EP4651997A1

EP4651997A1 - Spray tip, spray tip assembly, method of flowing spray fluid, method for making a rotatable spray tip

Info

Publication number: EP4651997A1
Application number: EP24705908.2A
Authority: EP
Inventors: David J. Thompson
Original assignee: Graco Minnesota Inc
Current assignee: Graco Minnesota Inc
Priority date: 2023-01-18
Filing date: 2024-01-17
Publication date: 2025-11-26
Also published as: CN120769778A; AU2024210886A1; WO2024155682A1

Abstract

A spray tip includes a handle forming a first end of the spray tip and a barrel connected to the handle. The barrel extends along a barrel axis from the handle to a second end of the spray tip. The barrel includes a cylindrical exterior surface and a tunnel extending through the barrel between a first tunnel end open through the cylindrical exterior surface and a second tunnel end open through the cylindrical exterior surface. The tunnel extends transverse to the barrel axis. A micro knurled patch is formed on the cylindrical exterior surface and extends circumferentially on the cylindrical exterior surface between the first tunnel end and the second tunnel end relative to the barrel axis.

Description

SPRAY TIP, SPRAY TIP ASSEMBLY, METHOD OF FLOWING SPRAY FLUID, METHOD FOR MAKING A ROTATABLE SPRAY TIP

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims priority to U.S. Provisional Application No. 63/439,787 filed January 18, 2023 and entitled “SPRAY TIP,” the disclosure of which is hereby incorporated by reference in its entirety.

BACKGROUND

The present disclosure relates generally to fluid spray systems and parts thereof. More particularly, this disclosure relates to spray gun and tip assemblies for spray guns.

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 guns typically receive paint or other coating fluid under pressure and atomize the spray fluid. The spray fluid is typically put under pressure by a piston or diaphragm, which is referred to as airless spray.

Due to the action of the piston or the diaphragm, pressure fluctuations, particularly on stopping and starting of spray or due to cyclical directional reversing of the piston or diaphragm, can be developed through a fluid flow path and a spray tip of the spray gun. The spray gun can also be bumped in the course of work, including when setting down or dropping the spray gun and/or when maneuvering in a work site, such as when climbing a ladder. These pressure fluctuations, vibrations, and bumps can misalign the spray tip mounted in the spray gun, causing errant spray.

SUMMARY

According to an aspect of the disclosure, a spray tip is disclosed for use in a spray gun. The spray gun includes a cylindrical barrel bore with a bore surface at least partially formed from metal and extending axially along a barrel axis into a tip housing. The spray gun also includes a cylindrical passage in the tip housing that extends through the cylindrical barrel bore along a spray axis. The spray axis is transverse to the barrel axis. The spray tip includes a handle and a barrel connected to the handle. The barrel extends along a tip axis and includes a cylindrical exterior surface formed of metal. The cylindrical exterior surface includes an untreated area. A micro knurled patch is formed into the cylindrical exterior surface. The micro knurled patch has a surface roughness that is different from a surface roughness of the untreated area of the cylindrical exterior surface. A tunnel extends through the barrel between a first tunnel end open through the exterior surface and a second tunnel end open through the exterior surface. The tunnel extending transverse to the tip axis. The micro knurled patch is configured to interface with the metal of the bore surface when the barrel is disposed in the barrel bore and when the tunnel is aligned with the spray axis.

According to an additional or alternative aspect of the disclosure, a spray tip assembly is disclosed through which a spray coating flows from an upstream direction to a downstream direction. The spray tip assembly includes a tip housing with a barrel bore extending into the tip housing along a mount axis. A surface of the barrel bore is at least partially formed of metal. A housing bore extends fully through the tip housing from an inlet of the tip housing to an outlet of the tip housing along a spray axis that is transverse to the mount axis. The housing bore intersects the barrel bore. A spray tip is rotatably mounted in the barrel bore of the tip housing. The spray tip includes a handle forming a first end of the spray tip. A barrel is connected to the handle and extends along a barrel axis from the handle into the barrel bore to a second end of the spray tip. The barrel axis is colinear with the mount axis. The barrel includes a cylindrical exterior surface formed from metal. A tunnel extends through the barrel between a first tunnel end open through the cylindrical exterior surface and a second tunnel end open through the cylindrical exterior surface. The tunnel extends transverse to the barrel axis and contains an outlet orifice configured to atomize spray fluid. A micro knurled patch is formed on the cylindrical exterior surface and extends circumferentially on the cylindrical exterior surface between the first tunnel end and the second tunnel end relative to the barrel axis. The micro knurled patch interfaces with the metal of the surface of the barrel bore when the tunnel is aligned with the spray axis.

According to another additional or alternative aspect of the disclosure, a method is disclosed for making a rotatable spray tip for a spray gun. The method includes forming a cylindrical barrel extending from a handle along a barrel axis. A tunnel is formed that extends transversely through the cylindrical barrel along a flow axis. The flow axis is transverse to the barrel axis. A cylindrical exterior surface of the cylindrical barrel is polished to form a surface polish of the cylindrical exterior surface. A patch of the cylindrical exterior surface is modified with a laser to form a micro knurled patch on the barrel with a surface roughness different from a surface roughness of the surface polish of the cylindrical exterior surface.

According to yet another additional or alternative aspect of the disclosure, a spray gun includes a spray control assembly with a gun body, a trigger, and a valve assembly. The valve assembly includes a valve that opens to release spray fluid and closes to block spray fluid. The valve assembly includes a valve outlet aperture disposed downstream of the valve. The spray gun also includes a spray tip module. The spray tip module includes a spray tip assembly through which a spray coating flows from an upstream direction to a downstream direction. The spray tip assembly includes a tip housing and a spray tip. The tip housing includes a barrel bore extending into the tip housing along a mount axis. A surface of the barrel bore is at least partially formed of metal. A housing bore extends fully through the tip housing from an inlet of the tip housing to an outlet of the tip housing along a spray axis that is transverse to the mount axis. The housing bore intersects the barrel bore. The spray tip is rotatably mounted in the barrel bore of the tip housing. The spray tip includes a handle forming a first end of the spray tip. A barrel is connected to the handle and extends along a barrel axis from the handle into the barrel bore to a second end of the spray tip. The barrel axis is colinear with the mount axis. The barrel includes a cylindrical exterior surface formed from metal and a tunnel extending through the barrel between a first tunnel end open through the cylindrical exterior surface and a second tunnel end open through the cylindrical exterior surface. The tunnel extends transverse to the barrel axis. The tunnel contains an outlet orifice configured to atomize spray fluid. A micro knurled patch is formed on the cylindrical exterior surface and extends circumferentially on the cylindrical exterior surface between the first tunnel end and the second tunnel end relative to the barrel axis. The micro knurled patch interfaces with the metal of the surface of the barrel bore when the tunnel is aligned with the spray axis. The tip housing connects the spray tip assembly to the gun body.

According to yet another additional or alternative aspect of the disclosure, a method is disclosed of flowing spray fluid for atomization and spraying through a spray tip assembly. The method includes rotating a barrel of a spray tip inside of a barrel bore of a tip housing such that a tunnel extending transversely through the barrel relative to a barrel axis of the barrel is aligned and fluidically connected to a passage in the tip housing. The passage extends through the tip housing from an inlet of the tip housing to an outlet of the tip housing. The passage also extends transversely through the barrel bore. Micro knurling on a cylindrical exterior surface of the barrel interfaces with a metal surface of the barrel bore when the tunnel is aligned with and fluidically connected to the passage. Spray fluid is emitted from a valve housing aperture formed in a valve housing and into the inlet of the tip housing. The spray fluid flows through the passage and into the tunnel extending transversely through the barrel of the spray tip. The spray fluid flows through a tip piece located within the tunnel. The tip piece forms an outlet orifice that atomizes the spray fluid into a fluid spray.

According to yet another additional or alternative aspect of the disclosure, a spray tip includes a handle forming a first end of the spray tip. A barrel is connected to the handle and extends along a barrel axis from the handle to a second end of the spray tip. The barrel includes a cylindrical exterior surface formed from metal and having a surface polish. A tunnel extends through the barrel between a first tunnel end that is open through the cylindrical exterior surface and a second tunnel end that is open through the cylindrical exterior surface. The tunnel extends transverse to the barrel axis. A micro knurled patch is formed on the cylindrical exterior surface and is disposed circumferentially on the cylindrical exterior surface between the first tunnel end and the second tunnel end relative to the barrel axis. The micro knurled patch includes a surface roughness that is different from a surface roughness of the surface polish of the cylindrical exterior surface.

According to yet another additional or alternative aspect of the disclosure, a spray tip module includes a tip housing defining a barrel bore extending along a mount axis. The tip housing also defines a housing bore extending fully through the tip housing along a spray axis. The housing bore also extends transversely through the barrel bore. The spray tip module also includes a spray tip with a handle forming a first end of the spray tip and a barrel connected to the handle. The barrel extends along a barrel axis from the handle to a second end of the spray tip. The barrel includes a cylindrical exterior surface formed from metal and having a surface polish. The tunnel extends through the barrel between a first tunnel end that is open through the cylindrical exterior surface and a second tunnel end that is open through the cylindrical exterior surface. The tunnel extends transverse to the barrel axis. A micro knurled patch is formed on the cylindrical exterior surface and is disposed circumferentially on the cylindrical exterior surface between the first tunnel end and the second tunnel end relative to the barrel axis. The micro knurled patch comprises a surface roughness that is different from a surface roughness of the surface polish of the cylindrical exterior surface. The spray tip is rotatably mountable in the barrel bore. The micro knurled patch interfaces with a metal surface of the barrel bore when the barrel is disposed in the barrel bore and when the tunnel is aligned with the spray axis.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a spray gun.

FIG. 2 is a partially exploded isometric view of the spray gun shown in FIG. 1. FIG. 3A is an isometric view of a spray gun with a spray tip in a first position associated with a spray state of the spray gun.

FIG. 3B is an isometric view of the spray gun of FIG. 3B with the spray tip in a second position associated with a de-clog state of the spray gun.

FIG. 4 is an isometric exploded view of a spray tip module.

FIG. 5 is an isometric view of a spray tip removed from a tip housing of the spray tip module of FIG. 4.

FIG. 6 is a partially exploded isometric view of the spray tip module of FIG. 5.

FIG. 7 is another partially exploded isometric view of the spray tip module of FIG. 6.

FIG. 8 is an isometric exploded view of the spray tip and a saddle seal portion of the spray tip module of FIG. 7.

FIG. 9 is a cross-sectional view of the spray gun of FIG. 1 taken along line A-A.

FIG. 10 is an enlarged view of detail B in FIG. 9.

FIG. 11 A is an isometric view of a spray tip module with a spray tip in a closed and unlocked state.

FIG. 1 IB is an isometric view of the spray tip module of FIG. HA with the spray tip in a spray state.

FIG. 11C is an isometric view of the spray tip module of FIG. HA with the spray tip in a de-clog state.

FIG. 12A is an isometric view of a spray tip.

FIG. 12B is another isometric view of the spray tip of FIG. 12A.

FIG. 12C is another isometric view of the spray tip of FIG. 12B.

DETAILED DESCRIPTION

The present disclosure relates to fluid sprayers. Fluid sprayers according to the disclosure include a pump that pressurizes a spray fluid, such as paint, varnishes, lacquer, finishes, 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 tip assembly is disposed downstream of the valve. The tip assembly receives the spray fluid and is configured to atomize the spray fluid into a fluid spray. The tip assembly includes a tip housing with a barrel bore and a spray tip with a barrel that is rotatable within the barrel bore. A portion of an exterior surface of the barrel is smooth to mate and seal with a saddle seal portion that is directly upstream of the spray tip. A portion of the exterior surface of the barrel includes a micro knurled patch that interfaces with the barrel bore.

The micro knurled patch of the barrel may increase resistance to rotation between the barrel and the barrel bore to decrease the likelihood of unintended rotation between the barrel and the barrel bore when the spray gun is bumped or vibrated, even if such movement is very small. Reducing the likelihood of even small movements of the spray tip assists in keeping the spray tip properly aligned within the tip housing. Keeping the spray tip properly aligned within the tip housing increases spray accuracy. The increased resistance between the barrel and the barrel bore may also reduce the likelihood of the spray tip accidentally falling out of the tip housing when the spray tip is rotated to an unlocked position by the user and the spray gun is turned sideways or upside down by the user. Preventing the spray tip from accidently falling out of the tip housing can spare the spray tip from damage, especially when dropped from a great height, such as from the top of a ladder.

In addition to assisting with spray tip alignment and increased spray accuracy, the micro knurled patch can be shaped to include technical information regarding the spray tip that is viewable to the user of the spray gun through a front opening of the tip housing when the spray tip is rotated within the barrel bore between a spray state and an un-clog state of the spray tip. Such technical information can allow the user to quickly and efficiently verify an orifice size, a spray pattern, a model number, and/or any other useful information regarding the spray tip without removing the spray tip from the spray gun. Having that information directly on the spray tip and viewable without removing the spray tip from the spray gun saves the user time and energy when verifying whether the spray gun has the spray tip with the desired orifice size and spray pattern.

Components can be considered to radially overlap when those components are disposed at common axial locations along an axis and such that a line extending radially from the axis will extend through each of the radially overlapping components. Components can be considered to axially overlap when those components are disposed at common radial and circumferential locations relative to an axis such that an axial line parallel to the axis extends through each of the axially overlapping components. Components can be considered to circumferentially overlap when aligned about the axis at a common radial distance from the axis such that a circle centered on the axis passes through each of the circumferentially overlapping components. FIGS. 1-3B will be discussed concurrently. FIG. 1 is an isometric view of spray gun 10. FIG. 2 is a partially exploded isometric view of spray gun 10. Spray gun 10 includes spray control assembly 12 and tip module 14. Spray control assembly 12 includes gun housing 16, gun handle 18, trigger 20, valve assembly 22, and housing mount 24. Spray tip 26, tip housing 28, tip mount 30, and guard 32 of tip module 14 are shown in FIGS. 1-3B. Spray tip 26 includes micro knurled patch 35. FIG. 3A is an isometric view of spray gun 10 with spray tip 26 in a first position associated with a spray state of spray gun 10. FIG. 3B is an isometric view of spray gun 10 with spray tip 26 in a second position associated with a de-clog state of the spray gun. Spray gun 10 also includes spray axis SA extending through tip module 14 and tip axis TA extending through spray tip 26 transverse to spray axis SA.

Spray gun 10 is configured to control flow of pressurized spray fluid to tip assembly 25 along spray axis SA. Tip module 14 is configured to receive the spray fluid from the spray control assembly 12 and includes spray orifice 34 that is shaped to atomize the spray fluid into a spray pattern that is output from spray gun 10. Spray gun 10 includes an internal valve that is actuated to an open state to allow flow of spray fluid to and through spray orifice 34 and that is actuated to a closed state to stop flow of the spray fluid to and through the spray orifice 34.

Gun housing 16 supports other components of spray gun 10. Gun handle 18 is formed on a bottom side of gun housing 16. In the example shown, gun handle 18 is formed separately from gun housing 16 and connected to gun housing 16, though it is understood that not all examples are so limited. For example, gun handle 18 can be formed monolithically with gun housing 16. Gun handle 18 and gun housing 16 can be considered to form a body of spray gun 10. Gun handle 18 extends from a bottom side of gun housing 16 in the example shown.

Trigger 20 is disposed forward of gun handle 18 in the example shown. Trigger 20 is configured to control actuation of the internal valve between open and closed states. Actuation of the trigger 20 causes the spray gun 10 to release spray fluid from the spray orifice 34 and release of the trigger 20 causes the spray gun 10 to cease release of spray fluid from the spray orifice 34. Fluid hose fitting 23 is configured to provide the spray fluid to spray gun 10 under pressure. Fluid hose fitting 23 can extend into spray gun 10 through a lower side of gun handle 18. While spray gun 10 is shown as including fluid hose fitting 23 configured to connect to a hose to provide spray fluid to spray gun 10 underpressure, it is understood that not all examples are so limited. For example, spray gun 10 can be configured to support a reservoir containing spray fluid and have a pump disposed within the gun housing 16. Fluid hose fitting 23 can include exterior threading to connect to interior threading of a connector of the fluid supply hose.

The valve assembly 22 includes the internal valve that opens to release spray fluid to spray tip 26 and closes to cease release of spray fluid. It is noted that, in some examples, valve assembly 22 can be a cartridge that is removable from gun housing 16. Valve assembly 22 can be partially located within gun housing 16 of spray gun 10, however other options are possible. In some examples, valve assembly 22 can be mounted to gun housing 16 by interfaced threading (e.g., on an exterior of a housing of valve assembly 22 and an interior of a bore within gun housing 16). In some examples, tip module 14 can hold valve assembly 22 within gun housing 16 by an interface between tip mount 30 and housing mount 24.

Housing mount 24 is configured to interface with tip mount 30 to mount tip assembly 14 to spray control assembly 12. Housing mount 24 can be formed at least partially by gun housing 16. In some examples, housing mount 24 can be formed fully or partially by valve assembly 22, such as on an exterior of a cartridge body of a cartridge of valve assembly 22. In some examples, housing mount 24 is formed as exterior threading, though it is understood that not all examples are so limited.

Tip module 14 is mountable to and dismountable from spray control assembly 12. In the example shown, tip mount 30 is interfaced with housing mount 24 to mount tip housing 28 to spray control assembly 12. In the example shown, tip mount 30 receives housing mount 24 to connect tip module 14 to other components of spray gun 10. Tip mount 30 can be a rotatable portion of tip housing 28 that is configured to interface with housing mount 24 to mount tip assembly 25. Tip mount 30 can be formed as a threaded connector. The housing mount 24 can be part of a gun housing 16 and/or valve assembly 22, amongst other options. In the example shown, the housing mount 24 is threaded complementary to internal threading of the tip mount 30 to facilitate mounting and secure attachment of the spray tip housing 28. In some examples, tip mount 30 is formed as a female threaded connector, though it is understood that not all examples are so limited. The housing mount 24 can be formed as a male threaded connector, though it is understood that not all examples are so limited. In the example shown, the housing mount 24 is received within tip mount 30 to mount tip module 14 to spray control assembly 12. The housing mount 24 can be formed by valve housing of valve assembly 22, can be formed separate from the valve assembly 22, or can be formed on the gun housing 16, among other options. Tip housing 28 is connected to tip mount 30. Tip mount 30 can rotate about spray axis SA independent of tip housing 28 to allow easier threading of tip mount 30 onto housing mount 24.

Spray tip 26 is supported by tip housing 28. Guard 32 is mounted to and extends from tip housing 28. Guard 32 can be overmolded onto tip housing 28, among other options. In other options, guard 32 can be integral to tip housing 28 such that guard 32 and tip housing 28 are made from the same material and form a single component. Spray tip 26 includes spray orifice 34 that is configured to atomize the spray fluid. Micro knurled patch 35 is formed on spray tip 26 and can interface with tip housing 28 with spray tip 26 mounted to tip housing 28. In some examples, the interface between spray tip 26 and tip housing 28 can produce sufficient friction and resistance between spray tip 26 and tip housing 28 to decrease unintended movement between spray tip 26 and tip housing 28 during operation of spray gun 10. For example, during operation of spray gun 10, the opening and closing of the internal valve of valve assembly 22 can cause pulsation and vibration of spray gun 10. The user can also inadvertently bump spray gun 10 against a ladder or any other object while moving into position prior to spraying spray gun 10. As these movements occur, micro knurled patch 35 can help keep spray tip 26 and spray orifice 34 in proper position relative to tip housing 28 and by engaging tip housing 28 to resist movement of spray tip 26. While micro knurled patch 35 can engage tip housing 28 to create friction and resistance between spray tip 26 and tip housing 28 in some examples, it is understood that the friction and resistance created by micro knurled patch 35 is small enough that the user can still manually rotate spray tip 26 within tip housing 28.

Spray tip 26 can be rotatably mounted to tip housing 28 such that spray tip 26 can be rotated about tip axis TA to reverse flow through spray tip 26 (such that fluid enters spray tip 26 through spray orifice 34), such as for clog removal. In FIG. 3A, spray tip 26 is in a first position that orientates spray tip 26 to a spray state where the spray fluid can move through spray tip 26 and exit through spray orifice 34 to form a desired atomized spray. When spray orifice 34 of spray tip 26 needs to be flushed, such as in the instance of a clog, spray tip 26 can be rotated 180 degrees about tip axis TA from the first position to a second position. When in the second position, spray tip 26 is in a de-clog state where spray orifice 34 has been reversed such that the spray fluid enters spray tip 26 through spray orifice 34 to flush and clean out spray orifice 34 and spray tip 26.

FIGS. 4-7 provide various views of tip module 14 at various angles and will be discussed together. FIG. 4 is an isometric exploded view of tip module 14. FIG. 5 is an isometric view of spray tip 26 removed from tip housing 28 of tip module 14. FIGS. 6 and 7 are both partially exploded isometric views of spray tip module 14. Spray tip assembly 36 of tip module 14 is shown in FIGS. 4-7. Spray tip assembly 36 includes spray tip 26, tip housing 28, and saddle seal portion 38. Spray tip assembly 36 can optionally include tip mount 30 and guard 32. First end 40, second end 42, tip handle 44, barrel 46, exterior surface 48, tunnel 49, flange 50, and tip piece 51 of spray tip 26 are shown. First portion 52 and second portion 54 of exterior surface 48 of barrel 46 are shown. Tunnel 49 of spray tip 26 can include first tunnel end 56 and second tunnel end 58. Barrel bore 60 of tip housing 28 is shown. Barrel bore 60 can include bore surface 61. Tip housing 28 also includes housing bore 62. Tip housing 28 and/or guard 32 can include slot 64 and track groove 66. A front edge of tip mount 30 can form stop face 68. As shown in FIG. 4, saddle seal portion 38 can include downstream end 70, upstream end 72, seal body 74, saddle surface 76, and upstream flow path 78. In some options, seal body 74 of saddle seal portion 38 can include metal portion 80 and elastomeric portion 82. Downstream direction DD and upstream direction UD are indicated in FIGS. 4, 6, and 7.

Spray tip 26 extends axially along tip axis TA from first end 40 to second end 42. Tip handle 44 forms first end 40 of spray tip 26 and barrel 46 is connected to tip handle 44 and extends axially from tip handle 44 along tip axis TA to second end 42. Barrel 46 can be cylindrical with a barrel axis that is parallel to tip axis TA. Exterior surface 48 of barrel

48 can be a cylindrical exterior surface that extends circumferentially around barrel 46 and tip axis TA and extends axially along tip axis TA between first end 40 and second end 42 of barrel 46. Tip handle 44 can be formed of polymer molded over an end of barrel 48. Barrel 48, including exterior surface 48 can be formed from metal, such as aluminum or stainless steel, among other options.

Tunnel 49 extends transversely through barrel 46 from first tunnel end 56 to second tunnel end 58. First tunnel end 56 opens through exterior surface 48 and second tunnel end 58 also opens through exterior surface 48. First tunnel end 56 is at a location on exterior surface 48 of barrel 46 that is radially opposite from second tunnel end 58 relative to tip axis TA. Tunnel 49 is a passage that extends straight through barrel 46 from first tunnel end 56 to second tunnel end 58 and is transverse to tip axis TA. Tip piece 51 is located inside of tunnel 49 and defines spray orifice 34 for atomizing the spray fluid. In some examples, additional elements and components can be located within tunnel 49, such as a retainer or pre-orifice piece, to retain tip piece 51 and/or condition fluid flow through tunnel

49 upstream from tip piece 51. Spray orifice 34 is a narrowing flow passage across tip piece 51 that causes atomization of the spray fluid into a fan or other shape. Spray orifice

34 can be of a cat-eye shape, among other options.

First portion 52 is most visible in FIGS. 6 and 7. First portion 52 of exterior surface 48 of barrel 46 can extend circumferentially between first tunnel end 56 and second tunnel end 58 relative to tip axis TA. First portion 52 of exterior surface 48 can be axially aligned with first tunnel end 56 and second tunnel end 58 relative to tip axis TA. In some examples, first portion 52 of exterior surface 48 can extend axially beyond first tunnel end 56 and second tunnel end 58 toward first end 40 and/or toward second end 42. Micro knurled patch 35 is formed on first portion 52 of exterior surface 48 in the example shown. When spray tip 26 is initially inserted into barrel bore 60, first portion 52 and micro knurled patch

35 face forward along spray axis SA in the downstream direction DD. When spray tip 26 is rotated in barrel bore 60 about tip axis TA to align tunnel 49 with spray axis SA, spray tip 26 is in an installed or "locked” state within barrel bore 60. When in the installed or locked state in barrel bore 60 of tip housing 28, first portion 52 and micro knurled patch 35 interface with bore surface 61 of barrel bore 60 such that micro knurled patch 35 can contact and engage bore surface 61 of barrel bore 60.

Second portion 54 is most visible in FIGS. 4 and 5. Second portion 54 of exterior surface 48 of barrel 46 is diametrically opposite of first portion 52 and micro knurled patch 35 relative to tip axis TA. Second portion 54 extends circumferentially between second tunnel end 58 and first tunnel end 56 relative to tip axis TA. Second portion 54 of exterior surface 48 can be axially aligned with first tunnel end 56 and second tunnel end 58 relative to tip axis TA. In some examples, second portion 54 of exterior surface 48 can extend axially beyond first tunnel end 56 and second tunnel end 58 toward first end 40 and/or toward second end 42. Second portion 54 is smooth and contains no laser marking in the example shown. In other words, second portion 54 is untreated, which is defined herein as not receiving the same laser treatment and medication as micro knurled patch 35. When spray tip 26 is initially inserted into barrel bore 60 of tip housing 28, second portion 54 interfaces with saddle surface 76 of saddle seal portion 38 to form a surface-to-surface seal between spray tip 26 and saddle seal portion 38. When spray tip 26 is rotated in barrel bore 60 about tip axis TA to align tunnel 49 with spray axis SA, spray tip 26 is in the installed or "locked” state within barrel bore 60. When in the installed or locked state in barrel bore 60 of tip housing 28, second portion 54 faces bore surface 61 of barrel bore 60 while saddle surface 76 of saddle seal portion 38 engages exterior surface 48 of barrel 46 around first tunnel end 56 or around second tunnel end 58. Flange 50 can extend transversely from barrel 46 relative to tip axis TA and can be positioned axially on barrel 46 between tip handle 44 and micro knurled patch 35. In the example of FIGS. 4-7, flange 50 extends along fifty percent or less of a circumference of exterior surface 48 of barrel 46. It is understood, however, that not all examples are so limited. When spray tip 26 is installed into barrel bore 60, flange 50 can move within track groove 66 as spray tip 26 is rotated about tip axis TA. Flange 50 interacts with stop face 68 to prevent full rotation of spray tip 26 within barrel bore 60 of tip housing 28. Flange 50 is positioned circumferentially on barrel 46 such that flange 50 will contact stop face 68 before micro knurled patch 35 can contact saddle surface 76 of saddle seal portion 38. In some examples, portions of micro knurled patch 35 can create variations in the exterior surface 48 (e.g., such that portions of the exterior surface 48 are slightly raised above other portions). Should micro knurled patch 35 contact saddle surface 76, micro knurled patch 35 could scour the sealing saddle surface 76 of saddle seal 38 resulting in undesirable wear on saddle seal 38, which could cause spray fluid to leak around barrel 46. By preventing micro knurled patch 35 from contacting saddle surface 76, flange 50 and contact stop face 68 preserve the surface-to-surface seal between barrel 46 and saddle seal portion 38. In the example of FIGS. 4-7, flange 50 and micro knurled patch 35 can be vertically aligned on barrel 46 relative to tip axis TA such that flange 50 projects directly vertically above first portion 52. It is understood, however, that not all examples are so limited. In other examples, flange 50 can be circumferentially offset from micro knurled patch 35 and still engage a stop face to prevent micro knurled patch 35 from contacting saddle surface 76.

Tip housing 28 defines barrel bore 60 and housing bore 62. Tip housing 28 can be formed from metal, such as aluminum or stainless steel. Barrel bore 60 extends along a mount axis into tip housing 28 such that barrel bore 60 is transverse to spray axis SA. Bore surface 61 of barrel bore 60 can also be formed from the same metal as tip housing 28, or can formed by a different metal or material than tip housing 28 through the use of a coating or liner inside of barrel bore 50. The flow of the spray fluid through tip housing 28 and tip module 14 follows spray axis SA. Thus, spray axis SA can also be referred to as a flow axis of tip module 14. Spray axis SA also generally defines an upstream direction UD and a downstream direction DD along which the spray fluid generally flows from upstream to downstream through tip module 14. When spray tip 26 is installed into barrel bore 60, the mount axis is colinear with tip axis TA. Housing bore 62 extends fully through tip housing 28 along spray axis SA. As housing bore 62 extends through tip housing 28, housing bore 62 extends transversely through barrel bore 60 such that barrel bore 60 and housing bore 62 intersect.

Guard 32 is mounted to and extends from tip housing 28. Guard 32 can be formed from a polymer and overmolded onto tip housing 28, among other options. In other options, guard 32 can be monolithically formed with tip housing 28. Barrel bore 60 can also extend through guard 32 along the mount axis to allow spray tip 26 access through guard 32. Track groove 66 is formed in guard 32 and/or tip housing 28 and extends partially around a circumference of barrel bore 60. Slot 64 extends axially into guard 32 and/or tip housing along the mount axis from an exterior of tip housing and tip module 14 to track groove 66. Slot 64 includes a profile that mates with a profile of flange 50 such that flange 50 can slide through slot 64 to access track groove 66 when spray tip 26 is inserted into barrel bore 60.

Stop face 68 is adjacent to track groove 66 and contact flange 50 to prevent barrel 46 from rotating more than 180 degrees inside barrel bore 60. As noted above, limiting motion of barrel 46 inside barrel bore 60, such as to about 180 degrees, prevents micro knurled patch 35 from contacting saddle surface 76 and interrupting the surface-to-surface seal between barrel bore 60 and saddle seal portion 38. In the example of FIGS. 4-7, a front edge of tip mount 30 can form stop face 68. In other examples, stop face 68 can be machined or molded into guard 32 and/or tip housing 28.

Saddle seal portion 36 includes seal body 74 extending axially along spray axis SA from upstream end 72 to downstream end 70. Seal body 74 can be divided into metal portion 80 and elastomeric portion 82. Elastomeric portion 82 can be adjacent to metal portion 80 in the upstream direction UD along spray axis SA and can form upstream end 72 of seal body 74. Metal portion 80 can be downstream from elastomeric portion 82 relative to the downstream direction DD along spray axis SA and can form downstream end 70 of seal body 74. Saddle surface 76 is formed on downstream end 70 and can be a metal surface.

Saddle surface 76 is formed as a curved downstream surface that interfaces with back portion 54 of exterior surface 48 of barrel 46. Saddle surface 76 is curved to be complementary to the cylindrical profile of barrel 46 to seal when mated. Barrel 46 can move relative to saddle surface 76 while within the saddle defined by saddle surface 76 as spray tip 26 rotates between the positions associated with the spray and de-clog states. The curved shape of exterior surface 48 of barrel 46 and the curvature of downstream saddle surface 76 are complementary to seal with one another. It is noted that such sealing can be by metal-to-metal contact between metal portion 80 of seal body 74 and metallic barrel 46. For example, seal body 46 can be formed from aluminum or stainless steel, among other options, and barrel 46 can be formed from aluminum or stainless steel, among other options.

Upstream flow path 78 is a passage that extends axially through both metal portion 80 and elastomeric portion 82 along spray axis SA. At upstream end 72, upstream flow path 78 forms a portion inlet. At downstream end 70, upstream flow path 78 forms a portion outlet. When saddle seal portion 38 and spray tip 26 are assembled into tip module 14, saddle seal portion 38 is inserted into housing bore 62 of tip housing 28 upstream from barrel bore 60 along spray axis SA. First end 40 of spray tip 26 and barrel 46 are inserted through slot 64 and into barrel bore 60. The profile of flange 50 is aligned with the profile of slot 64 such that flange 50 passes through slot 64 to track groove 66. When the profile of flange 50 is aligned to mate with the profile of slot 64, micro knurled patch 35 faces forward toward the downstream direction DD while the smooth back portion 54 of exterior surface 48 faces toward the upstream direction UD and toward saddle seal portion 38.

Once barrel 46 has been inserted into barrel bore 60 and flange 50 is axially aligned with track groove 66 relative to tip axis TA, the user can grip tip handle 44 and rotate spray tip 26 clockwise or counterclockwise about tip axis TA to turn flange 50 into track groove 66 to lock spray tip 26 into tip housing 28. In the example of FIGS. 4-7, when barrel 46 is initially inserted into barrel bore 60, flange 50 is not contacting stop face 68, tunnel 49 is misaligned with spray axis SA, micro knurled patch 35 faces forward toward the downstream direction DD, back portion 54 of exterior surface 48 faces toward the upstream direction UD, and saddle surface 76 is in direct contact with back portion 54 of exterior surface 48 such that exterior surface 48 of spray tip 26 is blocking upstream flow path 78.

When spray tip 26 is rotated clockwise or counterclockwise about tip axis TA inside barrel bore 60 (e.g., to the position associated with the spray state or the position associated with the de-clog state), flange 50 contacts stop face 68, micro knurled patch 35 interfaces with bore surface 61 of barrel bore 60, tunnel 49 is aligned with spray axis SA and with upstream flow path 78 such that the spray fluid can enter tunnel 49 from upstream flow path 78. Saddle surface 76 constantly contacts smooth portions of exterior surface 48 of barrel 46 as barrel 46 rotates within barrel bore 60 including portions in second portion 54 and around tunnel ends 56 ,58 thereby maintaining a metal-to-metal seal between barrel 46 and saddle seal portion 38. Due to flange 50 and stop face 68, micro knurled patch 35 does not interface or engage with saddle surface 76 as barrel 46 rotates within barrel bore 60, in the example shown. Micro knurled patch 35 interfaces with bore surface 61 of barrel bore 60 by radially overlapping with bore surface 61 of barrel bore 60. When micro knurled patch 35 interfaces with bore surface 61, micro knurled patch 35 can come into physical contact with bore surface 61. The physical contact between micro knurled patch 35 and bore surface 61 of barrel bore 60 can create resistance and friction between barrel 46 and barrel bore 60 to help to decrease the likelihood of unintended rotation between barrel 46 and barrel bore 60 when spray gun 10 is bumped or vibrated, even if such movement is very small. Reducing the likelihood of even small movements of spray tip 26 assists in keeping the spray tip 26 properly aligned within tip housing 28. Keeping spray tip 26 properly aligned within tip housing 28 increases spray accuracy. The increased resistance between barrel 46 and barrel bore 60 also reduces the likelihood of spray tip 26 accidentally falling out of tip housing 28 when spray tip 26 is rotated to an unlocked position by the user and spray gun 10 is turned sideways or upside down by the user. Preventing spray tip 26 from accidently falling out of tip housing 28 can spare spray tip 26 from damage, especially when dropped from a great height, such as from the top of a ladder.

FIG. 8 is an isometric exploded view with tip housing 28 omitted to better show spray tip 26 and saddle seal portion 38. As shown in FIG. 8, micro knurled patch 35 can be formed on first portion 52 of exterior surface 48. Micro knurled patch 35 can be circumferentially aligned on exterior surface 48 of barrel 46 with first tunnel end 56 (not visible in FIG. 8) and second tunnel end 58 relative to tip axis TA. By being directly circumferentially between first tunnel end 56 (not visible in FIG. 8) and second tunnel end 58 relative to tip axis TA, micro knurled patch 35 will be fully within metal tip housing 28 (shown above in FIGS. 4-7) and will fully interface with bore surface 61 of barrel bore 60 when tunnel 49 is aligned with spray axis SA. Further, micro knurled patch 35 can be visible through the downstream end of housing bore 62 such that the user can view micro knurled patch 35 without having to remove spray tip 26 from tip housing 28.

Micro knurled patch 35 comprises a surface modification of exterior surface that is performed by a laser on cylindrical exterior surface that causes a surface roughness of micro knurled patch 35 to be different from a surface roughness of the untreated areas of exterior surface 48 (such as second portion 54, the portion of exterior surface 48 encircling first tunnel end 56, and the portion of exterior surface 48 encircling the second tunnel end 58). Micro knurled patch 35 can be formed on exterior surface 48 by laser etching, laser engraving, laser annealing, laser carbon migration, laser coloration, laser foaming, laser charring, or any combinations thereof, among other options. In some examples, the surface roughness of micro knurled patch 35 can be greater than the surface roughness of the untreated areas of exterior surface 48. In some examples, the surface roughness of micro knurled patch 35 can be less than the surface roughness of the untreated areas of exterior surface 48.

At least in the instance of laser etching, micro knurled patch 35 includes micro etching 81 that extends into barrel 46 from exterior surface 48 of barrel 46. In some examples, micro etching 81 comprises a depth no greater than 0.01 inches (254 m) into barrel 46 from exterior surface 48. In some examples, micro etching comprises a depth of at least 0.00005 inches (1.27pm) into barrel 46 from exterior surface 48. In some examples, micro etching 81 can include a depth in the range of 0.00005 inches (1.27pm) to 0.01 inches (254pm) into barrel 46 from exterior surface 48. In the process of laser etching micro etching 81 into exterior surface 48, some material within micro knurled patch 35 can be raised and elevated above the rest of exterior surface 48 of barrel 46. This raised material helps micro knurled patch 35 to contact bore surface 61 of barrel bore 60 when spray tip 26 is rotated such that micro knurled patch 35 interfaces with bore surface 61 of barrel bore 60.

Micro etching 81 can be arranged in a pattern on exterior surface 48 of barrel 46. In the non-limiting example of FIG. 8, micro etching 81 is arranged into a plurality of rows and a plurality of columns to form a grid. The plurality of rows of micro etching 81 are disposed circumferentially between first tunnel end 56 and second tunnel end 58 relative to tip axis TA. Each row of micro etching 81 can have an axial thickness relative to tip axis TA in the range of 0.25mm (0.01 inches) - 5.08mm (0.2 inches) axially interspaced relative to tip axis TA with spaces that have an axial thickness in the range of 0.25mm (0.01 inches) - 5.08mm (0.2 inches) that do not include indentations (e.g., are smooth cylindrical surfaces). In some examples, the plurality of rows of micro etching 81 can extend circumferentially at a tilt relative to tip axis TA.

The plurality of columns of micro etching 81 are circumferentially between first tunnel end 56 and second tunnel end 58 relative to tip axis TA. Each column of the plurality of columns of micro etching 81 extends axially on barrel 46 relative to tip axis TA. Each column of micro etching 81 can have a circumferential thickness relative to tip axis TA in the range of 0.25mm (0.01 inches) - 5.08mm (0.2 inches) circumferentially interspaced relative to tip axis TA with spaces that have a circumferential thickness in the range of 0.25mm (0.01 inches) - 5.08mm (0.2 inches) that do not include indentations (e.g., are smooth cylindrical surfaces). Exterior surface 48 of the barrel 46 can be smooth between the plurality of rows of micro etching 81 and smooth between the plurality of columns of micro etching 81. In some examples, the plurality of columns of micro etching 81 can extend axially at a tilt relative to tip axis TA.

As shown in FIG. 8, saddle surface 76 is formed on downstream end 70 of seal body 74 and has a curved geometry that mates with exterior surface 48. When tunnel 49 is aligned with spray axis SA and spray tip 26 is in the position of the spray state, saddle surface 76 covers first tunnel end 56. When tunnel 49 is aligned with spray axis SA and spray tip 26 is in the position of the de-clog state, saddle surface 76 covers second tunnel end 58.

FIGS. 9 and 10 will be discussed concurrently. FIG. 9 is a cross-sectional view of spray gun 10 of FIG. 1 taken along line A-A. FIG. 10 is an enlarged view of detail B in FIG. 9. Spray gun 10 and tip module 14 shown in FIGS. 9 and 10 have the same arrangement as spray gun 10 and tip module 14 described above with reference to FIGS. 1-8. As shown in FIG. 9, valve assembly 22 can be a cartridge that is connected to tip module 14 and can be removable from gun housing 16 simply by manipulating latch 89 and pulling on tip module 14. As shown in FIGS. 9 and 10, saddle seal portion 38 is positioned axially between spray tip 26 and valve assembly 22 relative to spray axis SA (shown in FIG. 10). Elastomeric portion 82 of saddle seal portion 38 contacts a front end of valve assembly 22 and forms a seal around valve outlet aperture 87 (shown in FIG. 10) of valve assembly 22.

During operation of spray gun 10, the user can squeeze trigger 20 to open internal valve 85 of valve assembly 22. With internal valve 85 of valve assembly 22 open, the spray fluid is able to exit valve outlet aperture 87 and pass into upstream flow path 78 of saddle seal portion 38. The spray fluid then flows through upstream flow path 78 to spray tip 26. If spray tip 26 is in the position of the spray state such that tunnel 49 is aligned with spray axis SA and has first tunnel end 56 positioned upstream from second tunnel end 58, the spray fluid flows into first tunnel end 56, flows to tip piece 51, and then passes through spray orifice 34 as an atomized spray.

If spray tip 26 is in the position of the de-clog state such that tunnel 49 is aligned with spray axis SA and has second tunnel end 58 positioned upstream from first tunnel end 56, the spray fluid flows into second tunnel end 58, flows in reverse through spray orifice 34 to flush spray orifice 34 and tip piece 51, and then passes through first tunnel end 56. Micro knurled patch 35 can provide friction and resistance between spray tip 26 and tip housing 28 to reduce the likelihood that vibrations generated by the opening and closing of valve assembly 22 will move and rotate spray tip 26 and interrupt the spray pattern of the spray fluid exiting spray orifice 34.

Retainer piece 83 (shown in FIG. 10), can be inside tunnel 49 to retain tip piece 51 within tunnel 49. In some non-limiting examples, retainer piece 83 can be press-fitted into tunnel 49, threaded into tunnel 49, or snap-fitted into tunnel 49. Retainer piece 83 can be removable to allow removal and swapping of tip piece 51. In other examples, tip piece 51 is press-fitted into tunnel 49 and retainer piece 83 is omitted. As discussed below with reference to FIGS. 11A-11C, micro knurled patch 35 can be viewable through opening 84 of tip housing 28.

FIG. HA is an isometric view of tip module 14 with spray tip 26 in a closed and unlocked state. FIG. 1 IB is an isometric view of tip module 14 with spray tip 26 in a spray state. FIG. 11C is an isometric view of tip module 14 with spray tip 26 in a de-clog state. FIGS. 11 A-l 1C will be discussed together. Tip module 14 of FIGS. 11 A-l 1C has a similar arrangement to tip module 14 discussed above with reference to FIGS. 1-10. As shown in FIGS. 11A-11C, tip housing 28 includes opening 84 in a front of tip housing 28. Opening 84 is formed in tip housing 28 by housing bore 62 (see description of FIGS. 4-7) that extends fully through tip housing 28. When spray tip 26 is first inserted into tip housing 28, or when spray tip 26 is rotated about tip axis TA such that tunnel 49 is transverse with spray axis SA, micro knurled patch 35 on barrel 46 can be viewed through opening 84 by the user.

Micro knurled patch 35 can be shaped to include text, numbers, or symbols that convey technical information regarding spray tip 26 to the user. The user can view this technical information on spray tip 26 through opening 84 without removing spray tip 26 from tip housing 28. Such technical information can allow the user to quickly and efficiently verify a size of spray orifice size 34, a spray pattern of spray orifice 34, a model number of spray tip 26, and/or any other useful information regarding spray tip 26 without removing spray tip 26 from tip module 14. Having that information directly on spray tip 26 and viewable through tip housing 28 saves the user time and energy when verifying whether spray gun 10 has the correct spray tip 26 with the desired orifice size and spray pattern.

After the user has verified the information of spray tip 26 contained within micro knurled patch 35 and is ready to use spray tip 26 to produce an atomized patterned of spray fluid, the user can rotate spray tip 26 counterclockwise 90 degrees about tip axis TA from the position of FIG. HA such that tip piece 51 and spray orifice 34 are visible through opening 84, as shown in FIG. 1 IB. If the user needs to flush tip piece 51 and spray orifice 34, the user can rotate spray tip 26 clockwise 180 degrees about tip axis TA from the position of FIG. 1 IB, or clockwise 90 degrees about tip axis TA from the position of FIG. 11C, such that first tunnel end 56 is visible through opening 84. As spray tip 26 is moved to the various states shown in FIGS. 11 A-l 1C, micro knurled patch 35 does not come into contact with saddle surface 76 of saddle seal portion 38. By keeping micro knurled patch 35 from contacting saddle surface 76, the metal-to-metal seal between saddle seal portion 38 and barrel 46 is preserved. While micro knurled patch 35 has been described above as not interfacing or contacting saddle surface 76 of saddle seal portion 38, in some examples, it may be advantageous to allow barrel 46 of spray tip 26 to rotate 360 degrees within barrel bore 60 of tip housing 28 such that micro knurled patch 35 does selectively contact saddle surface 76 in some alternative or additional examples.

FIGS. 12A-12C will be discussed together. FIG. 12A-12C each provide an isometric view of spray tip 26, providing nearly 360 degrees of view of spray tip 26. As shown in FIGS. 12A-12C. Exterior surface 48 of barrel 46 is cylindrical and extends circumferentially around barrel 46 and tip axis TA. Exterior surface 48 extends axially along tip axis TA between tip handle 44 and second end 42 of spray tip 24. Exterior surface 48 is smooth with the exception of micro knurled patch 35.

Tunnel 49 extends transversely through barrel 46 from first tunnel end 56 to second tunnel end 58. First tunnel end 56 opens through exterior surface 48 and second tunnel end 58 also opens through exterior surface 48. First tunnel end 56 is at a location on exterior surface 48 of barrel 46 that is radially opposite from second tunnel end 58 relative to tip axis TA. Tunnel 49 is a passage that extends straight through barrel 46 from first tunnel end 56 to second tunnel end 58 and is transverse to tip axis TA. Tip piece 51 is located inside of tunnel 49 and defines spray orifice 34 for atomizing the spray fluid.

Micro knurled patch 35 is formed on exterior surface 48 and can extend circumferentially on exterior surface 48 between first tunnel end 56 and second tunnel end 58 relative to tip axis TA. Micro knurled patch 35 can be axially aligned with first tunnel end 56 and second tunnel end 58 relative to tip axis TA, such that micro knurled patch 35 radially overlaps with tunnel 49 relative to the tip axis. In some examples, a full axial length of micro knurled patch 35 along tip axis TA can radially overlap with tunnel 49. The micro knurled patch 35 does not extend directly axially above or below first and second tunnel ends 56, 58 of tunnel 49, in some examples. In some examples, the full axial length of micro knurled patch 35 can extend axially above first tunnel end 56 and second tunnel end 58 toward first end 40 and/or can extend axially below tunnel end 56 and second tunnel end 58 toward second end 42.

Micro knurled patch 35 can include a surface modification of exterior surface 48 that is performed by a laser on first portion 52 of exterior surface 48 that causes a surface roughness of micro knurled patch 35 to be different from a surface roughness of an untreated area of exterior surface 48, such as second portion 54. Second portion 54 can include a surface polish with a surface roughness that is different from the surface roughness of the micro knurled patch 35. The portions of exterior surface 48 that encircle first tunnel end 56 or second tunnel end 58 can also include the same surface polish as second portion 54. At least a portion of micro knurled patch 35 can extend radially above the surface polish of exterior surface 48 relative to tip axis TA.

Spray tip 26 can be made by forming barrel 46 as a cylinder with cylindrical exterior surface 48. Tunnel 49 is formed transversely through barrel 46 through drilling or boring transversely through barrel 46 along spray axis SA. Exterior surface 48 is polished to form the surface polish of exterior surface 48 of barrel 46. A patch of exterior surface 48, such as first portion 52, is modified by a laser to form micro knurled patch 35 on barrel 46 with a surface roughness different from the surface roughness of the surface polish of exterior surface 48. Tip piece 51 with spray orifice 34 inserted and installed in tunnel 49. Tip handle 44 is molded onto or otherwise affixed to barrel 46. Tip handle 44 can be formed or connected onto barrel 46 before or after exterior surface 48 is polished.

While the invention(s) 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(s) without departing from the essential scope thereof. For example, while micro knurled patch 35 has been described above as never interfacing or contacting saddle surface 76 of saddle seal portion 38, in some examples, it may be advantageous to allow barrel 46 of spray tip 26 to rotate 360 degrees within barrel bore 60 of tip housing 28 such that micro knurled patch 35 does selectively contact saddle surface 76. Therefore, it is intended that the invention(s) not be limited to the particular embodiment(s) disclosed, but that the invention(s) may 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. A spray tip for use in a spray gun, the spray gun having a cylindrical barrel bore with a bore surface at least partially formed from metal and extending axially along a barrel axis into a tip housing, the spray gun also having a cylindrical passage in the tip housing and extending through the cylindrical barrel bore along a spray axis that is transverse to the barrel axis, the spray tip comprising: a handle; a barrel connected to the handle and extending along a tip axis, the barrel comprising: a cylindrical exterior surface formed of metal and comprising: an untreated area of the cylindrical exterior surface; a micro knurled patch formed into the cylindrical exterior surface, wherein the micro knurled patch has a surface roughness that is different from a surface roughness of the untreated area of the cylindrical exterior surface; and a tunnel extending through the barrel between a first tunnel end open through the exterior surface and a second tunnel end open through the exterior surface, the tunnel extending transverse to the tip axis; wherein the micro knurled patch is configured to interface with the metal of the bore surface when the barrel is disposed in the barrel bore and when the tunnel is aligned with the spray axis.

2. The spray tip of claim 1, wherein the tunnel contains an outlet orifice configured to atomize spray fluid.

3. The spray tip of claim 1 or 2, wherein the micro knurled patch comprises a surface modification of the cylindrical exterior surface relative to the untreated area that is performed by a laser on the cylindrical exterior surface that causes the surface roughness of the micro knurled patch to be different from the surface roughness of the untreated area of the cylindrical exterior surface.

4. The spray tip of any preceding claim, wherein at least a portion of the micro knurled patch extends radially above the untreated area of the cylindrical exterior surface relative to the tip axis.

5. The spray tip of any preceding claim, wherein the micro knurled patch comprises at least one of etching, engraving, and inscribing of at least one of a pattern, a grid, text, and a symbol onto the cylindrical exterior surface of the barrel and/or into the barrel from the cylindrical exterior surface of the barrel.

6. The spray tip of any preceding claim, wherein the micro knurled patch is formed by at least one of laser etching, laser engraving, laser annealing, laser carbon migration, laser coloration, laser foaming, and laser charring of a portion of the cylindrical exterior surface.

7. The spray tip of any preceding claim, wherein the micro knurled patch comprises micro etching extending into the barrel from the exterior surface of the barrel a depth in the range of 0.00005 inches (1.27pm) to 0.01 inches (254pm).

8. The spray tip of any preceding claim, wherein the micro knurled patch comprises micro etching extending into the barrel from the exterior surface of the barrel a depth of at least 0.00005 inches (1.27pm).

9. The spray tip of any preceding claim, wherein the micro knurled patch comprises micro etching extending into the barrel from the exterior surface of the barrel a depth no greater than 0.01 inches (254pm).

10. The spray tip of any preceding claim, wherein the micro knurled patch comprises: a plurality of rows of etching extending circumferentially between the first tunnel end and the second tunnel end relative to the tip axis.

11. The spray tip of claim 10, wherein the exterior surface of the barrel is smooth between the plurality of rows of etching.

12. The spray tip of any of preceding claim, wherein the micro knurled patch comprises: a plurality of columns of etching circumferentially between the first tunnel end and the second tunnel end relative to the tip axis, wherein each column of the plurality of columns of etching extends axially on the barrel relative to the tip axis.

13. The spray tip of claim 12, wherein the exterior surface of the barrel is smooth between the plurality of columns of etching.

14. The spray tip of any preceding claim, wherein the untreated area of the cylindrical exterior surface of the barrel comprises: a smooth section diametrically opposite to the micro knurled patch relative to the tip axis, wherein the smooth section extends circumferentially from the second tunnel end to the first tunnel end relative to the tip axis.

15. The spray tip of any of any preceding claim, wherein the micro knurled patch is axially aligned on the exterior surface of the barrel with the first tunnel end and the second tunnel end relative to the tip axis.

16. The spray tip of any preceding claim, further comprising: a flange extending transversely from the barrel relative to the tip axis and positioned axially on the barrel between the handle and the micro knurled patch.

17. The spray tip of claim 16, wherein the flange extends along fifty percent or less of a circumference of the barrel.

18. The spray tip of claim 16 or 17, wherein the flange and the micro knurled patch are circumferentially aligned on the barrel relative to the tip axis.

19. A spray tip assembly through which a spray coating flows from an upstream direction to a downstream direction, the spray tip assembly comprising: a tip housing comprising: a barrel bore extending into the tip housing along a mount axis, wherein a surface of the barrel bore is at least partially formed of metal; a housing bore extending fully through the tip housing from an inlet of the tip housing to an outlet of the tip housing along a spray axis that is transverse to the mount axis, wherein the housing bore intersects the barrel bore; a spray tip rotatably mounted in the barrel bore of the tip housing, wherein the spray tip comprises: a handle forming a first end of the spray tip; a barrel connected to the handle and extending along a barrel axis from the handle into the barrel bore to a second end of the spray tip, wherein the barrel axis is colinear with the mount axis, and wherein the barrel comprises: a cylindrical exterior surface formed from metal; a tunnel extending through the barrel between a first tunnel end open through the cylindrical exterior surface and a second tunnel end open through the cylindrical exterior surface, the tunnel extending transverse to the barrel axis, and the tunnel containing an outlet orifice configured to atomize spray fluid; and a micro knurled patch formed on the cylindrical exterior surface and extending circumferentially on the cylindrical exterior surface between the first tunnel end and the second tunnel end relative to the barrel axis, wherein the micro knurled patch interfaces with the metal of the surface of the barrel bore when the tunnel is aligned with the spray axis.

20. The spray tip assembly of claim 19, wherein the micro knurled patch interfaces with the metal of the surface of the barrel bore by overlapping with the metal of the surface of the barrel bore when the tunnel is aligned with the spray axis.

21. The spray tip assembly of claim 19 or claim 20, wherein at least a portion of the micro knurled patch extends radially above the cylindrical exterior surface relative to the tip axis and contacts the surface of the barrel bore when the tunnel is aligned with the spray axis.

22. The spray tip assembly of any of claims 19-21, further comprising: a saddle seal portion inside the housing bore upstream from the spray tip, the saddle seal portion comprising: a seal body extending axially from an upstream end to a downstream end relative to the spray axis; an upstream flow path extending through the saddle seal portion from a portion inlet on the upstream end to a portion outlet on the downstream end; and a saddle surface formed on the downstream end of the seal body, wherein the saddle surface is metal and mates to the cylindrical exterior surface of the barrel to cover the first tunnel end or the second tunnel end when the tunnel is aligned with the spray axis.

23. The spray tip assembly of claim 22, wherein the saddle surface constantly contacts the cylindrical exterior surface of the barrel as the barrel rotates within the barrel bore.

24. The spray tip assembly of claim 23, wherein the micro knurled patch does not interface or engage with the saddle surface as the barrel rotates within the barrel bore.

25. The spray tip assembly of any of claims 19-24, wherein the micro knurled patch comprises a surface modification of the cylindrical exterior surface relative to an untreated area of the cylindrical exterior surface that is performed by a laser on the cylindrical exterior surface that causes a surface roughness of the micro knurled patch to be different from a surface roughness of the untreated area of the cylindrical exterior surface.

26. The spray tip assembly of any of claims 19-25, wherein the micro knurled patch comprises at least one of etching, engraving, and inscribing of at least one of a pattern, a grid, text, and a symbol onto the cylindrical exterior surface of the barrel and/or into the barrel from the cylindrical exterior surface of the barrel.

27. The spray tip assembly of any of claims 19-26, wherein the micro knurled patch is formed by at least one of laser etching, laser engraving, laser annealing, laser carbon migration, laser coloration, laser foaming, and laser charring of a portion of the cylindrical exterior surface.

28. The spray tip assembly of any of claims 19-27, wherein: the tip housing further comprises: a track groove formed in the tip housing and extending partially around a circumference of the barrel bore; and a stop face adjacent to the track; and the spray tip further comprises: a flange extending transversely from the barrel relative to the barrel axis and positioned axially on the barrel between the handle and the tunnel relative to the barrel axis, wherein the flange extends along fifty percent or less of a circumference of the barrel, wherein the flange extends into the track groove, wherein the flange contacts the stop face when the tunnel is aligned with the spray axis, and wherein the flange does not contact the stop face when the tunnel is misaligned with the spray axis.

29. The spray tip assembly of claim 28, wherein the flange and the micro knurled patch are circumferentially aligned on the barrel relative to the barrel axis.

30. The spray tip assembly of claim 28 or claim 29, wherein the tip housing further comprises: a slot extending axially into the tip housing along the mount axis from an exterior surface of the tip housing to the track groove, wherein the slot comprises a profile that mates with a profile of the flange.

31. The spray tip assembly of any of claims 19-30, wherein the cylindrical exterior surface is smooth and unmodified by laser as the cylindrical exterior surface extends circumferentially from the second tunnel end to the first tunnel end relative to the barrel axis and diametrically opposite to the micro knurled patch relative to the barrel axis.

32. The spray tip assembly of any of claims 19-31 , wherein the micro knurled patch is circumferentially aligned on the cylindrical exterior surface of the barrel with the first tunnel end and the second tunnel end relative to the barrel axis.

33. The spray tip assembly of any of claims 19-32, wherein the micro knurled patch comprises micro etching extending into the barrel from the exterior surface of the barrel a depth of at least 0.00005 inches (1.27pm).

34. The spray tip assembly of any of claims 19-33, wherein the micro knurled patch comprises micro etching extending into the barrel from the exterior surface of the barrel a depth no greater than 0.01 inches (254pm).

35. The spray tip assembly of any of claims 19-34, wherein the micro knurled patch comprises: a plurality of rows of micro etching extending circumferentially between the first tunnel end and the second tunnel end relative to the barrel axis.

36. The spray tip assembly of claim 35, wherein the cylindrical exterior surface of the barrel is smooth between the plurality of rows of micro etching.

37. The spray tip assembly of any of claims 19-36, wherein the micro knurled patch comprises: a plurality of columns of micro etching circumferentially between the first tunnel end and the second tunnel end relative to the barrel axis, wherein each column of the plurality of columns of micro etching extends axially on the barrel relative to the barrel axis.

38. The spray tip assembly of claim 37, wherein the cylindrical exterior surface of the barrel is smooth between the plurality of columns of micro etching.

39. A spray gun comprising: a spray control assembly comprising: a gun body; a trigger; and a valve assembly comprising a valve that opens to release spray fluid and closes to block spray fluid, the valve assembly comprising a valve outlet aperture disposed downstream of the valve; and a spray tip module comprising: the spray tip assembly of any one of claims 22-38; wherein the tip housing connects the spray tip assembly to the gun body; and wherein the upstream end of the seal body of the saddle seal seals with the valve assembly about the valve outlet aperture.

40. A method of flowing spray fluid for atomization and spraying through a spray tip assembly, the method comprising: rotating a barrel of a spray tip inside of a barrel bore of a tip housing such that a tunnel extending transversely through the barrel relative to a barrel axis of the barrel is aligned and fluidically connected to a passage extending through the tip housing from an inlet of the tip housing to an outlet of the tip housing, wherein the passage extends transversely through the barrel bore, and wherein micro knurling on a cylindrical exterior surface of the barrel interfaces with a metal surface of the barrel bore when the tunnel is aligned with and fluidically connected to the passage; emitting spray fluid from a valve housing aperture formed in a valve housing and into the inlet of the tip housing; flowing the spray fluid through the passage and into the tunnel extending transversely through the barrel of the spray tip; and flowing the spray fluid through a tip piece located within the tunnel, the tip piece forming an outlet orifice that atomizes spray fluid into a fluid spray.

41. The method of claim 40, further comprising: mating a metal saddle surface of a saddle seal portion inside of the passage to a portion of the cylindrical exterior surface of the barrel such that the metal saddle surface contacts the portion of the cylindrical exterior surface of the barrel as the barrel rotates within the barrel bore, wherein the saddle seal portion comprises an upstream flow path extending through the saddle seal portion to allow flow of the spray fluid across the saddle seal portion; rotating the barrel of the spray tip 180 degrees about the barrel axis inside the barrel bore to reverse a direction of flow through the tunnel and the tip piece for clog removal in the tunnel, wherein the micro knurling never interfaces with the metal saddle surface as the barrel rotates 180 degrees about the barrel axis, and wherein the portion of the exterior surface of the barrel inside of the barrel bore has a different surface roughness from the micro etching.

42. The method of claim 41, wherein the metal saddle surface constantly contacts the cylindrical exterior surface of the barrel as the barrel rotates within the barrel bore.

43. The method of claim 42, wherein the micro knurling does not interface or engage with the metal saddle surface as the barrel rotates within the barrel bore.

44. The method of any of claims 40-43, wherein the micro knurling interfaces with the metal surface of the barrel bore by overlapping with the metal surface of the barrel bore when the tunnel is aligned with the passage.

45. The method of claim 44, wherein at least a portion of the micro knurling extends radially above the cylindrical exterior surface relative to the barrel axis and contacts the metal surface of the barrel bore when the tunnel is aligned with the passage.

46. The method of any of claims 40-45, wherein the micro knurling comprises a surface modification of the cylindrical exterior surface relative to an untreated area of the cylindrical exterior surface that is performed by a laser on the cylindrical exterior surface that causes a surface roughness of the micro knurled patch to be different from a surface roughness of the untreated area of the cylindrical exterior surface.

47. A spray tip comprising: a handle forming a first end of the spray tip; a barrel connected to the handle and extending along a barrel axis from the handle to a second end of the spray tip, the barrel comprising: a cylindrical exterior surface formed from metal and comprising a surface polish; a tunnel extending through the barrel between a first tunnel end open through the cylindrical exterior surface and a second tunnel end open through the cylindrical exterior surface, the tunnel extending transverse to the barrel axis; and a micro knurled patch formed on the cylindrical exterior surface and disposed circumferentially on the cylindrical exterior surface between the first tunnel end and the second tunnel end relative to the barrel axis, wherein the micro knurled patch comprises a surface roughness different from a surface roughness of the surface polish of the cylindrical exterior surface.

48. The spray tip of claim 47, wherein the tunnel contains an outlet orifice configured to atomize spray fluid.

49. The spray tip of claim 47 or claim 48, wherein at least a portion of the micro knurled patch extends radially outward from the surface polish of the cylindrical exterior surface relative to the barrel axis.

50. The spray tip of any of claims 47-49, wherein the micro knurled patch comprises a surface modification of the cylindrical exterior surface that is performed by a laser on the cylindrical exterior surface that causes the surface roughness of the micro knurled patch to be different from the surface roughness of the surface polish of the cylindrical exterior surface.

51. The spray tip of any of claims 47-50, wherein the micro knurled patch comprises at least one of etching, engraving, and inscribing of at least one of a pattern, a grid, text, and a symbol onto the cylindrical exterior surface of the barrel and/or into the barrel from the cylindrical exterior surface of the barrel.

52. The spray tip of any of claims 47-51 , wherein the micro knurled patch is formed by at least one of laser etching, laser engraving, laser annealing, laser carbon migration, laser coloration, laser foaming, and laser charring of a portion of the cylindrical exterior surface.

53. The spray tip of any of claims 47-52, wherein the micro knurled patch is axially aligned on the exterior surface of the barrel with the first tunnel end and the second tunnel end relative to the barrel axis.

54. The spray tip of any of claims 47-53, further comprising: a flange extending transversely from the barrel relative to the barrel axis and positioned axially on the barrel between the handle and the micro knurled patch.

55. The spray tip of claim 54, wherein the flange extends along fifty percent or less of a circumference of the barrel.

56. The spray tip of claim 54 or claim 55, wherein the flange and the micro knurled patch are circumferentially aligned on the barrel relative to the barrel axis.

57. A spray tip module comprising: a tip housing defining a barrel bore extending along a mount axis and defining a housing bore extending fully through the tip housing along a spray axis, wherein the housing bore extends transversely through the barrel bore; the spray tip of any one of claims 47-57, wherein the spray tip is rotatably mountable in the barrel bore, and wherein the micro knurled patch interfaces with a metal surface of the barrel bore when the barrel is disposed in the barrel bore and when the tunnel is aligned with the spray axis.

58. A method for making a rotatable spray tip for a spray gun comprises: forming a cylindrical barrel extending from a handle along a barrel axis; forming a tunnel extending transversely through the cylindrical barrel along a flow axis, wherein the flow axis is transverse to the barrel axis; polishing a cylindrical exterior surface of the cylindrical barrel to form a surface polish of the cylindrical exterior surface; modifying a patch of the cylindrical exterior surface with a laser to form a micro knurled patch on the barrel with a surface roughness different from a surface roughness of the surface polish of the cylindrical exterior surface.

59. The method of claim 58, further comprising: inserting an outlet orifice in the tunnel, wherein the outlet orifice is configured to atomize spray fluid.

60. The method of claim 58 or claim 59, wherein at least a portion of the micro knurled patch extends radially outward from the surface polish of the cylindrical exterior surface relative to the barrel axis.

61. The method of any of claims 58-60, wherein the micro knurled patch comprises at least one of etching, engraving, and inscribing of at least one of a pattern, a grid, text, and a symbol onto the cylindrical exterior surface of the barrel and/or into the barrel from the cylindrical exterior surface of the barrel.