partially around the return hose 34 allowing the return hose 34 to snap fit into a channel of the holder 152 defined by the plurality of clips 174. The return hose 34 can similarly be released from the clips 174, such as by firm tugging to overcome the spring tension in the clips 174, to separate the return hose 34 from the holder 152. In various examples, only a single clip

[0164] 174 is present.

[0165] The holder 152 can include a diffuser 178. The diffuser 178 can be integrated into the body of the holder 152. The diffuser 178 is disposed at the output end 168 of the holder 152. The diffuser 178 is disposed at an end of the holder 152 opposite the mount end 166 that connects the holder 152 to the pump module 12. In the example shown, the return hose 34 outputs the return flow of spray fluid through the diffuser 178. The diffuser 178 can include a plurality of channels which spread out the flow of spray fluid (or cleaning fluid) from the return hose 34 into the reservoir 48 to avoid a stream which may create a mess if projected. In the example shown, the return hose 34 is fluidly and mechanically connected to the holder 152. The return hose 34 outputs the return flow of the pumped liquid to the diffuser 178 and the return flow exits from the diffuser 178 into the reservoir 48 or other container.

[0166] The holder 1 2 includes a holder body 176. Holder body 176 can form a main body of the holder 152. The holder body 176 can be elongate. The holder body 176 can be formed as a stem. The plurality of clips 174 can be positioned along the holder body 176. In some examples, the diffuser 178 can be formed monolithically with the holder body 176 of the holder 152. In some examples, the diffuser 178, holder body 176, and hook 164 can be formed monolithically.

[0167] Holder 152 is shown in a position associated with spray operation of the fluid sprayer 10 in FIGS. 5A and 5B. During spray operations, the inlet hose 32 extends to near a bottom end of the reservoir 48. The holder 152, and thus the return hose 34, extend into the reservoir 48 to provide a return flow of the spray fluid to the same reservoir 48 that the inlet hose 32 is drawing the spray fluid from. The holder 152 outputting the return flow of spray fluid into the reservoir 48 prevents waste as that returned spray fluid can again be drawn into fluid sprayer 10 through inlet hose 32.

[0168] As shown, holder 152 is positioned such that the return flow of spray fluid exits into the reservoir 48 at a location spaced vertically above the location that the spray fluid is drawn into the inlet hose 32. In the example shown, the spray fluid exits into the reservoir 48 through the diffuser 178 of the holder 152 while the spray fluid enters into the inlet hose 32 through filter 180 disposed at a distal end of the inlet hose 32 opposite the end connected to the inlet fitting 72.

[0169] The return location and intake location are spaced by vertical distance VD1. The vertical distance VD1 between the return location and the intake location allows for circulation of the spray fluid and can prevent the spray fluid that was just output through return hose 34 from being immediately ingested by inlet hose 32. The vertical distance VD1 can be between a lowest point of the return pathway at which the return flow of liquid is output from the pump module 12 (e.g., through diffuser 178) and the highest point of the intake (e.g., vertically highest location on filter 180) through which spray fluid is drawn into inlet hose 32. Return hose 34 is supported separately from inlet hose 32. The return hose 34 is not directly connected to or directly supported by the inlet hose 32. Instead, the return hose 34 is supported by holder 152 that can be directly connected to the primary housing 18 of the fluid sprayer 10. Having the return hose 34 supported separately from the inlet hose 32 provides for easier use of fluid sprayer 10, such as during flushing as the already pumped flushing fluid can be easily routed to a separate container rather than back into the container holding the supply of flushing fluid. The user can clip holder 152 to a can or other structure forming reservoir 48 to route the return flow of the fluid to that reservoir and the user can clip holder 152 to primary housing 18 during spray operations. The holder 152 directly connecting to primary housing 18 positions the return flow of spray fluid at a desired location within reservoir 48 relative to the inflow of spray fluid. The interface between the primary housing 18 and the holder 152 sets a height of the output of the return flow and ensures that the output of the return flow is at a desired position relative to inlet hose 32.

[0170] FIG. 6A is an isometric cutaway view showing an interior of fluid sprayer 10. FIG. 6B is an isometric cross-sectional view taken along line B-B in FIG. 6A. FIG. 6C is a cross-sectional view of fluid sprayer 10 similar to FIG. 6B showing piston 60 at an end of a suction stroke. FIG. 6D is a cross-sectional view of fluid sprayer 10 similar to FIG. 6B showing piston at an end of a pumping stroke. FIGS. 6A-6D are discussed together.

[0171] Motor 20 is at least partially disposed within primary housing 18. Motor 20 includes stator 56 that is configured to electromagnetically drive rotation of rotor 54. In the example shown, the motor 20 is disposed within motor housing 182. Motor housing 182 is a housing formed separately from primary housing 18. Motor housing 182 is disposed within primary housing 18. Rotor 54 is rotatably supported by motor bearings 184. Rotor 54 is configured to rotate on motor axis MA.

[0172] In the example shown, fan 186 is connected to rotor 54 to be rotated by rotor 54. Fan 186 is configured to draw cooling air into motor housing 182 and blow the cooling air towards drive 22. The fan 186 can, in some examples, blow cooling air through the motor 20, such as between rotor 54 and stator 56, between coils of stator 56, etc. The fan 186 is disposed at an air inlet 188 of the motor housing 182. Fan 186 is disposed at an opposite axial end of motor 20 from pinion 52.

[0173] Drive 22 is connected to motor 20 to receive the rotational output from motor 20. In the example shown, the drive 22 includes eccentric 64 that helps convert rotational motion output by the motor 20 to linear reciprocating motion that drives the piston 60 of the pump 24. The eccentric 64 includes a drive shaft 190. The drive shaft 190 includes a rounded portion around which an drive ring 192 is mounted. The drive shaft 190 may be a single piece or metal or be composed of multiple pieces of metal attached together.

[0174] A wobble bearing 194, in this case composed of an annular array of ball bearings, is between the drive ring 192 and the drive shaft 190. The ball bearings are disposed in angled groove 196 on the drive shaft 190. The angled groove 196 is canted such that rotation of the drive shaft 190 causes the drive ring 192 to rock forwards and rearwards, thereby generating the linear reciprocating motion.

[0175] Drive projection 198 extends from drive ring 192. Drive projection 198 is received within socket 200 of piston 60. It is noted that other structures may connect the drive ring 192 to the piston 60, including a projection of the piston 60 extending into a socket of the drive ring 192, among other options.

[0176] Gear 66 is disposed around the drive shaft 190. The gear 66 is connected to the drive shaft 190 such that rotation of the gear 66 causes rotation of the drive shaft 190. In the example shown, the drive shaft 190 is configured to rotate on a drive axis DA. The gear 66 is disposed coaxially with the drive shaft 190. Gear 66 interfaces with the pinion 52 of the motor 20 to receive the rotational output from the motor 20. Gear 66 can interface with the pinion 52 at a toothed interface.

[0177] The drive shaft 190 is rotatably supported by drive bearings 68. In the example shown, two drive bearings 68 support the drive shaft 190. The drive bearings 68 are located on the front and back sides of the drive shaft 190. The drive bearings 68 are supported by a drive housing 202 within which the drive 22 is at least partially contained.

[0178] Piston 60 is connected to drive 22 to be reciprocated along the pump axis PA by the drive 22. The piston 60 moves linearly along the piston axis PA to pump the spray fluid.

[0179] In the example shown, pump 24 further includes piston sleeve 204 through which the piston 60 extends. The piston sleeve 204 is held to manifold body 82 by seal retainer 80. The piston sleeve 204 can interface with the piston seal 78 to hold the piston seal 78 within the manifold body 82. The piston sleeve 204 can form a linear bearing along which the piston 60 moves during reciprocation of the piston 60. The piston sleeve 204 can reduce sear on the piston 60 and provide support for the piston 60.

[0180] In operation, the electric motor 20 outputs rotational motion to the pinion 52. The pinion 52 interfaces with the gear 66 of the drive 22. Rotation of the gear 66 also rotates the drive shaft 190 in a 1:1 relationship being that the gear 66 is fixed to the drive shaft 190. Rotation of the drive shaft 190 changes the orientation of the drive ring 192, being that the drive ring 192 is not allowed to rotate by being captured by the piston 60 (or other structure in various other examples). As such, as the drive shaft 190 rotates the drive ring 192 is forced to move due to rotation of this drive shaft 190, and due to the offset angled orientation of the bulb of the drive shaft 190, and of the angled groove 196, on which the drive ring 192 mounted, the drive ring 192 will wobble forwards and backwards with each rotation of the drive shaft 190. Such wobbling of the drive ring 192 causes the drive projection 198 to move back and forth which in turn moves the piston 60 back and forth in linear reciprocation to operate the pump 24 to pull paint in through the inlet check valve 74 and output the paint through the outlet check valve 76.

[0181] In the example shown, the drive projection 198 is located above the drive shaft 190. The drive projection extends vertically upward from the drive ring 192. In various examples, the drive projection extends upwards from a top dead center of the drive ring 192. In the example shown, the connection between the piston 60 and the drive 22 is at a top end of the drive 22. The connection between the piston 60 and the eccentric 64 is at the top of the eccentric 64. The connection between the piston 60 and the drive projection 198 is vertically above the drive bearings 68, vertically above the drive shaft 190, and vertically above the ball bearings located between the drive shaft 190 and the drive ring 192.

[0182] The connection between the pump 24 and the drive 22 is at the top end of the drive 22. This relationship can have various advantages. For example, any grease, oil, or worn metal from the drive bearing 68, interface of the drive shaft 190 and the ball bearings captured between the drive shaft 190 and the drive ring 192, and / or interface of the drive ring 192 with the ball bearings between the drive ring 192 and the drive shaft 190, which may fall, drip, or otherwise travel downwards, will not travel to the piston 60 and potentially interfere with the seals of the pump 24. Grease and / or oil can contaminate what is being pumped and may jeopardize the seal around the piston 60, and / or either of the outlet check valve 76 and / or inlet check valve 74. Moreover, wear shavings produced by metal interfaces could also score the piston 60 jeopardize the seal around the piston 60 or compromise the outlet check valve 76 and / or inlet check valve 74.

[0183] Having the connection between the piston 60 and the drive 22 at the top of the drive 22 substantially decreases the chances of such contamination moving over to the pump 24 because such compact wear components would have a tendency to travel downward due to gravity and thus avoid the piston 60.

[0184] The pump 24 includes only a single piston 60 in the example shown. While various other examples may have multiple pistons, the illustrated example includes only a single piston 60 operationally connected to the top of the eccentric 64. The single piston 60 is the only component of fluid sprayer 10 that draws spray fluid into fluid manifold 58. The single piston 60 in the only component of fluid sprayer 10 that places the spray fluid under pressure. The single piston 60 is the only component of fluid sprayer 10 that drives the spray fluid out of fluid manifold 58.

[0185] The pinion 52 of the motor 20 axially (along a forward-rearward axis, such as the motor axis MA and pump axis PA) overlaps with the piston 60, while also being offset radially relative to the piston 60. In other words, the pinion 52 and the piston 60 are not coaxial despite being axially overlapping. As shown, the pinion 52 is offset above the piston 60.

[0186] Pinion 52 interfaces with drive 22 at a top side of drive 22. The pinion 52 interfaces with the gear 66 of the drive 22 to provide the rotational input to the drive 22. The pinion 52 can be disposed at a top dead center location relative to the gear 66, it being understood that different portions of the gear 66 are disposed at the top dead center at different times during operation due to rotation of the gear 66.

[0187] In the example shown, both the motor 20 and the piston 60 interface with the drive 22 on a top side of the drive 22. The interface between the motor 20 and the drive 22 and the interface between the piston 60 and the drive 22 are both disposed vertically above the drive bearings 68. The interface between the motor 20 and the drive 22 and the interface between the piston 60 and the drive 22 are both disposed vertically above the drive axis DA. Such interfaces are disposed vertically above the wobble bearing 194 between the drive ring 192 and the drive shaft 190. The interfaces being disposed on a vertically upper side of the drive 22 provides for a compact configuration of fluid sprayer 10 and can prevent movement of contaminants to such interfaces.

[0188] The piston 60 connecting to a top of the drive 22 positions the pump 24 higher on the fluid sprayer 10 than if the piston 60 were connected to the drive 22 at other locations about the drive ring 192. The piston 60 being connected to the top of the drive 22 raises the inlet orifice 106, which allows for shorter legs 50 while still providing room for the inlet orifice 106 to be positioned directly vertically above the reservoir 48. Such a configuration provides for a compact fluid sprayer 10 that is able to provide a compact footprint by fitting directly vertically over the reservoir 48.

[0189] In the example shown, the motor 20 is held by two motor bearings 184. More specifically, the rotor 54 is rotatably supported by the two motor bearings 184. The two motor bearings 184 can be roller bearings having an annular array of ball bearings directly between two rings. The electric motor 20 is held, at least in part, by a motor housing 182. The motor housing 182 holds the rear motor bearing 184. For example, an outer race of the rear motor bearing 184 can be connected to the motor housing 182 and an inner race of the rear motor bearing 184 can be on the rotor 54.

[0190] The motor housing 182 contains and covers a majority of the motor 20 and structurally supports the motor 20. The motor housing 182 is mounted to drive housing 202. The motor housing 182 is connected to the drive housing 202 via housing fasteners 206. The housing fasteners 206 can be screws, bolts, etc. that extend through part of the motor housing 182 and extend into part of the drive housing 202. Threaded ends of the housing fasteners 206 can engage threading or other interfaces of the drive housing 202 to secure the housing fasteners 206, and thereby the motor housing 182, to the drive housing 202.

[0191] In the example shown, the motor housing 182 is cantilevered from the drive housing 202. In this way, the motor housing 182 is supported only by the drive housing 202. As such, the motor housing 182 is not directly supported by the primary housing 18. The motor housing 182 extends longitudinally rearward from the drive housing 202 in the rearward longitudinal direction LD2.

[0192] Drive housing 202 contains the drive 22. The drive housing 202 also contains at least a portion of the pump 24. For example, a portion of the fluid manifold 58 can be disposed within the drive housing 202. The piston 60 of the pump 24 extends into the drive housing 202. The piston 60 interfaces with the drive 22 at a location disposed within the drive housing 202. In the example shown, the piston 60 exits from the fluid manifold 58 directly into the drive housing 202.

[0193] The drive housing 202 receives the front one of the motor bearings 184. The front motor bearing 184 is spaced in the forward longitudinal direction LD 1 from the rear motor bearing 184. In the example shown, an outer race of the front motor bearing 184 is supported by drive housing 202 and an inner race of the front motor housing 182 can be on the rotor 54.

[0194] The motor 20 extends into the drive housing 202 to provide the rotational output to the drive 22. In the example shown, the drive housing 202 receives the pinion 52. The pinion 52 interfaces with the gear 66 at a location disposed within the drive housing 202.

[0195] In the example shown, the drive housing 202 supports the drive bearings 68. The drive 22 is rotatably supported on the drive housing 202 by the drive bearings 68.

[0196] In some examples, the drive housing 202 can be formed from a polymer shell. In some such examples, the drive housing 202 can be formed in a clamshell configuration. The front motor bearing 184 and / or the drive bearings 68 can directly contact the polymer shell to support the drive 22 and at least part of the motor 20.

[0197] In the example shown, the drive 22 is entirely contained within the drive housing 202. Part of the shell of the drive housing 202 extends forwards, rearwards, and entirely radially around the drive 22. In this particular example, the entirety of the drive housing 202 is contained within the primary housing 18.

[0198] Pump 24 is at least partially disposed within primary housing 18. In the example shown, fluid manifold 58 extends into and is at least partially supported by the drive housing 202. In some examples, the fluid manifold 58 can be supported only by the drive housing 202. In some examples, the fluid manifold 58 can be supported by the drive housing 202 and can be connected to the primary housing 18 to be at least partially supported by the primary housing 18. A portion of the fluid manifold 58 can extend out of the primary housing 18. In the example shown, the outlet fitting 28 is disposed outside of primary housing 18 to provide access to the user, such as for connecting or disconnecting the supply hose 16 to the fluid manifold 58.

[0199] During operation, the motor 20 generates a rotational output that is provided to the drive 22. The rotor 54 rotates on motor axis MA, which is disposed vertically above the reciprocation axis PA of the piston 60 and the rotational axis DA of the drive 22.

[0200] The pinion 52 interfaces with the gear 66 to drive rotation of the gear 66. The gear 66 causes rotation of the drive shaft 190. The drive projection 198 moves back and forth as the drive ring 192 wobbles due to the rotation of the drive shaft 190.

[0201] Such forward and backward motion of the drive projection 198 due to the wobbling of the drive ring 192 moves the piston 60 linearly forward and rearwards to increase and decrease the volume within the pumping chamber 90. Spray fluid is sucked up from the reservoir 48 via the inlet hose 32 as the piston moves rearward (in longitudinal direction LD2) through a suction stroke causing the spray fluid to move past the inlet check valve 74 into the pumping chamber 90. When the drive projection 198 moves forward the piston 60 is similarly pushed forward (in longitudinal direction LD1) through a pumping stroke to decrease the volume within the pumping chamber 90, closing the inlet check valve 74 and pushing the spray fluid from the pumping chamber 90 past the outlet check valve 76 and one or both of out through the outlet fitting 28 and through the recirculation valve 26, depending on the state of the spray gun 14.

[0202] FIG. 7A is a cross-sectional view taken along line A-A in FIG. 7B. FIG. 7B is a cross-sectional view taken along line B-B in FIG. 7A. FIGS. 7A and 7B are discussed together. A portion of the pump module 12 is shown in FIGS. 7A and 7B. Specifically, the recirculation valve 26 is shown in FIGS. 7A and 7B.

[0203] Recirculation valve 26 is at least partially disposed within the fluid manifold 58. A side projection 128 of the manifold body 82 at least partially contains the recirculation valve 26. The side projection 128 can be cylindrical, among other options.

[0204] Housing 116 is at least partially disposed within fluid manifold 58. In the example shown, housing 116 is connected to manifold body 82 by interfaced threading. In the example shown, retainer 118 is connected to housing 116 by interfaced threading. The ball 112 and seat 114 of the recirculation valve 26 are held within the housing 116. At least one seal ring 130 interfaces with housing 116 to prevent leakage of paint around housing 116. A stem seal 132 engages with the stem 110 to prevent leakage of paint between stem 110 and housing 116. The stem seal 132 can move with the stem 110 as the recirculation valve 26 is actuated open and closed.

[0205] Stem 110 extends out of fluid manifold 58 such that recirculation valve 26 is accessible from the exterior of fluid sprayer 10. In the example shown, stem 110 extend through retainer 118 and collar 208. Spring 120 interfaces with retainer 118 and with stem 110. In the example shown, the spring 120 interfaces with stem flange 126 of stem 110. The spring 120 interfaces with stem 110 to bias recirculation valve 26 towards the closed state. Spring 120 is at least partially disposed within retainer 118 in the example shown.

[0206] Collar 208 interfaces with retainer 118. In the example shown, the collar 208 is keyed to the retainer 118 such that cap 122 and retainer 118 rotate together. The collar 208 can be rotated to rotate the retainer 118 and thereby adjust the compression of the spring and the threshold pressure at which the spray fluid can cause the recirculation valve 26 to open.

[0207] Lever 70 is mounted on the stem 110. In the example shown, the lever 70 is mounted to the stem 110 at hinge 210. The lever 70 can be rotated such that a cam of the lever 70 engages the collar 208 to pull the stem 110 outward, resulting in the ball 112 disengaging from the seat 114. Such use of the lever 70 to disengage the ball 112 from the seat 114 converts the recirculation valve 26 for priming of the pump 24.

[0208] Branch orifice 134 opens into the spray passage 86 at a location downstream of the pumping chamber 90. The branch orifice 134 opens into the spray passage 86 at a location downstream of the outlet seat 98 of the outlet check valve 76. The branch orifice 134 provides an opening for spray fluid to flow into the return passage 124. The return passage 124 provides the return flow of paint for the reservoir 48. The return passage 124 is shown from the branch orifice 134 through the seat 114 and through a side passage 136.

[0209] The side passage 136 is disposed downstream of the seat 114 of the recirculation valve 26. The side passage 136 directs the fluid passing through the recirculation valve 26 back toward the reservoir 48 via return hose 34. The return hose 34 can connect with the return fitting 138 that is connected to the manifold body 82. The spray fluid can take this route when the recirculation valve 26 is manually opened for priming, and additionally or alternatively in a recirculation mode in which the spray fluid pressure causes the recirculation valve 26 to open.

[0210] In the example shown, the branch orifice 134 is aligned with structure of the outlet check valve 76. The branch orifice 134 radially overlaps with structure of the outlet check valve 76 relative to the pump axis PA. The branch orifice 134 is fluidly connected to the spray passage 86 at a location downstream of the outlet seat 98 of the outlet check valve 76. The branch orifice 134 opens into the spray passage 86 at a location intermediate with the outlet check valve 76, such that the branch orifice 134 is disposed upstream of a downstream end of the structure of the outlet check valve 76.

[0211] In the example shown, the branch orifice 134 opens into the spray passage 86 at a location that radially overlaps with the outlet spring 100 of the outlet check valve 76. In the example shown, the branch orifice 134 opens into the spray passage 86 at a location that radially overlaps with the outlet cage 102 of the outlet check valve 76. In various examples, the branch orifice 134 can radially overlap with the outlet ball 104 of the outlet check valve 76 during at least a portion of the period of operation. In some examples, the branch orifice 134 can radially overlap with the outlet ball 104 with outlet check valve 76 in an open state. In some examples, the branch orifice 134 can radially overlap with the outlet ball 104 with outlet check valve 76 in both an open state and a closed state. In some examples, the branch orifice 134 does not radially overlap with the outlet ball 104 but does radially overlap with other structure of outlet check valve 76.

[0212] The branch orifice 134 opening into the spray passage 86 at a location radially overlapping with structure of the outlet check valve 76 provides for a compact configuration of fluid sprayer 10 and allows the spray fluid to recirculate quickly after leaving the pumping chamber 90 and passing by the outlet valve seat 114.

[0213] Recirculation valve 26 can receive a flow of spray fluid via the return passage 124. However, the spray fluid does not flow along the return passage 124 when the recirculation valve 26 is closed. The recirculation valve 26 is closed by engagement of the ball 112 with the seat 114, as the ball 112 is urged towards the seat 114 by the spring 120. When the pressure of the spray fluid is high enough, the spray fluid can push hard enough on the ball 112 to overcome the spring 120 so that the ball 112 unseats from the seat 114 to open the recirculation valve 26. The point at which the pressure is high enough to open the recirculation valve 26, known as the crack pressure, is based on the compression of the spring 120. The crack pressure can also be referred to as the threshold pressure of the recirculation valve 26.

[0214] The compression of the spring 120 is set based on rotation of the collar 208. The spring 120 is captured within the housing 116 and the retainer 118, with the retainer 118 being directly connected to the housing 116 in this example. In the example shown, the housing 116 is connected to the manifold body 82 and the retainer 118 is connected to the manifold body 82 via the housing 116.

[0215] The retainer 118 is movable relative to the housing 116 to change a compression of the spring 120. In the example shown, the retainer 118 is connected to the housing 116 by interfaced threading and the retainer 118 is rotatable relative to the housing 116 to change the compression of the spring 120. Rotation of the retainer 118 relative to the housing 116 changes the depth of the space containing the spring 120, thus compressing or relaxing the spring 120 and changing the force biasing the ball 112 against the seat 114 by way of the stem 110.

[0216] Collar 208 is mounted to retainer 118. The collar 208 can be keyed to the retainer 118 to prevent relative rotation between the collar 208 an the retainer 118. In the example shown, rotating the collar 208 causes rotation of the retainer 118, thereby changing the biasing force exerted by the spring 120. The retainer 118 is rotated relative to the housing 116 by rotation of the collar 208, as discussed further below with regard to FIGS. 8A-8D, to move the retainer 118 relative to the housing 116 and change compression of the spring 120 to change the crack pressure of the recirculation valve 26.

[0217] In the example shown, the collar 208 includes rails 212 that define a slot 214 of the collar 208. The lever 70 is at least partially disposed within the slot 214. The lever 70 is disposed between the rails 212 defining the slot 214. Actuating the lever 70 can engage a cam which can hold the recirculation valve 26 open so the spray fluid can freely pass through the recirculation valve 26 during priming. When priming is complete, the lever 70 can be manually stored in the slot 214 to close the recirculation valve 26, though it is understood that the recirculation valve 26 can still open upon the crack pressure being reached. As further shown herein, slot 214 can change the orientation of the lever 70 as the collar 208 is rotated to change the output pressure of the fluid sprayer 10.

[0218] In the examples shown, the outlet fitting 28 is mounted to the fluid manifold 58. More specifically, the outlet fitting 28 is mounted to the manifold body 82 of the fluid manifold 58. The outlet fitting 28 extends into the manifold body 82 to connect to the manifold body 82. In the example shown, the outlet fitting 28 holds the outlet cage 102 of the outlet check valve 76 in the fluid manifold 58. In the example shown, the outlet fitting 28 is connected to the manifold body 82 by interfaced threading, though it is understood that other connection types are possible.

[0219] A fitting seal 216 is disposed between the outlet fitting 28 and the manifold body 82. The fitting seal 216 can be formed as an elastomeric seal, such as an o-ring, among other options. Fitting seal 216 help seal the outlet fitting 28 so that spray fluid flow and pressure does not leak past the outlet fitting 28 but rather only through the central bore of the outlet fitting 28.

[0220] In the example shown, the fitting seal 216 is disposed around the outlet check valve 76. In the example shown, the fitting seal 216 radially overlaps with structure of the outlet check valve 76 relative to the pump axis PA. In the example shown, the fitting seal 216 radially overlaps with the outlet spring 100 of the outlet check valve 76. In the example shown, the fitting seal 216 radially overlaps with the outlet cage 102 of the outlet check valve 76.

[0221] The fitting seal 216 is disposed downstream of the branch orifice 134 that opens into the spray passage 86. The fitting seal 216 can be considered to be disposed at a location downstream of the return passage 124 along the spray passage 86. As such, the fitting seal 216 prevents flow around the outlet fitting 28 but does not block flow to the return passage 124 and the recirculation valve 26.

[0222] FIG. 8A is an enlarged isometric view of a portion of fluid sprayer 10 showing collar 208 in a first position. FIG. 8B is an enlarged isometric view of a portion of fluid sprayer 10 showing collar 208 in a second position. FIG. 8C is an enlarged isometric view of a portion of fluid sprayer 10 showing collar 208 in a third position. FIG. 8D is an enlarged isometric view of a portion of fluid sprayer 10 showing lever actuated to place recirculation valve 26 in an open state. FIGS. 8A-8D are discussed together. FIGS. 8A- 8D demonstrate rotation of the collar 208 to change an outlet pressure of the fluid sprayer 10. As discussed above, collar 208 is connected to retainer 118 such that rotation of collar 208 changes the position of retainer 118 relative to housing 116, thereby changing a compression of the spring 120 of recirculation valve 26 and changing the crack pressure of the recirculation valve 26.

[0223] In the example shown, the collar 208 can be rotated approximately 180-degrees to change compression of the spring 120, though it is understood that other amounts of rotation are possible. Lever 70 is disposed within slot 214 of the collar 208. At least a portion of the lever 70 is disposed directly between the rails 212 of the collar 208. The lever 70 within the slot 214 can rotates with the collar 208 because the rails 212 which define the slot 214 engage the lever 70. The lever 70 being captured between the rails 212 causes lever 70 to rotate with collar 208. The lever 70 is not directly connected to the rails 212 in this example. Without such a slot 214, rotation of the collar 208 would not rotate the lever 70 and the collar 208 would rotate independent of the lever 70, which may result in the lever 70 getting in the way of accurately viewing the pressure control setting.

[0224] In the example shown, the collar 208 includes indicator 218 that is configured to provide a visual output to the user regarding the pressure setting. Indicia 220 are disposed on pump module 12. Alignment of the indicator 218 relative to the indicia 220 provides the visual output regarding the pressure setting of the fluid sprayer 10. In the example shown, the indicator 218 is formed as a projection forming a pointer that can be aligned along the indicia 220 to provide an indication of the pressure setting.

[0225] The orientation of the collar 208 in FIG. 8A corresponds with a lowest pressure setting, the orientation of the collar 208 in FIG. 8B represents an intermediate pressure setting, and the orientation of the collar 208 in FIG. 8C represents the highest pressure setting. FIG. 8D demonstrates actuation of lever 70 which converts the fluid sprayer 10 to the prime mode in which the recirculation valve 26 is held open such that all or essentially all of the spray fluid that is output by the pump 24 is routed through the return passage 124 and through the return hose 34 to the reservoir 48.

[0226] The lever 70 that actuates the fluid sprayer 10 between the prime mode and a spray mode, in which the recirculation valve 26 is normally closed but can be opened by spray fluid pressure, being connected to the collar 208 to rotate with the collar 208 provides significant advantages. The lever 70 rotating with the collar 208 ensures that the lever 70 will not block the indicator 218, thereby providing a clear line of sight for the user to determine the set output pressure. The lever 70 can provide an additional visual indication of the set pressure to the user. In the example shown, the lever 70 is aligned with the indicator 218 such that a grip of the lever 70 can provide a visual indication as to the orientation of the indicator 218 and the set pressure.

[0227] The lever 70 can also provide an interface for the user to adjust the threshold pressure of the recirculation valve 26. For example, the user can push on the sides of the lever 70 to cause rotation of the collar 208, thereby adjusting the set output pressure. Such a configuration provides an easy and intuitive arrangement for pressure control by the user.

[0228] FIG. 9A is an isometric view showing motor 20 exploded away from drive 22. FIG. 9B is an isometric view showing fluid manifold 58 exploded away from drive 22. FIGS. 9A and 9B are discussed together.

[0229] Drive 22 is disposed within drive housing 202. The drive housing 202 is configured to interface with the primary housing 18 to be supported by the primary housing 18. The motor housing 182 and fluid manifold 58 can be connected to the drive housing 202. In various examples, the motor housing 182 is directly connected to the drive housing 202 and indirectly connected to the primary housing 18 via the drive housing 202. The motor housing 182 can be cantilevered from the drive housing 202. In the example shown, the motor housing 182 is connected to the drive housing 202 by housing fasteners 206. Motor housing 182 can, in various examples, extend at least partially into drive housing 202. The motor housing 182 is connected to drive housing 202 at a rear housing end 222 of the drive housing 202 in this example.

[0230] Drive housing 202 can support others of the components that are disposed within primary housing 18. Drive housing 202 can connect others of the components disposed within primary housing 18 to primary housing 18. In the example shown, the drive housing 202 includes mount projections 224 that extend outward relative to other portions of the drive housing 202. The mount projections 224 are configured to interface with mount receivers 226 (best seen in FIG. 12) of the primary housing 18 to mount the drive housing 202 to the primary housing 18. In various examples, the drive housing 202 is supported only by the mount projections 224 as the drive housing 202 does not directly connect to any other frame structure.

[0231] In the example shown, the drive housing 202 includes mount projections 224 that extend laterally outward on the lateral sides of the drive housing 202. The mount projections 224 take several different forms in the example shown. For example, the drive housing 202 includes a plurality of cylindrical mount projections 224 and includes plurality of non-circular mount projections 224. The non-circular mount projections 224 are quadrangular in this example, though it is understood that not all examples are so limited. The quadrangular projections are formed as rectangular projections in the example shown. The mount projections 224 can locate the drive housing 202 relative to the primary housing 18 and can locationally fix the drive housing 202 within the primary housing 18.

[0232] Fluid manifold 58 is connected to drive housing 202 and extends outward from forward housing end 228 of drive housing 202. Fluid manifold 58 includes manifold projections 230 that are configured to interface with manifold receivers 232 of the drive housing 202 to mount the fluid manifold 58 to the drive housing 202. In the example shown, the manifold receivers 232 are formed within the cylindrical mount projections 224 of the drive housing 202, though it is understood that not all examples are so limited.

[0233] In the example shown, the fluid manifold 58 includes a plurality of the manifold projections 230 that are disposed in an array about the pump axis PA. The manifold projections 230 extend laterally outward in the example shown. The manifold projections 230 can be formed monolithically with the manifold body 82, among other options. In the example shown, the fluid manifold 58 includes a first plurality of the manifold projections 230 on a first lateral side of the manifold body 82 and a second plurality of the manifold projections 230 on a second lateral side of the manifold body 82.

[0234] In the example shown, the fluid manifold 58 is further configured to directly interface with the primary housing 18 to locate the fluid manifold 58 and pump 24 relative to the primary housing 18. It is understood, however, that not all examples are so limited. For example, fluid manifold 58 can be cantilevered from drive housing 202 and not directly interface with the primary housing 18.

[0235] In the example shown, the fluid manifold 58 includes side projection 234 that is configured to interface with a side receiver 236 of the primary housing 18. The side projection 234 can extend into the side receiver 236 to connect the fluid manifold 58 to the primary housing 18 and locate the pump 24 relative to the primary housing 18. The interfacing between the side projection 234 and the side receiver 236 can prevent rotation of the fluid manifold 58, such as on the pump axis PA, and assist in maintaining axial alignment of components of pump 24.

[0236] As shown, drive housing 202 can include openings for flow of cooling air through drive housing 202. The flow of air through drive housing 202 can provide cooling to the drive 22 and provide for longer life and efficient operation. In the example shown, the motor 20 includes fan 186 that pulls air into the motor 20 through an air inlet 188 at a rear end of the motor 20 to provide a cooling airflow for the motor 20. The fan 186 is disposed at a rear end of the motor 20. The fan 186 is configured to blow air in the forward longitudinal direction LD1 towards the drive 22.

[0237] Drive housing 202 includes inlet openings 238 and exhaust openings 240. The fluid sprayer 10 is configured such that the cooling air enters drive housing 202 through inlet openings 238 and exits from drive housing 202 through exhaust openings 240. It is understood that, while drive housing 202 can include multiple (two in the examples shown) inlet openings 238, some examples of drive housing 202 include a single inlet opening 238 or more than two inlet openings 238. It is understood that, while drive housing 202 can include multiple (two in the example shown) exhaust openings 240, some examples of drive housing 202 include a single exhaust opening 240 or more than two exhaust openings 240.

[0238] In the example shown, the inlet openings 238 are oriented longitudinally. The inlet openings 238 are oriented axially with regard to the motor axis MA on which the rotor 54 of the motor 20 rotates. In the example shown, the inlet openings 238 are oriented axially with regard to the pump axis PA on which the piston 60 of the pump 24 reciprocates.

[0239] In the example shown, the exhaust openings 240 are oriented laterally. The exhaust openings 240 are oriented towards the lateral sides 162 of the primary housing 18. The exhaust openings 240 can be open radially outward relative to an axis DA of the drive 22. The exhaust openings 240 are disposed downstream of the inlet openings 238 such that the cooling air enters into drive housing 202 through inlet openings 238 and exits from drive housing 202 through exhaust openings 240.

[0240] In the example shown, the inlet openings 238 are disposed vertically below the motor axis MA of the motor 20. The inlet openings 238 are disposed vertically below the pinion 52 of the motor 20. The inlet openings 238 are disposed vertically below the interface between the pinion 52 and the drive 22. The inlet openings 238 are disposed vertically below the interface between the pinion 52 and the gear 66.

[0241] In the example shown, the inlet openings 238 axially overlap with the fan 186 relative to the motor axis MA. In the example shown, the inlet openings 238 axially overlap with the fan 186 relative to the pump axis PA.

[0242] The exhaust openings 240 are spaced vertically from the inlet openings 238. The exhaust openings 240 are vertically offset from the inlet openings 238. In the example shown, the exhaust openings 240 are disposed vertically above the inlet openings 238. In the example shown, the exhaust openings 240 are disposed at least partially vertically above the pinion 52. The exhaust openings 240 are disposed at least partially vertically above the interface between pinion 52 and drive 22. The exhaust openings 240 are disposed at least partially vertically above the interface between the pinion 52 and the gear 66.

[0243] In the example shown, the exhaust openings 240 are spaced longitudinally from the inlet openings 238. The exhaust openings 240 are longitudinally offset from the inlet openings 238 in the direction of airflow from the fan 186. The exhaust openings 240 are longitudinally offset from the inlet openings 238 towards the pump 24. The exhaust openings 240 can be disposed longitudinally closer to the pump 24 than the inlet openings 238. In the example shown, the exhaust openings 240 are spaced from the inlet openings 238 in the forward longitudinal direction LD1.

[0244] During operation, the rotor 54 of the motor 20 spins on the motor axis MA. The fan 186 is connected to the rotor 54 such that the fan 186 can spin with the rotor 54. Rotation of the fan 186 pulls cooling air into the motor 20 and drives the cooling air in the forward longitudinal direction LD1. The cooling air flows through the motor housing 182, and in some examples through the motor 20 itself, towards the drive housing 202. The air is blown towards the inlet openings 238 and enters into the drive housing 202 through the inlet openings 238.

[0245] The cooling air flows within drive housing 202 and is output through exhaust openings 240. The cooling air provides cooling for various components of the drive 22, such as drive bearings 68, interfaces between components (e.g., the interface between pinion 52 and gear 66 the interface between piston 60 and drive ring 192, etc.), among others.

[0246] It is understood that, while the cooling air is directed towards the inlet openings 238, some portions of the air blown by fan 186 can exit into primary housing 18 at locations between the motor housing 182 and the drive housing 202. For example, portions of the motor 20 can be uncovered by the motor housing 182 such that the cooling air can exit into the primary housing 18 at locations upstream of the drive housing 202.

[0247] The inlet openings 238 are oriented in the flow direction of the cooling air being blown by the fan 186 such that the cooling air is directly blown towards and into the drive housing 202 to provide cooling.

[0248] Drive housing 202 including openings for flow of cooling air provides significant advantages. The fan 186 blows air to provide active cooling for the motor 20. The cooling air that Hows into the drive housing 202 encounters various components of the drive 22, providing cooling to such components. In some examples, drive housing 202 can be formed from a plastic, which can retain heat. The cooling air can provide cooling to both components of the drive 22 and to the drive housing 202 itself. Actively cooling the drive 22 and / or drive housing 202 reduces wear and increases useful life.

[0249] It is noted that the lateral side of a component shown in FIG. 9B is the opposite lateral side as was shown in FIG. 9A, demonstrating symmetry between the lateral sides of the structure of the manifold body 82, the drive housing 202, and the motor housing 182.

[0250] FIG. 10 is an isometric cutaway view of a portion of fluid sprayer 10 illustrating interior components within primary housing 18. As discussed previously, the drive housing 202 is directly connected to the primary housing 18 to be supported by the primary housing 18. The drive housing 202 includes mount projections 224 that are received within mount receivers 226 of the primary housing 18 to support the drive housing 202 within the primary housing 18. It is noted that in the example shown, some of the mount projections 224 are round and / or cylindrical, while some of the other mount projections 224 are rectangular. Further, some of the quadrangular mount projections 224 are orientated to be horizontally elongate while others are orientated to be vertically elongate.

[0251] Use of the non-circular mount projections 224 can provide solid engagement with the complementary structure receiving the mount projections 224 (such as primary housing 18) to protect from lateral, longitudinal, and vertical movement, as compared to rounded projections. The horizontal and vertical orientations of the mount projections 224 can further block vertical and longitudinal movements respectively.

[0252] Various of the mount projections 224 can provide a keyed interface between the drive housing 202 and the primary housing 18. The keyed interface prevents movement of the drive housing 202 relative to the primary housing 18, fixing the drive housing 202 relative to the primary housing 18. Fixing the drive housing 202 relative to the primary housing 18 and connecting the motor housing 182 to the primary housing 18 via the drive housing 202 provides alignment between interfacing rotating components (e.g., pinion 52 and gear 66). The motor housing 182 is located on the drive housing 202 rather than the primary housing 18, providing desired alignment between motor 20 and drive 22. The drive housing 202 is mounted to the primary housing 18 to support the drive 22 and motor 20 on the primary housing 18.

[0253] An interface between the stand 30 and the primary housing 18 is also shown in FIG. 10. As shown, the stand 30 includes a plurality of inserts 242. The inserts 242 can be configured as tabs. The inserts 242 can be snap fit tabs that include a ramped profile that can slide over an opposed surface until the ramp transitions to a ridge of the insert 242 and the insert 242 snaps over the opposed surface, locking the insert 242 in place. In this way, the stand 30 is snap fit to the primary housing 18. Stand 30 can be inserted from below into the primary housing 18 to rigidly and permanently connect the stand 30 to the primary housing 18. Stand 30, or each respective lateral portion of the stand 30, can be a single piece, such as of contiguous polymer. Such attachment of the stand 30 to the primary housing 18 can allow for a lightweight, inexpensive, compact configuration for shipping, and provide for easy assembly.

[0254] As shown, the stand 30 is directly connected to the primary housing 18. The interfacing between the stand 30 and the primary housing 18 is spaced away from the drive housing 202, the motor housing 182, and the fluid manifold 58. The drive housing 202 does not contact and does not directly connect to the stand 30. In the example shown, the drive housing 202 is connected to the stand 30 through the primary housing 18. The motor 20 is connected to the stand 30 through the drive housing 202 and the primary housing 18. The pump 24 is connected to the stand through the drive housing 202 and the primary housing 18.

[0255] The primary housing 18 provides the structural connection between the stand 30 and the moving components of the fluid sprayer 10 (e.g., pump 24, drive 22, motor 20). The stand 30 is directly connectable to the primary housing 18 to support the primary housing 18 on a support surface. Such a configuration can provide for a compact arrangement that is particularly convenient for shipping, as the fluid sprayer 10 can be shipped with the stand 30 separated from the pump module 12.

[0256] FIG. 11 is an enlarged cross-sectional view taken along line 11-11 in FIG. 10. FIG. 11 shows the interfaces between the manifold projections 230 of the pump 24 and the manifold receivers 232 of the drive housing 202. FIG. 11 further shows the interfacing between at least some of the mount projections 224 of the drive housing 202 and mount receivers 226 of the primary housing 18.

[0257] The pump 24 is mounted to the drive 22 at a dynamic interface to receive the linear reciprocating input from the drive 22. The body of the pump 24 (e.g., fluid manifold 58) is mounted to the drive housing 202 at a static interface such that the pump 24 is supported by the drive housing 202. In the example shown, the static interface is formed between the manifold projections 230 of the fluid manifold 58 and the manifold receivers 232 of the drive housing 202.

[0258] The manifold projections 230 extend outward from the manifold body 82 and into the manifold receivers 232 of the drive housing 202 to secure the pump 24 to the drive housing 202. The manifold projections 230 and the manifold receivers 232 are located on both lateral sides of the manifold body 82 and the drive housing 202, respectively.

[0259] In the example shown, a set of manifold projections 230 is disposed vertically above the pump axis PA and a set of manifold projections 230 is disposed vertically below the pump axis PA. The set of manifold projections 230 above the pump axis PA is disposed vertically above the piston 60. The set of manifold projections 230 below the pump axis PA is disposed vertically below the piston 60.

[0260] The upper set includes manifold projections 230 that extend in opposite lateral directions. The lower set includes manifold projections 230 that extend in opposite lateral directions. The multiple sets of manifold projections 230 disposed on opposite vertical sides of the pump axis PA provides firm connection and support between the pump 24 and drive housing 202, inhibiting relative movement of the fluid manifold 58 due to forces generated during pumping. The interfacing provides a rigid connection between the fluid manifold 58 and the drive housing 202 that resists rotational forces that can be transmitted through drive ring 192 to piston 60.

[0261] Mount projections 224 of drive housing 202 interface with mount receivers 226 of primary housing 18 to connect drive housing 202 to primary housing 18. The mount projections 224 shown in FIG. 11 are disposed coaxially with the manifold projections 230 of the pump 24. The recess that forms the manifold receiver 232 is disposed within the structure that forms the mount projection 224.

[0262] Aligning the interface between the fluid manifold 58 and drive housing 202 (between manifold projection 230 and manifold receiver 232) with the interface between drive housing 202 and primary housing 18 (between mount projection 224 and mount receiver 226) provides a strong and sturdy connection of the pump 24 to the primary housing 18. Such alignment facilitates transfer of forces to the primary housing 18, which are then transmitted through primary housing 18 to stand 30 and then to the support surface. Such alignment provides a robust connection that can provide for efficient operation and long operating life.

[0263] FIG. 12 is a cross-sectional view taken along line 12-12 in FIG. 6D showing the interfacing between drive housing 202 and primary housing 18 and the interfacing between fluid manifold 58 and drive housing 202.

[0264] In the example shown, the pump 24 directly interfaces with the drive housing 202 and directly interfaces with the primary housing 18. It is understood, however, that not all examples are so limited. In some examples, the pump 24 does not directly interface with the primary housing 18.

[0265] In the example shown, the body of the pump 24, such body formed by the fluid manifold 58 in this example, includes at least one side projection 234 in addition to the rearward manifold projections 230. The side projection 234 is disposed longitudinally forward of the manifold projections 230. The side projection 234 extends into a side receiver 236 of the primary' housing 18. The interface between the side projection 234 and the side receiver 236 provides a direct interface between the fluid manifold 58 and the primary housing 18. In the example shown, only a single direct interface is formed between fluid manifold 58 and primary housing 18, though it is understood that not all examples are so limited.

[0266] The direct interface between fluid manifold 58 and primary housing 18 can locate the pump 24 within the primary housing 18 and prevent rotation relative to the primary housing 18. The direct interfacing maintains a desired position and orientation of the fluid manifold 58 relative to the primary housing 18.

[0267] Fluid manifold 58 directly interfaces with the drive housing 202. As discussed above, the manifold projections 230 of the fluid manifold 58 extend into and are received by manifold receivers 232 of the drive housing 202. The interfacing between the manifold projections 230 and the manifold receivers 232 connects the fluid manifold 58 to the drive housing 202 and locates the pump 24 relative to the drive 22.

[0268] In the example shown, the pump body includes at least one front projection (side projection 234) received by a receiver of the primary housing 18 (side receiver 236) and includes at least one rearward projection (manifold projection 230) received by a receiver of the drive housing 202 (manifold receiver 232). As such, a first projection of the pump 24 can be received by a first housing (one of primary housing 18 and drive housing 202) and a second projection of the pump 24 can be received by a second housing (the other one of primary housing 18 and drive housing 202) formed separately from the first housing.

[0269] In the example shown, the pump 24 directly interfaces with the primary housing 18 at a location disposed longitudinally forward of the pumping chamber 90 and the pump 24 directly interfaces with the drive housing 202 at a location disposed longitudinally rearward of the pumping chamber 90. The side projection 234 and the manifold projections 230 being disposed on opposite axial sides of the pumping chamber 90 along the pump axis PA can maintain concentricity of the piston 60 on the pump axis PA, reducing wear and providing for longer operating life. The drive housing 202 directly interfaces with the primary housing 18 to connect the drive 22, motor 20, and pump 24 to the primary housing 18. In the example shown, the drive housing 202 includes a forward set of mount projections 224 that interface with primary housing 18, an intermediate set of mount projections 224 that interface with primary housing 18, and a rearward set of mount projections 224 that interface with the primary housing 18.

[0270] The forward mount projections 224 of the drive housing 202 are aligned with the manifold projections 230 of the fluid manifold 58. The forward mount projections 224 extend into mount receivers of the primary housing 18. In the example shown, the forward mount projections 224 are disposed longitudinally forward of the interface between piston 60 and drive 22. The forward mount projections 224 are disposed longitudinally rearward of the pumping chamber 90.

[0271] The intermediate mount projections 224 extend into intermediate mount receivers 226 of the primary housing 18. The intermediate mount projections 224 are disposed on opposite lateral sides of the drive housing 202.

[0272] In the example shown, the intermediate ones of the mount projections 224 radially overlap with the drive 22 along the drive axis DA. The intermediate ones of the mount projections 224 are longitudinally elongate in this example. The intermediate ones of the mount projections 224 are disposed directly radially outward of the gear 66 in the example shown. As such, the intermediate ones of the mount projections 224 can be in a verticallateral plane that extends through the interface between the pinion 52 and the gear 66. The intermediate ones of the mount projections 224 can be disposed directly laterally outward from the drive axis DA on which the drive shaft 190 rotates.

[0273] In the example shown, the intermediate mount projections 224 are disposed vertically below the forward mount projections 224. The intermediate mount projections 224 are disposed vertically below the rear ones of the mount projections 224. As such, the interface between the intermediate mount projections 224 and the intermediate mount receivers 226 can form a vertically lowest interface between the drive housing 202 and the primary housing 18.

[0274] The rear ones of the mount projections 224 extend into rear mount receivers 226 in the primary housing 18. The rear mount projections 224 are disposed on opposite lateral sides of the drive housing 202.

[0275] In the example shown, the rear ones of the mount projections 224 radially overlap with the motor 20 relative to the motor axis MA. The rear ones of the mount projections 224 are vertically elongate in this example. The rear ones of the mount projections 224 are disposed directly radially outward of the stator 56 of the motor 20. The rear ones of the mount projections 224 are disposed directly radially outward of the rotor 54 of the motor 20.

[0276] In some examples, the rear ones of the mount projections 224 can directly overlap with the motor housing 182, such as by radially overlapping with a portion of the motor housing 182. In the example shown, a portion of the motor housing 182 extends into the drive housing 202 with the motor 20 mounted to the drive housing 202. The rear ones of the mount projections 224 directly overlapping with a portion of the motor housing 182 provides a robust connection of the motor housing 182 to the primary housing 18 through the drive housing 202. The positioning of the rear ones of the mount projections 224 relative to the motor 20 and motor housing 182 provides a short pathway for force transmission to the primary housing 18.

[0277] FIG. 13A is a cutaway view showing flow of cooling air within fluid sprayer 10. FIG. 13B is a cross-sectional view showing a portion of fluid sprayer 10. FIGS. 13A and 13B are discussed together. The route of the cooling air is shown by arrows CA in FIG. 13B.

[0278] Primary housing 18 is configured to route cooling air to the motor housing 182 and is configured to receive exhaust air from drive housing 202. In the example shown, the primary housing 18 is further configured to filter the cooling air, such as to remove liquid spray fluid particles from the cooling air flowing to motor 20. During spraying, not all of the spray fluid particles adhere to the target surface. The spray fluid particles that end up in the air are referred to as overspray. Fluid sprayer 10 is configured to inhibit ingestion of overspray into motor 20 and drive 22.

[0279] In the example shown, the primary housing 18 includes upper baffle 244, lower baffle 246, rear wall 248, intermediate wall 250, and forward wall 252. A single lateral side 162 of the primary housing 18 is shown, but it is understood that one or more, up to all, of the upper baffle 244, lower baffle 246, rear wall 248, intermediate wall 250, and forward wall 252 can extend fully laterally across the interior of the primary housing 18. For example, primary housing 18 can be formed as a clamshell and each portion of the clamshell can include a portion of each of the upper baffle 244, lower baffle 246, rear wall 248, intermediate wall 250, and / or forward wall 252 which can mate to span the lateral width of the interior of the primary housing 18. Rear wall 248 can be formed by ribs that extend from the primary housing 18. The rear wall 248 can be formed by ribs that are formed on each portion of the primary housing 18 forming the clamshell of primary housing 18.

[0280] Intermediate wall 250 can be formed by ribs that extend from the primary housing 18. The intermediate wall 250 can be formed by ribs that are formed on each portion of the primary housing 18 forming the clamshell of primary housing 18.

[0281] Forward wall 252 can be formed by ribs that extend from the primary housing 18. The forward wall 252 can be formed by ribs that are formed on each portion of the primary housing 18 forming the clamshell of primary housing 18.

[0282] Upper baffle 244 is disposed longitudinally rearward from motor 20. Upper baffle 244 is spaced from motor 20 in the rearward longitudinal direction LD2. The upper baffle 244 extends vertically downward from the top side 158 of the primary housing 18. The upper baffle 244 does not extend to and does not contact the bottom side 160 of the primary housing 18 in the example shown. In the example shown, the upper baffle 244 extends downward from the top side 158 of the primary housing 18 to vertically beyond the motor axis MA. The upper baffle 244 axially overlaps with the motor 20 along the motor axis MA. The upper baffle 244 axially overlaps with the fan 186 relative to the motor axis MA. The upper baffle 244 can extend to axially overlap with a majority, up to all, of the motor 20 along the motor axis MA.

[0283] The fan 186 is oriented towards vent openings 254 at a rear end 156 of the primary housing 18. It is understood that primary housing 18 can also include vent openings 254 on lateral sides 162 of the primary housing 18. For example, the lateral ones of the vent openings 254 can be formed on one or both of the clamshell portions forming the primary housing 18, in examples in which the primary housing 18 is a clamshell.

[0284] The upper baffle 244 extends downward to overlap with the vent openings 254 on the rear end 156 of the primary housing 18. In some examples, the upper baffle 244 can overlap with a majority of the vent openings 254 at the rear end 156 of primary housing 18. In some examples, the upper baffle 244 can overlap with all of the vent openings 254 at the rear end 156 of primary housing 18.

[0285] Lower baffle 246 extends vertically from bottom side 160 of primary housing 18. Lower baffle 246 is disposed longitudinally forward of the upper baffle 244. Lower baffle 246 can be spaced from upper baffle 244 in the forward longitudinal direction LD1. Lower baffle 246 can be longitudinally offset from the upper baffle 244. In the example shown, the lower baffle 246 is disposed longitudinally between the upper baffle 244 and the motor 20. The lower baffle 246 may not axially overlap with the motor 20 in various examples. In the example shown, the lower baffle 246 does not axially overlap with the stator 56 or the rotor 54 of the motor 20. Instead, an upper end of the lower baffle 246 is disposed vertically below the motor 20.

[0286] The lower baffle 246 has a smaller vertical extent than the upper baffle 244 in this example. In the example shown, the lower baffle 246 does not directly overlap with the upper baffle 244, though it is understood that not all examples are so limited.

[0287] In the example shown, the lower baffle 246 is both longitudinally and vertically offset from the upper baffle 244. The multiple offsets between the upper baffle 244 and lower baffle 246 provide a serpentine flowpath for the cooling air between the rear vent openings 254 and the motor 20.

[0288] During operation, the upper baffle 244 overlaps with the motor 20 and some or all of the rear vent openings 254. The upper baffle 244 prevents airflow directly into the motor 20 from the rear vent openings 254. Instead, the air flows around the lower end of the upper baffle 244 and then to the motor 20. The upper baffle 244 can be considered to form an impingement plate on which overspray can impinge at a location upstream of the motor 20.

[0289] The lower baffle 246 is spaced longitudinally from the upper baffle 244. In the example shown, the lower baffle 246 extends from sloped lower wall 256 of the primary housing 18. The sloped lower wall 256 is sloped downwards as the sloped lower wall 256 extends forward from the rear end 156 of the primary housing 18. Liquid particles (e.g., overspray) that route around the upper baffle 244 can impinge on the lower baffle 246 at a location upstream of the motor 20. Further, any liquid particles that that may fall from the upper baffle 244 or out of the cooling air stream can collect in a collection area defined by the lower baffle 246 and the sloped lower wall 256. The fluid flow past the upper baffle 244 can be directed towards the lower baffle 246, which provides another layer of protection against the ingestion of overspray by the motor 20.

[0290] In the example shown, the cooling air flows downwards around the upper baffle 244 and then upwards towards the motor 20. The cooling air flows upwards towards the motor 20 against gravity, which can induce any liquid particles entrained in the flow of cooling air to drop out of the flow of the cooling air as pulled by gravity.

[0291] Primary housing 18 includes ribs that divide the interior of primary housing 18 into different flow chambers. The ribs can interface with various components within the primary housing 18 to define the chambers for the cooling air flow. Rear ribs 258a can together define the rear wall 248. The rear ribs 258a extend around motor housing 182 at a location axially between fan 186 and drive 22. The rear ribs 258a can be considered to form a seal with motor housing 182, it being understood that the seal can include a small gap between the rear ribs 258a and motor housing 182. As such, the rear ribs 258a do not necessarily contact the motor housing 182. The rear ribs 258a are configured to block flow of the air around motor housing 182 such that the air is instead pulled into the motor housing 182 by fan 186. The rear ribs 258a can fully annularly surround the motor housing 182.

[0292] The rear ribs 258a can be considered to divide a filter chamber 260 within primary housing 18 from a funnel chamber 262 within primary housing 18. The filter chamber 260 can be considered to form an intake chamber for the cooling air. The funnel chamber 262, which can be referred to as a motor chamber, can be disposed within motor housing 182. The upper baffle 244 and lower baffle 246 are disposed in the filter chamber 260 and are configured to filter liquid (e.g., overspray) particles out of the airflow at a location upstream of motor 20.

[0293] Intermediate ribs 258b can together define the intermediate wall 250. The intermediate ribs 258b extend around drive housing 202 in the example shown. It is understood, however, that intermediate ribs 258b can extend around motor housing 182 in various other examples. Intermediate ribs 258b are disposed longitudinally forward of rear ribs 258a. Intermediate ribs 258b are disposed longitudinally rearward of the exhaust openings 240 through the drive housing 202 in the example shown.

[0294] A funnel chamber 262 is disposed downstream of the filter chamber 260. The funnel chamber 262 is formed through motor housing 182 in the example shown. The cooling air is being funneled through motor housing 182 and towards drive housing 202. The cooling air passage can narrow through the funnel chamber 262 to direct the cooling air towards the drive housing 202.

[0295] It is understood that at least some portion of the cooling air exiting from motor housing 182 can be exhausted into primary housing 18 at a location between rear wall 248 and intermediate wall 250 and can then exit from primary housing 18 through lateral vent openings 254 that open into primary housing 18 at locations between rear wall 248 and intermediate wall 250. In some examples, the cooling air pathway is not closed between the funnel chamber 262 and the interior of drive housing 202. In some examples, the cooling air pathway is not closed between the funnel chamber 262 and inlet openings 238 of drive housing 202. Forward ribs 258c can together define the forward wall 252. The forward ribs 258c extend around the drive housing 202 in the example shown, though it is understood that not all examples are so limited. Forward ribs 258c are disposed longitudinally forward of intermediate ribs 258b. Forward ribs 258c are disposed longitudinally forward of the motor 20. Forward ribs 258c are disposed longitudinally forward of the gear 66 of the drive 22. Forward ribs 258c are disposed longitudinally forward of the interface between piston 60 and drive 22.

[0296] The forward wall 252 and intermediate wall 250 can be considered to at least partially define an exhaust chamber 264 within the primary housing 18. The exhaust openings 240 through the drive housing 202 are disposed within the exhaust chamber 264. The cooling air exhausted from the drive housing 202 is output into the exhaust chamber 264. At least one vent opening 254 of the primary housing 18 opens directly into the exhaust chamber 264. The at least one vent opening 254 that opens into the exhaust chamber 264 can be disposed on a lateral side 162 of the primary housing 18. In the example shown, at least one such vent opening 254 on each lateral side of the primary housing 18 is open directly into the exhaust chamber 264. The cooling air exhausted from drive housing 202 enters into exhaust chamber 264 and can then be exhausted from primary housing 18 through the vent opening 254.

[0297] Fluid sprayer 10 can be considered to include multiple phases for flow of cooling air. The cooling air initially flows through a filter phase. In the filter phase, liquid particles (e.g., overspray) are removed from the cooling air. The filter phase occurs upstream of the motor 20. The fan 186 of the motor 20 pulls the cooling air through the filter phase.

[0298] In the example shown, the upper baffle 244 is configured to inhibit direct flow of any liquid particles to the motor 20. The upper baffle 244 blocks linear flow between the vent openings 254 on the rear end 156 of the primary housing 18 and the motor 20. The cooling air flows around the lower end of the upper baffle 244 to reach the motor 20. The lower baffle 246 can further collect liquid droplets.

[0299] Downstream of the filter phase is a funneling phase. In the funneling phase, the cooling air is tunneled towards the drive 22. The cooling air is drawn into the motor housing 182, and can be drawn into the motor 20 itself, by fan 186. The cooling air is tunneled within the motor housing 182 towards the drive 22. The cooling air is tunneled into the drive housing 202 through the inlet openings 238 in drive housing 202. Rear wall 248 provides sealing with the motor housing 182 to prevent the cooling air from flowing around the motor housing 182. Instead, the cooling air is pulled into the motor housing 182 and blown through the motor 20 by the fan 186.

[0300] Downstream of the filter phase is an exhaust phase. In the exhaust phase, the cooling air is exhausted from the drive housing 202 and into the primary housing 18. The cooling air can be exhausted from the primary housing 18 through vent openings 254 that open into the exhaust chamber 264.

[0301] Intermediate wall 250 and forward wall 252 provide sealing for exhausting of the heated cooling air. It is understood that such walls can have openings for the passage of components, such as wires. It is further understood that such sealing is not air tight, but instead provides barriers to free flow of the cooling air. The exhausted cooling air is within the exhaust chamber 264 between the intermediate wall 250 and the forward wall 252 and flows out of the primary housing 18 through the vent openings 254 that open into the exhaust chamber 264. The intermediate wall 250 can prevent the heated cooling air from flowing back towards the motor 20 and around the motor housing 182.

[0302] The cooling configuration of fluid sprayer 10 provides significant advantages. Liquid particles are filtered from the cooling air prior to the cooling air being taken into the motor housing 182. The upper baffle 244 is disposed directly between vent openings 254 on the rear end 156 of the primary housing 18 and the air inlet 188 at the rear end of the motor 20. The upper baffle 244 provides an impingement plate on which the cooling air and entrained liquid particles impinge. The liquid particles can adhere to the upper baffle 244 while the cooling air moves through the serpentine passage at least partially defined by the upper baffle 244 and to the motor 20. Filtering the liquid particles out of the cooling air upstream of the motor 20 prevents such liquid particles from flowing into the motor 20 and drive 22, where such particles could accumulate and inhibit operation. Filtering the liquid particles out of the cooling air can provide for longer operational life and improved operating efficiency.

[0303] Upper baffle 244 and lower baffle 246 can cooperate to capture and retain liquid particles. The lower baffle 246 is spaced downstream from the upper baffle 244 in the direction of cooling air flow (forward longitudinal direction LD1 in this example). As the cooling air wraps around the lower end of the upper baffle 244 the cooling air can encounter the lower baffle 246, which can also collect liquid particles. Further, any liquid particles that fall from the cooling air flow or drip from the upper baffle 244 can collect in a catch basin at least partially defined by the lower baffle 246. The cooling air is funneled towards the drive and at least a portion of the cooling air is blown into the drive housing 202. The cooling air flowing through the drive housing 202 provides active cooling to components of the drive 22, such as the drive bearings 68. The inlet openings 238 are oriented in the rearward longitudinal direction LD2 and towards the motor 20. The inlet openings 238 are oriented upstream relative to the airflow such that the cooling air blown out of the motor 20 is blown towards the inlet openings 238. Providing active cooling to the drive 22 can increase the operational life of the drive 22 and provide for more efficient operation.

[0304] The cooling air configuration of fluid sprayer 10 provides for a compact configuration of fluid sprayer 10 and efficient cooling of various heat generating components. The cooling air provides active cooling for the motor 20 and for the drive 22. The cooling air is funneled by the motor 20 and blown into the drive housing 202. The fan 186 drives cooling air flow for both the motor 20 and the drive 22.

[0305] FIG. 14 is an isometric view showing a portion of fluid sprayer 10 with stand 30 exploded away from primary housing 18. As discussed above, the stand 30 is configured to snap fit to the primary housing 18. The stand 30 is directly connected to the primary housing 18. The stand 30 is not directly connected to any of the drive housing 202, the motor housing 182, or the fluid manifold 58.

[0306] The stand 30 is configured to support the pump module 12 on a support surface, such as the ground. The stand 30 is configured to snap fit to the primary housing 18. In the example shown, the stand 30 includes legs 50 and inserts 242. In the example shown, the stand 30 includes a first leg set and a second leg set, the first leg set and the second leg set configured to snap fit to the primary housing 18. In the example shown, each leg set includes a pair of legs 50, thought it is understood that not all examples are so limited.

[0307] Insert receivers 266 are formed in the primary housing 18. Specifically, the insert receivers 266 are open towards a bottom side 160 of the primary housing 18 such that the stand 30 and the inserts 242 can approach the insert receivers 266 from the bottom of the primary housing 18. The insert receivers 266 are disposed on the lateral sides 162 of the primary housing 18.

[0308] The stand 30 directly connects with the primary housing 18. The primary housing 18 is a shell which contains the motor 20, the drive 22, and the pump 24, amongst other components such as valves. The primary housing 18 obscures and protects these components that they are generally or entirely not visible to a user operating the fluid sprayer 10. The primary housing 18 may be referred to as a shroud. The primary housing 18 performs pinch guarding in that it keeps fingers of a user away from the motor 20 and the drive 22 and other moving components to avoid pinching, as well as protect these components from spayed spray fluid.

[0309] The drive housing 202 is entirely supported by the primary housing 18. The primary housing 18 can be a single piece of polymer or can be two polymer clamshell halves. The stand 30 does not connect with a platform and / or other frame, other than the primary housing 18 itself. As such, the drive housing 202 is not supported by any structure other than the primary housing 18. The stand 30 does not directly connect with the drive housing 202. Rather, the primary housing 18 forms an intermediary between the stand 30 and the drive housing 202.

[0310] In the example shown, the inserts 242 include fixing inserts 242a and guide inserts 242b. The insert receivers 266 include fixing receivers 266a and guide receivers 266b. The fixing inserts 242a are disposed between the guide inserts 242b. The fixing inserts 242a are configured to interface with the fixing receivers 266a and the guide inserts 242b are configured to interface with the guide receivers 266b.

[0311] The guide inserts 242b extend into the guide receivers 266b and are configured to maintain alignment of the stand 30 on the primary housing 18. In the example shown, the structure of the primary housing 18 extends around at least three sides of the guide inserts 242b. The guide inserts 242b are covered by structure of the primary housing 18 both laterally inwards and laterally outwards. The interfacing between the guide inserts 242b and the primary housing 18 prevents rotation of the stand 30 relative to the primary housing 18, maintaining the desired orientation of the stand 30 relative to the primary housing 18.

[0312] The fixing inserts 242a extend into the fixing receivers 266a and are configured to fix the stand 30 to the primary housing 18. In the example shown, the fixing inserts 242a are configured to snap fit on the primary housing 18. In the example shown, the fixing inserts 242a include tabs 268 that are configured to snap fit over shelves 270 of the fixing receivers 266a. The snap fit connection between the fixing inserts 242a and the fixing receivers 266a prevents the stand 30 from being pulled off of the primary housing 18. The interface between the fixing inserts 242a and the primary housing 18 fixes the stand 30 to the primary housing 18.

[0313] In the example shown, the stand 30 is configured to shift linearly to connect to the primary housing 18. The stand 30 can shift in mount direction MD to interface with and connect to the primary housing 18. The mount direction MD can be vertically upward. The mount direction MD can be towards the top side 158 of the primary housing 18. During mounting of the stand 30, the various inserts 242 are aligned with the various insert receivers 266 of the primary housing 18. The stand is shifted in mount direction MD towards primary housing 18 (or the pump module 12 is shifted in a direction opposite the mount direction MD and towards stand 30) such that the inserts 242 enter into the insert receivers 266. Specifically, the guide inserts 242b enter into the guide receivers 266b and the fixing inserts 242a enter into the fixing receivers 266a. The tabs 268 of the fixing inserts 242a pass over the shelves 270 of the fixing receivers 266a to fix the stand 30 to the primary housing 18.

[0314] In some examples, the guide inserts 242b can enter into the guide receivers 266b prior to the fixing inserts 242a entering into the fixing receivers 266a. In such an example, the guide inserts 242b being disposed in the guide receivers 266b can guide the stand 30 relative to the primary housing 18 during mounting, ensuring alignment of the fixing inserts 242a with the fixing receivers 266a.

[0315] The insert receivers 266 are disposed on an exterior of the primary housing 18. The insert receivers 266 are exposed on an exterior of the primary housing 18. The insert receivers 266 are thus accessible from the exterior of the primary housing 18 without having to disassembly or otherwise manipulate the primary housing 18 to gain access to such mounting locations. Such a configuration provides for easy assembly of the stand 30 to the primary housing 18.

[0316] FIG. 15A is an isometric view of a spray gun 314. FIG. 15B is a cross-sectional view of the spray gun 314 taken along line B-B in FIG. 15A. FIG. 15C is an enlarged detail view of detail C in FIG. 15B. FIGS. 15A-15C are discussed together. The spray gun 314 can be used with the previous examples of fluid sprayer 10 or can be used with any other fluid sprayer. The spray gun 314 is the same or substantially similar to spray guns 14 previously discussed and similar or same components are labeled with the same reference number except increased by “300” (e.g., spray tip 40 and spray tip 340). The spray gun 314 includes a guard 572. The guard 572 can protect the trigger 344 from inadvertent triggering.

[0317] Spray gun 314 further includes a handle piece 574. The handle piece 574 can be composed of a handle 338 and a fitting 576. The fitting 576 can include hex 578, which can facilitate connection to a wrench or other tool to facilitate threaded connection with the fitting 576. As further shown herein, the handle piece 574 is a unitary piece such that the fitting 576 of the handle 338 formed from one contiguous piece of metal. As such, the handle 338 and fitting 576 can be monolithic. The handle piece 574 includes a handle recess 580. The handle recess 580 can separate the fitting 576 from the handle 338. The handle recess 580 can be disposed directly between the handle 338 and the fitting 576. The recess 580 can accommodate a clip 582 of the guard 572. In this way, the guard 572 can connect with the handle piece 574 by the clip 582 engaging the recess 580. In some examples, the lateral arms of the clip 582 can snap fit into the recess 580 around the handle piece 574.

[0318] A central channel 584 goes through the handle piece 574 and includes a fluid filter 586 inside of the handle 338. The trigger 344 actuates spray valve 346 to open and close the spray valve 346 to allow spray from the nozzle 342.

[0319] The spray gun 314 includes a tip housing 588 and a tip guard 590. A valve housing 592 contains the valving components of the spray valve 346. The valve housing 592 can be formed separately from and mounted to a gun body 594 of the spray gun 314, though it is understood that not all examples are so limited. For example, the valve housing 592 can be threadedly connected to the gun body 594.

[0320] Mounted onto the valve housing 592 is a tip retainer 596. The tip retainer 596 is threaded on to the valve housing 592 in this example, however various other examples can include other types of connections such as press fit among other options. In this example, the threaded connection between the valve housing 592 and the tip retainer 596 is a permanent connection in that adhesive (e.g., glue) prevents rotation of the tip retainer 596 off of the valve housing 592 or relative to the valve housing 592 once assembled together.

[0321] It is important to be able to orientate the spray tip 340, and the nozzle 342, in a vertical or horizontal orientation because a spray pattern coming out of the nozzle 342 can be a fan, and the user may want to spray vertical or horizontal swaths. In standard spray guns, the orientation of the spray tip 340 and the nozzle 342 is changed by changing the orientation of the tip housing 588. The orientation of the tip housing 588 is changed by loosening the tip retainer 596 relative to the valve housing 592 (e.g., by de- threading), reorientating the tip housing 588 when loose, and then the tip retainer 596 is tightened back onto the valve housing 592 which locks the orientation of the tip housing 588 by pressing the tip housing 588 directly against the front end of the valve housing 592. But as mentioned previously for this example, the tip retainer 596 is not removable from the valve housing 592 after the spray gun 314 leaves the factory. Instead, the tip retainer 596 is maintained in a factory set position on the valve housing 592 throughout the life of the spray gun 314.

[0322] In the example shown, the orientation of the tip housing 588 is changed by having a frictional compression interface with the valve housing 592. Specifically, the tip housing 588 is separated from the valve housing 592 by a spacing gap 598. Such a spacing gap 598 is not present in standard spray guns because standard spray guns rely upon engagement between the rear end of the tip housing 588 with the forward end of the valve housing 592 to secure and lock the orientation of the valve housing 592. The spacing gap 598 prevents a direct metal-to-metal axial face contact between the tip housing 588 and the valve housing 592.

[0323] In the example shown, saddle seal 600 and gasket 602 are held by the tip housing 588 such that the saddle seal 600 engages the spray tip 340 while the gasket 602 engages the front end of the valve housing 592. The gasket 602 can have some elastic properties such that the gasket 602 can be compressed between the saddle seal 600 and the tip housing 588 to provide resistance to relative movement. As such, the compression of the gasket 602 still permits the tip housing 588 to be rotated by hand but upon release by the hand there is enough resistance provided by the compression of the gasket 602 such that the tip housing 588 stays in the intended orientation relative to the valve housing 592 during spraying. As such, the user can manually change the orientation of the tip housing 588 by overcoming frictional resistance between the gasket 602 and the valve housing 592.

[0324] FIG. 16A is a cross-sectional view of another example of spray gun 414 showing spray gun 414 in a non-spray state. FIG. 16B is a cross-sectional view of spray gun 414 showing spray gun 414 in a spray state. FIG. 16C is an enlarged view of detail C in FIG. 16B. FIG. 16D is a partially exploded view of spray gun 414. FIG. 16E is an isometric partially exploded view of spray gun 414. FIGS. 16A-16E are discussed together. Spray gun 414 is substantially the same as spray gun 14 and same or similar components are indicated with the same reference number except increased by “400” (e.g., spray tip 40 and spray tip 440). Spray gun 414 is substantially similar to spray gun 314 (FIGS. 15A-15C) except as discussed below. Components of spray gun 414 that are similar or the same as spray gun 314 are labeled with the same reference number except increased by “100” (e.g., tip housing 588 and tip housing 688).

[0325] Spray gun 414 includes gun body 694 that holds other components of spray gun 414. Handle piece 674 is connected to gun body 694 and depends from gun body 694. Spray valve 446 is configured to control emission of spray fluid from spray gun 414. Spray valve 446 includes valve housing 692. The valve housing 692 is attached to the gun body 694 via threading in this example. At least part of the valve housing 692 is received inside of gun body 694 of the spray gun 414. For example, valve housing 692 can be connected to gun body 694 by the interfaced threading, among other options. Spray valve 446 is configured to control emission of spray fluid from the spray gun 414. The spray valve 446 is actuatable between a closed state, associated with a non-spray state of spray gun 414, and an open state, associated with a spray state of spray gun 414. The spray valve 446 is shown in the closed state in FIG. 16A and in the open state in FIG. 16B.

[0326] Spray valve 446 includes needle 706 that is at least partially disposed within valve housing 692. Valve spring 708 interface with needle 706. The needle 706 is pushed forward by valve spring 708 to bias the spray valve 446 towards the closed state. The spring 756 biases the spray valve 446 to a normally closed state. The needle 706 is pulled backward by the trigger 444 to overcome the valve spring 708 to open the spray valve 446 for spraying. The needle 706 is configured to shift along a valve axis VA to actuate the spray valve 446 between the open state and the closed state. An upstream direction UD and downstream direction DD are indicated in FIGS. 16A and 16B. The upstream direction UD and downstream direction DD are axial directions along the spray axis SA and valve axis VA in this example.

[0327] In the example shown, the spray valve 446 further includes a ball 710 which engages a seat ring piece 712. The ball 710 is supported by the needle 706 and is configured to move with the needle 706. The seat ring piece 712 includes a central aperture 714 through which spray fluid can flow out of the valve chamber 716 formed within the valve housing 692. In the example shown, the valve chamber 716 is at least partially defined by the gun body 694 and is further at least partially defined by the valve housing 692. The flowpath of spray fluid to the spray gun 414 enters into the gun body 694 and fills into the valve chamber 716.

[0328] The ball 710, seat ring piece 712, and valve housing 692 can be considered to form a valve housing assembly. The ball 710 and seat ring piece 712 are within the valve housing 692 to form the valve housing assembly.

[0329] The ball 710 engages with the seat ring piece 712 to seal the central aperture 714 and prevent the flow of spray fluid out of the valve chamber 716. Actuation of the trigger 444 moves the needle 706 rearward which overcomes the valve spring 708 to move the ball 710 off of the seat ring piece 712 to allow flow of spray fluid from within the valve chamber 716 through the central aperture 714 to spray the spray fluid from the spray nozzle 442. When the trigger 444 is released, the valve spring 708 pushes the needle 706 forward which engages the ball 710 with the seat ring piece 712 to close flow through the central aperture 714 and stop spraying. When spraying, the spray fluid travel downstream between the central aperture 714 and the spray nozzle 442.

[0330] Spray tip 440 is mounted to gun body 694 and is configured to atomize the spray fluid into a spray pattern, such as a fan. The spray tip 440 is disposed in a tip housing 688. The tip housing 688 is connected to the gun body 694 by the tip retainer 696. In the example shown, the tip housing 688 is mounted to the gun body 694 by the tip retainer 696 and the valve housing 692. The tip retainer 696 is directly connected to the valve housing 692. In the example shown the tip retainer 696 is directly connected to the valve housing 692 by interfaced threading 704. It is understood, however, that not all examples are so limited. In various examples, the interfaced threading 704 forms a permanent connection such as by additional attachment by an adhesive (e.g., glue). Tip guard 690 is mounted to tip housing 688.

[0331] Spray tip 440 is mountable to tip housing 688. Spray tip 440 can be rotated on a tip axis TA to reverse the flow of spray fluid through the flowpath of the spray tip 440. For example, the spray tip 440 can be rotated about 180-degrees between a spray position and a de-clog position. The spray tip 440 can be rotated between a first state in which the nozzle 442 is oriented outward from spray valve 446 to atomize the flow of paint and a second state in which the nozzle 442 is oriented inward towards the spray valve 446 to reverse flow through the spray tip 440, such as for de-clogging the spray tip 440.

[0332] Spray tip 440 is disposed in a tip receiver 718 within the tip housing 688. The tip receiver 718 can be formed as a bore in the tip housing 688. The tip receiver 718 can, in various examples, be at least partially formed by the tip guard 690. The tip receiver 718 extends along the tip axis TA. A transverse bore 720 extends through the tip housing 688. The transverse bore 720 is disposed transverse to the tip receiver 718. The transverse bore 720 can be disposed orthogonal to the tip receiver 718. The transverse bore 720 can be disposed coaxially with the valve axis VA in various examples.

[0333] The spray tip 440 includes a tip barrel 722 that supports other components of the spray tip 440. The spray nozzle 442 is formed in a tip piece 724 that is supported by the barrel 722. The tip barrel 722 is disposed within the tip receiver 718. The tip barrel 722 extends out of the tip receiver 718 such that the spray tip 440 is accessible by the user, such as for removal and replacement or rotation between spray and de-clog states.

[0334] Sealing piece 726 is disposed between the seat ring piece 712 and the rotatable spray tip 440. In various examples, the sealing piece 726 seals with multiple other components. Specifically, in this example, the sealing piece 726 seals with the valve housing 692 and the spray tip 440.

[0335] Sealing piece 726 includes flow channel 728 that is configured to convey the flow of spray fluid between the spray valve 446 and the rotatable spray tip 440. Various examples of the sealing piece 726 may not include all of the aspects shown herein. Nevertheless, the various aspects of the illustrated example will be discussed, it being understood that not all features, or only one feature, may be implemented in various examples.

[0336] Sealing piece 726 includes seal body 730 that extends between the valve housing 692 and the spray tip 440. The seal body 730 can be disposed at least partially within the tip housing 688. The seal body 730 can be disposed at least partially within the valve housing 692. The seal body 730 is configured to convey the spray fluid between the spray valve 446 and the spray tip 440.

[0337] The sealing piece 726 includes tube 732. The tube 732 extends inside of a socket 734 of the valve housing assembly. More specifically, the tube 732 extends into a socket 734 of the valve housing 692. The socket 734 is disposed downstream from the seat ring piece 712. The socket 734 is radially wider than the central aperture 714 through the seat ring piece 712. An outlet aperture 736 extends between the central aperture 714 through the seat ring piece 712 and the socket 734 within which the tube 732 of the sealing piece 726 extends.

[0338] Sealing ring 738 is mounted on the sealing piece 726. More specifically, the sealing ring 738 is mounted in a seal groove 740 of the tube 732. The seal groove 740 can extend fully annularly about the tube 732. The sealing ring 738 interfaces with an interior cylindrical surface of the socket 734 to create an annular seal. The sealing ring 738 also generates an annular seal around the annular outward facing surface forming the seal groove 740 on the tube 732. Such sealing forces all of the spray fluid passing through the central aperture 714 to flow into the flow channel 728 as the only fluid pathway.

[0339] The sealing ring 738 is configured to provide a fluid seal between the sealing piece 726 and the valve housing 692. The sealing ring 738 provides a radial seal between the valve housing 692 and the sealing piece 726. In the example shown, the sealing ring 738 does not form an axial face seal with the valve housing 692. The sealing ring 738 can, in some examples, act to bias the sealing piece 726 into the spray tip 440, such as due to fluid pressure acting on the sealing ring 738. For example, the fluid pressure acting on the sealing ring 738 can bias the sealing piece 726 in the downstream direction DD to firmly engage with the tip barrel 722.

[0340] It is noted that the seal groove 740 exposes the sealing ring 738 to flowing paint, even though the sealing ring 738 is not directly in line of the shortest flow path through the sealing piece 726. In some examples, a straight line can be drawn from the interior of the central aperture 714 to the sealing ring 738 along the valve axis VA.

[0341] In the example shown ,the seal groove 740 includes a downstream wall 742 disposed on a downstream side of the sealing ring 738 and an upstream wall 744 disposed on an upstream side of the sealing ring 738. The sealing ring 738 is disposed between the downstream wall 742 and the upstream wall 744. In the example shown, the downstream wall 742 extends further radially outwards than the upstream wall 744. The downstream wall 742 can be considered to extend higher than the upstream wall 744. The downstream wall 742 is larger than the upstream wall 744 such that an outer end of the downstream wall 742 is closer to the valve housing 692 than an outer end of the upstream wall 744. The lower height of the upstream wall 744 allows the spray fluid to come into direct contact with the sealing ring 738.

[0342] The pressurized flow of spray fluid can flow over the upstream wall 744 to contact the sealing ring 738. The pressure exerted on the sealing ring 738 by the pressurized spray fluid can cause the sealing ring 738 to fill into the area over the upstream wall 744 and even into a gap (radial and / or axial) between the upstream wall and the valve housing 692. The deformation of the sealing ring 738 can help minimize dead space volume for fluid, such as air, to accumulate between the central aperture 714 and the rotatable spray tip 440. The reduction of such dead space enhances the quality of spray from the spray nozzle 442 by providing a smaller, clearer path for direct flow of spray fluid with minimal side branches and pockets.

[0343] A height of the upstream wall 744 is less than a height of the downstream wall 742. The height of the upstream wall 744 can be less than or equal to half of the height of the downstream wall 742. In some examples, the height of the upstream wall 744 can be less than or equal to one quarter of the height of the downstream wall 742. The heights of the upstream wall 744 and the downstream wall 742 can be taken from a base of the seal groove 740.

[0344] The configuration of the sealing ring 738 relative to the spray valve 446 provides for enhancements in spray quality. In the example shown, the sealing ring 738 is relatively smaller than various components of the spray valve 446 to help to minimize the dead spaces. Making the sealing ring 738 relatively smaller minimizes flow space of spray fluid and minimizes the effects of deformation of the sealing ring 738 as the hydraulic pressure changes within the flow path due to the spray valve 446 opening / closing as well as due to the cycling of the upstream pump.

[0345] In the example shown, the sealing ring 738 has an outer diameter OD1 and an inner diameter ID1. The seat ring piece 712 has an outer diameter OD2 and an inner diameter 1D2. The inner diameter 1D2 can be a diameter of the central aperture 714 through the seat ring piece 712.

[0346] In the example shown, the outer diameter OD1 of the sealing ring 738 is smaller than the outer diameter OD2 of the seat ring piece 712. In some examples, the outer diameter OD1 of the sealing ring 738 is no greater than the outer diameter OD2 of the seat ring piece 712.

[0347] In the example shown, the inner diameter ID1 of the sealing ring 738 is smaller than the inner diameter ID2 of the seat ring piece 712. As such, the sealing ring 738 can have a smaller inner diameter ID2 than the diameter ID2 of the central aperture 714. As such, the sealing ring 738 can axially overlap with the central aperture 714 along the valve axis VA. It is understood that, in various examples, the inner diameter ID1 of the sealing ring 738 is not larger than the inner diameter ID2 of the seat ring piece 712. In some examples, the inner diameter ID1 of the sealing ring 738 is no greater than the inner diameter ID2 of the seat ring piece 712.

[0348] The sealing ring 738 can have a smaller inner diameter ID1 than the smallest inner diameter ID3 of the downstream outlet aperture 736 of the valve housing 692.

[0349] The flow channel 728 of the sealing piece 726 has an inner diameter ID4 that is smaller than the inner diameter ID3 of the downstream outlet aperture 736 of the valve housing 692. The flow channel 728 of the sealing piece 726 has a smaller inner diameter ID4 than the inner diameter ID2 of the seat ring piece 712. The flow channel 728 of the sealing piece 726 has a smaller inner diameter ID4 than the inner diameter ID1 of the sealing ring 738. The inner diameter ID4 of the flow channel 728 can be a smallest diameter pathway between the valve chamber 716 and the tip barrel 722.

[0350] In the example shown, the sealing piece 726 includes a seal head 746 that is configured to engage with the tip barrel 722 to seal with the tip barrel 722. The seal head 746 is disposed at an opposite axial end of the sealing piece 726 from the seal groove 740. The seal head 746 includes a saddle face 748 that engages with the tip barrel 722. The saddle face 748 is curved to engage with the curved exterior surface of the tip barrel 722. The sealing piece 726 includes a neck 750 that extends between the seal head 746 and the seal body 730. In the example shown, the seal neck 750 forms a radially narrowest portion of the sealing piece 726. The seal neck 750 can form a radially narrowest portion of the sealing piece 726 downstream of the seal groove 740.

[0351] The seal neck 750 is a narrower part of the sealing piece 726 relative to the seal body 730 and the seal head 746. The seal neck 750 is formed, at least in part, by an annular alignment groove 752 between the seal head 746 and the seal body 730. The seal neck 750 allows the seal head 746 to articulate relative to the seal body 730. The seal neck 750 can be considered to allow the seal head 746 to gimbal for engagement with the tip barrel 722. The articulation provided by the seal neck 750 allows the seal head 746 to better interface, and accommodate imperfections or minor misalignment, with the tip barrel 722 of the rotatable spray tip 440 which may otherwise compromise sealing between the tip barrel 722 and the seal head 746. It is noted that the interface between the tip barrel 722 and the seal head 746 is a curved, saddle-like surface, as further shown herein, which benefits from proper alignment, such as that provided by the articulation of the seal head 746 to best interface with the tip barrel 722.

[0352] In the example shown, the seal body 730 includes a body flange 734 that extends radially outward relative to other portions of the sealing piece 726. The seal neck 750 extends between the body flange 754 and the seal head 746 in this example. The body flange 754 provides a bearing face for biasing of the seal head 746 into the tip barrel 722 to provide sealing between the sealing piece 726 and the spray tip 440.

[0353] In the example shown, the sealing piece 726 is biased into engagement against the tip barrel 722. The sealing piece 726 is biased into engagement with the tip barrel 722 by tip spring 756. The tip spring 756 is disposed axially between the valve housing 692 and body flange 754 of the sealing piece 726. The tip spring 756 can be a helical metal spring. The tip spring 756 can be formed as a wave spring, among other options.

[0354] The tip spring 756 pushes off from the distal face 758 of the valve housing 692 and urges the sealing piece 726 in the downstream direction DD. In the example shown, the tip spring 756 engages with the body flange 754 to provide the biasing force. The tip spring 756 biases the sealing piece 726 in the downstream direction DD which in turn forces the seal head 746 against the tip barrel 722 for a tighter interface provides sealing to minimize leakage.

[0355] The tip spring 756 biases the sealing piece 726 into engagement with the tip barrel 722. The tip spring 756 assists in maintaining the sealing engagement between seal head 746 and tip barrel 722 even when the spray gun 414 is in the non-spray state. With spray gun 414 in the non-spray state, the pressurized spray fluid is maintained upstream of the closed interface between the valve ball 710 and the seat ring piece 712. The tip spring 756 biases the sealing piece 726 into and maintains engagement between the seal head 746 and the tip barrel 722.

[0356] With spray gun 414 in the spray state, the spray fluid exits from the valve chamber 716 and flows downstream through the valve outlet aperture 736, through the sealing piece (within the flow channel 728), through the spray tip 440, and is emitted from the spray nozzle 442. As discussed above, the flow of pressurized spray fluid contacts the sealing ring 738. The pressurized spray fluid acting on the sealing ring 738 can further bias the sealing piece 726 into contact with the tip barrel 722, providing an even tighter seal to further prevent fluid leakage as the pressurized spray fluid is flowing from the sealing piece 726 to the spray tip 440.

[0357] In the example shown, the tip retainer 696 can be permanently mounted on the valve housing 692. For example, the tip retainer 696 can be connected to the valve housing 692 by interfaced threading 704 and further by adhesive (e.g., glue) that prevents moving of the tip retainer 696 relative to the valve housing 692. The tip retainer 696 is connected to the valve housing 692 such that the tip retainer 696 remains in a set position and orientation relative to the valve housing 692 throughout the operational life of spray gun 414. The tip retainer 696 is maintained in a factory set position on the valve housing 692 throughout the operational life of the spray gun 414. While tip retainer 696 is described as permanently mounted on valve housing 692 in a set position and orientation, it is understood that not all examples are so limited.

[0358] In the example shown, the tip retainer 696 includes a retainer 760 that axially overlaps with a housing shoulder 762 of the tip housing 688 to prevent the tip housing 688 from moving in the downstream direction DD and off of the tip retainer 696. In this particular example, a tip bearing 764 is disposed axially between the retainer 760 and the housing shoulder 762. The tip bearing 764 can be captured directly between the retainer 760 and the housing shoulder 762. The tip bearing 764 can be formed as a sleeve bearing, among other options. The tip bearing 764 includes axial faces that engage with the tip retainer 696 and the tip housing 688. The tip bearing 764 can assist in allowing tip housing 688 to rotate relative to the tip retainer 696 for reorientation of the nozzle 442 and thus the spray pattern emitted from nozzle 442. Conventional tip retainers can be unthreaded from conventional valve housings, which loosens the tip housing 688 allowing the orientation of the rotatable spray tip 440 and the spray nozzle 442 to be changed, such as for a vertical fan to a horizontal fan and vice versa. But in the present example, because the tip retainer 696 is permanently fastened to the valve housing 692, the tip retainer 696 does not rotate relative to the valve housing 692. As such, the tip retainer 696 cannot be loosened to allow for reorienting of the spray tip 440.

[0359] In the example shown ,the tip housing 688 can rotate inside of the tip retainer 696 and relative to the tip retainer 696 as the rotatable spray tip 440 rotates between different spray pattern orientations (e.g., between vertical and horizontal spray fan orientations). Clearance and / or rotatable interfaces are provided between the tip housing 688 and the valve housing 692 to allow the tip housing 688 to rotate relative to the valve housing 692 and tip retainer 696.

[0360] There is no direct axial interface between the tip housing 688 and the valve housing 692. The distal face 758 of the valve housing 692 is not in contact with any portion of the tip housing 688. An axial spacing gap 698 is formed between the upstream end 766 of the tip housing 688 and the axially closest portion of the valve housing 692 that axially overlaps with the upstream end 766 such that no hard stop interface is formed therebetween. The axial spacing gap 698 axially spaces the tip housing 688 and valve housing 692 such that the tip housing 688 does not axially interface with the valve housing 692.

[0361] In the example shown, the tip housing 688 receives a portion of the valve housing 692. A downstream portion of the valve housing 692 extends into the tip housing 688, but there is still no axial contacting between the valve housing 692 and the tip housing 688. The valve housing 692 extends into the tip housing 688 such that the distal face 758 of the valve housing 692 can contact the tip spring 756 and bias the tip spring 756 in the downstream direction DD to cause the tip spring 756 to bias the sealing piece 726 into the tip barrel 722.

[0362] In the example shown, tip housing 688 includes retaining flange 768 at upstream end 766 of the tip housing 688. The retaining flange 768 extends radially inwards towards the valve housing 692. The retaining flange 768 defines the receiving aperture 770 through which the valve housing 692 extends into the tip housing 688.

[0363] An inner diameter ID5 of the receiving aperture 770 can be larger than an outer diameter OD3 of the portion of the valve housing 692 extending through the receiving aperture 770. As such, a radial gap 772 can be formed between the tip housing 688 and valve housing 692. In various examples, the tip housing 688 does not directly contact the valve housing 692.

[0364] While in the factory and prior to assembly, the retaining flange 768 can maintain the tip spring 756 within the tip housing 688. Such a configuration can maintain the tip housing 688, the sealing piece 726, and the tip spring 756 as a single assembly in the factory prior to assembly onto valve housing 692 by tip retainer 696. This can provide for a reduction in part count and for easier assembly in the factory.

[0365] In some examples, the tip housing 688, tip guard 690, sealing piece 726, and tip retainer 696 can be assembled into a discrete module that is connectable to the valve housing 692 as the discrete module. The tip spring 756 maintains the sealing piece 726 within the tip housing 688 and prevents the sealing piece 726 from falling out of the tip housing 688. Such a configuration can provide for quick and easy assembly of that discrete module onto the valve housing 692. The discrete module can be seen in FIG. 16D exploded away from the valve housing 692.

[0366] The user typically rotates spray tip 440 to different orientations by grabbing the rotatable spray tip 440 and / or the tip guard 690 and exerting a rotational force about the spray axis SA along which the fluid is emitted from the spray nozzle 442. The spray axis SA can be coaxial with the valve axis VA. Such rotational force rotates the tip housing 688 but does not necessarily directly rotate the sealing piece 726. Therefore, the rotational motion is further conveyed from the tip housing 688 to the sealing piece 726 so that the saddle shape of the interface between the sealing piece 726 and the tip barrel 722 is maintained in alignment.

[0367] The barrel 722 is held within tip receiver 718 that is formed by the tip housing 688. The tip receiver 718 can also be formed in part by the tip guard 690. Tip receiver 718 can form, at least in part, a cylindrical space that forms an interference fit with the barrel 722 of the rotatable spray tip 440. The interference fit still allows the barrel 722 of the rotatable spray tip 440 to rotate within the tip receiver 718 to reverse the direction of flow of spray fluid through the spray nozzle 442 to remove clogs, and further allows removal of the barrel 722 from within the tip receiver 718.

[0368] FIG. 16D shows the tip retainer 696, together with the tip guard 690 and tip housing 688, having been dismounted from the rest of the spray gun 414. Specifically, the tip retainer 696 has been dismounted from the valve housing 692. However, in typical use the tip retainer 696 is permanently mounted on the valve housing 692 and is not dismountable. FIG. 16D further shows how the rotatable spray tip 440 can be removed from the tip housing 688 and tip guard 690 via moving the tip barrel 722 out of the tip receiver 718.

[0369] FIG. 17A is an isometric cross-sectional view showing the tip retainer 696 and tip housing 688 dismounted from the valve housing 692. FIG. 17B is a cross-sectional view taken along line B-B in FIG. 17A. FIGS. 17A and 17B are discussed together. As discussed above, the tip mounting assembly shown can be assembled into the illustrated configuration as a discrete module in the factory to provide a single part for assembly to the other portions of the spray gun 414 in the factory. The spray tip 440 is removed from the tip receiver 718 for clarity.

[0370] The tip housing 688 is at least partially disposed within the tip retainer 696. The sealing piece 726 is at least partially disposed within the tip housing 688. The sealing piece 726 can be retained in the tip housing 688 by the tip spring 756, which can be captured in the tip housing 688 between the retaining flange 768 and the body flange 754 of the sealing piece 726.

[0371] As shown, the seal head 746 includes a saddle face 748 that is oriented into the tip receiver 718. The saddle face 748 can form part of the cylindrical walls that form the tip receiver and that interface with the tip barrel 722 of the rotatable spray tip 440.

[0372] As previously mentioned, the tip housing 688 conveys rotational motion to the sealing piece 726 while the orientation of the spray pattern is changed ( e.g., between horizontal and vertical spray fans). This can be accomplished by keying the sealing piece 726 to the tip housing 688 so that rotation of the tip housing 688 also rotates the sealing piece 726.

[0373] In the example shown, seal aperture 774 is formed in the tip housing 688. The seal aperture 774 is open into the tip receiver 718. The seal head 746 is at least partially disposed in the seal aperture 774. The seal head 746 is keyed to the tip housing 688 at the seal aperture 774 to facilitate simultaneous rotation of the sealing piece 726 with the tip housing 688. The seal head 746 can be keyed to the seal aperture 774 such that the seal head 746 cannot rotate within the seal aperture 774.

[0374] In the example shown, the seal head 746 includes a noncircular outer perimeter which fits in a noncircular shape of the seal aperture 774 of the tip housing 688. In particular, the seal head 746 includes at least one lobe 776 (two lobes 776 in the example shown) which fit within at least one notch 778 (two notches 778 in the example shown) of the tip housing 688. While a pair of lobes 776 and a pair of notches 778 are shown, it is understood that a single lobe 776 and a single notch 778 may be implemented or more than two lobes 776 engaging in more than two notches 778 may be implemented.

[0375] The interfacing of the lobes 776 with the notches 778 forces the sealing piece 726 to rotate with the tip housing 688 by preventing relative rotation between the seal aperture 774 and the seal head 746. The keying profile can take an ovular shape, among other options. It is understood that the keyed interface between the seal head 746 and the tip housing 688 can be of any desired non-circular configuration that prevents relative rotation between the tip housing 688 and the sealing piece 726.

[0376] In the example shown, the seal head 746 includes a major dimension MD1 and a minor dimension MD2. The major dimension MD1 is a largest width of the seal head 746 and the minor dimension MD2 is a smallest width of the seal head 746. The seal aperture 774 has corresponding major and minor dimensions to form the keyed interface. In this example, the major dimension MD1 is canted to extend both circumferentially and axially relative to the tip axis TA. It is understood, however, that not all examples are so limited.

[0377] It is understood that sealing piece 726 can be keyed to the tip housing 688 in any desired manner suitable for preventing relative rotation between tip housing 688 and sealing piece 726. For example, the body flange 754 can include a non-circular configuration that interfaces with a non-circular inner surface of the tip housing 688, thereby keying the seal body 730 to the tip housing 688, among other options.

[0378] The keyed engagement between the sealing piece 726 and the tip housing 688 provides significant advantages. The saddle face 748 is curved about the tip axis TA to mate with the curved exterior surface of the tip barrel 722. Misalignment between the curved sealing surfaces (i.e., saddle face 748 and tip barrel 722) can generate gaps that allow for fluid leakage. The keyed engagement ensures that the curvature of the saddle face 748 is correctly oriented relative to the tip receiver 718, and thus the tip barrel 722, during rotation of the tip housing 688, regardless of whether spray tip 440 is present within tip receiver 718. As such, the seal head 746 is maintained in the desired orientation even when tip housing 688 is reoriented relative to tip retainer 696 while the spray tip 440 is dismounted.

[0379] FIG. 18 is an isometric view showing sealing piece 726 having been removed from tip housing 688 and flipped to an opposite orientation from when inserted into tip housing 688.

[0380] As shown, the seal head 746 of the sealing piece 726 includes lobes 776 such that the perimeter of seal head 746 is non-circular. The lobes 776 do not extend directly horizontally or directly vertically in the example shown. Instead, the lobes 776 are canted to extend both vertically and horizontally. It is understood, however, that in various other examples the lobes 776 can extend horizontally and / or vertically. The major dimension MD1 of the saddle face 748 can be considered to extend at least partially helically about the tip axis TA.

[0381] In the example shown, the seal head 746 includes a minor dimension MD2 and a major dimension MD1. The major dimension MD1 is larger than the minor dimension MD2. In the example shown, the largest dimension of the seal head 746 (major dimension MD1 in the example shown) is smaller than the diameter of the body flange 754. As such, the body flange 754 forms a largest radial portion of the sealing piece 726 in this example.

[0382] Seal aperture 774 is formed in the tip housing 688. The seal aperture 774 includes a shape complementary to that of the seal head 746. In the example shown, the seal aperture 774 includes notches 778 which fit the lobes 776 to rotationally lock the sealing piece 726 to the tip housing 688. The seal head 746 fits within the seal aperture 774, each having complementary shapes that prevent relative rotation when the seal head 746 is received within the seal aperture 774.

[0383] FIG. 19A is a plan view showing sealing piece 726 exploded away from tip housing 688. FIG. 19B is an isometric view showing sealing piece 726 exploded away from tip housing 688. FIGS. 19A and 19B are discussed together.

[0384] The curved shape of the saddle face 748 can be seen in FIGS. 19A and 19B. Furthermore, these views show the reduced diameter neck 750 which creates an annular alignment groove 752 between the seal head 746 and the seal body 730 and facilitates bending of the seal head 746 relative to the seal body 730. The neck 750 can flex to allow the seal head 746 to move relative to seal body 730 to best align the saddle face 748 with the tip barrel 722 to support sealing.

[0385] FIG. 20A is an isometric view of spray gun 414 showing the spray tip 440 in a first orientation. FIG. 20B is an isometric view of spray gun 414 showing the spray tip 440 in a second orientation. As shown, the spray tip 440 is oriented to generate a horizontal spray fan in FIG. 20A, in which the tip barrel 722 is oriented vertically. The spray tip 440 is oriented to generate a vertical spray fan in FIG. 20B, in which the tip barrel 722 is oriented horizontally.

[0386] As discussed above, the tip retainer 696 is maintained in a factory set orientation throughout the life of the spray gun 414. The tip retainer 696 is connected to the gun body 694, via the valve housing 692 in this example. The tip retainer 696 is maintained in the set orientation and a set position on the valve housing 692 during reorientation of the spray tip 440.

[0387] The user can reorient spray tip 440 by grasping a rotatable portion of the spray gun 414, such as the tip guard 690, the tip handle 780 of the spray tip 440, etc. The user can then exert a rotational force about the spray axis SA to cause the tip housing 688 to rotate relative to the stationary tip retainer 696. The spray tip 440, the tip housing 688, the tip guard 690, and the sealing piece 726 all rotate together during reorientation of the spray tip 440.

[0388] Components that are described as connected are not necessarily in contact with each other without an intermediary component, unless it is specified that they are directly connected, in which case the two components are in contact with each other. Although not necessarily stated, any two materials that are contacting in any of the figures can be described (e.g., specifically claimed) as directly connected, and any two components described herein as being connected can be described (e.g., specifically claimed), optionally, as directly connected.

[0389] Optional language is used herein describing what “can” or “may” be present, or what “various” embodiments or examples may include, not what is or must necessarily be present. Therefore, if in reference to an embodiment or example, it is stated that an aspect “may” or “can” be present, then that option can be included, or left out, of the embodiment or example, particularly in a claim. Each sentence or paragraph can refer to multiple, independent aspects. A claim can be amended with a select word or phrase from a sentence or paragraph without taking the whole sentence or paragraph.

[0390] The present disclosure uses multiple examples to demonstrate various inventive aspects. The inventive scope of this disclosure is not necessarily limited to any one of these embodiments, nor to all of them in just the manner shown and / or described. Rather, the inventive aspects demonstrated herein can be implemented in various other manners. One aspect or feature shown or described from one embodiment could be implemented on another embodiment in this disclosure even if not shown or described for that embodiment, or various embodiments not illustrated herein. The embodiments illustrated and / or discussed are intended to be illustrative and not limiting, and the described and / or illustrated features can be mixed and matched between different embodiments while including and excluding various features amongst the embodiments.

[0391] Components with common reference numbers can be structurally and functionally equivalent except to the limited extent specifically shown and / or described to be different. As such, aspects discussed and / or shown in connection with one embodiment can be present in another embodiment even if not discussed and / or shown for the other embodiment, particularly when common reference numbers are used.

[0392] Discussion of Non-Exclusive Examples:

[0393] The following are non-exclusive descriptions of possible examples of the present invention(s) according to various examples of the disclosure. It is understood that while specific examples may refer to back to specific others of the examples, each example can be claimed individually or in combination with any other example discussed below or otherwise within this disclosure, including as shown in the drawings.

[0394] Example 1. A fluid sprayer for spraying a spray fluid configured to coat a surface, the fluid sprayer comprising: an electric motor, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion on a motor axis; a drive which converts the rotational motion output by the electric motor into linear reciprocating motion; a pump, the pump receiving the linear reciprocating motion from the drive to linearly reciprocate a piston to pump the spray fluid; a spray nozzle which atomizes the spray fluid output by the pump; a trigger; and a spray valve that receives the spray fluid output by the pump and allows the spray fluid to flow to the spray nozzle when the trigger is in an actuated state and which blocks the spray fluid from flowing to the spray nozzle when the trigger is in a non-actuated state; wherein the electric motor operates to cause the piston pump to continuously pump the spray fluid with the trigger both in the actuated state and the non-actuated state.

[0395] Example 2. The fluid sprayer of example 1, further comprising: an inlet passage that routes the spray fluid from a reservoir to the piston pump; a return passage that routes the spray fluid output by the pump back to the reservoir; a spray passage that routes the spray fluid output by the pump to the spray nozzle; and a recirculation valve that routes the spray fluid along the return passage.

[0396] Example 3. The fluid sprayer of example 2, wherein: the recirculation valve routes the spray fluid along the return passage when the trigger is in the non-actuated state and the spray valve is consequently closed; and the recirculation valve returns the spray fluid pumped while the trigger is in the non-actuated state and the spray valve is closed back to the reservoir via the return passage.

[0397] Example 4. The fluid sprayer of example 3, wherein the fluid sprayer does not comprise a pressure sensor. Example 5. The fluid sprayer of any one of examples 3 and4, wherein the fluid sprayer does not comprise a control board.

[0398] Example 6. The fluid sprayer of any of examples 3-5, wherein the fluid sprayer comprises an electrical power input that receives electrical power.

[0399] Example 7. The fluid sprayer of example 6, wherein the fluid sprayer comprises electrical wiring that routes the electrical power from the electrical power input to the electric motor without any logic circuitry as part of the sprayer.

[0400] Example 8. The fluid sprayer of any one of examples 3-7, further comprising a power switch that, when actuated to an ON state routes electrical power to the electric motor such that the electric motor starts to rotate the rotor upon actuation of the power switch to the ON state, and when actuated to an OFF state interrupts electrical power from flowing to the electric motor such that the electric motor is depowered upon actuation of the power switch to the OFF state, wherein the power switch is a mechanical power switch.

[0401] Example 9. The fluid sprayer of example 8, further comprising a fuse located electrically between the mechanical power switch and the electric motor.

[0402] Example 10. The fluid sprayer of any one of examples 3-9, wherein the electric motor includes a thermal shutoff switch which, when actuated based on a temperate reaching a threshold, opens to interrupt electrical power from flowing and thereby causes the rotor to stop rotating, wherein the thermal shutoff switch is a mechanical switch.

[0403] Example 11. The fluid sprayer of any one of examples 1-10, further comprising a fluid manifold that at least partially contains the pump.

[0404] Example 12. The fluid sprayer of example 11, wherein the fluid manifold includes an inlet orifice, the inlet orifice located directly above a reservoir that stores a supply of the spray fluid when the fluid sprayer sprays the spray fluid.

[0405] Example 13. The fluid sprayer of example 12, further comprising an inlet hose that is partially submerged in the spray fluid within the reservoir and which routes the spray fluid from the reservoir into the fluid manifold.

[0406] Example 14. The fluid sprayer of example 13, wherein the inlet hose extends straight upwards without bending when routing the spray fluid into the fluid manifold from the reservoir when the fluid sprayer sprays the spray fluid.

[0407] Example 15. The fluid sprayer of any one of examples 12-14, wherein the piston reciprocates on a pump axis to pump the spray fluid, and at least part of the piston is located directly above the reservoir when the fluid sprayer sprays the spray fluid. Example 16. The fluid sprayer of any one of examples 11-15, further comprising a drain passage which returns the spray fluid to the reservoir, the drain passage comprising an outlet orifice located directly over the reservoir when the fluid sprayer sprays spray fluid.

[0408] Example 17. The fluid sprayer of any one of examples 11-16, further comprising an outlet fitting located downstream of the pump, and a supply hose which connects to a spray gun, the supply hose also connects to the outlet fitting for transporting the spray fluid output by the pump to the spray gun, the outlet fitting located directly over the reservoir when the fluid sprayer sprays spray fluid.

[0409] Example 18. The fluid sprayer of any one of examples 11-17, wherein the reservoir is a paint can.

[0410] Example 19. The fluid sprayer of example 18, wherein the paint can is formed from one of metal and plastic.

[0411] Example 20. The fluid sprayer of any one of examples 18 and 19, wherein the paint can is a one gallon container configured to hold at least one gallon of the spray fluid but not more than 1.5 gallons of the spray fluid.

[0412] Example 21. The fluid sprayer of any one of examples 18-20, wherein the fluid manifold is located above the paint can a distance not more than three quarters of a height of the paint can.

[0413] Example 22. The fluid sprayer of any of examples 16-20, wherein a bottom side of the fluid manifold is located above a top rim of the paint can a distance not more than one half of a height of the paint can.

[0414] Example 23. The fluid sprayer of any one of examples 16-20, wherein the piston is located above the paint can a distance not more than three quarters of a height of the paint can.

[0415] Example 24. The fluid sprayer of any one of examples 16-20, wherein the piston is located above a top rim of the paint can a distance not more than one half of a height of the paint can.

[0416] Example 25. The fluid sprayer of any one of examples 1-24, further comprising an outlet check valve disposed downstream of a pumping chamber of the pump, wherein a branch orifice of a return passage that directs the spray fluid back to the reservoir is located along the outlet check valve such that the branch orifice, with respect to the pump axis, overlaps with structure of the outlet check valve.

[0417] Example 26. The fluid sprayer of example 25, wherein the branch orifice radially overlaps with a spring of the outlet check valve relative to the pump axis. Example 27. The fluid sprayer of any one of examples 25 and 26, wherein the branch orifice does not radially overlap with a ball of the outlet check valve relative to the pump axis.

[0418] Example 28. The fluid sprayer of any one of examples 25 and 26, wherein the branch orifice does radially overlap with the ball of the outlet check valve with the outlet check valve open.

[0419] Example 29. The fluid sprayer of any one of examples 1-24, further comprising an outlet check valve disposed downstream of a pumping chamber of the pump, wherein a branch orifice of a return passage that directs the spray fluid back to the reservoir is located along the outlet check valve such that the branch orifice, with respect to the pump axis, overlaps with a cage of the outlet check valve.

[0420] Example 30. The fluid sprayer of example 29, wherein the branch orifice radially overlaps with a spring of the outlet check valve relative to the pump axis, the spring disposed within the cage.

[0421] Example 31. The fluid sprayer of any one of examples 2-30, wherein the recirculation valve includes a collar and a lever, the collar being rotatable to change a threshold pressure at which the recirculation valve opens to recirculate the spray fluid back to the reservoir.

[0422] Example 32. The paint sprayer of example 31, wherein the collar rotates the lever as the collar is rotated.

[0423] Example 33. The fluid sprayer of example 32, wherein the collar includes a slot inside of which the lever is at least partially located, wherein at least one side wall of the slot engage the lever to rotate the lever as the collar is rotated, and wherein the slot is open to allow the lever to be reorientated at least partially out of the slot to open the recirculation valve to place the fluid sprayer in a purge mode.

[0424] Example 34. The fluid sprayer of any one of examples 1-33, wherein the drive is a wobble drive in which a drive shaft rotates within an angled ring having a top side, the top side of the angled ring reciprocating forwards and backwards as the shaft is rotated due to rotational motion output by the electric motor, the piston connected to the top side of the angled ring such that the piston reciprocates through a pumping stroke and a suction stroke as the top side of the angled ring reciprocates forwards and backwards.

[0425] Example 35. The fluid sprayer of example 34, wherein the electric motor and the piston are located above the shaft. Example 36. The fluid sprayer of any one of examples 34 and 35, wherein the piston is the only piston of the fluid sprayer.

[0426] Example 37. The fluid sprayer of any one of examples 34-36, wherein the electric motor comprises a pinion that output the rotational motion, and the piston axially overlaps with the pinion along the pump axis.

[0427] Example 38. The fluid sprayer of any one of examples 1-37, further comprising a drive housing the holds the drive.

[0428] Example 39. The fluid sprayer of example 38, wherein the drive housing holds the pump.

[0429] Example 40. The fluid sprayer of example 39, wherein the pump partially extends out of the drive housing.

[0430] Example 41. The fluid sprayer of any one of examples 38-40, wherein the drive housing is a polymer clamshell with two sides that come together to capture the drive inside of the drive housing.

[0431] Example 42. The fluid sprayer of any one of examples 38-41, further comprising a motor housing that at least partially contains the electric motor, wherein the motor housing mounts to the drive housing.

[0432] Example 43. The fluid sprayer of example 42, wherein the motor housing is cantilevered from the drive housing such that the motor and the motor housing are only structurally supported by connecting to the drive and the drive housing.

[0433] Example 44. The fluid sprayer of any one of examples 42 and 43, wherein the motor housing is mounted to the drive housing by one or more screws.

[0434] Example 45. The fluid sprayer of any one of examples 42-44, wherein the drive housing receives and supports a motor bearing, a motor shaft which outputs the rotational motion extending through the motor bearing.

[0435] Example 46. The fluid sprayer of any one of examples 42-45, wherein the drive housing comprises a plurality of mount projections that extend outward from the drive housing to support the drive housing.

[0436] Example 47. The fluid sprayer of example 46, wherein the plurality of mount projections comprise a first plurality of mount projections which extend in a first lateral direction from the drive housing and a second plurality of mount projections which extend in a second lateral direction from the drive housing.

[0437] Example 48. The fluid sprayer of any one of examples 46 and 47, wherein a first group of the plurality of mount projections radially overlap with the pump relative to the pump axis and a second group of the plurality of mount projections radially overlap with the drive.

[0438] Example 49. The fluid sprayer of example 48, wherein a third group of the plurality of mount projections radially overlap with the motor.

[0439] Example 50. The fluid sprayer of any one of examples 46-49, wherein at least one mount projection of the plurality of mount projections is oriented vertically and at least one other mount projection of the plurality of mount projections is orientated horizontally.

[0440] Example 51. The fluid sprayer of any one of examples 46-50, wherein the plurality of mount projections engage a primary housing that houses the pump, the drive, and the motor to support the drive housing.

[0441] Example 52. The fluid sprayer of example 51, wherein the drive housing is only supported by the plurality of mount projections as the drive housing does not connect to any other frame structure.

[0442] Example 53. The fluid sprayer of any one of examples 1-51, further comprising a plurality of legs and a primary housing that contains the motor, the drive, and at least part of the pump, the plurality of legs attaching to the primary housing such that the motor, the drive, and the pump are supported by the plurality of legs indirectly through the primary housing.

[0443] Example 54. The fluid sprayer of example 53, wherein the plurality of legs snap-fit to the primary housing.

[0444] Example 55. The fluid sprayer of any one of examples 53 and 54, wherein the primary housing both structurally supports a housing of the drive and covers the drive, the motor, and at least part of the pump.

[0445] Example 56. The fluid sprayer of example 55, wherein the primary housing covers the drive, the motor, and at least part of the pump such that less than fifteen percent of all of the drive, the motor, and the pump are extend outside of the primary housing.

[0446] Example 57. The fluid sprayer of any one of examples 1-56, further comprising a return hose clip which attaches to a return hose and which includes a hook that can hang onto one or both of the fluid sprayer and a reservoir holding a supply of the spray fluid.

[0447] Example 58. The fluid sprayer of example 57, wherein the return hose clip includes a diffuser through which a return flow of the spray fluid is returned to the reservoir.

[0448] Example 59. A fluid sprayer for spraying a spray fluid configured to coat a surface, the fluid sprayer comprising: an electric motor, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion on a motor axis; a drive which converts the rotational motion output by the electric motor into linear reciprocating motion; a pump, the pump receiving the linear reciprocating motion from the drive to linearly reciprocate a piston to pump the spray fluid; a spray nozzle which atomizes the spray fluid output by the pump; a trigger; a spray valve that receives the spray fluid output by the pump and allows the spray fluid to flow to the spray nozzle when the trigger is in an actuated state and which blocks the spray fluid from flowing to the spray nozzle when the trigger is in a non-actuated state; a power supply that provides electrical power to the electric motor; a power switch actuatable between an ON state in which the electrical power is provided to the electric motor to cause the stator to rotate the rotor and an OFF state in which the electrical power is not provided to the electric motor; wherein the electric motor operates to cause the pump to continuously pump the spray fluid with the power switch in the ON state.

[0449] Example 60. A pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface, the pump module comprising: an electric motor, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion on a motor axis; a drive which converts the rotational motion output by the electric motor into linear reciprocating motion; a pump, the pump receiving the linear reciprocating motion from the drive to linearly reciprocate a piston to pump the spray fluid; a spray passage extending downstream from the pump to an outlet orifice; and a recirculation valve connected to spray passage at a location upstream of the outlet orifice, the recirculation valve configured to open at a threshold pressure of the spray fluid; wherein the electric motor operates to cause the piston to continuously reciprocate to pump the spray fluid with the pump module in an ON state; and wherein the recirculation valve is configured to open based on a fluid pressure downstream of the pump reaching the threshold pressure to provide a return flow of the spray fluid output from the pump to a reservoir of the spray fluid.

[0450] Example 61. The pump module of example 60, further comprising: a fluid manifold, wherein a pumping chamber of the pump is disposed in the fluid manifold, and wherein a return passage that routes the return flow of the spray fluid to the reservoir.

[0451] Example 62. The pump module of example 61, wherein the recirculation valve is mounted to the fluid manifold.

[0452] Example 63. The pump module of any one of examples 60-62, wherein the recirculation valve comprises: a needle movable along a recirculation valve axis to open and close the recirculation valve; a seat; a spring biasing the needle towards the seat to place the recirculation valve in a closed state, wherein a spring force of the spring exerted on the needle is adjustable to change the threshold pressure.

[0453] Example 64. The pump module of example 63, wherein a ball held by the needle engages with the seat to place the recirculation valve in a closed state.

[0454] Example 65. The pump module of any one of examples 63 and 64, wherein the recirculation valve includes a recirculation housing within which the seat is disposed, and the recirculation valve includes a retainer movable relative to the recirculation housing to adjust the spring force.

[0455] Example 66. The pump module of example 65, wherein the retainer is configured to rotate to change the spring force.

[0456] Example 67. The pump module of any one of examples 65 and 66, wherein the retainer is rotatable in a first rotational direction to increase a compression of the spring and thereby increase the threshold pressure, and the retainer in rotatable in a second rotational direction to decrease the compression of the spring and thereby decrease the threshold pressure.

[0457] Example 68. The pump module of any one of examples 63-67, wherein the recirculation valve further comprises: a lever connected to the needle, the lever actuatable to pull the needle away from the seat and maintain the recirculation valve in an open state.

[0458] Example 69. The pump module of example 68, wherein the recirculation valve further comprises: a collar, wherein rotation of the collar changes the spring force of the spring, and wherein the lever is mounted to the collar.

[0459] Example 70. The pump module of example 69, wherein the lever is partially disposed in a slot of the collar.

[0460] Example 71. The pump module of any one of examples 69 and 70, wherein the lever is connected to the collar such that the lever rotates with the collar.

[0461] Example 72. A pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface, the pump module comprising: a primary housing; an electric motor disposed in the primary housing, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion on a motor axis; a drive housing connected to the primary housing; a drive disposed in the drive housing, the drive configured to convert the rotational motion output by the electric motor into linear reciprocating motion; a pump, the pump receiving the linear reciprocating motion from the drive to linearly reciprocate a piston to pump the spray fluid; a stand connected to the primary housing, the stand configured to support the primary housing on a support surface; wherein the electric motor, the drive, and the pump are indirectly connected to the stand by the primary housing.

[0462] Example 73. The pump module of example 72, wherein the drive housing includes a plurality of mount projections that extend into a plurality of mount receivers formed in the primary housing.

[0463] Example 74. The pump module of example 73, wherein a first subset of the plurality of mount projections is disposed on a first lateral side of the drive housing and a second subset of the plurality of mount projections is disposed on a second lateral side of the drive housing.

[0464] Example 75. The pump module of any one of examples 73 and 74, wherein at least one of the plurality of mount projections is formed as a quadrangle.

[0465] Example 76. The pump module of any one of examples 73-75, wherein at least one of the plurality of mount projections is circular.

[0466] Example 77. The pump module of any one of examples 72-76, wherein the drive housing does not directly contact the stand.

[0467] Example 78. The pump module of any one of examples 72-77, wherein the electric motor is at least partially disposed in a motor housing, the motor housing connected to the drive housing.

[0468] Example 79. The pump module of example 78, wherein the motor housing is at least partially disposed within the drive housing.

[0469] Example 80. The pump module of any one of examples 78 and 79, wherein the motor housing is cantilevered from the drive housing.

[0470] Example 81. The pump module of any one of examples 78-80, wherein the motor housing is connected to the primary housing by the drive housing.

[0471] Example 82. The pump module of any one of examples 78-81, wherein the motor housing does not directly contact the primary housing.

[0472] Example 83. The pump module of any one of examples 73-77, wherein the electric motor is at least partially disposed in a motor housing, the motor housing connected to the drive housing, and wherein at least one mounting projection of the plurality of mounting projections is disposed directly laterally outward of the electric motor.

[0473] Example 84. The pump module of any one of examples 73-82, wherein a first mounting projection of the plurality of mounting projections is disposed directly laterally outward of the electric motor. Example 85. The pump module of example 84, wherein a second mounting projection of the plurality of mounting projections is disposed directly laterally outward of the drive.

[0474] Example 86. The pump module of example 85, wherein a third mounting projection of the plurality of mounting projections radially overlaps with the piston.

[0475] Example 87. The pump module of any one of examples 72-77, wherein the piston of the pump extends into a fluid manifold, the fluid manifold directly connected to the drive housing.

[0476] Example 88. The pump module of example 87, wherein the fluid manifold includes a plurality of manifold projections that extend into a plurality of manifold receivers of the drive housing.

[0477] Example 89. The pump module of any one of examples 87 and 88, wherein the fluid manifold includes at least one forward projection that extends into a forward receiver of the primary housing such that the fluid manifold directly interfaces with the primary housing.

[0478] Example 90. The pump module of any one of examples 72-89, wherein the stand includes a first leg set and a second leg set, and wherein the first leg set and the second leg set snap fit to the primary housing.

[0479] Example 91. The pump module of example 90, wherein the first leg set includes a pair of legs.

[0480] Example 92. A pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface, the pump module comprising: a primary housing; an electric motor disposed in the primary housing, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion on a motor axis; a drive housing directly connected to the primary housing; a drive disposed in the drive housing, the drive configured to convert the rotational motion output by the electric motor into linear reciprocating motion; a pump, the pump receiving the linear reciprocating motion from the drive to linearly reciprocate a piston within a fluid manifold to pump the spray fluid; wherein the fluid manifold is directly connected to the drive housing.

[0481] Example 93. The pump module of example 92, wherein the fluid manifold directly interfaces with the primary housing.

[0482] Example 94. The pump module of any one of examples 92 and 93, further comprising: a stand connected to the primary housing, the stand configured to support the primary housing on a support surface; wherein the electric motor, the drive, and the pump are indirectly connected to the stand by the primary housing.

[0483] Example 95. The pump module of any one of examples 92-94, wherein: the drive housing includes a plurality of mount projections that extend into a plurality of mount receivers of the primary housing to connect the drive housing to the primary housing.

[0484] Example 96. The pump module of example 95, wherein the fluid manifold includes a plurality of manifold projections that extends into a plurality of manifold receivers of the drive housing.

[0485] Example 97. The pump module of example 96, wherein the plurality of manifold projections are co-located with the plurality of mount projections.

[0486] Example 98. The pump module of example 96, wherein a first manifold receiver of the plurality of manifold receivers is formed within a first mount projection of the plurality of mount projections.

[0487] Example 99. The pump module of any one of examples 92-98, wherein the drive includes a plurality of drive bearings disposed within the drive housing.

[0488] Example 100. A pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface, the pump module comprising: a primary housing; an electric motor disposed in the primary housing, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion on a motor axis; a drive disposed in the primary housing, the drive configured to convert the rotational motion output by the electric motor into linear reciprocating motion; a pump disposed at least partially within the primary housing, the pump receiving the linear reciprocating motion from the drive to linearly reciprocate a piston to pump the spray fluid; and a stand connected to the primary housing, the stand configured to support the primary housing on a support surface, wherein the stand is snap fit to the primary housing.

[0489] Example 101. The pump module of example 100, wherein the electric motor, the drive, and the pump are indirectly connected to the stand by the primary housing.

[0490] Example 102. The pump module of any one of examples 100 and 101, wherein: the stand includes a first leg set that snap fits to the primary housing, the first leg set includes a plurality of inserts; and the primary housing includes a plurality of insert receivers configured to receive the plurality of inserts.

[0491] Example 103. The pump module of example 102, wherein the plurality of inserts includes at least one guide insert and at least one fixing insert, the at least one fixing insert configured to snap fit on the primary housing. Example 104. The pump module of any one of examples 102 and 103, wherein the plurality of insert receivers are open on an exterior of the primary housing.

[0492] Example 105. The pump module of any one of examples 103-104, wherein the at least one guide insert includes a pair of guide inserts, the at least one fixing insert includes a pair of fixing inserts, and the pair of fixing inserts are disposed between the pair of guide inserts.

[0493] Example 106. The pump module of any one of examples 102-105, wherein the plurality of inserts are configured to enter into the plurality of insert receivers by relative linear movement.

[0494] Example 107. The pump module of any one of examples 100-106, wherein the stand is configured to mount to the primary housing by relative linear movement.

[0495] Example 108. A pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface, the pump module comprising: an electric motor, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion on a motor axis; a drive connected to the electric motor, the drive configured to convert the rotational motion output by the electric motor into linear reciprocating motion; and a pump connected to the drive, the pump receiving the linear reciprocating motion from the drive to linearly reciprocate a piston to pump the spray fluid; wherein the piston is connected to the drive on a top side of the drive.

[0496] Example 109. The pump module of example 108, wherein the electric motor includes a pinion that interfaces with the drive on the top side of the drive.

[0497] Example 110. The pump module of example 108, wherein the drive includes: a drive shaft configured to rotate on a drive axis; a gear connected to the drive shaft to rotate 1 : 1 with the drive shaft; and an angled ring mounted on the drive shaft, wherein rotation of the drive shaft causes the angled ring to rock forward and rearward.

[0498] Example 111. The pump module of example 110, wherein the electric motor is connected to the gear to provide the rotational motion to the gear, and wherein the piston is connected to the angled ring to receive the linear reciprocating motion from the angled ring.

[0499] Example 112. The pump module of example 111, wherein a pinion of the electric motor interfaces with the gear at a top dead center of the gear.

[0500] Example 113. The pump module of any one of examples 111 and 112, wherein the piston interfaces with the angled ring at a top dead center of the angled ring. Example 114. The pump module of any one of examples 110-113, wherein the piston and the electric motor interface with the drive at locations disposed vertically above the drive axis.

[0501] Example 115. The pump module of any one of examples 110-114, wherein a projection of the angled ring extends into a socket of the piston.

[0502] Example 116. The pump module of any one of examples 110-115, wherein the pump axis is disposed vertically above the drive axis, and wherein the motor axis is disposed vertically above the drive axis.

[0503] Example 117. The pump module of any one of examples 108-116, wherein the piston axially overlaps with an interface between the electric motor and the drive.

[0504] Example 118. The pump module of any one of examples 108-117, wherein the piston is an only piston of the pump.

[0505] Example 119. A pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface, the pump module comprising: an electric motor, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion on a motor axis; a drive which converts the rotational motion output by the electric motor into linear reciprocating motion; a pump, the pump receiving the linear reciprocating motion from the drive to linearly reciprocate a piston on a pump axis to pump the spray fluid; a spray passage extending downstream from the pump to an outlet orifice; an outlet check valve disposed downstream of the pump; and a return passage that routes the spray fluid output by the pump back to the reservoir, the return passage fluidly connected to the spray passage at a branch orifice; a recirculation valve within the return passage, the recirculation valve configured to open at a threshold pressure of the spray fluid; wherein the branch orifice opens into the spray passage at a location that radially overlaps with the outlet check valve.

[0506] Example 120. The pump module of example 119, wherein: the outlet check valve includes an outlet ball that engages an outlet seat with the outlet check valve closed, the outlet ball spaced from the outlet seat with the outlet check valve open; the outlet check valve includes an outlet spring biasing the outlet ball into engagement with the outlet seat; and the branch orifice radially overlaps with the outlet spring.

[0507] Example 121. The pump module of example 120, wherein the branch orifice radially overlaps with the ball. Example 122. The pump module of any one of examples 120 and 121, wherein the outlet check valve includes a cage, the spring braced against the cage, and wherein the branch orifice radially overlaps with the cage.

[0508] Example 123. The pump module of any one of examples 120-122, wherein the recirculation valve includes: a needle movable along a recirculation valve axis to open and close the recirculation valve; a seat; and a spring biasing the needle towards the seat to place the recirculation valve in a closed state.

[0509] Example 124. The pump module of example 123, wherein the recirculation valve axis extends through the outlet check valve.

[0510] Example 125. The pump module of example 123, wherein the reciprocation valve axis extends through the outlet ball with the outlet check valve in the open state.

[0511] Example 126. The pump module of example 123, wherein the reciprocation valve axis extends through the outlet spring.

[0512] Example 127. The pump module of any one of examples 123-126, wherein a spring force of the spring exerted on the needle is adjustable to change the threshold pressure.

[0513] Example 128. A pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface, the pump module comprising: an electric motor, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion on a motor axis; a drive which converts the rotational motion output by the electric motor into linear reciprocating motion; a pump, the pump receiving the linear reciprocating motion from the drive to linearly reciprocate a piston on a pump axis to pump the spray fluid; a spray passage extending downstream from the pump to an outlet orifice; and a recirculation valve connected to spray passage at a location upstream of the outlet orifice, the recirculation valve configured to open at a threshold pressure of the spray fluid, the recirculation valve including: a spring biasing the recirculation valve to a closed state; a lever accessible from an exterior of the pump module, the lever configured to actuate the recirculation valve to an open state and hold the recirculation valve in the open state; and a collar configured to rotate to change a compression of the spring to thereby change the threshold pressure; wherein the lever is connected to the collar such that the lever rotates with the collar.

[0514] Example 129. The pump module of example 128, the recirculation valve comprises: a needle movable along a recirculation valve axis to open and close the recirculation valve; and a seat; wherein the spring biases the needle towards the seat to place the recirculation valve in the closed state. Example 130. The pump module of example 129, wherein a ball held by the needle engages with the seat to place the recirculation valve in a closed state.

[0515] Example 131. The pump module of any one of examples 129 and 130, wherein the recirculation valve includes a recirculation housing within which the seat is disposed, and the recirculation valve includes a retainer movable relative to the recirculation housing to adjust the spring force, the collar connected to the retainer to move the retainer to change the compression of the spring.

[0516] Example 132. The pump module of any one of examples 129-131, wherein the lever is connected to the needle, the lever actuatable to pull the needle away from the seat and maintain the recirculation valve in an open state.

[0517] Example 133. The pump module of any one of examples 128-132, wherein the collar is rotatable in a first rotational direction to increase the compression of the spring and thereby increase the threshold pressure, and the collar in rotatable in a second rotational direction to decrease the compression of the spring and thereby decrease the threshold pressure.

[0518] Example 134. The pump module of any one of examples 128-133, wherein the lever is partially disposed in a slot of the collar.

[0519] Example 135. The pump module of example 134, wherein the lever is hingedly connected to the collar.

[0520] Example 136. The pump module of example 135, wherein the lever is connected to a sidewall of the collar, the sidewall at least partially defining the slot.

[0521] Example 137. A pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface, the pump module comprising: a primary housing having a front end, a rear end, a top side, a bottom side, a first lateral side, a second lateral side, at least one rear vent opening through the rear end, and at least one lateral vent opening through at least one of the first lateral side and the second lateral side; an electric motor disposed within the housing, the electric motor comprising a rotor configured to rotate on a motor axis and a stator, the electric motor configured to output rotational motion, the electric motor at least partially disposed in a motor housing; a drive at least partially disposed within the primary housing, the drive configured to convert rotational motion output by the electric motor into linear reciprocating motion, the drive supported by a drive housing; a pump, the pump receiving linear reciprocating motion from the drive to linearly reciprocate a piston along a pump axis to pump the spray fluid; and an upper baffle extending between the first lateral side and the second lateral side and extending towards the bottom side from the top side, wherein the upper baffle is disposed between the rear end and an air intake of the electric motor.

[0522] Example 138. The pump module of example 137, wherein the upper baffle is disposed directly between the at least one rear vent opening and the electric motor.

[0523] Example 139. The pump module of any one of examples 137 and 138, wherein the at least one rear vent opening includes a plurality of rear vent openings, and wherein the upper baffle axially overlaps with each rear vent opening of the plurality of rear vent openings.

[0524] Example 140. The pump module of any one of examples 137-139, further comprising: a lower baffle extending towards the top side from the bottom side, the lower baffle disposed closer to the electric motor than the upper baffle.

[0525] Example 141. The pump module of example 140, wherein the lower baffle does not axially overlap with the upper baffle along the motor axis.

[0526] Example 142. The pump module of any one of examples 140 and 141, wherein an upper end of the lower baffle is spaced vertically from a lower end of the upper baffle.

[0527] Example 143. The pump module of any one of examples 140-142, wherein a height of the upper baffle is greater than a height of the lower baffle.

[0528] Example 144. The pump module of any one of examples 140-143, wherein the lower baffle does not axially overlap with the at least one rear vent opening.

[0529] Example 145. The pump module of any one of examples 137-144, further comprising: a rear wall extending between the first lateral side and the second lateral side and extending around the motor housing.

[0530] Example 146. The pump module of example 145, wherein the rear wall extends fully annularly about the motor housing.

[0531] Example 147. The pump module of any one of examples 145 and 146, further comprising: an intermediate wall extending between the first lateral side and the second lateral side, the intermediate wall disposed axially between an air intake of the electric motor and an exhaust opening through the drive housing.

[0532] Example 148. The pump module of example 147, wherein the intermediate wall extends around the drive housing.

[0533] Example 149. The pump module of example 148, wherein the intermediate wall extends fully around the drive housing. Example 150. The pump module of any one of examples 147-149, further comprising: a forward wall extending between the first lateral side and the second lateral side, the forward wall disposed around the drive housing.

[0534] Example 151. The pump module of example 150, wherein the intermediate wall and the forward wall define an exhaust chamber into which the exhaust opening of the drive housing opens.

[0535] Example 152. The pump module of any one of examples 137-151, wherein the electric motor includes a fan configured to blow cooling air through the motor housing and into the drive housing.

[0536] Example 153. The pump module of example 152, wherein the drive housing includes at least one inlet opening through which the cooling air enters into the drive housing and at least one exhaust opening through which the cooling air is exhausted from the drive housing.

[0537] Example 154. The pump module of example 153, wherein the at least one inlet opening is oriented axially towards the electric motor.

[0538] Example 155. The pump module of any one of examples 153 and 154, wherein the at least one exhaust opening is oriented laterally.

[0539] Example 156. A pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface, the pump module comprising: a primary housing having a front end, a rear end, a top side, a bottom side, a first lateral side, a second lateral side, at least one rear vent opening through the rear end, and at least one lateral vent opening through at least one of the first lateral side and the second lateral side; an electric motor disposed within the primary housing, the electric motor comprising a rotor configured to rotate on a motor axis and a stator, the electric motor configured to output rotational motion, the electric motor at least partially disposed in a motor housing; a drive at least partially disposed within the primary housing, the drive configured to convert rotational motion output by the electric motor into linear reciprocating motion, the drive supported by a drive housing; and a pump, the pump receiving linear reciprocating motion from the drive to linearly reciprocate a piston along a pump axis to pump the spray fluid; wherein a cooling air pathway extends through the rear end, through the motor housing, through the drive housing, and out from the drive housing into an exhaust chamber in the housing.

[0540] Example 157. The pump module of example 156, wherein the cooling air pathway includes a serpentine passage between the rear end and the motor housing. Example 158. The pump module of example 157, wherein the cooling air pathway narrows as the cooling air pathway extends from the rear end to the drive housing.

[0541] Example 159. The pump module of any one of examples 156-158, wherein the cooling air pathway includes a filter stage, a funnel stage, and an exhaust stage.

[0542] Example 160. The pump module of example 159, wherein the fdter stage is disposed between the rear end and the electric motor.

[0543] Example 161. The pump module of any one of examples 159 and 160, wherein the funnel stage extends through the motor housing.

[0544] Example 162. The pump module of any one of examples 159-161, wherein an upper baffle is disposed between the rear end and the electric motor, the upper baffle extending between the first lateral side and the second lateral side, the upper baffle disposed directly between the electric motor and a rear vent opening of the housing.

[0545] Example 163. A pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface, the pump module comprising: a primary housing having a front end, a rear end, a top side, a bottom side, a first lateral side, a second lateral side, at least one rear vent opening through the rear end, and at least one lateral vent opening through at least one of the first lateral side and the second lateral side; an electric motor disposed within the primary housing, the electric motor comprising a rotor configured to rotate on a motor axis and a stator, the electric motor configured to output rotational motion, the electric motor at least partially disposed in a motor housing; a drive at least partially disposed within the primary housing, the drive configured to convert rotational motion output by the electric motor into linear reciprocating motion, the drive supported by a drive housing; a pump, the pump receiving linear reciprocating motion from the drive to linearly reciprocate a piston along a pump axis to pump the spray fluid; and wherein the primary housing includes an intake chamber, a motor chamber within the motor housing, and a drive chamber within the drive housing, and wherein a cooling air pathway extends from the intake chamber, through the motor chamber, and into the drive chamber.

[0546] Example 164. The pump module of example 163, wherein the intake chamber includes a serpentine passage.

[0547] Example 165. The pump module of any one of examples 163 and 164, wherein the cooling air pathway is not closed between the motor chamber and the drive chamber.

[0548] Example 166. A pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface, the pump module comprising: a primary housing having a front end, a rear end, a top side, a bottom side, a first lateral side, a second lateral side; an electric motor disposed within the primary housing, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion; a drive disposed at least partially within the primary housing, the drive configured to convert rotational motion output by the electric motor into linear reciprocating motion; a pump, the pump receiving linear reciprocating motion from the drive to linearly reciprocate a piston along a pump axis to pump the spray fluid; an inlet passage that routes the spray fluid from a reservoir to the piston pump; a return passage that routes the spray fluid output by the pump back to the reservoir; an inlet hose fluidly connected to the inlet passage and extending downward from an inlet of the piston pump; a return hose fluidly connected to the return passage; and a holder mountable to a projection of the housing, wherein holder holds the return hose.

[0549] Example 167. The pump module of example 166, wherein an intake of the inlet hose is spaced vertically from an output of the return hose.

[0550] Example 168. The pump module of example 167, wherein a distal end of the holder is spaced vertically from a filter of the intake hose.

[0551] Example 169. The pump module of any one of examples 166-168, wherein the holder includes a diffuser that receives the spray fluid from the return hose.

[0552] Example 170. The pump module of any one of examples 166-169, wherein the holder is mounted to the projection of the housing during spray operation of the fluid sprayer.

[0553] Example 171. The pump module of any one of examples 166-170, wherein the holder includes a clip that connects to the projection.

[0554] Example 172. The pump module of example 171, wherein the clip and the projection include interfacing flats.

[0555] Example 173. The pump module of example 171, wherein the clip connects to the projection at an anti-rotation interface.

[0556] Example 174. A spray gun for spraying a spray fluid, the spray gun comprising: a gun body; a spray tip including a spray nozzle; a spray valve displaceable between an open state and a closed state, the spray valve allowing flow of spray fluid to the spray tip in the open state and blocked flow of the spray fluid to the spray tip in the closed state; a handle piece depending from the gun body, the handle piece including a handle and a fitting, the fitting configured to attach to a supply hose which provides spray fluid to the spray gun, wherein the handle piece, including the fitting and the handle, is monolithic.

[0557] Example 175. The spray gun of example 174, wherein the handle piece, including the fitting and the handle, are made from a single continuous piece of metal. Example 176. The spray gun of any one of examples 174 and 175, wherein the handle piece includes a recess between the handle and the fitting for receiving part of a guard of the spray gun.

[0558] Example 177. The spray gun of example 176, wherein the guard includes a clip configured to snap fit in the recess.

[0559] Example 178. The spray gun of any one of examples 174-177, further comprising: a valve housing connected to the gun body; a tip housing within which the spray tip is at least partially disposed; and a seal located between the valve housing and the tip housing; wherein the valve housing is spaced from the tip housing while the seal is compressed between the tip housing and the valve housing to provide a friction fit that prevents the tip housing from freely rotating relative to the valve housing but allows the tip housing to be rotated relative to the valve housing by hand without any tool.

[0560] Example 179. The spray gun of example 178, wherein the tip housing is connected to the valve housing by a tip retainer, the tip retainer permanently connected to the valve housing at a set location and in a set orientation.

[0561] Example 180. The spray gun of example 179, wherein the tip retainer is connected to the valve housing by interfaced threading and an adhesive.

[0562] Example 181. A spray gun valve assembly, the spray gun valve assembly comprising: a valve housing assembly, the valve housing assembly comprising a valve housing, a seat ring piece located within the valve housing, and a ball located within the valve housing, the ball and the seat ring piece configured so that the ball engages the seat ring piece to block passage of spray fluid and further so that the ball disengaging from the seat ring piece permits passage of spray fluid; a sealing piece, the sealing piece comprising an internal channel extending along a spray axis and through which spray fluid flows after having passed by the ball and the seat ring piece when disengaged; and a sealing ring that seals with the sealing piece, the sealing ring disposed on a radial exterior of the sealing piece.

[0563] Example 182. The spray gun valve assembly of example 181, wherein the sealing ring interfaces with the valve housing assembly to create an annular seal for flow of spray fluid from the valve housing assembly to the sealing piece.

[0564] Example 183. The spray gun valve assembly of example 182, wherein the sealing ring is exposed to spray fluid while interfacing with the valve housing assembly to create the annular seal. Example 184. The spray gun valve assembly of any one of examples 182 and 183, wherein an outermost diameter of the sealing ring is smaller than an outermost diameter of the seat ring piece.

[0565] Example 185. The spray gun valve assembly of any one of examples 182-184, wherein an innermost diameter of the sealing ring is smaller than an innermost diameter of the seat ring piece.

[0566] Example 186. The spray gun valve assembly of any one of examples 182-185, wherein the sealing piece comprises a tube on which the sealing ring is mounted.

[0567] Example 187. The spray gun valve assembly of example 186, wherein at least part of the sealing piece is located outside of the valve housing while the tube extends inside of the valve housing.

[0568] Example 188. The spray gun valve assembly of example 187, wherein the sealing ring is located inside of the valve housing, such that the sealing ring radially engages with the valve housing.

[0569] Example 189. The spray gun valve assembly of any one of examples 186-188, wherein the tube comprises an annular groove in which the sealing ring is mounted.

[0570] Example 190. The spray gun valve assembly of example 189, wherein the annular groove is formed by a first wall and a second wall, the second wall closer to the seat ring piece than the first wall is to the seat ring piece, the first wall higher than the second wall.

[0571] Example 191. The spray gun valve assembly of any one of examples 186-190, wherein the tube extends closer to the seat ring piece than the sealing ring extends to the seat ring piece.

[0572] Example 192. The spray gun valve assembly of any one of examples 181-191, wherein the sealing ring is an elastomer O-ring.

[0573] Example 193. The spray gun valve assembly of any one of examples 181-192, wherein the sealing piece is configured to seal with a rotatable spray tip, the rotatable spray tip rotatable to reverse flow of the spray fluid through the rotatable spray tip to unclog the rotatable spray tip without disassembly of the spray gun valve assembly.

[0574] Example 194. The spray gun valve assembly of example 193, wherein the sealing piece comprises a saddle face that interfaces with a barrel of the rotatable spray tip to seal the sealing piece with the barrel to inhibit leaking of spray fluid when flowing from the sealing piece to the rotatable spray tip.

[0575] Example 195. The spray gun valve assembly of example 194, wherein the sealing piece comprises a seal head and a sealing piece body, the saddle face formed on a first end of the seal head, a second end of the seal head at least partially defining an annular groove extending around the sealing piece to define a neck of the sealing piece, the neck located between the seal head and the sealing piece body.

[0576] Example 196. The spray gun valve assembly of example 195, wherein the neck permits the seal head to move relative to the sealing piece body.

[0577] Example 197. The spray gun valve assembly of example 496, wherein the neck permitting the seal head to move relative to the sealing piece body facilitates sealing of the saddle face with the barrel of the rotatable spray tip despite misalignment between the sealing piece and the barrel.

[0578] Example 198. The spray gun valve assembly of any one of examples 181-192, further comprising a tip housing, the tip housing comprising a tip receiver configured to hold a rotatable spray tip, the rotatable spray tip rotatable when being held by the tip housing to reverse flow of spray fluid through the rotatable spray tip to unclog the rotatable spray tip without disassembly of the spray gun valve assembly.

[0579] Example 199. The spray gun valve assembly of example 198, wherein the sealing piece is keyed relative to the tip housing such that rotation of the tip housing to change an orientation of the rotatable spray tip, which changes orientation of a spray fan of spray fluid emitted from the rotatable spray tip, also rotates the sealing piece.

[0580] Example 200. The spray gun valve assembly of any one of examples 194-199, wherein the sealing piece seals with the barrel of the rotatable spray tip.

[0581] Example 201. The spray gun valve assembly of any one of examples 193-200, wherein the sealing ring seals with the sealing piece and the sealing ring further seals with the valve housing to inhibit leakage of the spray fluid when flowing from the valve housing to the rotatable spray tip via a channel inside of the sealing piece.

[0582] Example 202. The spray gun valve assembly of any one of examples 198-201, wherein the sealing piece is partially received within an aperture of the tip housing to assemble a keyed interface between the sealing piece and the tip housing.

[0583] Example 203. The spray gun valve assembly of example 202, wherein the sealing piece comprises a seal head that is received within the aperture of the tip housing that accounts for the sealing piece being partially received within the aperture.

[0584] Example 204. The spray gun valve assembly of any one of examples 202 and 203, wherein the seal head has at least one lobe that is respectively received in at least one notch of the aperture to inhibit rotation of the tip housing relative to the sealing piece. Example 205. The spray gun valve assembly of any one of examples 202-204, wherein the keyed interface is non-circular such that the seal head cannot rotate within the aperture.

[0585] Example 206. The spray gun valve assembly of any one of examples 181-205, further comprising a spring located between the valve housing and the sealing piece, the spring urging the sealing piece against a barrel of a rotatable spray tip.

[0586] Example 207. The spray gun valve assembly of example 206, wherein the spring engages the valve housing.

[0587] Example 208. The spray gun valve assembly of any one of examples 206 and 207, wherein the spring engages the sealing piece.

[0588] Example 209. The spray gun valve assembly of any one of examples 206-208, wherein at least part of a tube of the sealing piece extends within the spring.

[0589] Example 210. The spray gun valve assembly of any one of examples 206-209, wherein the spring engages a flange of the sealing piece.

[0590] Example 211. The spray gun valve assembly of any one of examples 206-210, wherein the spring is formed as a wave spring.

[0591] Example 212. A spray gun comprising: a gun body; a trigger; a handle; and the spray gun valve assembly of any one of examples 181-211.

[0592] Example 213. A spray gun valve assembly for a spray gun, the spray gun valve assembly comprising: a valve housing having a seat ring piece located within the valve housing and a ball configured to engage the seat ring piece to place a spray valve in a closed state and the ball configured to disengage from the seat ring piece to place the spray valve in an open state; a tip housing; a sealing piece at least partially disposed in the tip housing, the sealing piece including an internal channel extending along a spray axis and through which spray fluid flows after having passed by the ball and the seat ring piece; and a spring biasing the sealing piece away from the valve housing and into the tip housing.

[0593] Example 214. The spray gun valve assembly of example 213, wherein the sealing piece is at least partially disposed within the valve housing.

[0594] Example 215. The spray gun valve assembly of any one of examples 213 and 214, wherein a downstream end of the valve housing extends into the tip housing.

[0595] Example 216. The spray gun valve assembly of example 215, wherein the spring is compressed between the downstream end of the valve housing and a portion of the sealing piece. Example 217. The spray gun valve assembly of example 213, wherein the valve housing includes a housing socket disposed downstream of the seat ring piece, and wherein the sealing piece is at least partially disposed in the housing socket.

[0596] Example 218. The spray gun valve assembly of example 217, wherein the sealing piece includes a tube that extends within the housing socket, and wherein the spring extends around the tube.

[0597] Example 219. The spray gun valve assembly of example 218, wherein the sealing piece includes a sealing piece body, the tube formed as a portion of the sealing piece body, and the sealing piece body includes a body flange extending radially outward relative to the tube.

[0598] Example 220. The spray gun valve assembly of example 219, wherein the spring is disposed directly axially between the body flange and the valve housing.

[0599] Example 221. The spray gun valve assembly of any one of examples 218-220, wherein a sealing ring is mounted on the tube and disposed radially between the sealing piece and the valve housing.

[0600] Example 222. The spray gun valve assembly of example 221, wherein the sealing ring is disposed in a seal groove formed on the tube, the seal groove between a first wall and a second wall, the first wall extending further radially outward than the second wall.

[0601] Example 223. The spray gun valve assembly of example 222, wherein the second wall is disposed closer to the seat ring piece than the first wall.

[0602] Example 224. The spray gun valve assembly of any one of examples 222 and 223, wherein a height of the second wall is less than or equal to half of a height of the first wall.

[0603] Example 225. The spray gun valve assembly of example 224, wherein the height of the second wall is less than or equal to one quarter of the height of the first wall.

[0604] Example 226. The spray gun valve assembly of any one of examples 221-225, wherein the sealing ring is exposed to the spray fluid downstream of the seat ring piece.

[0605] Example 227. The spray gun valve assembly of any one of examples 219-226, wherein the sealing piece includes a seal head having a saddle face, the saddle face configured to sealingly engage a barrel of a spray tip with the barrel disposed in the tip housing.

[0606] Example 228. The spray gun valve assembly of example 227, wherein the sealing piece includes a neck disposed between the seal head and the sealing piece body, the neck being thinner than the seal head and the sealing piece body. Example 229. The spray gun valve assembly of example 228, wherein the neck is configured to flex to allow the seal head to gimbal relative to the sealing piece body.

[0607] Example 230. The spray gun valve assembly of example 228, wherein the neck is configured to flex to allow the seal head to reorient relative to the sealing piece body.

[0608] Example 231. The spray gun valve assembly of any one of examples 228-230, wherein an annular groove extends fully circumferentially around the neck, the annular groove disposed axially between the seal head and the sealing piece body.

[0609] Example 232. The spray gun valve assembly of example 231, wherein the annular groove is disposed directly axially between the seal head and the body flange.

[0610] Example 233. The spray gun valve assembly of any one of examples 227-232, wherein the seal head interfaces with the tip housing at a keyed interface.

[0611] Example 234. The spray gun valve assembly of example 233, wherein a perimeter of the seal head is non-circular.

[0612] Example 235. The spray gun valve assembly of any one of examples 233 and 234, wherein the seal head includes at least one lobe and a receiving aperture of the tip housing within which the seal head is disposed includes at least one notch that receives the at least one lobe to rotationally lock the seal head and the tip housing together about the spray axis.

[0613] Example 236. The spray gun valve assembly of any one of examples 213-235, wherein the tip housing does not axially interface with the valve housing.

[0614] Example 237. The spray gun valve assembly of any one of examples 213-235, wherein no hard stop interface is formed between the tip housing and the valve housing.

[0615] Example 238. The spray gun valve assembly of any one of examples 213-237, wherein the tip housing includes a retaining flange at an upstream end of the tip housing, the retaining flange axially overlapping with the spring to retain the spring within the tip housing.

[0616] Example 239. The spray gun valve assembly of any one of examples 213-238, further comprising a tip retainer connecting the tip housing to the valve housing, the tip retainer permanently connected to the valve housing in a set orientation and at a set position.

[0617] Example 240. The spray gun valve assembly of any one of examples 213-239, wherein the spring is a wave spring.

[0618] Example 241. A spray gun valve assembly for a spray gun, the spray gun valve assembly comprising: a valve housing having a seat ring piece located within the valve housing and a ball configured to engage the seat ring piece to place a spray valve in a closed state and the ball configured to disengage from the seat ring piece to place the spray valve in an open state; a tip housing having a tip receiver configured to receive a barrel of a spray tip and having a receiving aperture open into the tip receiver; and a sealing piece at least partially disposed in the tip housing, the sealing piece including an internal channel extending along a spray axis and through which spray fluid flows after having passed by the ball and the seat ring piece, the sealing piece including: a seal head having a saddle face, the seal head disposed within the receiving aperture and the saddle face configured to engage the barrel to seal with the barrel; a sealing piece body; and a neck extending between and connecting the sealing piece body and the seal head, the neck configured to flex to allow pivoting of the seal head for aligning the saddle face and the barrel.

[0619] Example 242. The spray gun valve assembly of example 241, wherein an annular groove is disposed directly axially between the seal head and the sealing piece body, the annular groove extending fully around the neck.

[0620] Example 243. The spray gun valve assembly of any one of examples 241 and 242, wherein a spring is disposed within the tip housing, the spring biasing the seal head into the receiving aperture.

[0621] Example 244. The spray gun valve assembly of any one of examples 241-243, wherein the sealing piece is keyed to the tip housing to prevent rotation of the sealing piece relative to the tip housing on the spray axis.

[0622] Example 245. The spray gun valve assembly of example 244, wherein a keyed interface between the sealing piece and the tip housing is formed between the seal head and the receiving aperture.

[0623] Example 246. The spray gun valve assembly of any one of examples 241-245, wherein the sealing piece body includes a tube that is at least partially disposed within the valve housing.

[0624] Example 247. The spray gun valve assembly of example 246, wherein a sealing ring is mounted on the tube to block flow of the spray fluid around the sealing piece.

[0625] Example 248. The spray gun valve assembly of example 247, wherein the sealing ring is disposed in a seal groove disposed between a first wall and a second wall, and wherein a height of the first wall is greater than a height of the second wall.

[0626] Example 249. The spray gun valve assembly of example 248, wherein the second wall is disposed axially closer to the seat ring piece than the first wall.

[0627] Example 250. The spray gun valve assembly of any one of examples 248 and 249, wherein a first portion of the sealing ring extending radially outward beyond an outer end of the second wall is larger than a second portion of the sealing ring axially overlapping the second wall.

[0628] Example 251. The spray gun valve assembly of any one of examples 247-250, wherein the sealing ring forms a radial seal between the sealing piece and the valve housing.

[0629] Example 252. The spray gun valve assembly of any one of examples 247-251, wherein the sealing ring engages the valve housing and the sealing piece.

[0630] Example 253. The spray gun valve assembly of any one of examples 241-252, further comprising a tip retainer connecting the tip housing to the valve housing, the tip retainer permanently connected to the valve housing in a set orientation and at a set position.

[0631] Example 254. A spray gun valve assembly for a spray gun, the spray gun valve assembly comprising: a valve housing having a seat ring piece located within the valve housing and a ball configured to engage the seat ring piece to place a spray valve in a closed state and the ball configured to disengage from the seat ring piece to place the spray valve in an open state; a tip housing having a tip receiver configured to receive a barrel of a spray tip and having a receiving aperture open into the tip receiver; and a sealing piece at least partially disposed in the tip housing, the sealing piece including an internal channel extending along a spray axis and through which spray fluid flows after having passed by the ball and the seat ring piece, the sealing piece including: a seal head having a saddle face, the seal head disposed within the receiving aperture and the saddle face configured to engage the barrel to seal with the barrel; wherein the sealing piece is keyed to the tip housing to prevent relative rotation between the sealing piece and the tip housing on the spray axis.

[0632] Example 255. The spray gun valve assembly of example 254, wherein the sealing piece is keyed to the tip housing by an interface between the seal head and the receiving aperture.

[0633] Example 256. The spray gun valve assembly of any one of examples 254 and 255, wherein the seal head includes at least one lobe and the receiving aperture includes at least one notch receiving the at least one lobe to key the sealing piece to the tip housing.

[0634] Example 257. The spray gun valve assembly of any one of examples 254-256, further comprising a spring biasing the seal head into the receiving aperture.

[0635] Example 258. The spray gun valve assembly of any one of examples 254-257, wherein the sealing piece further comprises: a sealing piece body; and a neck extending between and connecting the sealing piece body and the seal head, the neck configured to flex to allow pivoting of the seal head for aligning the saddle face and the barrel. Example 259. The spray gun valve assembly of any one of examples 254-258, further comprising a tip retainer connecting the tip housing to the valve housing, the tip retainer permanently connected to the valve housing in a set orientation and at a set position.

[0636] Example 260. A spray gun valve assembly for a spray gun, the spray gun valve assembly comprising: a valve housing having a seat ring piece located within the valve housing and a ball configured to engage the seat ring piece to place a spray valve in a closed state and the ball configured to disengage from the seat ring piece to place the spray valve in an open state; a tip housing having a tip receiver configured to receive a barrel of a spray tip and having a receiving aperture open into the tip receiver; a sealing piece at least partially disposed in the tip housing, the sealing piece including an internal channel extending along a spray axis and through which spray fluid flows after having passed by the ball and the seat ring piece; and a sealing ring disposed on the sealing piece and forming a radial seal between the sealing piece and the valve housing.

[0637] Example 261. The spray gun valve assembly of example 260, wherein the sealing piece includes a tube at least partially disposed within the valve housing, the sealing ring mounted in a seal groove formed on the tube.

[0638] Example 262. The spray gun valve assembly of example 261, wherein the seal groove is formed between a first wall and a second wall, and wherein a height of the first wall is greater than a height of the second wall.

[0639] Example 263. The spray gun valve assembly of example 262, wherein the second wall is disposed axially closer to the seat ring piece than the first wall.

[0640] Example 264. The spray gun valve assembly of any one of examples 262 and 263, wherein the height of the second wall is less than or equal to one half of the height of the first wall.

[0641] Example 265. The spray gun valve assembly of example 264, wherein the height of the second wall is less than or equal to one quarter of the height of the second wall.

[0642] Example 266. The spray gun valve assembly of any one of examples 260-265, wherein the sealing ring is exposed to a flow of the spray fluid downstream of the seat ring piece.

[0643] Example 267. The spray gun valve assembly of any one of examples 260-266, wherein the sealing ring is formed as an elastomer ring.

[0644] Example 268. The spray gun valve assembly of any one of examples 260-267, wherein the sealing ring is formed as an O-ring. Example 269. The spray gun valve assembly of any one of examples 260-268, wherein the sealing piece includes a seal head having a saddle face, the saddle face configured to engage a barrel of a spray tip to seal with the barrel.

[0645] Example 270. The spray gun valve assembly of any one of examples 260-269, wherein an inner diameter of the sealing ring no greater than an inner diameter of the seat ring piece.

[0646] Example 271. The spray gun valve assembly of any one of examples 260-269, wherein an inner diameter of the sealing ring is less than an inner diameter of the seat ring piece.

[0647] Example 272. The spray gun valve assembly of any one of examples 260-271, wherein an outer diameter of the sealing ring is no greater than an outer diameter of the seat ring piece.

[0648] Example 273. The spray gun valve assembly of any one of examples 260-271, wherein an outer diameter of the sealing ring is less than an outer diameter of the seat ring piece.

[0649] Example 274. A spray gun valve assembly for a spray gun, the spray gun valve assembly comprising: a valve housing having a seat ring piece located within the valve housing and a ball configured to engage the seat ring piece to place a spray valve in a closed state and the ball configured to disengage from the seat ring piece to place the spray valve in an open state; a tip housing having a tip receiver configured to receive a barrel of a spray tip and having a receiving aperture open into the tip receiver; a sealing piece at least partially disposed in the tip housing, the sealing piece including an internal channel extending along a spray axis and through which spray fluid flows after having passed by the ball and the seat ring piece; and a sealing ring disposed on the sealing piece, wherein an upstream side of the sealing ring is directly exposed to the spray fluid downstream of the seat ring piece.

[0650] Example 275. The spray gun valve assembly of example 274, wherein the sealing ring is disposed in a seal groove on the sealing piece.

[0651] Example 276. The spray gun valve assembly of example 275, wherein the seal groove is formed between a first wall and a second wall, and wherein a height of the first wall is greater than a height of the second wall.

[0652] Example 277. The spray gun valve assembly of example 276, wherein the second wall is disposed axially closer to the seat ring piece than the first wall. Example 278. The spray gun valve assembly of any one of examples 276 and 277, wherein the height of the second wall is less than or equal to one half of the height of the first wall.

[0653] Example 279. The spray gun valve assembly of example 278, wherein the height of the second wall is less than or equal to one quarter of the height of the second wall.

[0654] Example 280. The spray gun valve assembly of any one of examples 276-279, wherein a first portion of the sealing ring extending radially outward beyond an outer end of the second wall is larger than a second portion of the sealing ring axially overlapping the second wall.

[0655] Example 281. The spray gun valve assembly of any one of examples 274-280, wherein the sealing ring is disposed directly radially between the sealing piece and the valve housing.

[0656] Example 282. The spray gun valve assembly of any one of examples 274-281, wherein the sealing ring radially engages with the valve housing.

[0657] Example 283. The spray gun valve assembly of any one of examples 274-282, wherein an inner diameter of the sealing ring no greater than an inner diameter of the seat ring piece.

[0658] Example 284. The spray gun valve assembly of any one of examples 274-282, wherein an inner diameter of the sealing ring is less than an inner diameter of the seat ring piece.

[0659] Example 285. The spray gun valve assembly of any one of examples 274-284, wherein an outer diameter of the sealing ring is no greater than an outer diameter of the seat ring piece.

[0660] Example 286. The spray gun valve assembly of any one of examples 274-284, wherein an outer diameter of the sealing ring is less than an outer diameter of the seat ring piece.

[0661] Example 287. A spray gun comprising: a gun body; a handle; and the spray gun valve assembly of any one of examples 213-286.

[0662] Example 288. The spray gun of example 287, further comprising a trigger.

[0663] Example 289. A tip assembly for a spray gun, the tip assembly comprising: a tip housing having a tip receiver configured to receive a spray tip; a tip guard connected to the tip housing; a tip retainer within which the tip housing is at least partially disposed; a sealing piece disposed within the tip housing; and a tip spring retaining the sealing piece within the tip housing. Example 290. The tip assembly of example 289, wherein the sealing piece is keyed to the tip housing.

[0664] Example 291. The tip assembly of any one of examples 289 and 290, wherein the sealing piece includes an internal channel extending along a spray axis, the internal channel configured to convey spray fluid to the tip receiver.

[0665] Example 292. The tip assembly of example 291, wherein the sealing piece includes a tube that extends away from the tip receiver, and wherein the tip spring extends around the tube.

[0666] Example 293. The tip assembly of example 292, wherein the sealing piece includes a sealing piece body, the tube formed as a portion of the sealing piece body, and the sealing piece body includes a body flange extending radially outward relative to the tube.

[0667] Example 294. The tip assembly of example 293, wherein the tip spring is disposed directly axially between the body flange and the valve housing.

[0668] Example 295. The tip assembly of any one of examples 292-294, wherein a sealing ring is mounted on the tube.

[0669] Example 296. The tip assembly of example 295, wherein the sealing ring is disposed in a seal groove formed on the tube, the seal groove disposed between a first wall and a second wall, the first wall extending further radially outward than the second wall.

[0670] Example 297. The tip assembly of example 296, wherein the first wall is disposed closer to the tip receiver than the second wall.

[0671] Example 298. The tip assembly of any one of examples 296 and 297, wherein a height of the second wall is less than or equal to half of a height of the first wall.

[0672] Example 299. The tip assembly of example 298, wherein the height of the second wall is less than or equal to one quarter of the height of the first wall.

[0673] Example 300. The tip assembly of any one of examples 289-299, wherein the sealing piece includes a seal head having a saddle face, the saddle face configured to at least partially define the tip receiver and sealingly engage a barrel of the spray tip with the barrel disposed in the tip housing.

[0674] Example 301. The tip assembly of example 300, wherein the sealing piece includes a neck disposed between the seal head and a sealing piece body, the neck being thinner than the seal head and the sealing piece body.

[0675] Example 302. The tip assembly of example 301, wherein the neck is configured to flex to allow the seal head to gimbal relative to the sealing piece body. Example 303. The tip assembly of example 301, wherein the neck is configured to flex to allow the seal head to reorient relative to the sealing piece body.

[0676] Example 304. The tip assembly of any one of examples 301-303, wherein an annular groove extends fully circumferentially around the neck, the annular groove disposed axially between the seal head and the sealing piece body.

[0677] Example 305. The tip assembly of example 304, wherein the annular groove is disposed directly axially between the seal head and the body flange.

[0678] Example 306. The tip assembly of any one of examples 300-305, wherein the seal head interfaces with the tip housing at a keyed interface.

[0679] Example 307. The tip assembly of example 306, wherein a perimeter of the seal head is non-circular.

[0680] Example 308. The tip assembly of any one of examples 289-307, wherein the tip assembly is formed as a discrete module that is mountable to a spray gun as the discrete module.

[0681] While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.

Claims

CLAIMS:

1. A fluid sprayer for spraying a spray fluid configured to coat a surface, the fluid sprayer comprising: an electric motor, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion on a motor axis; a drive which converts the rotational motion output by the electric motor into linear reciprocating motion; a pump, the pump receiving the linear reciprocating motion from the drive to linearly reciprocate a piston to pump the spray fluid; a spray nozzle which atomizes the spray fluid output by the pump; a trigger; and a spray valve that receives the spray fluid output by the pump and allows the spray fluid to flow to the spray nozzle when the trigger is in an actuated state and which blocks the spray fluid from flowing to the spray nozzle when the trigger is in a non-actuated state; wherein the electric motor operates to cause the piston pump to continuously pump the spray fluid with the trigger both in the actuated state and the nonactuated state.

2. The fluid sprayer of claim 1, further comprising: an inlet passage that routes the spray fluid from a reservoir to the piston pump; a return passage that routes the spray fluid output by the pump back to the reservoir; a spray passage that routes the spray fluid output by the pump to the spray nozzle; and a recirculation valve that routes the spray fluid along the return passage.

3. The fluid sprayer of claim 2, wherein: the recirculation valve routes the spray fluid along the return passage when the trigger is in the non-actuated state and the spray valve is consequently closed; and the recirculation valve returns the spray fluid pumped while the trigger is in the nonactuated state and the spray valve is closed back to the reservoir via the return passage.

4. The fluid sprayer of claim 3, wherein the fluid sprayer does not comprise a pressure sensor.

5. The fluid sprayer of any one of claims 3 and4, wherein the fluid sprayer does not comprise a control board.

6. The fluid sprayer of any of claims 3-5, wherein the fluid sprayer comprises an electrical power input that receives electrical power.

7. The fluid sprayer of claim 6, wherein the fluid sprayer comprises electrical wiring that routes the electrical power from the electrical power input to the electric motor without any logic circuitry as part of the sprayer.

8. The fluid sprayer of any one of claims 3-7, further comprising a power switch that, when actuated to an ON state routes electrical power to the electric motor such that the electric motor starts to rotate the rotor upon actuation of the power switch to the ON state, and when actuated to an OFF state interrupts electrical power from flowing to the electric motor such that the electric motor is depowered upon actuation of the power switch to the OFF state, wherein the power switch is a mechanical power switch.

9. The fluid sprayer of claim 8, further comprising a fuse located electrically between the mechanical power switch and the electric motor.

10. The fluid sprayer of any one of claims 3-9, wherein the electric motor includes a thermal shutoff switch which, when actuated based on a temperate reaching a threshold, opens to interrupt electrical power from flowing and thereby causes the rotor to stop rotating, wherein the thermal shutoff switch is a mechanical switch.

11. The fluid sprayer of any one of claims 1-10, further comprising a fluid manifold that at least partially contains the pump.

12. The fluid sprayer of claim 11, wherein the fluid manifold includes an inlet orifice, the inlet orifice located directly above a reservoir that stores a supply of the spray fluid when the fluid sprayer sprays the spray fluid.

13. The fluid sprayer of claim 12, further comprising an inlet hose that is partially submerged in the spray fluid within the reservoir and which routes the spray fluid from the reservoir into the fluid manifold.

14. The fluid sprayer of claim 13, wherein the inlet hose extends straight upwards without bending when routing the spray fluid into the fluid manifold from the reservoir when the fluid sprayer sprays the spray fluid.

15. The fluid sprayer of any one of claims 12-14, wherein the piston reciprocates on a pump axis to pump the spray fluid, and at least part of the piston is located directly above the reservoir when the fluid sprayer sprays the spray fluid.

16. The fluid sprayer of any one of claims 11-15, further comprising a drain passage which returns the spray fluid to the reservoir, the drain passage comprising an outlet orifice located directly over the reservoir when the fluid sprayer sprays spray fluid. no17. The fluid sprayer of any one of claims 11-16, further comprising an outlet fitting located downstream of the pump, and a supply hose which connects to a spray gun, the supply hose also connects to the outlet fitting for transporting the spray fluid output by the pump to the spray gun, the outlet fitting located directly over the reservoir when the fluid sprayer sprays spray fluid.

18. The fluid sprayer of any one of claims 11-17, wherein the reservoir is a paint can.

19. The fluid sprayer of claim 18, wherein the paint can is formed from one of metal and plastic.

20. The fluid sprayer of any one of claims 18 and 19, wherein the paint can is a one gallon container configured to hold at least one gallon of the spray fluid but not more than 1.5 gallons of the spray fluid.

21. The fluid sprayer of any one of claims 18-20, wherein the fluid manifold is located above the paint can a distance not more than three quarters of a height of the paint can.

22. The fluid sprayer of any of claims 16-20, wherein a bottom side of the fluid manifold is located above a top rim of the paint can a distance not more than one half of a height of the paint can.

23. The fluid sprayer of any one of claims 16-20, wherein the piston is located above the paint can a distance not more than three quarters of a height of the paint can.

24. The fluid sprayer of any one of claims 16-20, wherein the piston is located above a top rim of the paint can a distance not more than one half of a height of the paint can.

25. The fluid sprayer of any one of claims 1-24, further comprising an outlet check valve disposed downstream of a pumping chamber of the pump, wherein a branch orifice of a return passage that directs the spray fluid back to the reservoir is located along the outlet check valve such that the branch orifice, with respect to the pump axis, overlaps with structure of the outlet check valve.

26. The fluid sprayer of claim 25, wherein the branch orifice radially overlaps with a spring of the outlet check valve relative to the pump axis.

27. The fluid sprayer of any one of claims 25 and 26, wherein the branch orifice does not radially overlap with a ball of the outlet check valve relative to the pump axis.

28. The fluid sprayer of any one of claims 25 and 26, wherein the branch orifice does radially overlap with the ball of the outlet check valve with the outlet check valve open.

29. The fluid sprayer of any one of claims 1-24, further comprising an outlet check valve disposed downstream of a pumping chamber of the pump, wherein a branch orifice of a return passage that directs the spray fluid back to the reservoir is located along theoutlet check valve such that the branch orifice, with respect to the pump axis, overlaps with a cage of the outlet check valve.

30. The fluid sprayer of claim 29, wherein the branch orifice radially overlaps with a spring of the outlet check valve relative to the pump axis, the spring disposed within the cage.

31. The fluid sprayer of any one of claims 2-30, wherein the recirculation valve includes a collar and a lever, the collar being rotatable to change a threshold pressure at which the recirculation valve opens to recirculate the spray fluid back to the reservoir.

32. The paint sprayer of claim 31, wherein the collar rotates the lever as the collar is rotated.

33. The fluid sprayer of claim 32, wherein the collar includes a slot inside of which the lever is at least partially located, wherein at least one side wall of the slot engage the lever to rotate the lever as the collar is rotated, and wherein the slot is open to allow the lever to be reorientated at least partially out of the slot to open the recirculation valve to place the fluid sprayer in a purge mode.

34. The fluid sprayer of any one of claims 1-33, wherein the drive is a wobble drive in which a drive shaft rotates within an angled ring having a top side, the top side of the angled ring reciprocating forwards and backwards as the shaft is rotated due to rotational motion output by the electric motor, the piston connected to the top side of the angled ring such that the piston reciprocates through a pumping stroke and a suction stroke as the top side of the angled ring reciprocates forwards and backwards.

35. The fluid sprayer of claim 34, wherein the electric motor and the piston are located above the shaft.

36. The fluid sprayer of any one of claims 34 and 35, wherein the piston is the only piston of the fluid sprayer.

37. The fluid sprayer of any one of claims 34-36, wherein the electric motor comprises a pinion that output the rotational motion, and the piston axially overlaps with the pinion along the pump axis.

38. The fluid sprayer of any one of claims 1-37, further comprising a drive housing the holds the drive.

39. The fluid sprayer of claim 38, wherein the drive housing holds the pump.

40. The fluid sprayer of claim 39, wherein the pump partially extends out of the drive housing.

41. The fluid sprayer of any one of claims 38-40, wherein the drive housing is a polymer clamshell with two sides that come together to capture the drive inside of the drive housing.

42. The fluid sprayer of any one of claims 38-41, further comprising a motor housing that at least partially contains the electric motor, wherein the motor housing mounts to the drive housing.

43. The fluid sprayer of claim 42, wherein the motor housing is cantilevered from the drive housing such that the motor and the motor housing are only structurally supported by connecting to the drive and the drive housing.

44. The fluid sprayer of any one of claims 42 and 43, wherein the motor housing is mounted to the drive housing by one or more screws.

45. The fluid sprayer of any one of claims 42-44, wherein the drive housing receives and supports a motor bearing, a motor shaft which outputs the rotational motion extending through the motor bearing.

46. The fluid sprayer of any one of claims 42-45, wherein the drive housing comprises a plurality of mount projections that extend outward from the drive housing to support the drive housing.

47. The fluid sprayer of claim 46, wherein the plurality of mount projections comprise a first plurality of mount projections which extend in a first lateral direction from the drive housing and a second plurality of mount projections which extend in a second lateral direction from the drive housing.

48. The fluid sprayer of any one of claims 46 and 47, wherein a first group of the plurality of mount projections radially overlap with the pump relative to the pump axis and a second group of the plurality of mount projections radially overlap with the drive.

49. The fluid sprayer of claim 48, wherein a third group of the plurality of mount projections radially overlap with the motor.

50. The fluid sprayer of any one of claims 46-49, wherein at least one mount projection of the plurality of mount projections is oriented vertically and at least one other mount projection of the plurality of mount projections is orientated horizontally.

51. The fluid sprayer of any one of claims 46-50, wherein the plurality of mount projections engage a primary housing that houses the pump, the drive, and the motor to support the drive housing.

52. The fluid sprayer of claim 51, wherein the drive housing is only supported by the plurality of mount projections as the drive housing does not connect to any other frame structure.

53. The fluid sprayer of any one of claims 1-51, further comprising a plurality of legs and a primary housing that contains the motor, the drive, and at least part of the pump, the plurality of legs attaching to the primary housing such that the motor, the drive, and the pump are supported by the plurality of legs indirectly through the primary housing.

54. The fluid sprayer of claim 53, wherein the plurality of legs snap-fit to the primary housing.

55. The fluid sprayer of any one of claims 53 and 54, wherein the primary housing both structurally supports a housing of the drive and covers the drive, the motor, and at least part of the pump.

56. The fluid sprayer of claim 55, wherein the primary housing covers the drive, the motor, and at least part of the pump such that less than fifteen percent of all of the drive, the motor, and the pump are extend outside of the primary housing.

57. The fluid sprayer of any one of claims 1-56, further comprising a return hose clip which attaches to a return hose and which includes a hook that can hang onto one or both of the fluid sprayer and a reservoir holding a supply of the spray fluid.

58. The fluid sprayer of claim 57, wherein the return hose clip includes a diffuser through which a return flow of the spray fluid is returned to the reservoir.

59. The fluid sprayer of any one of claims 1-58, further comprising a spray gun valve assembly comprising: a valve housing within which the spray valve is disposed; a tip housing; a sealing piece at least partially disposed in the tip housing, the sealing piece including an internal channel extending along a spray axis and through which spray fluid flows after having passed by the spray valve; and a spring biasing the sealing piece away from the valve housing and into the tip housing60. The fluid sprayer of any one of claims 1-58, further comprising a spray gun valve assembly comprising: a valve housing within which the spray valve is disposed; a tip housing having a tip receiver configured to receive a barrel of a spray tip and having a receiving aperture open into the tip receiver;a sealing piece at least partially disposed in the tip housing, the sealing piece including: a seal head having a saddle face, the seal head disposed within the receiving aperture and the saddle face configured to engage the barrel to seal with the barrel; a sealing piece body; and a neck extending between and connecting the sealing piece body and the seal head, the neck configured to flex to allow pivoting of the seal head for aligning the saddle face and the barrel.

61. A fluid sprayer for spraying a spray fluid configured to coat a surface, the fluid sprayer comprising: an electric motor, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion on a motor axis; a drive which converts the rotational motion output by the electric motor into linear reciprocating motion; a pump, the pump receiving the linear reciprocating motion from the drive to linearly reciprocate a piston to pump the spray fluid; a spray nozzle which atomizes the spray fluid output by the pump; a trigger; a spray valve that receives the spray fluid output by the pump and allows the spray fluid to flow to the spray nozzle when the trigger is in an actuated state and which blocks the spray fluid from flowing to the spray nozzle when the trigger is in a non-actuated state; a power supply that provides electrical power to the electric motor; a power switch actuatable between an ON state in which the electrical power is provided to the electric motor to cause the stator to rotate the rotor and an OFF state in which the electrical power is not provided to the electric motor; wherein the electric motor operates to cause the pump to continuously pump the spray fluid with the power switch in the ON state.

62. A pump module of a fluid sprayer for spraying a spray fluid configured to coat a surface, the pump module comprising: an electric motor, the electric motor comprising a rotor and a stator, the electric motor configured to output rotational motion on a motor axis;a drive which converts the rotational motion output by the electric motor into linear reciprocating motion; a pump, the pump receiving the linear reciprocating motion from the drive to linearly reciprocate a piston to pump the spray fluid; a spray passage extending downstream from the pump to an outlet orifice; and a recirculation valve connected to spray passage at a location upstream of the outlet orifice, the recirculation valve configured to open at a threshold pressure of the spray fluid; wherein the electric motor operates to cause the piston to continuously reciprocate to pump the spray fluid with the pump module in an ON state; and wherein the recirculation valve is configured to open based on a fluid pressure downstream of the pump reaching the threshold pressure to provide a return flow of the spray fluid output from the pump to a reservoir of the spray fluid.

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