Solenoid plunger connection for a fluid sprayer

Abstract

A plunger (88) of a solenoid is mechanically connected to a spray valve (36). The plunger (88) is configured to be electromagnetically displaced to actuate the spray valve (36) to an open state. A rod (132) extends between and connects the plunger (88) and the spray valve (36). The plunger (88) is clamped to the rod (132) to fix the plunger (88) to the rod (132).

Description

[0001] SOLENOID PLUNGER CONNECTION FOR A FLUID SPRAYER

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

[0003] This application claims priority to U.S. Provisional Application No. 63 / 676,041 filed July 26, 2024 and entitled “SOLENOID PLUNGER CONNECTION FOR A FLUID SPRAYER,” the disclosure of which is hereby incorporated by reference in its entirety.

[0004] BACKGROUND

[0005] This disclosure relates generally to fluid sprayers. More specifically, this disclosure relates to airless fluid sprayers.

[0006] Fluid sprayers include pumps that pressure spray fluid and drive the spray fluid to a nozzle for outputting the spray fluid as an atomized fluid spray. Fluid sprayers include spray guns that can be held and manipulated by the user. The spray gun includes an internal valve that controls flow of the pressurized fluid to the nozzle. A trigger controls actuation of the valve between open and closed states. Typically, the trigger is mechanically connected to the valve such that the user is required to physically displace the valve from the closed state to the open state. Displacing the valve to the open state requires the user to overcome the hydraulic pressure of the spray fluid, which can lead to user fatigue and inefficient spray operations.

[0007] SUMMARY

[0008] According to an aspect of the disclosure, an assembly for controlling release of spray fluid from a spray gun includes a spray valve; a plunger of a solenoid, the plunger configured to be moved by an electromagnetic field to actuate the spray valve to an open state by the plunger displacing along an actuation axis; and a rod. The plunger includes a plunger base; a first plunger arm extending from the plunger base along the actuation axis; a second plunger arm extending from the plunger base along the actuation axis, the second plunger arm spaced from the first plunger arm by a slot; and a rod bore extending within the plunger base and between the first plunger arm and the second plunger arm. The rod extends along the actuation axis between the spray valve and the plunger to connect the spray valve and the plunger. The rod is at least partially disposed in the rod bore. The rod is clamped between the first plunger arm and the second plunger arm to fix the plunger on the rod.

[0009] According to an additional or alternative aspect of the present disclosure, an assembly for controlling release of spray fluid from a spray gun includes a spray valve; a plunger of a solenoid, the plunger configured to be moved by an electromagnetic field to actuate the spray valve to an open state by the plunger displacing along an actuation axis; and a rod extending along the actuation axis between the spray valve and the plunger to connect the spray valve and the plunger. The rod is at least partially disposed in a rod bore within the plunger. The rod is clamped to the plunger.

[0010] According to another additional or alternative aspect of the present disclosure, a method of assembling a cartridge for use in a spray gun includes bracing a cartridge body of the cartridge against an indexer; magnetically drawing a plunger of a solenoid along a rod and against a hard stop, the rod connected to a spray valve of the cartridge; and clamping the plunger on the rod to fix the plunger at a set location on the rod.

[0011] According to another additional or alternative aspect of the present disclosure, an assembly for controlling release of spray fluid from a spray gun includes a spray valve; a plunger of a solenoid, the plunger configured to be moved by an electromagnetic field to actuate the spray valve to an open state by the plunger displacing along an actuation axis, the plunger including: a connection bore extending into a first end of the plunger; and a rod bore extending into a second end of the plunger; a rod extending along the actuation axis between the spray valve and the plunger to connect the spray valve and the plunger, the rod at least partially disposed in the rod bore; and a collet connected to the plunger and connected to the rod within the connection bore to fix the rod axially relative to the plunger.

[0012] BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1 is a schematic block diagram of a spray system.

[0014] FIG. 2 shows a spray system.

[0015] FIG. 3A is an isometric view of a spray gun.

[0016] FIG. 3B is an isometric exploded view of the spray gun.

[0017] FIG. 4 is a cross-sectional view taken along line 4-4 in FIG. 3A.

[0018] FIG. 5A is a cross-sectional view showing fluid handling components of a spray gun.

[0019] FIG. 5B is an exploded view of the components shown in FIG. 5A.

[0020] FIG. 6 is an enlarged view of detail 6 in FIG. 5A.

[0021] FIG. 7 is a plot illustrating flow of electromagnetic flux.

[0022] FIG. 8 is an isometric view of a cartridge.

[0023] FIG. 9 is a cross-sectional view taken along line 9-9 in FIG. 8 showing a connection between a plunger and a rod. FIG. 10 is a cross-sectional view taken along line 10-10 in FIG. 9.

[0024] FIG. 11 is an isometric view showing a plunger and a rod.

[0025] FIG. 12 is an elevational view of a cartridge in a pre-assembly state.

[0026] FIG. 13 is an isometric view of the cartridge within a locating assembly.

[0027] FIG. 14 is a cross-sectional view taken along line 14-14 in FIG. 13.

[0028] FIG. 15 is an enlarged view of detail 15 in FIG. 14.

[0029] FIG. 16A is a first isometric view of a solenoid plunger.

[0030] FIG. 16B is a second isometric view of the solenoid plunger.

[0031] FIG. 16C is a cross-sectional view taken along line C-C in FIG. 16A.

[0032] FIG. 17A is an isometric view of a collet.

[0033] FIG. 17B is a front elevational view of the collet.

[0034] FIG. 17C is a side elevational view of the collet.

[0035] DETAILED DESCRIPTION

[0036] The present disclosure relates to spray systems. Spray systems according to the disclosure include a pump that pressurizes a spray fluid, such as paint, varnishes, lacquer, finishes, textures, adhesives, treatments, and other coatings, among other options, and drives the spray fluid through a conduit, such as a hose, to an applicator, such as a spray gun. The spray gun includes a spray valve that is actuatable between a closed state and an open state to control emission of spray fluid from the spray gun. A trigger of the spray gun is mechanically disconnected from the spray valve such that the spray gun does not mechanically displace the spray valve. An electric actuator, such as a solenoid, is connected to the spray valve to actuate the spray valve.

[0037] A spray control assembly is fluidly connected to the pump to receive fluid output by the pump. The spray gun of the spray control assembly is fluidly connected to a module of the spray control assembly. The fluid pumped by the pump can flow through the module and then downstream to the spray gun.

[0038] The spray gun can include a solenoid operatively connected to the spray valve to actuate the spray valve from the closed state to the open state. The spray gun includes a trigger that is operatively connected to the solenoid to cause actuation of the solenoid to cause actuation of the spray valve. The module of the spray control assembly can be electrically connected to the spray gun to provide electrical energy to the spray gun for powering the solenoid. The module can, in some examples, be configured to support one or more batteries for providing electrical energy. The spray gun can include a solenoid operatively connected to the spray valve to actuate the spray valve from the closed state to the open state. The spray valve can be, but is not necessarily, disposed within a cartridge that is mountable to and dismountable from a body of the spray gun as a single unit. The cartridge can include electromagnetic components of the solenoid. In some examples, the cartridge can include a plunger of the solenoid that is caused to move due to electric current provided to a stator of the solenoid.

[0039] The solenoid plunger can be part of the cartridge that mounts to and dismounts from the gun body. The stator of the solenoid can remain mounted within and supported by the gun body with the cartridge dismounted from the gun body. The plunger can be at least partially disposed within a housing of the cartridge to protect the plunger. In some examples, the plunger can be fully enclosed within a housing of the cartridge.

[0040] The spray valve of the spray gun is configured to open a certain distance to provide quality sprays of the spray fluid. An travel distance for an armature of the solenoid can set the distance that the spray valve can open. The size of the axial gap can be set by fixing the plunger of the solenoid at a set location along a rod that connects the plunger to the spray valve.

[0041] The housing that at least partially encloses the plunger can be configured as a flux director. The housing can include a flux permeability zone configured to direct electromagnetic flux. The housing can include a flux resistance zone formed from non- ferric material. The flux permeability zone directs electromagnetic flux along an efficient flux path relative to the plunger to displace the plunger and thus cause opening of the spray valve.

[0042] The plunger is fixed to the rod that connects the spray valve and the solenoid. The plunger can be clamped to the rod to fix the location of the plunger along the rod. The plunger can be clamped at a specific location along the rod to set an opening distance of the spray valve. According to some aspects, the plunger can be clamped to the rod by a fastener that pulls arms of the plunger towards each other to clamp the rod between the arms.

[0043] Components can be considered to radially overlap when those components are disposed at common axial locations along an axis. A radial line extending orthogonally from 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 the axis. An axial line parallel to the axis will extend 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.

[0044] FIG. 1 is a schematic block diagram of spray system 10. FIG. 2 shows a spray system 10. FIGS. 1 and 2 will be discussed together. Spray system 10 includes pumping assembly and spray control assembly 14. Pumping assembly 12 includes motor 16, stand 18, pump 20, and spray controller 22. Spray control assembly 14 includes spray gun 24, module 26, and conduit 28. Spray gun 24 includes gun body 30 having gun handle 32 and includes trigger 34, spray valve 36, solenoid 38, and nozzle 40. Module 26 includes module body 42 and assembly controller 44. Conduit 28 includes fluid hose 46, conductors 48, and sheath 50.

[0045] Spray system 10 is configured to generate pressurized flows of spray fluid and output the spray fluid as a fluid spray for spraying onto a substrate. Spray system 10 includes pumping assembly 12 that includes pump 20 that is configured to output the spray fluid under pressure. Motor 16, which can be an electric motor including a rotor and a stator, is operatively connected to pump 20 to cause pumping by pump 20. The motor 16 can be a rotor stator type electric motor, amongst other options. A drive system, such as an eccentric and crank, can convert rotational motion output by the motor 16 into linear reciprocating motor that drives a fluid displacer, such as a piston, of the pump 20. Stand 18 is configured to support other components of pumping assembly 12. Stand 18 can include legs and / or wheels, among other options.

[0046] The pumping assembly 12 can be a conventional sprayer. The pump 20 can be a piston -type pump that puts spray fluid under pressure for airless spraying (e.g., airless spray not using pressurized or flowing air to atomize paint), but could also be a diaphragm pump. Airless spraying is typically done between 500-7500 pounds per square inch (psi), and more typically between 800-3000 psi. The pump 20 is driven by motor 16. The pumping assembly 12 outputs the paint under pressure via a supply line 52. The pumping assembly 12 can draw the spray fluid from a fluid reservoir 21, such as formed by a bucket or other container.

[0047] Transducer 54 is shown. It is understood that transducer 54 may not be present in various examples. Transducer 54 is operatively associated with the spray fluid downstream of pump 20 and upstream of spray gun 24. Transducer 54 is configured to generate information regarding one or more properties of the spray fluid. In some examples, transducer 54 can be configured as a pressure sensor that is configured to generate information regarding a pressure of the spray fluid. In some examples, transducer 54 can be configured as a flow sensor configured to generate information regarding the flow of the spray fluid (e.g., flow rate among other options). It is understood that some examples that include transducer 54 can include both pressure and flow sensors, among other sensor options. Transducer 54 is configured to generate parameter information regarding a parameter of the spray fluid at a location downstream of the pump 20 and upstream of the nozzle 40.

[0048] Spray controller 22 is configured to control operation of motor 16 to control output of pressurized spray fluid by pumping assembly 12. Spray controller 22 is operatively connected to other components of pumping assembly 12 to control operation of the other components of pumping assembly 12. Spray controller 22 is operatively connected to motor 16, electrically and / or communicatively, to control operation of motor 16. Spray controller 22 can be operatively connected to assembly controller 44, electrically and / or communicatively, to receive commands from spray control assembly 14. Spray controller 22 can be operatively connected to transducer 54 to receive parameter signals from transducer 54. For example, transducer 54 can be configured to provide pressure data, flow data, etc. to spray controller 22. The spray controller 22 can be configured to direct power to the electric motor 16 based on the parameter information generated by the transducer 54 and / or based on commands received from spray control assembly 14.

[0049] Spray controller 22 is configured to store software, implement functionality, and / or process instructions. Spray controller 22 is configured to perform any of the functions discussed herein, including receiving an output from any sensor referenced herein, detecting any condition or event referenced herein, and controlling operation of any components referenced herein. Spray controller 22 can be of any suitable configuration for controlling operation of components of pumping assembly 12, receiving signals from components of pumping assembly 12, gathering data, processing data, etc. Spray controller 22 can include hardware, firmware, and / or stored software, and spray controller 22 can be entirely or partially mounted on one or more circuit boards. Spray controller 22 can be of any type suitable for operating in accordance with the techniques described herein. While spray controller 22 is illustrated as a single unit, it is understood that spray controller 22 can be formed as multiple discrete controllers. In some examples, spray controller 22 can be implemented as a plurality of discrete circuity subassemblies.

[0050] Spray control assembly 14 is connected to pumping assembly 12 by supply line 52.

[0051] Supply line 52 fluidly connects spray control assembly 14 to pumping assembly 12 such that spray control assembly 14 receives the pressurized spray fluid output by pump 20. Spray control assembly 14 does not include a pump. Spray control assembly 14 does not include components that move to put fluid under pressure, such as pistons or diaphragms.

[0052] The spray control assembly 14 can be worn by a user during spraying. For example, the module 26 can be worn via a strap 56 that attaches to the module 26. The module 26 can be worn in the manner of a belt or satchel via the strap 56 wrapping around the user, however other options are possible. The conduit 28 extends from the module 26 to the spray gun 24. The fluid hose 46 of the conduit 28 provides a flow passage for the flow of spray fluid, such as paint, from the module 26 to the spray gun 24. The conduit 28 can also include one or more conductors 48 that conduct signals and / or power between the module 26 and spray gun 24.

[0053] Module 26 is configured to connect to supply line 52 to receive the spray fluid output by pumping assembly 12. For example, module 26 can include an inlet fitting that attaches to the supply line 52 to mechanically and fluidly connect the module 26 to the supply line 52. During operation, paint can be drawn by suction into the pump 20 from a bucket or other reservoir and put under pressure by the pump 20 and then be output by the pump 20 and through the supply line 52 to the module 26. The spray fluid continues from module 26, through the conduit 28, and to the spray gun 24 where it is output into an atomized spray fan through nozzle 40 onto a wall or other targeted surface. It will be understood that many types of pumps and sprayers can be used with the spray control assembly 14.

[0054] Module 26 can be supported on the user by strap 56. The supply line 52 connects to module 26 to provide spray fluid to the spray control assembly 14. The supply line 52 connects to module 26 such that the weight of supply line 52 is carried by module 26. The weight of the supply line 52 is not transmitted through module 26 and up conduit 28 to be carried by the spray gun 24 and thus by the hand of the user. Instead, the weight of the supply line 52 is supported by module 26, which is supported on the user by strap 56. Such a configuration provides for easier and more ergonomic spraying by the user as the user is not required to carry and support the weight of the supply line 52 in the user’s hand. Such a configuration can be particularly useful when spraying in elevated locations such that the length of supply line 52 not on the ground and supported by the user increases which increases the weight of the supply line 52, such as when the user is on a ladder.

[0055] Module 26 receives the flow of spray fluid output by the pump 20. Conduit 28 extends between module 26 and spray gun 24. Sheath 50 encloses other components of conduit 28. Fluid hose 46 extends between module 26 and spray gun 24 to convey the spray fluid from module 26 to spray gun 24 under pressure. Conductors 48 extend between electrical components of spray gun 24 and module 26. Conductors 48 can be formed as wires, among other options. Conductors 48 are disposed external to fluid hose 46 and are not exposed to the spray fluid flowing within fluid hose 46 in the example shown. In the example shown, one more conductors 48 can extend between trigger 34 and assembly controller 44 and between solenoid 38 and assembly controller 44. Sheath 50 encloses conductors 48 and fluid hose 46. Conductors 48 are configured to transmit signals (communication and / or power) between module 26 and spray gun 24.

[0056] Spray gun 24 is configured to receive the pressurized fluid pumped by pump 20. The pressurized spray fluid flows through module 26 and conduit 28 prior to flowing to spray gun 24. The pressurized fluid flows through fluid hose 46 to spray gun 24 and is output from spray gun 24 through nozzle 40 as an atomized spray of the spray fluid. Spray gun 24 is operatively connected to assembly controller 44 for controlling emission of the spray fluid from spray gun 24.

[0057] Gun body 30 supports other components of spray gun 24. Gun handle 32 is formed as a projection that is configured to be grasped by a single hand of a user. Gun handle 32 can be formed integral with (e.g., monolithically) or separately from gun body 30.

[0058] Trigger 34 is operatively connected to assembly controller 44 to provide spray signals to the assembly controller 44. Trigger 34 is formed on a front side of gun handle 32. In the example shown, the trigger 34 is connected to assembly controller 44 by a wired connection through conduit 28. Actuation of the trigger 34 generates a spray signal that is transmitted to assembly controller 44 to cause the assembly controller 44 to initiate spraying by spray gun 24. Depressing the trigger 34 can cause the assembly controller 44 to direct power to the solenoid 38 to cause the solenoid 38 to open the spray valve 36. Upon release of the trigger 34, the assembly controller 44 can reduce power to the solenoid 38 to allow the spray valve 36 to close.

[0059] Nozzle 40 is configured to emit the spray fluid as an atomized fluid spray. Nozzle 40 forms the outlet of the spray gun 24 through which the spray fluid is sprayed. Nozzle 40 can be shaped to form the spray pattern emitted by spray gun 24.

[0060] Spray valve 36 is disposed within spray gun 24. Spray valve 36 is supported by gun body 30. Spray valve 36 is disposed upstream of nozzle 40. Spray valve 36 is configured to control flow of the spray fluid to nozzle 40 for emission from spray gun 24. Spray valve 36 is actuatable between a closed state, in which spray valve 36 prevents the spray fluid from flowing to nozzle 40, and an open state, in which the spray fluid can flow through spray valve 36 to nozzle 40 for emission from the spray gun 24. The spray valve 36 includes an actuatable seal that can be moved to allow or prevent flow of spray fluid through spray valve 36.

[0061] Solenoid 38 is operatively connected to spray valve 36 to control actuation of the spray valve 36 between closed and open states. For example, an armature of the solenoid 38 can be connected to a movable component of the spray valve 36 such that movement of the armature causes movement of valving components of the spray valve 36. Solenoid 38 can be configured as a single-acting solenoid that displaces the spray valve 36 from one state to the other (e.g., from the closed state to the open state) or a double-acting solenoid that displaces the spray valve 36 from the open state to the closed state and from the closed state to the open state. Solenoid 38 can be operatively connected to module 26 via one or more conductors 48 to receive power and / or communication signals from module 26.

[0062] Power source 58 is configured to provide power to electric powered components of spray control assembly 14 (e.g., assembly controller 44 and solenoid 38). Power source 58 can be formed as an electric battery (e.g., rechargeable lithium ion based, among other options). Power source 58 can be supported by the module body 42. In some examples, the battery forming the power source 58 can be mounted externally on module body 42. In other examples the battery forming the power source 58 can be mounted internally to the module body 42. The battery forming the power source 58 can be a type commonly used with power tools, such as that used to power electric cordless drills.

[0063] Assembly controller 44 is operatively connected to other components of spray control assembly 14 to control operation of the other components of spray control assembly 14. Assembly controller 44 is operatively connected to trigger 34, electrically and / or communicatively, such as via conductors 48, to receive control signals from trigger 34. For example, trigger 34 can be configured to provide spray signals to assembly controller 44 to cause assembly controller 44 to cause opening of spray valve 36 to cause spraying by spray gun 24. Trigger 34 can be configured to provide spray signals to assembly controller 44 to cause assembly controller 44 to cause closing of spray valve 36 to stop spraying by spray gun 24. Assembly controller 44 is operatively connected to solenoid 38, electrically and / or communicatively, such as via conductors 48, to control activation of solenoid 38 and thereby control actuation of spray valve 36.

[0064] Assembly controller 44 is configured to store software, implement functionality, and / or process instructions. Assembly controller 44 is configured to perform any of the functions discussed herein, including receiving an output from any sensor referenced herein, detecting any condition or event referenced herein, and controlling operation of any components referenced herein. Assembly controller 44 can be of any suitable configuration for controlling operation of components of spray control assembly 14, receiving signals from components of spray control assembly 14, providing control signals to pumping assembly 12, gathering data, processing data, etc. Assembly controller 44 can include hardware, firmware, and / or stored software, and assembly controller 44 can be entirely or partially mounted on one or more circuit boards. Assembly controller 44 can be of any type suitable for operating in accordance with the techniques described herein.

[0065] Control circuitry 60, in one example, is configured to implement functionality and / or process instructions. For example, control circuitry 60 can be capable of processing instructions stored in memory 62. Examples of control circuitry 60 can include one or more of a processor, a microprocessor, a controller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or other equivalent discrete or integrated logic circuitry. Control circuitry 60 can be entirely or partially mounted on one or more circuit boards.

[0066] Memory 62 can be configured to store information before, during, and / or after operation. Memory 62, in some examples, is described as computer-readable storage media. In some examples, a computer-readable storage medium can include a non- transitory medium. The term “non-transitory” can indicate that the storage medium is not embodied in a carrier wave or a propagated signal. In certain examples, a non-transitory storage medium can store data that can, over time, change (e.g., in RAM or cache). In some examples, memory 62 is a temporary memory, meaning that a primary purpose of memory 62 is not long-term storage. Memory 62, in some examples, is described as volatile memory, meaning that memory 62 does not maintain stored contents when power to assembly controller 44 is turned off. Examples of volatile memories can include random access memories (RAM), dynamic random access memories (DRAM), static random access memories (SRAM), and other forms of volatile memories. In some examples, memory 62 is used to store program instructions for execution by control circuitry 60. Memory 62, in one example, is used by software or applications to temporarily store information during program execution.

[0067] Memory 62, in some examples, also includes one or more computer-readable storage media. Memory 62 can be configured to store larger amounts of information than volatile memory. Memory 62 can further be configured for long-term storage of information. In some examples, memory 62 includes non-volatile storage elements. Examples of such non-volatile storage elements can include magnetic hard discs, optical discs, flash memories, or forms of electrically programmable memories (EPROM) or electrically erasable and programmable (EEPROM) memories.

[0068] The assembly controller 44 can include any type of circuit, such as programmable circuit, integrated circuit, or logic array, and other supporting circuitry to carry out any of the functions referenced herein. For example, assembly controller 44 can receive power from the power source 58 and can supply electrical energy to the spray gun 24 via one or more conductors 48. To control the solenoid 38 of the spray gun 24, as further discussed herein, the assembly controller 44 can receive one or more signals to indicate actuation of the trigger 34 and the need to provide power to the solenoid 38 to open and close the spray valve 36 based on whether the trigger 34 is actuated or released. In some examples, assembly controller 44 can be communicatively connected to spray controller 22, such as by communications circuitry. For example, the communications circuitry can be configured for wireless communications with spray controller 22 to facilitate spray control assembly 14 communicating with pumping assembly 12. The assembly controller 44 can be configured for communicating in any wired or wireless manner with the pumping assembly 12. For example, assembly controller 44 can command pumping assembly 12 to operate its electric motor 16 in synchrony with the spray control assembly 14 such as by opening the spray valve 36 and starting the motor 16 in sequence or at the same time.

[0069] In some examples, pulling of the trigger 34, as sensed by a sensor; such as a reed switch, proximity, hall effect, or other type of transducer which senses actuation of a trigger 34; directly starts the electric motor 16 of the pumping assembly 12. In some examples, release of the trigger 34, as sensed by the sensor, directly stops the electric motor 16 of the pumping assembly 12. For example, the assembly controller 44 can be configured to generate and provide a start command to the spray controller 22 based on the assembly controller 44 receiving a signal indicating actuation of the trigger 34. The assembly controller 44 can be configured to generate and provide a stop command to the spray controller 22 based on the assembly controller 44 receiving a signal indicating release of the trigger 34. The solenoid 38 can be activated in response to the signal indicating actuation of the trigger 34, causing the spray valve 36 to open. The solenoid 38 can be deactivated in response to the signal indicating release of the trigger 34, causing the spray valve 36 to close. It is understood that the signal indicating release of the trigger 34 can, in some examples, be formed by cessation of teh signal indicating actuation of the trigger 34. The user can cause the spray control assembly 14 to generate and send a start command signal based on the user actuating the trigger 34. The user actuating the trigger 34 can cause the sensor that senses actuation of the trigger 34 to generate a trigger actuated signal. The trigger actuated signal causes the assembly controller 44 to output the start command signal. The start command signal is received by the pumping assembly 12. The pumping assembly 12 causes the electric motor 16 to start and run in response to the start command signal to cause pumping by the pump 20.

[0070] The user can cause the spray control assembly 14 to generate and send a stop command signal based on the user releasing the trigger 34. The user releasing the trigger 34 can cause the sensor that senses actuation and release of the trigger 34 to generate a trigger release signal. The trigger release signal causes the assembly controller 44 to output the stop command signal. The stop command signal is received by the pumping assembly 12. The pumping assembly 12 causes the electric motor 16 stop in response to the stop command signal to stop pumping by the pump 20. It is understood that the trigger release signal can be a discrete signal generated on release of the trigger 34 or can be cessation of the trigger actuated signal.

[0071] In some examples, the pumping assembly 12 is configured to operate in a dual control mode. In such a configuration, the pumping assembly 12 is configured to control operation of the motor 16 based on control signals from the spray control assembly 14 and / or based on signals from the transducer 54. For example, the pumping assembly 12 can be configured to start operation of the motor 16 based on receipt of a start command signal from the spray control assembly 14 or based on the transducer 54 indicating a drop in pressure, which drop in pressure indicates that the spray valve 36 is open for spraying by the spray gun 24. The pumping assembly 12 can be configured to stop operation of the motor 16 based on receipt of a stop command signal from the spray control assembly 14 or based on the transducer 54 indicating a rise in pressure, which rise in pressure indicates that the spray valve 36 is closed to stop spraying by spray gun 24. Such a configuration provides reliable operation of spray system 10 even if the spray control assembly 14 becomes communicatively disconnected from the pumping assembly 12.

[0072] FIG. 3A is an isometric view of spray gun 24. FIG. 3B is an isometric exploded view of spray gun 24. FIG. 4 is a cross-sectional view taken along line 4-4 in FIG. 3A. FIGS. 3A-4 are discussed together. Gun body 30 including upper housing 31 and gun handle 32, trigger 34, spray valve 36, solenoid 38, nozzle 40, cartridge 82, sensor 64, spray tip 80, and valve housing 86 of spray gun 24 are shown. Solenoid 38 includes coil section 84 and plunger 88.

[0073] Forward, rearward, upper, and lower directions are indicated in various of the figures. It is understood that components are shown in relative position to each other, particularly as viewed in FIG. 4, and such relative positions are intended as being claimable relative to each other. It is further understood that the relative positions of various components are not intended as limiting and such components can be disposed in other locations relative to each other.

[0074] Spray gun 24 is configured to receive a flow of spray fluid under pressure and emit that flow of spray fluid as an atomized fluid spray through nozzle 40. Gun body 30 supports other components of spray gun 24. Upper housing 31 surrounds solenoid 38. Upper housing 31 supports valve housing 86. Gun handle 32extends from upper housing 31. Gun handle 32is configured to be grasped by a single hand of a user during operation of spray gun 24.

[0075] Trigger 34 projects from a front side of gun handle 32. Trigger 34 is configured to be actuated to control spraying by spray gun 24. Sensor 64 is disposed at least partially within gun body 30. In the example shown, a portion of sensor 64 is disposed in gun body 30 and a sensed component is supported by trigger 34. The sensed component can be a magnet, among other options. Pulling of the trigger 34 can cause the sensor 64 to sense the sensed component, such as the magnetic field generated by a magnet of or forming the sensed component, thereby causing the sensor 64 to generate the trigger actuated signal. Release of the trigger 34 can cause the sensor 64 to stop sensing the sensed component, thereby causing the sensor 64 to generate the trigger released signal, which trigger release signal can be cessation of the trigger actuated signal.

[0076] Conduit 28 extends through a bottom side of gun handle 32 such that a far end 78 of conduit 28 is disposed within spray gun 24. Fluid hose 46 extends out of sheath 50 and to gun fitting 90. The gun fitting 90 projects from valve housing 86, through it is understood that other configurations are possible. Conductors 48 extend out of sheath 50 at the location within the spray gun 24. In the example shown, a first subset of the conductors 48 extend to sensor 64 and provide communication between sensor 64 and assembly controller 44. In the example shown, a second subset of conductors 48 extend to solenoid 38 and provide signals (e.g., electrical power) to solenoid 38 to control operation of solenoid 38. The sheath 50 terminates at a location below the trigger 34. The fluid hose 46 and conductors 48 exit from sheath 50 at a location disposed vertically above the bottom end of the gun handle 32 and vertically below each of the locations that the components exiting from sheath 50 connect with components of spray gun 24. In the example shown, the sheath 50 terminates at a location vertically below the sensor 64, the gun fitting 90, and the coil section 84. The sheath 50 terminates at a location vertically below the upper housing 31.

[0077] Valve housing 86 is disposed at least partially within gun body 30. In the example shown, housing body 92 of valve housing 86 is partially disposed within gun body 30 and partially disposed outside of gun body 30. Valve housing 86 is disposed within and supported by upper housing 31. Valve housing 86 is connected to gun fitting 90 and fluidly connects to fluid hose 46 via gun fitting 90. Valve housing 86 is fluidly connected to fluid hose 46 to receive pressurized spray fluid from fluid hose 46. Valve housing 86 is disposed vertically above gun handle 32.

[0078] Tip assembly 118 is connected to spray gun 24. Tip assembly 118 is mountable at tip mount 122. Tip mount 122 is formed as a portion of gun body 30 in the example shown. It is understood, however, that in various examples the tip mount 122 can be formed as a portion of valve housing 86. Tip mount 122 is formed as exterior threading configured to interface with a mounting portion of tip assembly 118 to mount tip housing 120 to spray gun 24. Spray tip 80 is supported by tip housing 120. Spray tip 80 includes nozzle 40 that is configured to atomize the pressurized spray fluid.

[0079] Valve housing 86 includes housing bore 94 that extends along axis VA. Housing bore 94 is open such that cartridge 82 can move into housing bore 94 in axial direction ADI along valve axis VA and can move out of housing bore 94 in axial direction AD2. In the example shown, the housing bore 94 is open in axial direction AD2 and closed in axial direction ADI. The axial direction ADI is an upstream direction along axis VA and axial direction AD2 is a downstream direction along axis VA.

[0080] Valve housing 86 is configured to connect to fluid hose 46 to receive pressurized spray fluid output by fluid hose 46. Valve housing 86 includes gun inlet 96 that extends through a wall of valve housing 86 and is in fluid communication with housing chamber 98. Gun inlet 96 forms an inlet port through valve housing 86. Housing chamber 98 is disposed at least partially defined by valve housing 86. Housing chamber 98 is formed as a radially enlarged portion of housing bore 94. Housing chamber 98 can be at least partially defined by a groove, such as an annular groove, formed in valve housing 86. Housing chamber 98 is fluidly connected to fluid hose 46 to receive pressurized spray fluid from conduit 28 and module 26. The housing chamber 98 extends annularly about the cartridge 82 to provide spray fluid to the cartridge 82.

[0081] Valve housing 86 is configured to receive cartridge 82 such that cartridge 82 is at least partially disposed within valve housing 86. Cartridge 82 is fixed to valve housing 86 when installed within spray gun 24 such that cartridge 82 is mechanically supported by valve housing 86. The cartridge 82 can thus be considered to be indirectly connected to the gun body 30 by the valve housing 86.

[0082] In the example shown, the cartridge 82 is connected to valve housing 86 at fixation 100. Fixation 100 is located respectively on the cartridge 82 and the valve housing 86 to secure the cartridge 82 to the valve housing 86. In this example, the fixation 100 is complementary threading between cartridge body 104 and housing body 92, however other attachment mechanisms are possible, such as tab-in-groove, friction fit, or bayonet connection amongst other possibilities. As such, the cartridge 82 can be rotated to move the cartridge 82 out of the housing bore 94 of the valve housing 86 or can be rotated in the opposite direction to move the cartridge 82 into the housing bore 94 of the valve housing 86.

[0083] In the example shown, fixation 100 is formed between housing mount 102 formed on the interior of valve housing 86 and cartridge mount 116 formed on an exterior of cartridge body 104. The housing mount 102 is formed as interior threads within the housing bore 94. The cartridge mount 116 is formed as exterior threads on a portion of cartridge body 104. It is understood that housing mount 102 and cartridge mount 116 can be formed as connective structure other than threads, such as projections that mate in a bayonet style connection, among other connection options. The housing mount 102 and cartridge mount 116 are configured to axially overlap each other to secure the cartridge 82 to the valve housing 86 and prevent the cartridge 82 from moving axially out of the housing bore 94.

[0084] Cartridge body 104 includes fluid housing 106 and base 108. The fluid housing 106 and base 108 can be connected together in any desired manner. For example, the fluid housing 106 and base 108 can be threaded together. In various other examples, a single housing may be provided, however in this example the fluid housing 106 forms a forward housing part that principally contains the spray valve 36 while the base 108 forms a rearward part that, in the example shown, contains the plunger 88 part of the solenoid 38. The base 108 can be exposed to the pressure within the fluid chamber 110 but does not radially surround the fluid chamber 110 and thus may not be in the manner of a pressure vessel. Fluid housing 106 does radially surround fluid chamber 110 and can thus be considered to be in the form of a pressure vessel.

[0085] Base 108 is connected to fluid housing 106 at a threaded interface in the example shown. It is understood, however, that base 108 and fluid housing 106 can be connected in any desired manner. Base 108 extends into fluid housing 106 to connect with fluid housing 106 in this example. Base 108 extends into fluid housing 106 to form the threaded interface between base 108 and fluid housing 106. Base 108 includes exterior threading and fluid housing 106 include interior threading in the example shown. The base 108 extending into the fluid housing 106 to connect to fluid housing 106 can provide for a cartridge 82 having a radially smaller footprint. In the example shown, the interface between base 108 and fluid housing 106 is disposed axially between forward seal 124 and rearward seal 126. The interface between fluid housing 106 and base 108 is disposed to radially overlap with housing chamber 98. The interface between fluid housing 106 and base 108 being axially between forward seal 124 and rearward seal 126 means that no additional sealing is required to form the interface as any fluid leakage through the interface is between fluid handling regions (e.g., housing chamber 98 and fluid chamber 110.

[0086] Outlet 112 is formed at a downstream end of cartridge body 104. Cartridge 82 is configured to emit spray fluid through outlet 112. Ports 114 are formed through cartridge body 104. Ports 114 are formed through fluid housing 106 in the example shown. Ports 114 are configured to admit spray fluid into fluid chamber 110 from housing chamber 98 of valve housing 86. Ports 114 can receive spray fluid from the channel that extends through the valve housing 86. Ports 114 form inlets of the cartridge 82 that admit spray fluid into the cartridge 82. In the example shown, an array of ports 114 are formed about the cartridge body 104.

[0087] The ports are 114 axially between a forward seal 124 and a rearward seal 126. The forward seal 124 and rearward seal 126 are disposed on opposite axial sides of the ports 114. The forward seal 124 and rearward seal 126 are disposed on opposite axial sides of the gun inlet 96 through the valve housing 86. The forward seal 124 and rearward seal 126 are configured to sealingly engage with both the valve housing 86 and the cartridge body 104. The forward seal 124 and rearward seal 126 are disposed to axially seal the housing chamber 98. The forward seal 124 and rearward seal 126 seal the cartridge 82 around the ports 114 to route all spray fluid into and through the ports 114 and therefore into the fluid chamber 110. In the example shown, forward seal 124 is disposed on and supported by fluid housing 106 and rearward seal 126 is disposed on and supported by base 108. The forward seal 124 and / or rearward seal 126 can be formed as O-rings, such as those formed from rubber or other type of compliant, sealing material.

[0088] Spray valve 36 is disposed within cartridge body 104. Spray valve 36 includes seat 128, such as a ceramic or carbide ring, which interfaces with ball 130 in the example shown. In the example shown, ball 130 is configured to interface with seat 128 and such interfacing of the ball 130 and the seat 128 closes the spray valve 36 but moving the ball 130 away from the seat 128 opens the spray valve 36 to allow spray fluid within the fluid chamber 110 to exit through the outlet 112. The spray valve 36 is actuatable between an open state, in which the fluid chamber 110 is fluidly connected to outlet 112 such that spray fluid can flow through outlet 112 and to nozzle 40, and a closed state, in which the fluid chamber 110 is fluidly disconnected from outlet 112 and nozzle 40.

[0089] Spray valve 36 is disposed at a forward end of cartridge 82. Spray valve 36 is disposed at a location axially outside of valve housing 86 in the example shown. Spray valve 36 is disposed at a location such that valve housing 86 does not radially overlap with the interface between ball 130 and seat 128. Spray valve 36 is disposed forward of gun handle 32. Spray valve 36 is disposed at a forward end of cartridge 82. The spray valve 36 is disposed at an opposite end of cartridge from plunger 88. The chamber within which spray valve 36 is disposed is axially separated from the chamber that plunger 88 is disposed within by base 108 and dynamic seal 136.

[0090] Rod 132 is configured to connect spray valve 36 to solenoid 38 such that solenoid 38 can actuate spray valve 36. Rod 132 can be a wire or other stiff, high tensile component which, in this example, extends from the plunger 88 of the solenoid to the ball holder 134. Ball 130 is mounted to ball holder 134.

[0091] Dynamic seal 136 is located around the rod 132. Dynamic seal 136 separates the high pressure within the fluid chamber 110 from the dry components, such as the solenoid 38. The dynamic seal 136 can be a rubber component compressed circumferentially around the rod 132 to prevent the escape of spray fluid from around the rod 132. Dynamic seal 136 is supported by base 108 in the example shown. Dynamic seal 136 extends at least partially within base 108 such that base 108 radially overlaps with dynamic seal 136. Dynamic seal 136 sealingly engages with rod 132 and rod 132 can slide relative to dynamic seal 136 during actuation of spray valve 36.

[0092] Spring 138 is disposed within fluid chamber 110. Spring 138 is configured to bias spray valve 36 into the closed state. Spring 138 urges the spray valve 36 towards the closed state. Spring 138 biases ball 130 into seat 128 to close spray valve 36 and maintain spray valve 36 in the closed state. The spring 138 is disposed within fluid chamber 110 in the example shown such that spring 138 is exposed to spray fluid, through it is understood that in various other examples the spring 138 can be outside of the fluid chamber 110. In some examples the spring 138 is a dry component that is not exposed to the spray fluid. In the example shown, the spring 138 radially surrounds the rod 132 such that rod 132 extends within and through spring 138. Spring 138 is disposed coaxially with rod 132 on valve axis VA. The spring 138 is disposed coaxially with spray valve 36 and outlet 112 in the example shown. The spring 138 interfaces with base 108 and ball holder 134 to bias the spray valve 36 towards the closed state.

[0093] Solenoid 38 is fully disposed within gun body 30 with cartridge 82 mounted to valve housing 86. Solenoid 38 is fully disposed within upper housing 31 with cartridge 82 mounted to valve housing 86. In the example shown, a portion of solenoid 38 is supported by the valve housing 86 such that that portion of the solenoid 38 remains mounted to the valve housing 86 with cartridge 82 dismounted. Solenoid 38 is configured to actuate spray valve 36 inside of the cartridge 82. The solenoid 38 includes coil section 84 and plunger 88. Plunger 88 can be considered to form an armature of the solenoid 38. In the example shown, coil section 84 is supported by valve housing 86. Coil section 84 remains mounted within gun body 30 with cartridge 82 dismounted. The coil section 84 forms the stator of the solenoid 38.

[0094] Coil 176 is located within the coil section 84. The coil 176 generates an electromagnetic field by running electrical current through one or more wound conductors, such as one or more copper conductors wound into a plurality of loops. The conductors can be in the form of round wire, flat ribbon strand, etc. The electromagnetic field can pull or repel magnetically sensitive materials. Such magnetically sensitive materials are located within and / or form portions of the plunger 88. For example, the plunger 88 can be formed from ferrous material that is pulled by the electromagnetic field generated by the coil 176. The plunger 88 can contain soft magnetic metal that can be easily magnetized and demagnetized at low magnetic fields. The plunger 88 can be pulled towards and / or through the pocket of the coil 176 when the coil 176 is electrically activated with electrical current. The plunger 88 can additionally or alternatively include a magnet. Such pulling overcomes the spring 138 within the cartridge 82 to open the spray valve 36.

[0095] Coil section 84 extends annularly about the plunger 88. In the example shown, the coil section 84 is partially radially overlapped with the plunger 88 and partially radially overlapped with a portion of the cartridge body 104 that axially overlaps with the plunger 88. Coil 176 does not axially overlap with plunger 88 in the example shown.

[0096] The solenoid 38 is able to actuate the valve 36 by the rod 132 that extends from within the fluid chamber 110 and through the dynamic seal 136. The rod 132 can be adhered, pinched, crimped, swaging, or otherwise attached directly to the plunger 88. In the example shown, the rod 132 extends through the plunger 88. The rod 132 can extend fully axially through the plunger along the axis VA. In the example shown, the rod 132 extends entirely through the plunger 88 such that the rod 132 extends forward and rearward of the plunger 88. However, in various other examples, the rod 132 does not extend rearward of the plunger 88. In some examples, the rod 132 terminates inside of the plunger 88.

[0097] Part of solenoid 38 is included in cartridge 82. Cartridge 82 includes the valve 36 and the plunger 88, but in this example does not include a coil, such as coil 176. Plunger 88 is located within plunger guard 140. The plunger guard 140 can be part of the cartridge body 104. In the example shown, the plunger guard 140 is formed as part of the base 108. The plunger guard 140 extends rearward beyond the plunger 88 such that the plunger 88 remains within a plunger chamber 142 of the plunger guard 140. Such a configuration is advantageous because, when the cartridge 82 is outside of the valve housing 86, the plunger 88 is still protected within the plunger guard 140. Such risks may include the bending of the rod 132 if the plunger 88 was exposed. In some examples, the plunger 88 may extend partially outside of the plunger guard 140 when the plunger 88 is pulled by the coil 176, such as in examples not including end cap 144. In various other examples, the full extent of travel of the plunger 88 still keeps the plunger 88 within the plunger guard 140 such that the plunger 88 does not extend beyond or past the plunger guard 140. As such, the plunger 88 reciprocates within the plunger guard 140. The exterior of the plunger 88 can be cylindrical and the plunger chamber 142 can likewise be cylindrical such that only a small air gap exists between the plunger 88 and the plunger guard 140. Other shapes, such as squares and hexes among other options, are possible.

[0098] Plunger 88 is disposed within a plunger chamber 142 within cartridge body 104. The plunger chamber 142 is closed in both axial directions ADI, AD2 in the example shown. A portion of base 108 and dynamic seal 136 are disposed axially between plunger chamber 142 and fluid chamber 110. In the example shown, end cap 144 blocks a rear end of plunger chamber 142. End cap 144 closes plunger chamber 142 in axial direction ADI and base 108 closes plunger chamber 142 in axial direction AD2. End cap 144 is disposed over the rear end of plunger chamber 142 to protect plunger 88 from contact damage and from contaminants. The end cap 144 can seal the plunger chamber 142 or can be vented. The end cap 144 can be a disc. The end cap 144 can be the same outer diameter as the portion of base 108 radially defining plunger chamber 142. The end cap 144 can be swaged, press fit, welded, or threaded onto the base 108, amongst other connection options. It is understood that, in various other examples, cartridge 82 does not include end cap 144 and plunger chamber 142 can be open along the axis VA.

[0099] As shown, solenoid 38 can be broken up into two solenoid parts based upon the removal of the cartridge 82. Specifically, the plunger 88 is part of the cartridge 82 and is removed and is replaced with a different but mechanically identical cartridge 82 to operate with the same coil 176. Coil section 84 is part of the valve housing 86 and remains mounted with other components of spray gun 24. Coil section 84 can operate multiple different plungers 88 of multiple different cartridges 82. Is contemplated that over the life of the spray gun 24, the cartridge 82 will be replaced while the coil section 84 will remain over the life of the spray gun 24 or at least over the life of many cartridges 82. As such, part, but not all, of the solenoid 38 will be replaced each time the cartridge 82 is replaced. In various other examples, the entirety the solenoid 38 can be part of the cartridge 82 such that the entirety a solenoid 38 is replaced with each cartridge 82 replaced. It is noted that including the plunger 88 as part of the cartridge 82 can lead to enhanced reliability because the spacing between the plunger 88 and the spray valve 36 can be particularly important, because solenoids 38 have short stroke lengths and the spray valves 36 likewise rely on short stroke lengths. As such, the position of the plunger 88 has to be located within a very small margin relative to the spray valve 36, which can best be controlled in a manufacturing environment rather than via the user, such as when threading the cartridge 82 into the housing bore 94. For example, if the user does not thread the cartridge 82 to a proper degree, then solenoid 38 may not pull the proper distance to actuate the spray valve 36. But the electromagnetic field generated by the coil 176 may be broad such that there is more operational variability in the position of the plunger 88 relative to the coil 176 so long as the plunger 88 is in a fixed, known distance from the spray valve 36, as linked via the rod 132, set under factory conditions.

[0100] Cartridge body 104 can define a travel distance of the plunger 88, thereby setting an opening distance of the spray valve 36. The opening distance of the spray valve 36, which is an axial distance that the ball 130 displaces from the seat 128 in the example shown, is set within a very small margin to properly control flow through the outlet 112 and downstream through the nozzle 40 for generation of the atomized fluid spray. Opening too large or too small can lead to low quality spray. In the example shown, the end cap 144 can define a travel limit of the plunger 88, thereby defining the opening distance of the spray valve 36.

[0101] In the example shown, the end cap 144 includes cap recess 146. Cap recess 146 is configured such that an end of rod 132 that extends through plunger 88 can extend into end cap 144 to radially overlap with structure of end cap 144. In some examples, the rod 132 extends into but does not contact the end cap 144, which protects the rod 132 from bending due to contacting the end cap 144. The cap recess 146 allows for rod 132 to extend fully through plunger 88 for fixing to plunger 88 on a rear side of plunger 88. The end cap 144 can define a limit of travel for the plunger 88, and thus an opening distance of the spray valve 36, while the rod 132 that projects beyond plunger 88 is received in a portion of end cap 144 to prevent bending of rod 132.

[0102] Spray gun 24 is configured for easy and ergonomic spraying. Pulling trigger 34 generates a trigger activated signal that causes electrical power to coil 176. Coil 176 generates an electromagnetic field that pulls plunger 88 in axial direction ADI. Plunger 88 displaces spray valve 36 to the open state and spray fluid flows downstream through outlet 112 and then through nozzle 40 to be output as an atomized fluid spray. Plunger 88 displaces spray valve 36 via rod 132. Rod 132 is connected to plunger 88 and ball 130 to pull ball 130 off of seat 128. The trigger 34 is not mechanically connected to spray valve 36 to actuate spray valve 36. The user does not have to overcome the pressure in fluid chamber 110 to actuate the spray valve 36 to the open state, reducing user fatigue and providing for more efficient spray operations.

[0103] The cartridge 82 mounts to and dismounts from the valve housing 86 as a single unit. The cartridge 82 is a unitary assembly that includes spray valve 36 and the actuator of spray valve 36 (such actuator formed by plunger 88 in the example shown) in the same assembly that mounts together and dismounts together. Both the actuator that opens spray valve 36 (e.g., plunger 88) and the actuator that closes spray valve (e.g., spring 138) are included in the unitary assembly of cartridge 82. The cartridge 82 includes all components that mechanically actuate the spray valve 36 to both the open state and the closed state. In the example shown, the components that electromagnetically actuate the spray valve 36 remain mounted with valve housing 86 with cartridge 82 dismounted.

[0104] The cartridge 82 can mount to and dismount the valve housing 86 by manipulation of the cartridge 82 alone. With tip assembly 118 removed, the cartridge 82 can be mounted within housing bore 94 and / or dismounted from housing bore 94 without manipulating other components of spray gun 24. The trigger 34 does not need to be shifted or manipulated to mechanically interface with any actuator of the spray valve 36. Instead, all mechanical interfaces for displacing the spray valve 36 are part of the unitary assembly of cartridge 82. In the example shown, all mechanical actuators (e.g., the spring 138 and plunger 88) for displacing the spray valve 36 are disposed within the cartridge body 104. Such mechanical actuators are enclosed within cartridge body 104 such that the components are not accessible from outside of cartridge body 104 by any other mechanical element to cause actuation of spray valve 36 during spray operations.

[0105] All mechanical actuators being part of cartridge 82 reduces wear on flow control components of cartridge 82 and can provide for a more robust and long lasting configuration. The mechanical actuators are disposed coaxially on the valve axis VA and are disposed within cartridge body 104. The mechanical actuators are configured to displace the movable seal of the spray valve 36 along the actuation axis AA, which is coaxial with the axis VA. The mechanical actuators are coaxially aligned and no mechanical interface that could impart side loading on rod 132 is formed with cartridge 82 during mounting of cartridge 82.

[0106] Spray gun 24 provides a balanced configuration that allows for easy use of spray gun 24. The cartridge 82 spans the gun handle 32 such that cartridge 82 extends forward of gun handle 32 and extends rearward of at least a portion of a rear side of gun handle 32. The valve housing 86 spans across handle such that valve housing 86 extends both forward and rearward of portions of gun handle 32. The valve housing 86 and cartridge 82 spanning the gun handle 32can balance spray gun 24 when the user is grasping the gun handle 32.

[0107] The mechanical actuators of spray valve 36 (e.g., spring 138 and plunger 88) and the electromechanical actuator of spray valve 36 (e.g., coil section 84) are disposed within support body 154 of gun body 30. The fluid hose 46 and the conductors 48 that connect to solenoid 38 pass through gun handle 32. The spray fluid enters into valve housing 86 and the electrical conductors 48 connect to solenoid 38 at locations within support body 154.

[0108] The cartridge 82 extends from within gun body 30 to outside of gun body 30 with cartridge 82 mounted to valve housing 86. The cartridge 82 extends from within valve housing 86 to outside of valve housing 86 with cartridge mounted to valve housing 86. The cartridge 82 extends out of valve housing 86 such that cartridge 82 can be accessed from outside of valve housing 86, such as by a tool (e.g., a wrench), by engaging a portion of cartridge body 104 outside of valve housing 86 to form or break the static interface formed at fixation 100.

[0109] FIG. 5A is a cross-sectional view showing fluid handling components of spray gun 24. FIG. 5B is an exploded view of the components shown in FIG. 5 A. FIGS. 5 A and 5B are discussed with continued reference to FIGS. 3A-4. Valve housing 86 includes fluid receiver 148, coil housing 150, and solenoid cap 152. Fluid receiver 148 is fluidly connected to fluid hose 46 to receive the spray fluid from the conduit 28. Fluid receiver 148 is configured to receive and connect to cartridge 82. Fixation 100 is formed between cartridge body 104 and fluid receiver 148. In the example shown, housing bore 94 extends fully axially through fluid receiver 148. In the example shown the housing bore 94 is formed partially within the fluid receiver 148 and partially within coil housing 150. The base 108 of cartridge 82 extends into coil housing 150 to radially overlap with coil section 84 with cartridge 82 mounted to valve housing 86.

[0110] Coil housing 150 is connected to fluid receiver 148. In the example shown, support body 154 of coil housing 150 includes coil mount 156, housing portion 158a, and housing portion 158b. Coil mount 156 is configured to interface with a portion of fluid receiver 148 to mount coil housing 150 to fluid receiver 148. In the example shown, the coil mount 156 is configured to interface with the fluid receiver 148 at a threaded interface. In the example shown, the coil mount 156 includes exterior threading configured to interface with interior threading formed within the fluid receiver 148. While coil housing 150 is shown as connected to fluid housing 106 by a threaded interface, it is understood that not all examples are so limited. For example, coil housing 150 can be swaged, press fit, welded, or otherwise connected to fluid housing 106.

[0111] The coil mount 156 extends into the fluid receiver 148 to connect to the fluid receiver 148 in the example shown. The coil mount 156 extends into the fluid receiver 148 such that the coil housing 150 radially overlaps with the fluid receiver 148 at the interface between coil housing 150 and fluid receiver 148. In the example shown, a portion of the coil housing 150 is radially within a portion of the fluid receiver 148 such that a radial line extending from the valve axis VA passes first through the coil housing 150 and then through the fluid receiver 148 at the interface therebetween. The coil mount 156 extending into the valve housing 86 to connect to valve housing 86 provides for a smaller footprint for cartridge 82 and can assist in positioning coil 176 closer to plunger 88 to more efficiently actuate plunger 88. Housing portion 158a extends from coil mount 156. Housing portion 158a projects radially outward from coil mount 156. In the example shown, housing portion 158a projects radially outward of portions of the fluid receiver 148. As such, the coil housing 150 can both radially and axially overlap with the fluid receiver 148. The housing portion 158a can brace against an axial end face of the fluid receiver 148. The coil housing 150 can be configured such that portions of coil housing 150 are disposed directly radially inward of structure of the fluid receiver 148 and portions of coil housing 150 extend radially outward of structure of the fluid receiver 148.

[0112] Housing portion 158b extends from housing portion 158a. Housing portion 158b extends axially outward from housing portion 158b. In some examples, housing portion 158b can be disposed orthogonal to housing portion 158a, though it is understood that not all examples are so limited. Housing portion 158b extends to a rearward end of valve housing 86.

[0113] In the example shown, coil section 84 is disposed within an area overlapped by housing portion 158a and housing portion 158b. The coil section 84 radially overlaps with housing portion 158b. The coil section 84 axially overlaps with housing portion 158a. In the example shown, the coil section 84 axially overlaps with fluid receiver 148.

[0114] Outer notch 160 is formed at the interface between housing portion 158a and housing portion 158b. Outer notch 160 can extend fully annularly about the axis VA. Coil section 84 is seated within outer notch 160. Coil section 84 can extend fully annularly about the axis VA. Coil section 84 being seated within outer notch 160 locates coil section 84 axially and radially relative to the housing bore 94, and thus relative to the plunger 88 that is installed with and removed with cartridge 82. It is understood, however, that coil housing 150 can receive coil section 84 within outer notch 160 regardless of whether spray valve 36 is mountable with a cartridge 82 or not. In some examples, spray valve 36 is supported by valve housing 86 but not disposed within a removable cartridge 82.

[0115] Solenoid cap 152 is connected to support body 154 of coil housing 150 in the example shown. Solenoid cap 152 can be considered to form a portion of valve housing 86. Solenoid cap 152 forms a portion of coil housing 150 in the example shown. Solenoid cap 152 is disposed at an opposite axial end of the housing bore 94 from mount opening 162 through which the cartridge 82 enters into and exits from the housing bore 94. In the example shown, solenoid cap 152 extends to close a second end of the housing bore 94 opposite the first end at which mount opening 162 is formed. The solenoid cap 152 extends such that the axis VA extends through structure of the solenoid cap 152 in the example shown. The solenoid cap 152 can be disposed coaxially with plunger 88 and rod 132 on valve axis VA. The solenoid cap 152 can be disposed coaxially with cartridge 82 with cartridge 82 mounted to valve housing 86.

[0116] In the example shown, solenoid cap 152 is mounted to support body 154 by mount flange 164 of solenoid cap 152 being captured by receiver 166 of support body 154. For example, solenoid cap 152 can be positioned on coil housing 150 and then receiver 166 can be bent to axially overlap with the radially outer portions of mount flange 164 to secure solenoid cap 152 on support body 154. It is understood, however, that solenoid cap 152 can be mounted to coil housing 150 in any desired manner, such as by interfaced threading, swaging, welding, brazing, etc.

[0117] In the example shown, solenoid cap 152 includes inner notch 168. Inner notch 168 interfaces with coil section 84 on a radially inner side of coil section 84. Inner notch 168 is formed at the interface between shoulder 170 and notch body 172. Notch body 172 extends to radially overlap with coil section 84. Notch body 172 can radially overlap with one or more coils 176 of coil section 84. Shoulder 170 is disposed between mount flange 164 and notch body 172. Shoulder 170 extends to axially overlap with coil section 84. Shoulder 170 can axially overlap with coils 176 of coil section 84.

[0118] Coil section 84 is clamped between and received within outer notch 160 and inner notch 168. Outer notch 160 and inner notch 168 can radially and axially locate the coil section 84 relative to the actuation axis AA and housing bore 94. The stator portion of the solenoid 38 is axially captured between outer notch 160 and inner notch 168. Outer notch 160 is open radially inward and in axial direction ADI. Inner notch 168 is open radially outward and in axial direction AD2. Outer notch 160 and inner notch 168 oppose each other to capture coil section 84 therebetween.

[0119] In the example shown, an electrical connector 174 extends through solenoid cap 152 the electrical connector 174 connects with coil 176 to provide electrical power signals to coil 176. The electrical connector 174 extends axially to connect between coil 176 and conductor 48 in the example shown. It is understood, however, that in various other examples the electrical connector 174 can extend radially, such as through support body 154. Electrical connector 174 is spaced in axial direction ADI from all fluid pathways within valve housing 86 and cartridge 82, isolating the electrical connections between conductors 48 and coil section 84 from the spray fluid.

[0120] Cartridge 82 is mountable to and removable from the valve housing 86. Such removal can be facilitated by rotation to unfix the cartridge 82 from the valve housing 86. The housing bore 94 within which the cartridge 82 is at least partially disposed when mounted to valve housing 86 is disposed coaxially with cartridge 82 during mounting and dismounting of cartridge 82. The cartridge 82 can be removed for servicing and / or replacement. The same or a different cartridge 82 can then be reinserted into the housing bore 94.

[0121] In some examples, valve housing 86 can define a mounted position of the cartridge 82. For example, cartridge 82 can be configured to extend into valve housing 86 until a portion of valve housing 86 resists further movement of cartridge 82 in axial direction ADI. In the example shown, the solenoid cap 152 is configured to limit displacement of cartridge 82 into housing bore 94 in axial direction ADI. The end cap 144 can bottom out on the notch body 172 of the solenoid cap 152 to limit further displacement of cartridge 82 into housing bore 94, which can indicate to a user that cartridge 82 is fully and properly installed.

[0122] Spray gun 24 provides significant advantages. Cartridge 82 is mountable to and removable from valve housing 86 as a single unitary assembly. The cartridge body 104 supports both the spray valve 36 that controls flow of spray fluid through cartridge body 104 and the plunger 88 that is electromagnetically actuated to actuate the spray valve 36. The plunger 88 can be fixed relative to the spray valve 36 such that the plunger 88 mounts with and dismounts with the spray valve 36. The plunger 88 can be fixed at a location along the rod 132 to set the opening distance of the spray valve 36, providing for a set opening distance for each actuation of spray valve 36, providing for more consistent and high quality spraying.

[0123] Plunger 88 is at least partially disposed within cartridge body 104 in the examples shown. The cartridge body 104 can protect the plunger 88 from undesirable contact damage. The cartridge body 104 can shield the plunger 88 and prevent torquing of the plunger that could bend the rod 132.

[0124] In the example shown, the plunger 88 is fully contained within cartridge body 104 such that plunger 88 is axially and radially overlapped by structure that the plunger 88 moves relative to during actuation of spray valve 36. The end cap 144 axially overlapping with plunger 88 can set a displacement distance of the plunger 88, thereby setting an opening distance of the spray valve 36. The displacement distance of the plunger 88 being set by cartridge body 104 provides for a consistent stroke distance for the plunger 88, and thus the spray valve 36, for each actuation of the spray valve 36. The stator of solenoid 38 is assembled by axial stacking of components along the valve axis VA. Coil housing 150 extends axially into fluid receiver 148 to connect to fluid receiver 148. The coil housing 150 being radially inward of the fluid receiver 148 at that connection interface, which connection interface connects the coil section 84 to the fluid receiver 148 that supports the cartridge 82 and thus the plunger 88, facilitates a more compact configuration of cartridge 82. The cartridge body 104 can be closely fit to the portion of coil housing 150 that defines the housing bore 94. The coil section 84 can be placed radially closer to valve axis VA and thus to plunger 88, providing for more efficient operation.

[0125] The coil section 84 is axially captured between outer notch 160 and inner notch 168. The coil section 84 can slide axially into the outer notch 160 to be positioned within the outer notch 160. The solenoid cap 152 can then be assembled to support body 154 such that inner notch 168 receives a portion of coil section 84. The coil section 84 is axially captured within the opposed notches. The coil section 84 is also radially captured by the opposed notches. Capturing the coil section 84 axially and radially locates the coil section 84 relative to housing bore 94 and thus relative to the location that plunger 88 is disposed with cartridge 82 mounted to valve housing 86.

[0126] The coil section 84 is captured between support body 154 and solenoid cap 152. Solenoid cap 152 can shift axially relative to support body 154 to interface with support body 154. The solenoid cap 152 can axially and radially support the coil section 84. The axial stacking of the stator (e.g., coil section 84) and stator support (e.g., coil housing 150) provides for a compact configuration of the stator section of the solenoid 38. Such a configuration can provide for a smaller gun body 30 for enclosing portions of the valve housing 86, allowing for a more ergonomic and easier to manipulate spray gun 24.

[0127] FIG. 6 is an enlarged view of detail 6 in FIG. 5A. FIG. 7 is a plot illustrating flow of electromagnetic flux. FIGS. 6 and 7 are discussed together with continued reference to FIGS. 1-5B.

[0128] Plunger 88 is offset from coil 176. In the example shown, plunger is offset from coil 176 both radially and axially. A first part of the plunger 88 radially overlaps the coil 176 and a second part of the plunger 88 does not radially overlap the coil 176. The second part of the plunger 88 is closer to the spray valve 36 than the first part of the plunger 88. If this were reversed such that the part of the plunger 88 that does not radially overlap with the coil 176 is located on the opposite side of the coil 176, farther away from the spray valve 36, then the rod 132 or equivalent structure would need to span the entire distance of the coil 176, making for a less compact assembly and harder to manage spray gun 24.

[0129] Plunger 88 is radially offset from coil 176. The radial offset between plunger 88 and coil 176 generates air gaps that are disruptive to the flow of electromagnetic flux. Plunger guard 140 extends into the solenoid gap 188 formed between plunger 88 and coil section 84. The plunger guard 140 includes flux permeability zone 190 and flux reluctance zone 192. The flux permeability zone 190 is formed from a first type of material, such as ferromagnetic material, or other type of material that attracts and channels the flow of electromagnetic flux. The flux reluctance zone 192 is formed from a second type of material, such as non-ferromagnetic material, or other type of material that does not attract and channel the flow of electric magnetic flux. It can be appreciated that the zones are tubular in shape, with the plunger 88 moving radially inward of the zones while the coil housing 150 is radially outward of the zones. In this and various other examples, these different zones are formed by different structures. For example, the flux permeability zone 190 is formed from steel, such as stainless steel, while the flux reluctance zone 192 is formed by aluminum or polymer, amongst other nonferrous material options.

[0130] In the example shown, the flux permeability zone 190 is shown as formed from root part 194. The root part 194 can be contiguous with the base 108, such that the parts are formed from the same piece of material. As such, ferric material can axially overlap with plunger 88 axially between plunger 88 and spray valve 36. The ferric material can axially overlap with plunger 88 upstream of plunger 88. In some examples, a contiguous piece of ferric material can radially and axially overlap with plunger 88. The flux permeability zone 190 can, in some examples, not radially overlap with coils 176. In some examples, the flux permeability zone 190 does not radially overlap with coil section 84. The flux permeability zone 190 being spaced axially from coil section 84 assists in routing flow of electromagnetic flux to displace plunger 88 in the downstream direction. The flux permeability zone 190 is spaced axially from coil section 84 in an opposite axial direction from the axial direction that the plunger 88 displaces during opening of spray valve 36.

[0131] The flux reluctance zone 192 is shown as formed from extension part 196. In the example shown, the extension part 196 is connected to the root part 194. In particular, the extension part 196 is only connected to the root part 194 and not to other parts of cartridge body 104. The extension part 196 can be formed from aluminum, polymer, zinc, or other type of non-ferrous material. In the example shown, the extension part 196 is cantilevered from the root part 194. The extension part 196 extends to radially overlap with coils 176. The extension part 196 partially radially overlaps with coil section 84 and partially does not radially overlap with coil section 84.

[0132] The extension part 196 interfaces with the root part 194 at zone interface 198. The extension part 196 is disposed radially outward from the root part 194 at zone interface 198 in the example shown, though it is understood that in other examples root part 194 can be disposed radially outward of extension part 196. The zone interface 198 is partially formed from ferric material and partially formed from nonferric material. The zone interface 198 does not radially overlap with the coil section 84 in the example shown.

[0133] The plunger 88 is disposed within the plunger chamber 142. The plunger 88 is configured to reciprocate within the plunger chamber 142 during actuation of the spray valve 36. The plunger chamber 142 is partially defined by the flux permeability zone 190 and partially defined by the flux reluctance zone 192. The plunger chamber 142 is partially defined by root part 194 and partially defined by extension part 196. The plunger chamber 142 is axially defined by ferric material (e.g., of end cap 144 and base 108) and radially defined by ferric material (e.g., forming flux permeability zone 190) and nonferric material (e.g., flux permeability zone 190). The amount of plunger 88 radially overlapping with flux reluctance zone 192 increases with plunger 88 being electromagnetically displaced in axial direction ADI during opening of the spray valve 36. The amount of plunger 88 radially overlapping with flux reluctance zone 192 decreases with plunger 88 being displaced in axial direction AD2 during closing of spray valve 36. The amount of plunger 88 radially overlapping with flux permeability zone 190 decreases with plunger 88 being electromagnetically displaced in axial direction ADI during opening of the spray valve 36. The amount of plunger 88 radially overlapping with flux permeability zone 190 increases with plunger 88 being displaced in axial direction AD2 during closing of spray valve 36.

[0134] Having flux permeability zone 190 and flux reluctance zone 192 can coax the flow of electromagnetic flux to enhance the operation of the solenoid 38. The need to coax comes about from the presence of the plunger guard 140 which on one hand provides mechanical protection for the plunger 88 when not mounted in the spray gun 24, but provides a solenoid gap 188 between the coil 176 and the plunger 88 in which the electromagnetic field can diminish power. The entirety of the plunger guard 140 can be made of ferrous material which can help direct the flow of flux, but some parts of the plunger guard 140 being ferromagnetic can be counterproductive. Specifically, the part of the plunger guard 140 that is directly radially between the plunger 88 and the coil 176 can provide a flux short circuit, whereas axial projection of the magnetic field outward fosters better electromagnetic interaction with the whole of the plunger 88. Accordingly, the flux reluctance zone 192 is made of material that does not support the flow of electromagnetic flux whereas the material that forms the flux permeability zone 190 that is outside of the radial overlap between the coil 176 and the plunger 88 is formed from ferromagnetic material to coax the flux path out along this non-overlapping area.

[0135] In the example shown, the support body 154, solenoid cap 152, base 108 including root part 194, and end cap 144 can be formed from ferromagnetic material to support the flow of electromagnetic flux. As shown in FIG. 9, there appears to be a gap in the flow of electromagnetic flux (represented by arrows EF) along the flux reluctance zone 192 which can be formed as an air gap or can be filled with extension part 196 which is not made from ferromagnetic material. As shown, the flux within the plunger 88 extends axially outward and towards the flux permeability zone 190 which causes it to interact with more of the plunger 88 before being routed through the ferromagnetic material of the coil housing 150 back towards the coil 176. If the flux reluctance zone 192 were filled with ferromagnetic material in the same manner as the flux permeability zone 190, then significantly less of the flux would be projected along the flux permeability zone 190 and less of the flux would be flowing over the entirety of the plunger 88, diminishing the performance of the solenoid 38.

[0136] Flux permeability zone 190 and flux reluctance zone 192 provide significant advantages. Flux reluctance zone 192 does not support flow of electromagnetic flux such that the electromagnetic flux is routed axially outward relative to the radial overlap between coil section 84 and plunger 88. Such a configuration facilitates stronger pull of the plunger 88, allowing for a lower voltage to be delivered to the coil 176, which can decrease heating and can allow a smaller battery to be used and can allow for longer battery life.

[0137] Plunger 88 is disposed within the plunger guard 140 that protects plunger 88 and rod 132 when cartridge 82 is disconnected from spray gun 24. The plunger guard 140 radially surrounding the plunger 88 and extending axially beyond the plunger 88 in the upstream direction ADI fully radially encloses the plunger 88 protecting from bending contact that could bend rod 132 and harm the functionality of cartridge 82. The presence of plunger guard 140 generates the large solenoid gap 188 which diminishes performance by creating one or more air gaps between coil section 84 and plunger 88. The flux reluctance zone 192 shifts material that can route electromagnetic flux axially from coil section 84 to enhance performance of solenoid 38 while also enclosing plunger 88 to protect plunger 88. FIG. 8 is an isometric view of cartridge 82. FIG. 9 is a cross-sectional view taken along line 9-9 in FIG. 8 showing a connection between plunger 88 and rod 132. FIG. 10 is a cross-sectional view of cartridge 82 taken along line 10-10 in FIG. 9. FIG. 11 is an isometric view showing plunger 88 and rod 132. FIGS. 8-11 are discussed together.

[0138] Cartridge body 104 includes fluid housing 106 and base 108. The fluid housing 106 and base 108 can be connected together in any desired manner. For example, the fluid housing 106 and base 108 can be threaded together. In various other examples, a single housing may be provided, however in this example the fluid housing 106 forms a forward housing part that principally contains the spray valve 36 while the base 108 forms a rearward part that, in the example shown, contains the plunger 88 part of the solenoid 38. The base 108 can be exposed to the pressure within the fluid chamber 110 but does not radially surround the fluid chamber 110 and thus may not be in the manner of a pressure vessel. Fluid housing 106 does radially surround fluid chamber 110 and can thus be considered to be in the form of a pressure vessel.

[0139] Outlet 112 is formed at a downstream end of cartridge body 104. Cartridge 82 is configured to emit spray fluid through outlet 112. Ports 114 are formed through cartridge body 104. Ports 114 are formed through fluid housing 106 in the example shown. Ports 114 are configured to admit spray fluid into fluid chamber 110 from housing chamber 98 of valve housing 86. Ports 114 can receive spray fluid from the channel that extends through the valve housing 86. Ports 114 form inlets of the cartridge 82 that admit spray fluid into the cartridge 82. In the example shown, an array of ports 114 are formed about the cartridge body 104.

[0140] Spray valve 36 is disposed within cartridge body 104. Spray valve 36 includes seat 128, such as a ceramic or carbide ring, which interfaces with ball 130 in the example shown. In the example shown, ball 130 is configured to interface with seat 128 and such interfacing of the ball 130 and the seat 128 closes the spray valve 36 but moving the ball 130 away from the seat 128 opens the spray valve 36 to allow spray fluid within the fluid chamber 110 to exit through the outlet 112. The spray valve 36 is actuatable between an open state, in which the fluid chamber 110 is fluidly connected to outlet 112 such that spray fluid can flow through outlet 112 and to nozzle 40, and a closed state, in which the fluid chamber 110 is fluidly disconnected from outlet 112 and nozzle 40.

[0141] Rod 132 is configured to connect spray valve 36 to solenoid 38 such that solenoid 38 can actuate spray valve 36. Rod 132 can be a wire or other stiff, high tensile component which, in this example, extends from the plunger 88 of the solenoid 38 to the ball holder 134. Ball 130 is mounted to ball holder 134.

[0142] Dynamic seal 136 is located around the rod 132. Dynamic seal 136 separates the high pressure within the fluid chamber 110 from the dry components, such as the plunger 88. The dynamic seal 136 can be a rubber component compressed circumferentially around the rod 132 to prevent the escape of spray fluid from around the rod 132. Dynamic seal 136 is supported by base 108 in the example shown. Dynamic seal 136 extends at least partially within base 108 such that base 108 radially overlaps with dynamic seal 136. Dynamic seal 136 sealingly engages with rod 132 and rod 132 can slide relative to dynamic seal 136 during actuation of spray valve 36.

[0143] Spring 138 is configured to bias spray valve 36 into the closed state. Spring 138 urges the spray valve 36 towards the closed state. In the example shown, spring 138 is disposed within fluid chamber 110. Spring 138 biases ball 130 into seat 128 to close spray valve 36 and maintain spray valve 36 in the closed state. The spring 138 is disposed within fluid chamber 110 in the example shown such that spring 138 is exposed to spray fluid, through it is understood that in various other examples the spring 138 can be outside of the fluid chamber 110. In some examples the spring 138 is a dry component that is not exposed to the spray fluid. In the example shown, the spring 138 radially surrounds the rod 132 such that rod 132 extends within and through spring 138. Spring 138 is disposed coaxially with rod 132 on valve axis VA. The spring 138 is disposed coaxially with spray valve 36 and outlet 112 in the example shown. The spring 138 interfaces with base 108 and ball holder 134 to bias the spray valve 36 towards the closed state.

[0144] The solenoid 38 is configured to actuate the spray valve 36 by rod 132 that extends from within the fluid chamber 110 and through the dynamic seal 136. Plunger 88 forms the portion of the solenoid 38 that mechanically displaces the movable component of spray valve 36. The plunger 88 is fixed to the rod 132. Displacement of plunger 88 in axial direction ADI causes displacement of rod 132 to open the spray valve 36.

[0145] The rod 132 extends at least partially within the plunger 88. In the example shown, the rod 132 extends through the plunger 88. The rod 132 can extend fully axially through the plunger along the axis VA. In the example shown, the rod 132 extends entirely through the plunger 88 such that the rod 132 extends forward and rearward of the plunger 88. However, in various other examples, the rod 132 does not extend rearward of the plunger 88. In some examples, the rod 132 terminates inside of the plunger 88. Plunger 88 is disposed within plunger chamber 142. In the example shown, the plunger chamber 142 is disposed within cartridge body 104. While plunger 88 and spray valve 36 are described as included in a removable and replaceable cartridge 82, it is understood that not all examples ae so limited. The plunger chamber 142 is closed in both axial directions ADI, AD2 in the example shown. A portion of base 108 and dynamic seal 136 are disposed axially between plunger chamber 142 and fluid chamber 110.

[0146] In the example shown, end cap 144 blocks a rear end of plunger chamber 142. End cap 144 closes plunger chamber 142 in axial direction ADI and base 108 closes plunger chamber 142 in axial direction AD2. End cap 144 is disposed over the rear end of plunger chamber 142 to protect plunger 88 from contact damage and from contaminants. The end cap 144 can seal the plunger chamber 142 or can be vented. The end cap 144 can be a disc. The end cap 144 can be the same outer diameter as the portion of base 108 radially defining plunger chamber 142. The end cap 144 can be swaged, press fit, welded, or threaded onto the base 108, amongst other connection options. It is understood that, in various other examples, cartridge 82 does not include end cap 144 and plunger chamber 142 can be open along the axis VA.

[0147] Plunger 88 is located within plunger guard 140. The plunger guard 140 can be part of the cartridge body 104. In the example shown, the plunger guard 140 is formed as part of the base 108. The plunger guard 140 extends rearward beyond the plunger 88 such that the plunger 88 remains within a plunger chamber 142 of the plunger guard 140 throughout operation, though it is understood that not all examples are so limited. Such a configuration is advantageous because, when the cartridge 82 is outside of the valve housing 86, the plunger 88 is still protected within the plunger guard 140. Such risks may include the bending of the rod 132 if the plunger 88 was exposed and impacted. In some examples, the plunger 88 may extend partially outside of the plunger guard 140 when the plunger 88 is pulled by the coil 176, such as in examples not including end cap 144. In various other examples, the full extent of travel of the plunger 88 still keeps the plunger 88 within the plunger guard 140 such that the plunger 88 does not extend beyond or past a distal end of the plunger guard 140.

[0148] The plunger 88 reciprocates within the plunger guard 140. The exterior of the plunger 88 can be cylindrical and the plunger chamber 142 can likewise be cylindrical such that only a small air gap exists between the plunger 88 and the plunger guard 140. Other shapes, such as squares and hexes are possible, among other options. The spacing between the plunger 88 and the spray valve 36 can be particularly important, because solenoids 38 have short stroke lengths and the spray valves 36 likewise rely on short stroke lengths. As such, the position of the plunger 88 has to be located within a very small margin relative to the spray valve 36, which can best be controlled in a manufacturing environment rather than via the user, such as when threading the cartridge 82 into the housing bore 94. For example, if the user does not thread the cartridge 82 to a proper degree, then solenoid 38 may not pull the proper distance to actuate the spray valve 36. But the electromagnetic field generated by the coil 176 may be broad such that there is more operational variability in the position of the plunger 88 relative to the coil 176 so long as the plunger 88 is in a fixed, known distance from the spray valve 36, as linked via the rod 132, set under factory conditions.

[0149] A hard stop can define a travel distance of the plunger 88, thereby setting an opening distance of the spray valve 36. In the example shown, the hard stop can be formed by the cartridge body 104, though it is understood that not all examples are so limited. The opening distance of the spray valve 36, which is an axial distance that the ball 130 displaces from the seat 128 in the example shown, is set within a very small margin to properly control flow through the outlet 112 and downstream through the nozzle 40 for generation of the atomized fluid spray. Opening too large or too small can lead to low quality spray. In the example shown, the end cap 144 can define a travel limit of the plunger 88, thereby defining the opening distance of the spray valve 36.

[0150] In the example shown, the end cap 144 includes cap recess 146. Cap recess 146 is configured such that an end of rod 132 that extends through plunger 88 can extend into end cap 144 to radially overlap with structure of end cap 144. In some examples, the rod 132 extends into but does not contact the end cap 144, which protects the rod 132 from bending due to contacting the end cap 144. The cap recess 146 allows for rod 132 to extend fully through plunger 88 for fixing to plunger 88. The rod 132 extending fully through plunger 88 allows for movement of plunger 88 along rod 132 during assembly to a desired location for setting the opening distance of spray valve 36. The end cap 144 can define a limit of travel for the plunger 88, and thus an opening distance of the spray valve 36, while the rod 132 that projects beyond plunger 88 is received in a portion of end cap 144 to prevent bending of rod 132.

[0151] Plunger 88 is clamped to rod 132 in the example shown. Plunger 88 includes plunger base 200, plunger arms 202a, 202b, slot 204, rod bore 206, and passage 208. Plunger fastener 210 is connected to plunger 88 to clamp rod 132 between plunger arms 202a, 202b.

[0152] Plunger base 200 is disposed at a first axial end of plunger 88. Plunger arms 202a, 202b extend axially from plunger base 200. In the example shown, the plunger arms 202 extend to an opposite second axial end of plunger 88 from plunger base 200. Plunger arms 202a, 202b are cantilevered from plunger base 200 in the example shown.

[0153] The first axial end of plunger 88 is oriented axially downstream in direction AD2 in the example shown. The second axial end of plunger 88, to which plunger arms 202a, 202b extend, is oriented axially upstream in direction ADI in the example shown. The end of plunger 88 axially closest to spray valve 36 along actuation axis AA can also be referred to as a proximal end of plunger 88. The end of plunger 88 opposite the proximal end can also be referred to as a distal end of plunger 88. The plunger arms 202a, 202b extend in axial direction ADI to the distal end of plunger 88 in the example shown.

[0154] Rod bore 206 extends axially within plunger 88. In the example shown, the rod bore 206 extends fully axially through plunger 88. Rod bore 206 is disposed coaxially with actuation axis AA in the example shown. Rod 132 is disposed within rod bore 206. Rod 132 can extend fully axially through rod bore 206, though not all examples are so limited.

[0155] Rod bore 206 is partially defined by plunger base 200 and partially defined by plunger arms 202a, 202b. Rod bore 206 is fully radially enclosed, along actuation axis AA, within plunger base 200. Rod bore 206 is partially radially enclosed, along actuation axis AA, within plunger arms 202a, 202b. Plunger base 200 extends fully annularly around the portion of rod bore 206 within plunger base 200. In some examples, rod bore 206 can form the only opening fully through plunger base 200.

[0156] Each plunger arm 202a, 202b extends partially circumferentially around the rod 132. In the example shown, a rod groove 212 is formed in each plunger arm 202a, 202b. The rod grooves 212 are formed in the surfaces of the plunger arms 202a, 202b defining the slot 204. The rod grooves 212 are opposed from each other and open into the slot 204. The portion of the rod bore 206 formed through plunger arms 202a, 202b is defined by the opposed rod grooves 212. Each rod groove 212 extends partially around the rod 132.

[0157] Slot 204 is formed in plunger 88. Slot 204 is formed along a cut plane that extends axially along the rod bore 206 and actuation axis AA. The slot 204 extends partially axially through plunger 88 and fully radially through plunger 88. Slot 204 is disposed between plunger arms 202a, 202b and divides plunger arms 202a, 202b such that plunger arms 202 are cantilevered from plunger base 200. The plunger arms 202a, 202b are spaced from each other across slot 204.

[0158] As best seen in FIG. 10, slot 204 extends for a majority of the axial length LI of plunger 88 relative to actuation axis A A. Slot 204 has an axial length L2 along actuation axis AA. The length L3 of plunger base 200 can form the remainder of the length of the plunger 88, such that length LI is equal to length L2 plus length L3. The length L2 of the slot 204 greater than half of the length LI of the plunger 88. In some examples, the length L2 of the slot 204 is at least 70% of the length LI of the plunger 88. In some examples, the length L2 of the slot 204 is at least 75% of the length LI of the plunger 88. In some examples, the length L2 of the slot 204 can be up to 80% of the length LI of the plunger 88. In some examples, the length L2 of the slot 204 can be greater than 80% of the length LI of the plunger 88. In some examples, the length L2 of the slot 204 can be greater than about 85% of the length LI of the plunger 88. The relatively long length L2 of slot 204 relative to the length L3 of plunger base 200 facilitates flexing of the plunger arms 202a, 202b such that plunger arms 202a, 202b can be pulled together to reduce a width of slot 204 and clamp rod 132 between plunger arms 202a, 202b.

[0159] Passage 208 is formed in plunger 88. In the example shown, passage 208 is formed in both plunger arm 202a and plunger arm 202b. Passage 208 extends fully through plunger arm 202a in the example shown such that passage 208 is open through two locations on plunger arm 202a. Passage 208 is open on an exterior of plunger arm 202a and on a inner face 214 of plunger arm 202a defining slot 204. Passage 208 extends fully through plunger arm 202b in the example shown such that passage 208 is open through two locations on plunger arm 202a. Passage 208 is open on an exterior of plunger arm 202b and on an inner face 214 of plunger arm 202b defining slot 204. Passage 208 includes arm recess 216 and receiver 218 in the example shown. Passage 208 can extend along a passage axis PA.

[0160] In the example shown, each plunger arm 202a, 202b includes a proximal portion 220 that extends from plunger base 200 and a distal portion 222 that extends from the proximal portion 220 to the distal end of each plunger arm 202a, 202b. The distal end of each plunger arm 202a, 202b is the end opposite the end connected to the plunger base 200. The proximal portion 220 and the distal portion 222 can each extend for half of the length of each plunger arm 202a, 202b. The proximal portion 220 can be considered to form an inner arm portion and the distal portion 222 can be considered to form an outer arm portion.

[0161] In the example shown, the passage 208 is formed through the distal portion 222 of each plunger arm 202a, 202b. The passage 208 is disposed axially closer to the distal end of plunger 88 (relative to actuation axis AA) than to plunger base 200. Passage 208 is formed in distal portions 222 of plunger arms 202a, 202b to facilitate flexing of plunger arms 202a, 202b and thus clamping of the rod 132 by the plunger arms 202a, 202b. Positioning the passage 208 in the distal portion 222 of each plunger arm 202a, 202b increases the length of the moment arm from the plunger base 200, facilitating flexing and clamping with less required force.

[0162] In the example shown, the passage 208 is radially offset from the rod 132. The passage axis PA is offset from the actuation axis AA along which the rod bore 206 and rod 132 extend. The passage 208 is configured such that the passage axis PA does not intersect with the actuation axis AA. In the example shown, the passage axis PA is oriented perpendicular to, but is offset from, the actuation axis AA of the rod bore 206. In some examples, the passage 208 is disposed such that the passage axis PA is oriented orthogonal to the cut plane of the slot 204.

[0163] Passage 208 is offset from rod bore 206 and rod 132 such that plunger fastener 210 does not directly contact rod 132. The plunger fastener 210 does not directly clamp the rod 132 to the plunger 88 but instead pulls plunger arms 202a, 202b together to reduce the size of slot 204 and clamp rod 132 between plunger arms 202a, 202b. The plunger fastener 210 directly interfaces with the plunger 88 and the plunger 88 clamps on the rod 132. The plunger fastener 210 pulling the plunger arms 202a, 202b together to reduce the size of slot 204 exerts even forces along the length of rod 132, inhibiting bending or other deformation of the rod 132 during clamping. A fastener directly interfacing with the rod 132 could exert a point load that causes bending of the rod 132. While passage 208 is offset from rod bore 206 and rod 132, it is understood that not all examples are so limited.

[0164] Arm recess 216 is formed in plunger arm 202a. Arm recess 216 extends fully through plunger arm 202a. Arm recess 216 includes outer recess 224 and inner recess 226. Outer recess 224 is open through the exterior surface of plunger arm 202a. Inner recess 226 extends between outer recess 224 and slot 204. Outer recess 224 and inner recess 226 can be formed as cylindrical bores, among other options.

[0165] Passage shoulder 228 is disposed between outer recess 224 and inner recess 226. Passage shoulder 228 extends radially inward relative to passage axis PA such that a radial width of the arm recess 216 reduces between outer recess 224 and inner recess 226.

[0166] Receiver 218 is axially aligned with arm recess 216 along passage axis PA.

[0167] Receiver 218 is into slot 204. In the example shown, receiver is further open through the exterior of plunger arm 202b such that receiver 218 extends fully through plunger arm 202b. Receiver 218 is configured to interface with plunger fastener 210 to connect the plunger fastener 210 to plunger 88. In the example shown, receiver 218 includes interior threading configured to interface with exterior threading on plunger fastener 210, though it is understood that other connection interfaces are possible.

[0168] Passage 208 is configured to receive plunger fastener 210. Plunger fastener 210 interfaces with plunger 88 to clamp rod 132 between plunger arms 202a, 202b. Plunger fastener 210 extends through arm recess 216 and into receiver 218. Outer recess 224 is configured such that the fastener head 230 of fastener 210 is disposed within outer recess 224. In the example shown, outer recess 224 is configured to house fastener head 230 such that fastener head 230 is recessed within outer recess 224 and from the exterior of plunger 88. Plunger fastener 210 is stopped from moving further axially towards plunger arm 202b by fastener head 230 interfacing with passage shoulder 228. Passage shoulder 228 axially overlaps with fastener head 230 along passage axis PA to limit displacement of fastener 210 through plunger arm 202a. extends from fastener head 230. Fastener shaft 232 extends through inner recess 226, across slot 204, and into receiver 218. In the example shown, fastener shaft 232 includes exterior threading that interfaces with the threading of receiver 218 to connect fastener 210 and plunger 88. Rotating fastener 210 drives fastener 210 further into passage 208 and receiver 218. The fastener head 230 bottoms out on passage shoulder 228. Further rotation of plunger fastener 210 pulls plunger arms 202a, 202b together such that plunger arms 202a, 202b clamp on rod 132 to fix plunger 88 at a location along rod 132.

[0169] In the example shown, outer recess 224 extends radially outward from passage axis PA such that at least a portion of outer recess 224 radially overlaps with rod 132 relative to actuation axis AA. Such a configuration facilitates fastener head 230 axially overlapping with rod 132 relative to passage axis PA. The axial forces exerted by fastener 210 along passage axis PA are thus better aligned with rod 132 to facilitate secure clamping of rod 132 between plunger arms 202a, 202b while maintaining coaxial alignment of rod 132 on actuation axis AA.

[0170] As discussed above, plunger 88 is formed from magnetically conductive material. Plunger fastener 210 can be formed from magnetically conductive material, such as iron or an alloy of iron (e.g., steel or an alloy thereof). Forming plunger fastener 210 from magnetically conductive material facilitates improved performance by filling in at least a portion of the voids formed by passage 208 and slot 204 with magnetically conductive material, increasing the volume of such material forming the armature of the solenoid 38. In some examples, both the plunger 88 and plunger fastener 210 form the magnetically conductive material that forms the armature of the solenoid 38.

[0171] While plunger 88 and rod 132 are shown as part of cartridge 82, it is understood that not all examples are so limited. For example, plunger 88 can be clamped to rod 132 within a gun body 30 of a spray gun 24 in which there is not a removable and replaceable cartridge 82.

[0172] Plunger 88 clamping on rod 132 provides significant advantages. Plunger 88 is clamped to rod 132 to fix the position of plunger 88 along rod 132. The plunger 88 can be clamped such that the rod 132 is not directly interfaced with by the plunger fastener 210. In some examples, the rod 132 may not be permanently affixed to the plunger 88 (e.g., by welding, brazing, etc.) but can be held only by clamping. Such a configuration can allow for recycling and reuse of various components (e.g., the plunger 88) after the useful life of the spray valve 36 has expired. Clamping of the plunger 88 on the rod 132 also provides for a quick and efficient manner of connection that does not require additional skill or expertise to form the connection other than the ability to tighten the clamp by the plunger fastener 210.

[0173] The rod 132 is clamped between the plunger arms 202a, 202b. The plunger arms 202a, 202b extend for a majority of the total length of the plunger 88, providing a large surface area over which the clamping force can be exerted on the rod 132. Such force distribution inhibits bending or other deformation of the rod 132. In some examples, the rod 132 is not contacted by the plunger fastener 210 that pulls the plunger arms 202a, 202b together to clamp the rod 132.

[0174] The rod 132 is partially disposed in the rod grooves 212 formed in each plunger arm 202a, 202b. The rod grooves 212 extend partially annularly around the rod 132. The rod 132 being disposed in the rod grooves 212 concentrically aligns the rod 132 on the actuation axis AA to maintain concentricity between the spray valve 36 and the plunger 88. Maintaining concentricity avoids off-axis forces on rod 132 that could cause bending or other deformation.

[0175] Rod grooves 212 wrap partially around rod 132 increasing the contact area between the plunger arm 202a, 202b and rod 132 relative to a flat surface interfacing with rod 132. The increased contact area spreads the clamping load across an increased surface area of the rod 132, inhibiting bending or other deformation that can be caused by point loads.

[0176] The passage 208 and plunger fastener 210 are offset from the rod bore 206 and rod 132. The plunger fastener 210 does not directly contact or otherwise directly interface with rod 132. The plunger fastener 210 is spaced from rod 132 and not in contact with rod 132. The passage 208 does extend through or intersect with the rod bore 206. The plunger fastener 210 and rod 132 being spaced from each other and out of contact avoids the plunger fastener 210 exerting point loads on the rod 132, thereby avoiding undesirable bending or other deformation.

[0177] FIG. 12 is an elevational view of cartridge 82 in a pre-assembly state. FIG. 13 is an isometric view of cartridge 82 within a locating assembly 234. FIG. 14 is a cross- sectional view taken along line 14-14 in FIG. 13. FIG. 15 is an enlarged view of detail 15 in FIG. 14. FIGS. 12-15 are discussed together. Plunger 88 is fixed on rod 132 to set an opening distance of the spray valve 36. The plunger 88 can be fixed to a particular location along the rod 132, the particular location accounting for the opening distance of the spray valve 36 to thereby set the opening distance by fixing the location of the plunger 88 on the rod 132. The plunger 88 can be fixed at a location along the rod spaced a spacing distance from a hard stop (e.g., as formed by the downstream end of the cartridge body 104 (e.g., formed by end cap 144)), the spacing distance setting the opening distance of the spray valve 36.

[0178] In the example shown, the plunger 88 is clamped to the rod 132 to fix the plunger 88 along the rod 132. In examples in which the plunger 88 is included in a cartridge 82, the plunger 88 can be affixed to the rod 132 with the cartridge 82 in the pre-assembly state shown in FIG. 12. In the preassembly state, the cartridge body 104 is partially disassembled to expose portions of the plunger 88. In the example shown, the portion of plunger guard 140 forming the flux reluctance zone 192 and the end cap 144 are not assembled to cartridge 82 with the cartridge 82 in the pre-assembly state.

[0179] Plunger 88 is partially exposed such that the plunger fastener 210 can be accessed for torquing and thus clamping of rod 132 between plunger arms 202a, 202b. The passage 208 is aligned with the flux reluctance zone 192 such that the passage axis PA extends through the flux reluctance zone 192 portion of the plunger guard 140.

[0180] Plunger 88 is fixed along rod 132 to set the opening distance of spray valve 36. As discussed above, the cartridge 82 can be configured such that end cap 144 defines the travel limit of the plunger 88. Plunger 88 can be fixed relative to the location of the inner face 180 of the end cap 144 to set the allowable travel distance for the plunger 88 and thus set the opening distance for the spray valve 36.

[0181] The plunger 88 is secured to the rod 132 as part of a manufacturing assembly step.

[0182] Before the extension part 196 that forms the flux reluctance zone 192 and the end cap 144 are installed, the plunger 88 is clamped on the rod 132 to set the location of the plunger 88 on the rod 132. The extension part 196 and end cap 144 can then be secured to the cartridge body 104. For example, the extension part 196, which can also be referred to as a guard piece, can be placed over plunger 88 and connected to the other portions of plunger guard 140, such as by welding among other options. The end cap 144 can be connected to the extension part 196 to enclose the plunger chamber 142 and define the travel limit for plunger 88. The end cap 144 can be connected to plunger guard 140 by welding, among other options.

[0183] During manufacturing, the plunger 88 can be located at a particular position along the rod 132 before being fixed to the rod 132. To locate the plunger 88 at the particular location along the rod 132, the plunger 88 can be shifted along the rod 132 until disposed at the particular location along the rod 132. To achieve ideal spacing, the plunger 88 may be set against an indexing fixture and then the rod 132 and plunger 88 can be fixed together. The location of the plunger 88 on the rod 132 can be set relative to a position of the plunger guard 140 when the valve is closed, which ensures that the plunger 88 is ideally positioned to be influenced by the electromagnetic field of the coil and to open the spray valve a desired opening distance.

[0184] In the example shown, plunger 88 is first positioned over rod 132 and cartridge is placed in locating assembly 234. Locating assembly 234 includes assembly body 236, brace 238, knob 240, indexer 242, and locator 244. Indexer 242 includes access aperture 250.

[0185] Cartridge body 104 is placed in receiving slot 248 of assembly body 236. The cartridge body 104 is oriented such that plunger 88 is oriented towards indexer 242 and the output end of cartridge 82 is oriented towards knob 240. Plunger 88 is at least partially disposed within locating chamber 246 formed in indexer 242.

[0186] As best seen in FIG. 15, cartridge body 104 is located such that index shoulder 252 of indexer 242 is received in locating notch 254 of cartridge body 104. The index shoulder 252 interfacing with cartridge body 104 provides the indexing feature for locating the plunger 88 along the rod 132. In the example shown, locating notch 254 is formed on plunger guard 140. The locating notch 254 is formed on a portion of plunger guard 140 forming the flux permeability zone 190 in the example shown. The index shoulder 252 interfacing with cartridge body 104 defines a limit of movement for cartridge body 104 towards indexer 242. The distance between chamber base 256 and the indexing interface between indexer 242 and cartridge 82 is configured to set the opening distance for the spray valve 36. Plunger 88 is pulled into contact with chamber base 256 and secured in that position to set the opening distance.

[0187] The cartridge 82 can be secured between the brace 238 and indexer 242. Brace 238 can be displaced axially along actuation axis AA to secure cartridge body 104 between brace 238 and indexer 242. For example, knob 240 can be connected to brace 238 such that rotation of knob 240 can cause advancement or retraction of brace 238, to secure and release cartridge 82.

[0188] Locator 244 is placed proximate the plunger 88 to draw plunger 88 into locating chamber 246 and towards chamber base 256. Locator 244 includes or is formed from one or more magnets that pull the plunger 88 to a rearward limit of travel. In the example shown, chamber base 256 limits displacement of plunger 88 in direction AD2. In the example shown, the plunger 88 is located at a position corresponding to the closed state of the spray valve 36. With the plunger 88 fixed on the rod 132, a gap will be formed rearward of the plunger 88 (e.g., between the plunger 88 and the end cap 144) that sets the opening distance for the spray valve 36.

[0189] With the plunger 88 drawn to a rearward limit of travel along rod 132, plunger 88 is clamped onto rod 132 to secure the plunger 88 at a desired location along the rod 132. Access aperture 250 is open to locating chamber 246. The passage 208 is accessible through access aperture 250. The plunger fastener 210 can be engaged by a tool, such as a wrench, driver, etc., through access aperture 250 and torqued to clamp the plunger 88 on the rod 132.

[0190] In the example shown, access aperture 250 includes sidewalls 258. The access aperture 250 is configured such that a width of access aperture 250 is greater at locations further away from plunger 88. In the example shown, the sidewalls 258 diverge from each other away from locating chamber 246. The sloped side walls 258 increase the width of access aperture 250 away from locating chamber 246. The access aperture 250 can be considered to narrow towards locating chamber 246. The sloped sidewalls 258 facilitate access to the plunger fastener 210 from different angles to torque the plunger fastener 210 and clamp the plunger 88 on the rod 132. The sloped sidewalls 258 can facilitate access to the plunger fastener 210 in the passage 208 that is offset from the actuation axis AA, on which the plunger 88 is pulled by locator 244 while allowing rotation of a tool within access aperture 250 to torque the plunger fastener 210.

[0191] With the plunger 88 clamped on the rod 132, the brace 238 is retracted to release the cartridge 82. Extension part 196 is connected to the flux directing portion of plunger guard 140, such as by welding among other connection options. The extension part 196 lengthens the plunger chamber 142 such that the plunger chamber 142 extends axially beyond the distal end of plunger 88. The end cap 144, in examples including end cap 144, is connected to plunger guard 140 to enclose the plunger 88 within plunger chamber 142. The end cap 144 can be connected to extension part 196. The end cap 144 can be connected to plunger guard 140 in any desired manner, such as by welding among other options. With end cap 144 connected to plunger guard 140, gap 178 (FIG. 10) is formed between plunger 88 and inner face 180 of end cap 144. The gap 178 defines the opening distance of the spray valve 36.

[0192] Clamping of plunger 88 on rod 132 to set the opening distance of spray valve 36 provides significant advantages. The plunger 88 is the mechanical actuator of the spray valve 36 that actuates the spray valve 36 to an open state. Setting the plunger 88 along the rod 132 provides a known, controllable opening distance for spray valve 36 that remains consistent throughout the operational life of cartridge 82. The plunger 88 remains fixed to rod 132 and mounts with and dismounts with cartridge 82. The plunger 88 being located on the rod 132 both sets the position of the plunger 88 relative to the spray valve 36 for mechanical actuation and also locates the plunger 88 within cartridge body 104 for efficient positioning relative to coil section 84 when cartridge 82 mounts to valve housing 86.

[0193] The plunger 88 clamping on the rod 132 provides for quick and efficient locating of the plunger 88 for setting of the opening distance. The plunger 88 is pulled (e.g., magnetically by locator 244) to a desired location along rod 132 (e.g., as set by indexer 242) and the plunger fastener 210 is torqued to cause the plunger 88 to clamp onto the rod 132. The plunger 88 is thus fixed to the rod 132 at the desired location. In examples in which plunger 88 and spray valve 36 are components of a cartridge 82, the remainder of the cartridge body 104 can be assembled together to form the assembled cartridge 82.

[0194] FIG. 16A is a first isometric view of plunger 288. FIG. 16B is a second isometric view of plunger 288. FIG. 16C is a cross-sectional view of plunger 288 taken along line C-C in FIG. 16A. FIG. 17A is an isometric view of collet 462. FIG. 17B is a front elevational view of collet 462. FIG. 17C is a side elevational view of collet 462. FIGS. 16A-17C are discussed together. Plunger 288 is substantially similar to plunger 88 (FIGS. 8-11) except that plunger 288 is connected to rod 132 in a different manner from the clamping of plunger 88. Components of plunger 288 that are the same as or similar to components of plunger 88 are labeled with the same reference number except increased by “200” (e.g., rod bore 406 and rod bore 206). Plunger 288 includes plunger body 464 having locators 466, rod bore 406, connection bore 468. Plunger body 464 includes axial ends 470a, 470b, inner threads 472, and stop face 474.

[0195] Plunger 288 is configured to connect to rod 132 to connect the plunger 288 to the spray valve 36 such that the solenoid 38 can actuate the spray valve 36 open. Plunger 288 is connected to rod 132 by collet 462 in this example. The collet 462 is configured to directly connect to the plunger 288 and directly connect to the rod 132 to secure the plunger 288 and rod 132 together.

[0196] Rod bore 406 extends into plunger body 464 through axial end 470a. Axial end 470a is configured to be oriented towards spray valve 36. Connection bore 468 extends into plunger body 464 through axial end 470b. Axial end 470b is configured to be oriented away from spray valve 36.

[0197] Inner threads 472 are formed within connection bore 468. In the example shown, the inner threads 472 do not extend a full axial distance of the connection bore 468 between axial end 470b and stop face 474. It is understood, however, that not all examples are so limited. In various examples, the inner threads 472 can extend a majority of the length L4 of the connection bore 468 between axial end 470b and stop face 474.

[0198] Stop face 474 extends radially inward from connection bore 468. Stop face 474 is disposed between connection bore 468 and rod bore 406. A diameter DI of the stop face 474 at the rod bore 406 is greater than a diameter D2 of the rod bore 406. The stop face 474 narrows towards the rod bore 406. The stop face 474 can be formed fully annularly about the actuation axis AA. The stop face 474 can be conical, among other options.

[0199] Stop wall 475 is disposed at an end of connection bore 468 towards the rod bore 406. The stop wall 475 is configured to interface with the collet 462 to limit a distance that the collet 462 can extend into the connection bore 468. The stop wall 475 is disposed at the intersection between the rod bore 406 and the stop face 474.

[0200] Locators 466 are formed on an exterior of the plunger body 464. The locators 466 are formed as grooves in the exterior of the plunger body 464. The locators 466 can be formed as slots on the exterior of plunger 288. The locators 466 have flat bases in this example. In the example shown, the plunger 288 includes a pair of locators 466 formed on opposite sides of the plunger body 464. The pair of locators 466 can be disposed 180- degrees apart about the actuation axis AA. While plunger 288 is shown as including a pair of locators 466, it is understood that not all examples are so limited. In this particular example, the locators 466 provide a locating feature that sets a position of the plunger 288 relative to the rod 132. For example, a wrench can engage with the plunger 288 within the locators 466. The wrench abutting against an end of the cartridge defining the plunger chamber 142 locates the plunger 288 along the actuation axis AA and at a set position along the rod 132. The wrench can further hold the plunger 288 to prevent rotation of the plunger 288 on the actuation axis AA while the collet 462 clamps on the rod 132.

[0201] Collet 462 is configured to engage the rod 132 within the plunger body 464 to connect the plunger 288 and rod 132 together. Collet 462 includes collet body 476, neck 478, tail 480, and rod passage 482. Collet body 476 includes body base 484, clamp arms 486, clamp slots 488, head 490, nose 492, and outer threads 494. Each clamp arm 486 includes a clamp face 496 and rod groove 498.

[0202] Collet 462 is configured to receive rod 132 and secure rod 132 to plunger 288. Rod passage 482 extends within collet 462. Rod passage 482 can, in various examples, extend fully axially through collet 462. Rod passage 482 is at least partially formed in collet body 476. Rod passage 482 can extend through neck 478. Rod passage 482 can extend within, and in various examples through, tail 480.

[0203] Collet body 476 is configured to extend into plunger 288 to connect rod 132 with plunger 288. Collet body 476 is at least partially disposed within plunger 288 with collet 462 connected to plunger 288. Collet body 476 can be disposed fully within the plunger 288 in various examples.

[0204] Clamp arms 486 form a portion of the collet body 476. Clamp arms 486 are formed in an annular array about the actuation axis AA. The clamp arms 486 extends from body base 484. Clamp slots 488 are disposed between adjacent ones of the clamp arms 486. Clamp slots 488 allow clamp arms 486 to flex relative to each other. Body base 484 can extend fully annularly about the actuation axis AA. The clamp arms 486 are cantilevered from body base 484 in the example shown.

[0205] Outer threads 494 are formed on collet body 476. In the example shown, the outer threads 494 are formed at least partially on one or more of the clamp arms 486. A portion of the outer threads 494 can be formed on each of the clamp arms 486. In some examples, the outer threads 494 extend rearward beyond the ends of the clamp slots 488. In some examples, the outer threads 494 can be at least partially formed on the body base 484.

[0206] Head 490 is disposed at an opposite end of collet body 476 from body base 484.

[0207] Head 490 is formed by the multiple clamp arms 486 in this example. The head 490 extends axially beyond the outer threads 494. The head 490 does not include exterior threading in this example.

[0208] Nose 492 is disposed at an opposite end of head 490 from body base 484. Nose 492 is disposed at a distal end of collet body 476. Nose is formed by the sloped clamp faces 496 of the multiple clamp arms 486. The nose 492 can include a conical exterior. In the example shown, the nose 492 is frustoconical.

[0209] Clamp faces 496 are formed at ends of the clamp arms 486 opposite the body base 484. The clamp faces 496 are disposed at the distal ends of the clamp arms 486. Each clamp face 496 is formed as a sloped surface. The clamp faces 496 are formed on the exterior of the collet 462. The clamp faces 496 are sloped inwards towards the actuation axis AA. The clamp faces 496 can be considered to form a conical exterior portion of the collet 462. In the example shown, the clamp faces 496 form a frustoconical end of the collet 462.

[0210] The clamp faces 496 are disposed at angle a relative to the actuation axis AA. The stop face 474 is disposed at angle p relative to the actuation axis AA. In some examples, angle a can be between about 20-60 degrees. In some examples, angle a is about 30- degrees. In some examples, angle can be between about 20-60 degrees. In some examples, angle P is about 30-degrees. Angle a can be the same as angle P in various examples.

[0211] End face 495 is disposed at an axial end of collet 462. End face 495 is disposed at an end of the collet body 476 opposite the body base 484. The end face 495 is formed by a plurality of flats at the end of each clamp arm 486. The end face 495 is configured to interface with the stop wall 475 to limit a distance that collet 462 extends into plunger 288.

[0212] In the example shown, each clamp arm 486 includes a rod groove 498 on the inner side of the clamp arm 486. The rod grooves 498 are oriented radially inwards towards the actuation axis AA. The rod grooves 498 can together form a portion of the rod passage 482 within the collet 462. The rod grooves 498 can be curved to mate with the exterior curvature of the rod 132. In various examples, the rod grooves 498 can together form a cylindrical passage.

[0213] Tail 480 projects rearward away from the collet body 476. Tail 480 includes a faceted exterior in this example. The tail 480 can have a hexed exterior, among other options. Tail 480 is configured to interface with a tool that connects the collet 462 to plunger 288. Neck 478 is disposed between and connects collet body 476 and tail 480. Neck 478 can be formed as a relatively thin portion of the collet 462 between the collet body 476 and the tail 480. Neck 478 is configured as a shear neck in the example shown. Neck 478 is configured to shear at a threshold force, causing the tail 480 to disconnect from the collet body 476. For example, neck 478 can be configured to shear at a force of about 50 inch pounds (in- lb) (about 5.65 newton meters (Nm)), though it is understood that other threshold force values are possible, such as 25 in-lb (about 2.82 Nm), 75 in-lb (about 8.47 Nm), 100 in-lb (about 11.30 Nm), among other options.

[0214] During assembly, the plunger 288 is aligned at a desired position on the rod 132. For example, a wrench or other tool can engage with the locators 466 on the exterior of the plunger 288 and that tool can abut against the rear end 260 of the base 108. Such abutment positively locates the plunger 288 along the rod 132. The tool engaging with the locators 466 can also prevent rotation of plunger 288 during attachment of the collet 462 to the plunger 288.

[0215] The collet 462 is inserted into the plunger 288. The collet body 476 enters into the connection bore 468 through the axial end 470b of plunger 288. The rod 132 passes into the rod passage 482 within collet 462. The outer threads 494 of the collet 462 are engages with the inner threads 472 within the plunger 288. The collet 462 is rotated, such as by a tool engaging with the tail 480, and the interface between the inner threads 472 and outer threads 494 displaces the collet 462 further axially into the plunger 288.

[0216] The collet 462 is displaced within the connection bore 468 towards axial end 470a of the plunger 288. The displacement of the collet 462 causes the clamp faces 496 to engage with stop face 474 within plunger 288. The ramped profiles of the clamp faces 496 and the stop face 474 causes the clamp arms 486 to flex radially inward as the collet 462 continues to displace into plunger 288. The clamp arms 486 flex inward and tightly engage with the rod 132 to clamp onto the rod 132 and fix the rod 132 axially relative to the collet 462. The rod 132 is thereby clamped by the collet 462 to be fixed to the collet 462 while the collet 462 is fixed to the plunger 288 by interfaced threading.

[0217] With the rod 132 clamped by the collet 462, the tail 480 can continue to be torqued. The tail 480 is torqued until the threshold force is reached, which causes the neck 478 to shear and thereby detaches the tail 480 from the collet body 476. With the tail 480 detached, the remaining portion of the collet 462 that is connected to the plunger 288 can, in some examples, be fully recessed within the plunger 288. The collet 462 connecting the rod 132 to the plunger 288 provides significant advantages. Collet 462 is clamped onto rod 132 due to a mechanical clamping force exerted on the collet 462 by structure of the plunger 288. The collet 462 holds onto the rod 132 to prevent the rod 132 from moving axially relative to the collet 462, preventing any slippage of the rod 132 and thus of the plunger 288 along the rod 132. The collet 462 is directly mechanically connected to both the rod 132 and the plunger 288.

[0218] Interfaced threading connects the collet 462 to the plunger 288 in this example. The interfaced threading provides a mechanical connection that holds the collet 462 to the plunger 288 and prevents axial movement of the collet 462 relative to the plunger 288 once installed. The interfaced threading also provides axial displacement of the collet 462 relative to the plunger 288 during clamping onto the rod 132. The axial displacement of the collet 462 into the plunger 288 causes the collet 462 to clamp onto and hold the rod 132 relative to the plunger 288.

[0219] In this example, the tail 480 is configured to provide a connection point for a tool to engage with the collet 462 and displace the collet 462 relative to the plunger 288 to thereby cause the collet 462 to clamp onto the rod 132. The neck 478 is configured to shear once the collet 462 is clamped onto the rod 132 as additional torquing of the tail 480 will not advance the collet 462 further into the plunger 288, thereby increasing the force on the neck 478. Once the threshold shear force is reached, the neck 478 shears and the tail 480 detaches from the collet body 476. This leaves the collet body 476 connected to the plunger 288 and clamped onto the rod 132. The neck 478 shearing to disconnect the tail 480 provides for easy installation and for a more compact configuration for operation with plunger 288 fixed to rod 132 by collet 462.

[0220] 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. Any single feature, or any combination of features from one embodiment show herein, may be utilized in a different embodiment independent from the other features shown in the embodiment herein. Accordingly, the scope of the invention(s) and any claims thereto are not limited to the particular to the embodiments and / or combinations of the features shown herein, but rather can include any combination of one, two, or more features shown herein.

Claims

CLAIMS:

1. An assembly for controlling release of spray fluid from a spray gun, the assembly comprising: a spray valve; a plunger of a solenoid, the plunger configured to be moved by an electromagnetic field to actuate the spray valve to an open state by the plunger displacing along an actuation axis, the plunger including: a plunger base; a first plunger arm extending from the plunger base along the actuation axis; a second plunger arm extending from the plunger base along the actuation axis, the second plunger arm spaced from the first plunger arm by a slot; and a rod bore extending within the plunger base and between the first plunger arm and the second plunger arm; and a rod extending along the actuation axis between the spray valve and the plunger to connect the spray valve and the plunger; wherein the rod is at least partially disposed in the rod bore; wherein the rod is clamped between the first plunger arm and the second plunger arm to fix the plunger on the rod.

2. The assembly of claim 1, wherein the slot extends along a cut plane, the cut plane extending along the actuation axis.

3. The assembly of any one of claims 1 and 2, wherein the first plunger arm is cantilevered from the plunger base.

4. The assembly of any one of claims 1-3, wherein the second plunger arm is cantilevered from the plunger base.

5. The assembly of any one of claims 1-4, further comprising: a passage disposed within the plunger, the passage at least partially formed in the first plunger arm and in the second plunger arm, and the passage offset from the rod bore.

6. The assembly of claim 5, wherein the passage extends fully through the first plunger arm such that the passage is open through an exterior of the first plunger arm and an inner surface of the first plunger arm, the inner surface of the first plunger arm at least partially defining the slot.

7. The assembly of any one of claims 5 and 6, wherein the passage extends fully through the second plunger arm such that the passage is open through an exterior of the second plunger arm and an inner surface of the second plunger arm, the inner surface of the second plunger arm at least partially defining the slot.

8. The assembly of any one of claims 5-7, wherein the passage does not intersect the rod bore.

9. The assembly of any one of claims 5-8, wherein the passage extends along a passage axis, the passage axis not intersecting the actuation axis.

10. The assembly of claim 9, wherein the passage axis is disposed perpendicular to the actuation axis.

11. The assembly of any one of claims 9 and 10, wherein the passage axis is disposed orthogonal to the slot.

12. The assembly of any one of claims 5-11, wherein the passage includes: a recess disposed within the first assembly arm, the recess including an outer portion and an inner portion between the outer portion and the slot, wherein a passage shoulder extends inwards to narrow the passage between the outer portion and the inner portion; and a receiver disposed within the second assembly arm.

13. The assembly of claim 12, wherein the receiver includes interior threading.

14. The assembly of any one of claims 5-13, wherein the passage is formed in a distal portion of the first plunger arm and in a distal portion of the second plunger arm.

15. The assembly of claim 14, wherein the passage is disposed axially closer along the actuation axis to a distal end of the first assembly arm than to the plunger base.

16. The assembly of any one of claims 1-15, further comprising: a plunger fastener at least partially disposed in the plunger, the plunger fastener fixing the plunger on the rod.

17. The assembly of claim 16, wherein the plunger fastener pulls the first plunger arm and the second plunger arm together to reduce a size of the slot and clamp the rod.

16. The assembly of any one of claims 14 and 15, wherein the plunger fastener extends through the first plunger arm and into the second plunger arm.

17. The assembly of any one of claims 14-16, wherein the plunger fastener is directly connected to the second plunger arm.

18. The assembly of claim 17, wherein the plunger fastener is threadedly connected to the second plunger arm.

19. The assembly of any one of claims 14-18, wherein the plunger fastener is formed from a magnetically conductive material.

20. The assembly of any one of claims 1-19, wherein: the slot is disposed between an inner surface of the first plunger arm and an inner surface of the second plunger arm; a first rod groove extends into the inner surface of the first plunger arm; and the first rod groove extends at least partially around the rod.

21. The assembly of claim 20, wherein a second rod groove extends into the inner surface of the second plunger arm, the second rod groove extending at least partially around the rod.

22. The assembly of any one of claims 1-21, wherein a length of the slot is at least half of a length of the plunger.

23. The assembly of claim 22, wherein the length of the slot is at least seventy percent of the length of the plunger.

24. The assembly of claim 22, wherein the length of the slot is at least seventy- five percent of the length of the plunger.

25. The assembly of claim 22, wherein the length of the slot is at least eighty percent of the length of the plunger.

26. The assembly of claim 22, wherein the length of the slot is greater than eighty-five percent of the length of the plunger.

27. The assembly of any one of claims 1-4, further comprising: a passage formed in the first plunger arm and the second plunger arm, the passage extending along a passage axis; and a plunger fastener disposed within the passage, the plunger fastener interfacing with the first plunger arm and the second plunger arm to clamp the rod between the first plunger arm and the second plunger arm.

28. The assembly of claim 27, wherein the passage is formed in a distal portion of the first plunger arm and in a distal portion of the second plunger arm.

29. The assembly of any one of claims 27 and 28, wherein the passage axis is disposed further from the plunger base along the actuation axis than from a distal end of the first plunger arm.

30. A cartridge for use in a spray gun, the spray gun comprising a solenoid coil, the cartridge comprising: a cartridge body defining a fluid chamber and having an inlet and an outlet; andthe assembly of any one of claims 1-29 disposed at least partially within the cartridge body; wherein the spray valve is disposed within the cartridge body and includes an actuatable seal located fluidly between the inlet and the outlet; and wherein the cartridge body, the spray valve, and the plunger are integrated into a unitary assembly that is insertable into the spray gun and removable from the spray gun as the unitary assembly.

31. An assembly for controlling release of spray fluid from a spray gun, the assembly comprising: a spray valve; a plunger of a solenoid, the plunger configured to be moved by an electromagnetic field to actuate the spray valve to an open state by the plunger displacing along an actuation axis; and a rod extending along the actuation axis between the spray valve and the plunger to connect the spray valve and the plunger; wherein the rod is at least partially disposed in a rod bore within the plunger; and wherein the rod is clamped to the plunger.

32. The assembly of claim 31, wherein the plunger further comprises: a plunger base; a first plunger arm extending from the plunger base; and a second plunger arm extending from the base; wherein the rod is clamped between the first plunger arm and the second plunger arm.

33. The assembly of any one of claims 31 and 32, wherein a clamping force is applied to the plunger at a location radially offset from the actuation axis.

34. The assembly of claim 31, further comprising: a collet clamping the rod to the plunger.

35. The assembly of claim 34, wherein the collet extends into the plunger and is clamped onto the rod.

36. The assembly of any one of claims 34 and 35, wherein the collet is connected to the plunger by interfaced threading.

37. The assembly of claim 36, wherein the collet includes outer threads and the plunger includes inner threads, the outer threads interfacing with the outer threads to form the interfaced threading.

38. The assembly of any one of claims 34-37, wherein the collet includes a plurality of clamp arms, the plurality of clamp arms engaging the rod.

39. The assembly of any one of claims 34-37, wherein the collet comprises: a collet body engaging the plunger and the rod; a tail; and a neck connecting the collet body and the tail, the neck formed as a shear neck configured to shear at a threshold force.

40. The assembly of claim 39, wherein the threshold force is 100 in-lb or less.

41. The assembly of claim 39, wherein the threshold force is 50 in-lb or less.

42. The assembly of any one of claims 39-41, wherein an exterior of the tail is faceted.

43. The assembly of any one of claims 39-42, wherein the collet body includes: a body base; and a plurality of clamp arms extending from the body base.

44. The assembly of claim 43, wherein each clamp arm of the plurality of clamp arms is cantilevered from the body base.

45. The assembly of any one of claims 43 and 44, wherein each clamp arm of the plurality of clamp arms includes a sloped clamp face, wherein the plunger includes a stop face, and wherein the stop face is configured to engaged the sloped clamp face to bias each clamp arm of the plurality of clamp arms radially inward to engage the rod.

46. The assembly of any one of claims 34-45, wherein an exterior of the plunger includes a pair of locators.

47. The assembly of claim 46 wherein the pair of locators are formed as a pair of slots.

48. The assembly of any one of claims 46 and 47, wherein a first locator of the pair of locators is disposed 180-degrees apart from a second locator of the pair of locators.

49. An assembly for controlling release of spray fluid from a spray gun, the assembly comprising: a spray valve; a plunger of a solenoid, the plunger configured to be moved by an electromagnetic field to actuate the spray valve to an open state by the plunger displacing along an actuation axis, the plunger including: a connection bore extending into a first end of the plunger; and a rod bore extending into a second end of the plunger; a rod extending along the actuation axis between the spray valve and the plunger to connect the spray valve and the plunger, the rod at least partially disposed in the rod bore; and a collet connected to the plunger and connected to the rod within the connection bore to fix the rod axially relative to the plunger.

50. The assembly of claim 49, wherein the collet clamps on the plunger and the collet is connected to the plunger by interfaced threading.

51. The assembly of any one of claims 49 and 50, wherein the collet includes outer threads and the plunger includes inner threads, the outer threads interfacing with the outer threads to form the interfaced threading.

52. The assembly of any one of claims 49-51, wherein the collet includes a plurality of clamp arms, the plurality of clamp arms engaging the rod.

53. The assembly of any one of claims 49-52, wherein the collet comprises: a collet body engaging the plunger and the rod; a tail; and a neck connecting the collet body and the tail, the neck formed as a shear neck configured to shear at a threshold force.

54. The assembly of claim 53, wherein the threshold force is 100 in-lb or less.

55. The assembly of claim 53, wherein the threshold force is 50 in-lb or less.

56. The assembly of any one of claims 53-55, wherein an exterior of the tail is faceted.

57. The assembly of any one of claims 53-56, wherein the collet body includes: a body base; and a plurality of clamp arms extending from the body base.

58. The assembly of claim 57, wherein each clamp arm of the plurality of clamp arms is cantilevered from the body base.

59. The assembly of any one of claims 57 and 58, wherein each clamp arm of the plurality of clamp arms includes a sloped clamp face, wherein the plunger includes a stop face, and wherein the stop face is configured to engaged the sloped clamp face to bias each clamp arm of the plurality of clamp arms radially inward to engage the rod.

60. The assembly of claim 59, wherein the stop face extends annularly about the actuation axis and is sloped.

61. The assembly of any one of claims 57-60, wherein each clamp arm of the plurality of clamp arms includes a rod groove oriented radially inwards towards the actuation axis.

62. The assembly of any one of claims 49-61, wherein an exterior of the plunger includes a pair of locators.

63. The assembly of claim 62 wherein the pair of locators are formed as a pair of slots.

64. The assembly of any one of claims 62 and 63, wherein a first locator of the pair of locators is disposed 180-degrees apart from a second locator of the pair of locators.

65. A method of assembling a cartridge for use in a spray gun, the method comprising: bracing a cartridge body of the cartridge against an indexer; magnetically drawing a plunger of a solenoid along a rod and against a hard stop, the rod connected to a spray valve of the cartridge; and clamping the plunger on the rod to fix the plunger at a set location on the rod.

66. The method of claim 65, wherein clamping the plunger on the rod to fix the plunger at a set location on the rod comprises: drawing a first plunger arm of the plunger and a second plunger arm of the plunger together to clamp the rod between the first plunger arm and the second plunger arm.

67. The method of claim 65, further comprising: torquing a fastener to draw the first plunger arm and the second plunger arm together.

68. The method of claim 65, wherein clamping the plunger on the rod to fix the plunger at a set location on the rod comprises:reducing a size of a slot formed between a first plunger arm of the plunger and a second plunger arm of the plunger to clamp the rod within the slot.

69. The method of any one of claims 65-68, further comprising: connecting an end cap of the cartridge to the cartridge body to enclose the plunger within a plunger chamber after clamping the plunger on the rod.

70. The method of any one of claims 65-69, further comprising: connecting a guard piece to the cartridge body to at least partially enclose the plunger within a plunger chamber after clamping the plunger on the rod.

71. The method of claim 70, wherein the guard piece forms a flux reluctance zone of the cartridge body.

72. The method of any one of claims 70 and 71, further comprising: connecting an end cap of the cartridge to the guard piece to enclose the plunger within the plunger chamber.

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