EP4662011A1

EP4662011A1 - Plural component spray gun and cartridge

Info

Publication number: EP4662011A1
Application number: EP24713591.6A
Authority: EP
Inventors: II Augustine T. Sierra; Kyle J. MCKELLIPS; John R. Ingebrand
Original assignee: Graco Minnesota Inc
Current assignee: Graco Minnesota Inc
Priority date: 2023-02-09
Filing date: 2024-02-08
Publication date: 2025-12-17
Also published as: WO2024168131A1

Abstract

A plural component spray gun provides flows of constituent materials and compressed gas to a downstream mix chamber in which the constituent materials mix to form a plural component material. The valves of the plural component spray gun are configured to control the flows of both the constituent material and the compressed gas and are configured such that the compressed gas flows when the constituent material flow is shut off and the constituent material flows when the compressed gas flow is shut off. The valves are disposed in one or more cartridges that are mountable to a gun body of the spray gun. The cartridge fully contains the flow control elements for both constituent material and compressed gas.

Description

PLURAL COMPONENT SPRAY GUN AND CARTRIDGE

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims priority to U.S. Provisional Application No. 63/444,506 filed February 9, 2023 and entitled “PLURAL COMPONENT SPRAY GUN AND CARTRIDGE,” the disclosure of which is hereby incorporated by reference in its entirety.

BACKGROUND

The present disclosure concerns spraying of plural component mixtures. More particularly, the present disclosure concerns sprayers and components of sprayers that spray plural component mixtures.

Spray foam, typically created by mixing isocyanate and polyol resin components, is one broad type of sprayable plural component fluids. Plural components can also be glues, adhesives, coatings, and other materials. For example, epoxies can be sprayed. Individual constituent materials are flowed to a spray gun, mixed within the spray gun to form a plural component material, and sprayed as a single solution. The single solution can be referred to as a plural component material as it is formed from the multiple constituent components.

The constituent components are typically mixed in a spray gun and then sprayed in a matter of milliseconds due to the quick reacting and setting nature of the fluids. Mixing can occur within a mix chamber of the gun. The mix chamber can form part of the nozzle of the gun in various embodiments. Due to the quick setting nature of the combined fluids, special attention has to be paid to maintenance of the guns. For example, any component residue left in a gun such as in or around the mix chamber can react when exposed to its complementary component or can otherwise dry. Clogs and other obstructions can interfere with the mechanical operation of the spray gun and interfere with proper mixing and spraying. Various aspects of the present disclosure concern improving maintenance to extend service life and/or improve spray performance, amongst others.

SUMMARY

According to an aspect of the disclosure, a cartridge is configured for use in a plural component spray gun, the plural component spray gun having a mix chamber and configured to be supplied with a compressed gas, a first constituent material, and a second constituent material. The cartridge includes a cartridge body having a mount end and a dispense end; a first multi-fluid valve disposed at least partially within the cartridge body, the first multi-fluid valve actuatable along a first valve axis between a first spray state which permits flow of the first constituent material to the mix chamber and a first non-spray state which blocks flow of the first constituent material to the mix chamber; a second multi-fluid valve disposed at least partially within the cartridge body and actuatable along a second valve axis between a first spray state which permits flow of the first constituent material to the mix chamber and a first non-spray state which blocks flow of the first constituent material to the mix chamber; a first downstream port is open on the cartridge body and fluidly connected to the first multi-fluid valve, wherein the first constituent material is output from the cartridge body through the first downstream port; and a second downstream port open on the cartridge body and fluidly connected to the first multi-fluid valve, wherein the second constituent material is output from the cartridge body through the second downstream port. The first downstream port is spaced from the second downstream port such that the first constituent material and the second constituent material fully exit from within the cartridge body as separate flows.

According to an additional or alternative aspect of the disclosure, a cartridge is configured for use in a plural component spray gun, the plural component spray gun having a mix chamber and configured to be supplied with a compressed gas, a first constituent material, and a second constituent material. The cartridge includes a cartridge body; a first main bore formed in the cartridge body; a first multi-fluid valve disposed at least partially within the first main bore, the first multi-fluid valve actuatable along a first valve axis between a first spray state which permits flow of the first constituent material to the mix chamber and a first non-spray state which blocks flow of the first constituent material to the mix chamber; a first gas port configured to provide compressed gas to the first multifluid valve; and a first material port configured to provide the first constituent material to the first multi-fluid valve. The first material port is disposed downstream from the first gas port.

According to another additional or alternative aspect of the disclosure, a cartridge is configured for use in a plural component spray gun, the plural component spray gun having a mix chamber and configured to be supplied with a compressed gas, a first constituent material, and a second constituent material. The cartridge includes a cartridge body having a mount end and a dispense end; a first main bore formed within the cartridge body and extending to a first downstream port open through the dispense end; a first multifluid valve disposed at least partially within the first main bore, the first multi-fluid valve actuatable along a first valve axis between a spray state which permits flow of the first constituent material to the mix chamber and blocks flow of compressed gas to the mixing chamber, a transition state which blocks flow of the first constituent material and the compressed gas to the mix chamber, and a purge state which blocks flow of the first constituent material and allows flow of the compressed gas to the mix chamber; a second main bore formed within the cartridge body and extending to a second downstream port open through the dispense end; and a second multi-fluid valve disposed at least partially within the second main bore and actuatable along a second valve axis to control flows of the second constituent material and the compressed gas to the mix chamber through the second downstream port. The first downstream port is spaced from the second downstream port such that flows controlled by the first multi-fluid valve exit the cartridge body separately from flows controlled by the second multi-fluid valve.

According to yet another additional or alternative aspect of the disclosure, a valve assembly is configured for use in a cartridge for use in a plural component spray gun, the plural component spray gun having a mix chamber and the cartridge configured to be supplied with a compressed gas, a first constituent material, and a second constituent material. The valve assembly includes a mount plate; a yoke; a first multi-fluid valve connected to the yoke and configured to shift along a first valve axis, wherein at least a portion of the first multi-fluid valve extends through the mount plate to connect to the yoke; and a second multi-fluid valve connected to the yoke and configured to shift along a second valve axis, wherein at least a portion of the second multi-fluid valve extends through the mount plate to connect to the yoke.

According to yet another additional or alternative aspect of the disclosure, a plural component spray gun is configured to be supplied with compressed gas, a first constituent material, and a second constituent material and to output a plural component material formed by mixing of the first constituent material and the second constituent material. The plural component spray gun includes a gun body; a cartridge mountable to and dismountable from the gun body as a single unit; and a mix chamber. The cartridge includes a cartridge body having a dispense end and a mount end; a first multi-fluid valve disposed at least partially within the cartridge body, the first multi-fluid valve actuatable along a first valve axis between a first spray state which permits flow of the first constituent material to a first downstream port and out of the cartridge body and a first non-spray state which blocks flow of the first constituent material to the first downstream port; and a second multi-Huid valve disposed at least partially within the cartridge body, the second multifluid valve actuatable along a second valve axis between a second spray state which permits flow of the second constituent material to a second downstream port and out of the cartridge body and a second non-spray state which blocks flow of the second constituent material to the second downstream port. The mix chamber is mounted to the dispense end such that the mix chamber is supported by the cartridge body.

According to yet another additional or alternative aspect of the disclosure, a method of spraying includes shifting a first inner needle of a first multi-fluid valve in an upstream direction and along a first valve axis of the first multi-fluid valve; contacting a first inner needle head of the first inner needle with a first outer needle through which the first inner needle at least partially extends, thereby shutting off a flow of compressed gas through the first multi-fluid valve; and displacing the first outer needle in the upstream direction by the first inner needle to unseat the first outer needle from a first outer needle seat, thereby opening a flow of a first constituent material through the first multi-fluid valve and downstream to a mix chamber.

According to yet another additional or alternative aspect of the disclosure, a cartridge is configured for use in a plural component spray gun, the plural component spray gun having a mixing chamber, the plural component spray gun configured to be supplied with a compressed gas and a first constituent material. The cartridge includes a first cartridge body; and a first valve located at least partially within the first cartridge body operable in a spray state which permits flow of the first constituent material to the mix chamber and in a non-spray state which blocks flow of the first constituent material to the mix chamber. The first cartridge body is configured to mount to the plural component spray gun.

BRIEF DESCRIPTION OF THE DRAWINGS

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

FIG. 2 is an exploded view showing portions of the spray gun.

FIG. 3 is a cross-sectional view of the spray gun taken along line 3-3 in FIG. 1.

FIG. 4A is a cross-sectional view of the spray gun taken along line 4-4 in FIG. 1 showing the gun in a purge state.

FIG. 4B is a cross-sectional view of the spray gun taken along line 4-4 in FIG. 1 showing the gun in a transition state.

FIG. 4C is a cross-sectional view of the spray gun taken along line 4-4 in FIG. 1 showing the gun in a spray state.

FIG. 5 is a cross-sectional view of the valve cartridge.

FIG. 6A is a first isometric view of a valve cartridge.

FIG. 6B is a second isometric view of the valve cartridge. FIG. 6C is a third isometric view of the valve cartridge.

FIG. 7 is a cross-sectional view of a cartridge.

FIG. 8A is an isometric view of a valve assembly.

FIG. 8B is a cross-sectional view of the valve assembly taken along line B-B in FIG. 8A.

FIG. 9A is an isometric view of a flow control valve.

FIG. 9B is a cross-sectional view of the flow control valve taken along line B-B in FIG. 9A.

FIG. 10 is an isometric view of an air needle.

FIG. 11 is a partial isometric view of a spray gun showing an interface between a manifold and a gun body.

FIG. 12 is an isometric view of a spray gun.

FIG. 13 is a sectional view of a valve cartridge.

FIG. 14A is a cross-sectional view taken along line 14-14 in FIG. 12 showing the spray gun in a purge state.

FIG. 14B is a cross-sectional view taken along line 14-14 in FIG. 12 showing the spray gun in a transition state.

FIG. 14C is a cross-sectional view taken along line 14-14 in FIG. 12 showing the spray gun in a spray state.

DETAILED DESCRIPTION

The present disclosure relates generally to plural component sprayers. In plural component sprayers, multiple constituent components are mixed within a mix chamber. Spray foam, typically created by mixing isocyanate and polyol resin components, is one broad type of sprayable plural component fluids. Plural components can also be glues, adhesives, coatings, and other materials. For example, epoxies can be sprayed. In the disclosure, a first constituent material can also be referred to as a “A component” or “A component liquid” and a second constituent material can also be referred to as a “B component” or a “B component liquid.”

A cartridge of the present disclosure provides quick and efficient assembly of a spray gun for spraying and disassembly for maintenance. The cartridge is mountable to and dismountable as a single unit. The cartridge contains the valving components that control flow of constituent materials to a mix chamber for combination into the plural component material and for spraying. The cartridge further contains the valving components that control flow of compressed gas to the mix chamber, such as for purging of residue. The valving components control flows of constituent materials and flows of compressed gas to the mix chamber.

Cartridges according to the present disclosure output the constituent materials to the mix chamber. The mix chamber is disposed downstream of the cartridge such that the mix chamber is not at least partially disposed within the cartridge. The cartridge can support one or multiple flow control valves that control flow of compressed gas and constituent material to the mix chamber. The constituent material fully exits from the cartridge to enter into the mix chamber such that the flows of constituent material do not combine at any location that is radially overlapped by the body of the cartridge.

Cartridges according to the present disclosure are mountable to the spray gun at a dynamic connection interface. The dynamic interface conveys mechanical force to the valves of the cartridge to actuate the valves between various flow states. The cartridge includes a yoke that is configured to receive the mechanical forces from an actuator of the spray gun and conveys the mechanical forces to the valving components to actuate the valving components.

Cartridges according to the present disclosure are mountable to the spray gun at a static connection interface. The static interface fixes the cartridge to the gun body of the spray gun. The static interface prevents relative movement of the cartridge along a spray axis to maintain the cartridge mounted on the gun body. A body of the cartridge interfaces with the gun body to mount the cartridge to the gun body. The static interface and the dynamic interface can be configured to mount the cartridge to the spray gun such that the dynamic connection interface and the static connection interface are simultaneously formed during mounting and simultaneously broken during dismounting.

Flow control valves according to the present disclosure can be configured to control flows of both compressed gas and constituent material downstream from the flow control valve. The flow control valve can include nested flow controllers, with one flow controller movable to turn on and off flow of compressed gas to the mix chamber and the other flow controller movable to turn on and off flow of a constituent material to the mix chamber. Multiple flow control valves can be assembled together to form a valve assembly that can be mountable to and removable from a cartridge body of the cartridge as a single unit.

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

FIG. 1 is an isometric view of spray gun 10. Gun body 12, cartridge 14, mix chamber 16, trigger 18, manifold 20, and gas fitting 22 of spray gun 10 are shown.

Gun body 12 supports other components of spray gun 10. Gun body 12 can be formed from polymer and/or metal. Gun body 12 can form the structural frame of the spray gun 10. The spray gun 10 further includes a handle 24. The handle 24 can be part of the gun body 12. For example, the gun body 12 and handle 24 can be monolithically formed. In other examples the handle 24 can be formed separately from the gun body 12 and connected thereto. For example, the handle 24 may be formed from a different material from the gun body 12 and attached to the gun body 12. The handle 24 permits the spray gun 10 to be held and operated by a single hand of a user. The spray gun 10 includes a trigger 18. Actuation of the trigger 18 by one or multiple fingers can cause spraying from the spray gun 10 and release of the trigger 18 can cease spraying from the spray gun 10.

Cartridge 14 is mounted to gun body 12. Cartridge 14 includes valving components, discussed in more detail below, that control flows of compressed gas and constituent material to the mix chamber 16. Manifold 20 is fluidly connected to cartridge 14 and is configured to direct flows of constituent materials to the cartridge 14. In the example shown, the manifold 20 is configured to direct a first flow of a first constituent material to the cartridge and a second flow of a second constituent material to the cartridge 14. The constituent materials do not mix within the manifold 20 or the cartridge 14. Instead, the cartridge 14 is configured to output the materials to mix chamber 16 that is disposed downstream of the cartridge 14. Manifold 20 can include fittings or other types of connectors for a first constituent component, a second constituent component, and, in some examples, compressed gas.

Mix chamber 16 is supported by gun body 12. In the example shown, mix chamber 16 is indirectly supported by gun body 12 in that mix chamber 16 is connected to cartridge 14 that is connected to gun body 12. Material sprayed from the spray gun 10 is released from the nozzle 26, typically as a stream or pattern such as a cone. In the example shown, the nozzle 26 is integrated with the mix chamber 16 such that nozzle 26 is formed by mix chamber housing 52, however in various other examples they may be separate. Constituent materials are combined in the mix chamber 16 into a mixed fluid which is sprayed from the nozzle 26.

In the example shown, spray gun 10 includes gas fitting 22 that projects from a rear end of the gun body 12. Gas fitting 22 is configured to receive a flow of compressed gas, such as compressed air, nitrogen, etc., into the gun body 12. The compressed gas can be utilized to cause actuation of the valving components within cartridge 14 and/or as purge gas, as discussed in more detail below. The cartridge 14 is supplied with a flow of the pressurized gas.

During operation, actuation of trigger 18 in a first direction towards the handle 24 causes the valves within cartridge 14 to shift to allow flows of the constituent materials downstream to the mix chamber 16 for mixing and emission through nozzle 26. Actuation in the first direction can also shut off flow of compressed gas through the valves to the mix chamber 16. Actuation of the trigger 18 in a second direction away from the handle 24 causes the valves within cartridge 14 to shift to shut off the flows of the constituent material. Actuation in the second direction can also reopen the flowpaths of the compressed gas through the valves and to the mix chamber 16.

Spray gun 10 can be configured as a low pressure spray gun, though it is understood that other configurations are possible. Low pressure spray guns differ from impingement type plural component sprayers (i.e., high pressure spray guns) in that the constituent materials mix within a mix chamber 16 that has a static mixer 54 that blends the constituent materials to form the plural component material. Higher pressure spray guns utilize impingement type mixing in which the constituent materials are jetted into a mix bore and mix within the mix bore without obstructions within the mix bore. Low pressure spray guns can utilize component material pressures up to about 2.41 Megapascal (MPa) (about 350 pounds per square inch (psi)). Some examples of low pressure spray guns can utilize component material pressures up to about 1.72 MPa (about 250 psi). Some examples of low pressure spray guns can experience even lower component material pressures at the cartridge 14, such as up to about 1.03 MPa (about 150 psi), such as due to pressure losses in hoses providing the plural component material to the cartridge 14. High pressure plural component sprayers are configured to operate at pressures of at least about 4.83 MPa (about 700 psi).

FIG. 2 is an exploded view showing a portion of spray gun 10. Cartridge 14 and gun body 12 are shown. Cartridge body 28 and cartridge mounts 30 of cartridge 14 are shown. Gun mounts 32 of gun body 12 are shown. Cartridge 14 is configured to mount to gun body as a single unit such that mounting of cartridge 14 mounts all valving components of spray gun 10 that control flow to the mix chamber 16.

Cartridge 14 is configured to mount by axial shifting of cartridge 14 or gun body 12 along spray axis SA, along which the nozzle 26 is oriented and the plural component material is output, and then relative rotation between cartridge 14 and gun body 12. As shown, the cartridge 14 is first displaced such that a portion of cartridge 14 enters into gun body 12 (shown by arrow MD1) and the cartridge 14 is then rotated relative to gun body 12 to secure the connections between cartridge 14 and gun body 12 (shown in arrow RD1).

In the example shown, cartridge mounts 30 are formed as projections on the exterior of cartridge body 28. In the example shown, gun mounts 32 are formed as projections on the interior of gun body 12. During mounting, the cartridge mounts 30 pass through gaps formed between the gun mounts 32 and the gun mounts 32 similarly pass through gaps formed between the cartridge mounts 30. Relative rotation then aligns the cartridge mounts 30 and gun mounts 32 to prevent axial shifting of the cartridge 14 and gun body 12 relative to each other along the spray axis SA. The interface between the cartridge mounts 30 and gun mounts 32 can be considered to form the static connection between cartridge 14 and gun body 12. In some examples, the static connection can be formed by relative rotation of less than a half turn. In some examples, the static connection can be formed by relative rotation of less than a quarter turn. In some examples, the static connection can be formed by relative rotation of one eighth of a turn.

In addition to forming a static connection, mounting of the cartridge 14 forms a dynamic connection that is configured to actuate the valves of cartridge 14, which dynamic connection is discussed in more detail below. The dynamic and static connections can be formed simultaneously during mounting of the cartridge 14 to the gun body 12 and the dynamic and static connections can be broken simultaneously during dismounting of the cartridge 14 from the gun body 12.

FIG. 3 is a cross-sectional view of spray gun 10 taken along line 3-3 in FIG. 1. The cross-section shown shows the air pathways for actuation of the valving components of spray gun 10 and for flow of mixer air. Gun body 12, cartridge 14, mix chamber 16, trigger 18, manifold 20, gas fitting 22, nozzle 26, trigger valve 34, piston 36, and return spring 38 of spray gun 10 are shown. Gun body 12 includes valve bore 40, gas passage 42, actuation passage 44a, actuation passage 44b, exhaust passage 46, mount cavity 48, and piston chamber 50. Mix chamber 16 includes mix chamber housing 52 and static mixer 54. In the example shown, spray gun 10 is pneumatically actuated such that directing compressed gas to actuation passage 44a causes the valves of cartridge 14 to actuate to shut off flow of compressed gas to mix chamber 16 and to allow flow of constituent material to mix chamber 16 and such that directing the compressed gas to actuation passage 44b causes the valves of cartridge 14 to actuate to shut off flow of constituent material to mix chamber 16 and to allow flow of compressed gas to mix chamber 16.

Valve bore 40 is formed in gun body 12. Trigger valve 34 is disposed at least partially within valve bore 40. Trigger valve 34 projects out of valve bore 40 towards trigger 18 such that trigger 18 can contact and actuate trigger valve 34. Trigger valve spring 56 interfaces with an end of trigger valve 34 opposite trigger 18. Trigger valve spring 56 is configured to return trigger valve 34 to the state shown in FIG. 3 upon release of trigger 18.

Gas passage 42 extends between valve bore 40 and mount cavity 48. Gas passage 42 is configured to provide compressed gas to mount cavity 48 and thus to cartridge 14. In the example shown, gas passage 42 is fluidly connected to the source of compressed air throughout operation such that compressed gas flows cartridge 14 regardless of the actuation state of trigger 18. In the example shown, a gas bore 58 extends partially through trigger valve 34 to provide the compressed gas to gas passage 42.

Actuation passage 44a extends between valve bore 40 and piston chamber 50. Actuation passage 44a opens to piston chamber 50 on a first side of piston 36. Actuation passage 44b extends between valve bore 40 and piston chamber 50. Actuation passage 44b opens to piston chamber 50 on a second side of piston 36. In the example shown spray gun 10 is in a purge state in which compressed gas flows through the valves of cartridge 14 and to mix chamber 16 and flows of constituent material to mix chamber 16 are shut off. In such a state the trigger valve 34 directs compressed gas to actuation passage 44b while actuation passage 44a is fluidly connected to exhaust passage 46. The compressed gas flowing through actuation passage 44b biases piston 36 in the downstream direction DD. On actuation of trigger 18, the trigger valve 34 shifts such that actuation passage 44a is fluidly connected to the source of compressed gas and actuation passage 44b is fluidly connected to exhaust passage 46. The compressed gas flowing through actuation passage 44a drives piston 36 in the upstream direction UD and piston 36 actuates the valves of cartridge 14 to allow flow of constituent material to mix chamber 16, as discussed in more detail below. With trigger actuated, compressed gas within the portion of piston chamber 50 fluidly connected to actuation passage 44b can be vented through actuation passage 44b and exhaust passage 46.

Return spring 38 is disposed within piston chamber 50. Return spring 38 is configured to bias piston 36 in the downstream direction DD. Return spring 38 can return piston 36 to shut off the flows of the constituent materials. For example, the return spring 38 can assist the pneumatic pressure in returning piston 36 in the downstream direction DD or if pneumatic pressure is lost during operation.

Mixer supply channel 60 is formed in cartridge 14. In the example shown, mixer supply channel 60 extends fully axially through cartridge body 28 along the spray axis SA. The mixer supply channel 60 is fluidly connected to mount cavity 48 such that mixer supply channel 60 receives compressed gas from gas passage 42. Mixer supply channel 60 is fluidly connected to mixer gas channel 62 formed in static mixer 54. Mixer supply channel 60 is configured to provide the compressed gas to mixer gas channel 62 within static mixer 54, which compressed gas is then output from the static mixer 54 and into mix chamber 16 at a location spaced in the downstream direction DD from cartridge 14.

Check valve 72 is at least partially disposed within cartridge body 28. Check valve 72 is a one-way valve that allows flow out of the mixer supply channel 60 in the downstream direction DD and prevents flow in the upstream direction UD. Check valve 72 can prevent constituent or plural component material from entering into mixer supply channel 60, which could clog mixer supply channel 60 and lead to flow upstream into gun body 12.

Manifold 20 is mounted to cartridge 14 in the example shown. Manifold 20 is configured to provide flows of the constituent materials to the cartridge 14.

Mix chamber 16 is mounted to cartridge 14. Static mixer 54 disposed within mix chamber housing 52. Static mixer 54 includes projections that break up the direct flow of liquids and forces turbulence to foster mixing of the constituent materials to form the plural component material. In some examples, the projections can extend helically around and along a stem of static mixer 54.

Piston 36 includes piston head 64 and piston shaft 66. Piston mount 68 is formed at an end of piston shaft 66. Piston head 64 is disposed within piston chamber 50 and is configured to be acted upon by the compressed gas flowing through actuation passage 44a and actuation passage 44b to cause displacement of piston 36. Piston shaft 66 extends from piston head 64, out of piston chamber 50, and into mount cavity 48. Piston mount 68 is formed on piston shaft 66. In the example shown, piston mount 68 is formed at a distal end of piston shaft 66 opposite the end connected to piston head 64. Piston mount 68 is configured to interface with a yoke 70 of cartridge 14 to form the dynamic connection interface.

FIG. 4A is a cross-sectional view taken along line 4-4 in FIG. 1 showing the spray gun 10 in a purge state. FIG. 4B is a cross-sectional view taken along line 4-4 in FIG. 1 showing the spray gun 10 in a transition state. FIG. 4C is a cross-sectional view taken along line 4-4 in FIG. 1 showing the spray gun 10 in a spray state. FIG. 5 is a cross- sectional view of the cartridge 14 as shown in FIG. 4A with the cartridge 14 in the purge state. FIGS. 4A-5 are discussed together and with continued reference to FIGS. 1-3.

Gun body 12, cartridge 14, mix chamber 16, manifold 20, gas fitting 22, nozzle 26, piston 36, and return spring 38 of spray gun are shown. Mount cavity 48 and piston chamber 50 of gun body 12 are shown. Cartridge 14 includes cartridge body 28; valve assembly 74; multi-fluid valves 76a, 76b (collectively herein “multi-fluid valve 76” or “multi-fluid valves 76”); yoke 70; main bores 78a, 78b (collectively herein “main bore 78” or “main bores 78”); mixer supply channel 60; and cartridge mounts 30. Cartridge body 28 includes mount end 80, main body portion 82, and dispense end 84. Multi-fluid valves 76a, 76b respectively include inner needles 86a, 86b (collectively herein “inner needle 86” or “inner needles 86”); outer needles 88a, 88b (collectively herein “outer needle 88” or “outer needles 88”); bushings 90a, 90b (collectively herein “bushing 90” or “bushings 90”); and valve springs 92a, 92b (collectively herein “valve spring 92” or “valve springs 92”).

Cartridge 14 is mounted to gun body 12 at a static interface between cartridge mounts 30 and body mounts 32. Cartridge 14 is mounted to piston 36 at a dynamic interface between piston 36 and yoke 70. The static interface supports cartridge 14 on gun body 12 while the dynamic interface actuates multi-fluid valves 76 between various states.

The mount end 80 of cartridge 14 is configured to interface with gun body 12 to statically mount the cartridge 14 to the gun body 12. In the example shown, mount end 80 has a smaller radial width RW1 than the radial width RW2 of main body portion 82 of cartridge body 28. The main body portion 82 radially overlaps with the gun body 12 at the static interface. In the example shown, the main body portion 82 extends into mount cavity 48 such that a portion of cartridge body 28 is disposed directly radially inward of the gun body 12. In the example shown, the radial width RW2 of the main body portion is greater than the radial width RW3 of the opening into mount cavity 48. The larger radial width RW2 can, in some examples, act as a stop to prevent cartridge 14 from being shifted further axially into mount cavity 48 in the upstream direction UD during mounting of the cartridge 14.

The mount end 80 of cartridge 14 can axially overlap with portions of gun body 12. For example, the mount end 80 of cartridge 14 can receive portions of the gun body 12 such that the mount end 80 and gun body 12 axially overlap with a portion of the gun body 12 disposed directly axially between portions of the mount end 80. In the example shown, the body mounts 32 are disposed in mount grooves 98a that are formed directly axially between cartridge mounts 30 and cartridge shoulder 94. In additional or alternative examples, gun body 12 can receive portions of the mount end 80 of cartridge 14 such that the mount end 80 and gun body 12 axially overlap with a portion of the mount end 80 disposed directly axially between portions of the gun body 12. In the example shown, the cartridge mounts 30 extend into mount grooves 98b formed directly axially between body mounts 32 and body shoulder 96.

In the example shown, the cartridge mounts 30 are spaced in the upstream direction UD to not radially overlap with the main bores 78. It is understood, however, that in some examples the cartridge mounts 30 can, fully or partially, radially overlap with the main bores 78. Body mounts 32 can fully, partially, or not radially overlap with the main bores 78. In the example shown, a portion of the axial length of the body mounts 32 radially overlap with the main bores 78.

Body groove 100 is formed on an exterior surface of cartridge body 28. In the example shown, the body groove 100 is formed on mount end 80. Body groove 100 is a seal groove that is configured to support cartridge seal 152 to provide a sealed interface between cartridge body 28 and gun body 12. Cartridge seal 152 can be an elastomer seal, such as an o-ring seal among other options. The body groove 100 is disposed between the end face 102b of cartridge body 28 and body mounts 32. End face 102b can also be referred to as an upstream end face of the cartridge body 28. Body groove 100 can extend fully annularly around cartridge body 28. The cartridge seal 152 is configured to engage with cartridge body 28 and gun body 12 to prevent compressed gas from leaking from mount cavity 48 between cartridge body 28 and gun body 12. The cartridge seal 152 seals between the exterior of cartridge body 28 and an interior surface of gun body 12. While cartridge seal 152 is supported by cartridge body 28 in the example shown, it is understood that cartridge seal 152 can be supported by gun body 12 in various other examples.

Dispense end 84 of cartridge body 28 is disposed on an opposite axial side of main body portion 82 from mount end 80. Dispense end 84 is configured to interface with mix chamber 16. The dispense end 84 can directly connect to mix chamber 16. The dispense end 84 directly supports the mix chamber 16. The mix chamber 16 is indirectly supported by the gun body 12 via the cartridge 14. In the example shown, mix chamber 16 is mounted to cartridge 14 by a threaded interface between mix chamber housing 52 and cartridge body 28, though it is understood that other connection types are possible. In the example shown, the dispense end 84 is received within the mix chamber housing 52 such that portions of the mix chamber housing 52 are disposed directly radially outside of exterior portions of the cartridge body 28.

Multi-fluid valves 76 are configured to control flows of compressed gas and constituent material to mix chamber 16. Each multi-fluid valve 76 is actuatable along a valve axis VA. The multi-fluid valves 76 are configured to actuate between forward positions associated with the purge state (FIG. 4A), intermediate positions associated with the transition state (FIG. 4B), and rearward positions associated with the spray state (FIG. 4C).

Each multi-fluid valve 76 is disposed at least partially within the cartridge body 28. The multi-fluid valve 76 is actuatable along a valve axis VA between a first spray state which permits flow of the first constituent material to the mix chamber and a first nonspray state which blocks flow of the first constituent material to the mix chamber. In some examples, the multi-fluid valve 76 is operable in the first spray state to permit flow of the first constituent material past the multi-fluid valve 76 and to the mix chamber 16 and block flow of the compressed gas through the multi-fluid valve 76 to the mix chamber 16. In some examples, the multi-fluid valves 76 are operable in the first non-spray state to block flow of the first constituent material past the multi-fluid valve 76 to the mix chamber 16 and permit flow of the compressed gas through the multi-fluid valve 76 to the mix chamber 16.

Valve assembly 74 is mounted to cartridge body 28. In the example shown, valve assembly 74 includes both multi-fluid valves 76a, 76b and yoke 70. Yoke 70 is connected to multi-fluid valve 76a and to multi-fluid valve 76b such that shifting of yoke 70 simultaneously actuates both multi-fluid valves 76a, 76b. In the example shown, valve assembly 74 further includes mount plate 104 and yoke spring 106. Yoke spring 106 interfaces with yoke 70 and is configured to bias yoke 70 in the upstream direction UD. Yoke spring 106 biases yoke 70 in the upstream direction UD to position yoke 70 for connection with piston 36 during mounting of cartridge 14, ensuring that piston mount 68 can enter into yoke mount 108 during mounting to form the dynamic interface. In the example shown, the yoke aperture 110 within which yoke mount 108 is formed extends fully axially through yoke 70. The yoke aperture 110 extending fully axially through yoke 70 allows compressed gas to flow through yoke 70, such as to mixer supply channel 60.

Mount plate 104 is configured to mount to cartridge body 28 to secure valve assembly 74 to cartridge body 28. For example, mount plate 104 can be secured to cartridge body 28 by fasteners (FIG. 3), such as threaded fasteners that extend through mount plate 104 and into cartridge body 28.

Valve assembly 74 can be mounted to and removed from cartridge body 28 as a single unit. Such a configuration allows the user to quickly and easily swap out multi-fluid valves 76a, 76b by removing the valve assembly 74 as a single unit and then installing a new valve assembly 74 on cartridge body 28 as a single unit. Such a configuration reduces part count and loose parts which can be difficult to handle during assembly and can be easily lost.

Multi-fluid valve 76a is disposed within main bore 78a. Main bore 78a extends within cartridge body 28 and is open in both the upstream direction UD and the downstream direction DD. Main bore 78a can include annular steps and/or ramps or other structures which changes a diameter of main bore 78a along the axial length of main bore 78a. As such, the main bore 78a can have a variable radial width. The main bore 78a may also be accessed by ports, such as gas port 112a which can feed compressed gas to the multi-fluid valve 76a, and the material port 114a which can feed the constituent material to the multifluid valve 114a. The cartridge 14 further includes downstream port 116a. The downstream port 116a in this embodiment is formed as the termination of the main bore 78a and is formed in the cartridge body 28, however not all embodiments are so limited and the downstream port 116a may be formed from other materials or components. Downstream port 116a is open through end face 102a of cartridge body 28. End face 102a can also be referred to as a downstream end face of the cartridge body 28.

Multi-fluid valve 76b is disposed within main bore 78b. Main bore 78b extends within cartridge body 28 and is open in both the upstream direction UD and the downstream direction DD. Main bore 78b can include annular steps and/or ramps or other structures which changes a diameter of main bore 78b along the axial length of main bore 78b. As such, the main bore 78b can have a variable radial width. The main bore 78b may also be accessed by ports, such as gas port 112b which can feed compressed gas to the multi-Huid valve 76b, and the material port 114b which can feed the constituent material to the multifluid valve 76b. The cartridge 14 further includes downstream port 116b. The downstream port 116b in this embodiment is formed as the termination of the main bore 78b and is formed in the cartridge body 28, however not all embodiments are so limited and the downstream port 116b may be formed from other materials or components. Downstream port 116b is open through the end face 102a of cartridge body 28.

In the example shown, body chamber 118 is formed within cartridge body 28. Body chamber 118 extends partially axially into cartridge body 28. The body chamber 118 extends into mount end 80 of cartridge body 28. The mount end 80 is configured to interface with gun body 12 to mount cartridge 14 to gun body 12. Each of mixer supply channel 60, main bore 78a, and main bore 78b are open to body chamber 118. The body chamber 118 is fluidly connected to the supply of compressed gas through gas passage 42. Body chamber 118 is thus pneumatically pressurized throughout operation regardless of whether spray gun 10 is in the purge state, transition state, or spray state.

The main bores 78a, 78b and the mixer supply channel 60 are fluidly connected to body chamber 118 to receive compressed gas from body chamber 118. In the example shown, the gas port 112a of main bore 78a is formed as the upstream termination of main bore 78a that is open to body chamber 118. The gas port 112a is thus disposed coaxially with other portions of main bore 78a on the valve axis VA of the multi-fluid valve 76a. In the example shown, the gas port 112a does not extend through a radial wall of the main bore 78a. The gas port 112a does not extend radially through the cartridge body 28. In the example shown, the gas port 112b of main bore 78b is formed as the upstream termination of main bore 78b that is open to body chamber 118. The gas port 112b is thus disposed coaxially with other portions of main bore 78b on the valve axis VA of the multi-fluid valve 76b. In the example shown, the gas port 112b does not extend through a radial wall of the main bore 78b. The gas port 112b does not extend radially through the cartridge body 28. In the example shown, the compressed gas enters main bores 78a, 78b through gas ports 112a, 112b, respectively, that are disposed coaxially with the downstream ports 116a, 116b, respectively, through which the compressed gas is output from the main bores 78a, 78b.

While cartridge 14 is shown as including gas ports 112a, 112b that are disposed coaxially with the downstream ports 116a, 116b, it is understood that not all examples are so limited. In some examples, portions of the main bores 78a, 78b are angled relative to other portions of the main bores 78a, 78b. For example, portions of main bores 78a, 78b downstream of the outer needle seats 136 can converge towards each other or diverge away from each other. For example, those portions of the main bores 78a, 78b can be angled towards the spray axis SA. Material port 114a extends through a bottom side of cartridge 14 and is open to main bore 78a. Material port 114a is disposed axially between gas port 112a and downstream port 116a. Material port 114a is configured to provide a constituent component, such as A component liquid, to main bore 78a. Material port 114b extends through a bottom side of cartridge 14 and is open to main bore 78b. Material port 114b is disposed axially between gas port 112b and downstream port 116b. Material port 114b is configured to provide a constituent component, such as B component liquid, to main bore 78b.

In the example shown, the material ports 114a, 114b extend through the side walls of the main bores 78a, 78b, respectively. In the example shown, the material ports 114a, 114b are offset from the valve axes VA. For example, an axis along the material port 114a extends radially offset from the valve axis VA of multi-fluid valve 76a such that the axis of the material port 114a does not intersect the valve axis VA of multi-fluid valve 76a. Similarly, an axis along the material port 114b extends radially offset from the valve axis VA of multi-fluid valve 76b such that the axis of the material port 114b does not intersect the valve axis VA of multi-fluid valve 76b. Such a configuration prevents at least a portion of the inflow of constituent material from directly impinging on the multi-fluid valve 76, reducing wear and increasing operational life.

In the example shown, the material ports 114 are disposed axially between the gas ports 112 and the downstream ports 116. The material ports 114 provide the pressurized constituent material to component chambers 138. The compressed gas is provided to the main bore 78 at a location that is upstream of the component chamber 138 and upstream of the material port 114. The compressed gas is routed through the multi-fluid valve 76 while maintaining fluid isolation from the constituent material. Such a configuration can reduce or eliminate complex routing of the compressed gas providing for an easier to manufacture and operate cartridge 14.

In the example shown, each multi-fluid valve 76 includes an inner needle 86 located at least partially within an outer needle 88. The multi-fluid valves 76 are configured to mediate flows of multiple fluids (e.g., compressed gas and constituent material). In this case, the mediation is done by having two flow controllers (e.g., the inner needle 86 and the outer needle 88). One or both of the outer needle 88 and the inner needle 86 is movable relative to the other one of the inner needle 86 and the outer needle 88. The inner needle 86 is configured to translate to seat and unseat to control flow of the compressed gas to the mix chamber 16. The outer needle 88 is configured to translate, such as along valve axis VA, to seat and unseat to control flow of constituent material to the mix chamber 16.

The inner needle 86 and the outer needle 88 are nested in the example shown. The inner needle 86 is at least partially disposed within the outer needle 88. In the example shown, the inner needle 86 extends axially beyond the outer needle 88 in both the upstream direction UD and the downstream directions DD such that the inner needle 86 is axially longer than the outer needle 88. In the example shown, the inner needle 86 extends entirely through the outer needle 88. The inner needle 86 can be coaxial with the outer needle 88 (along valve axis VA). Each of the inner needle 86 and the outer needle 88 can move linearly coaxial with respect to each other along valve axis VA.

Generally speaking, movement and sealing of the inner needle 86 alternately blocks and passes compressed gas from the gas port 112 to the mix chamber 16. Generally speaking, movement and sealing of the outer needle 88 alternately blocks and passes constituent material from the material port 114 to the mix chamber 16.

The inner needle 86 includes inner needle head 120, inner needle body 122, and inner needle tail 124. The inner needle head 120 is disposed at a downstream end of the inner needle 86. Inner needle neck 121 extends between and connects inner needle head 120 and inner needle body 122. The inner needle neck 121 has a smaller radial width than either of the inner needle head 120 or the inner needle body 122. For example, the inner needle neck 121 can have a smaller diameter than the inner needle head 120. The inner needle neck 121 can have a smaller cross-sectional area orthogonal to the valve axis VA than the inner needle body 122. The inner needle tail 124 is disposed at an upstream end of inner needle 86. Inner needle body 122 extends between and connects inner needle head 120 and inner needle tail 124.

The inner needle head 120 is configured to seat on and unseat from inner needle seat 126 to control flow of compressed gas downstream to the mix chamber 16. The inner needle tail 124 is configured to connect to yoke 70 such that yoke 70 can exert driving force on inner needle 86 in both the upstream direction UD and the downstream direction DD. In the example shown, inner needle 86 can be considered to extend out of the main bore 78 and into the body chamber 118. In the example shown, the inner needle 86 extends through the gas port 112 to interface with the yoke 70. The inner needle 86 interfaces with the yoke 70 within the body chamber 118.

The inner needle head 120 can be wider than an upstream portion of the inner needle 86. The inner needle 86 extends fully axially through the inner channel 128 formed within outer needle 88. The inner needle head 120 is wider than the inner channel 128 formed within the outer needle 88 such that the inner needle head 120 can seat at a downstream end of the inner channel 128 to block flow of the compressed gas and unseat from the downstream end of the inner channel 128 to permit flow of the compressed gas. In the example shown, the needle channel 128 can be considered to form a gas flowpath for compressed gas to flow downstream through main bore 78 and to the mix chamber 16. Inner needle head 120 can seat within inner channel 128 formed within the outer needle 88 at inner needle seat 126, the inner needle head 120 being narrower than inner needle seat 126 at the points of engagement between the inner needle head 120 and the inner needle seat 126. In the example shown, the inner needle seat 126 is formed by a downstream portion of the outer needle 88. As shown, both inner needle seat 126 and the inner needle head 120 are tapered, such that their engagement can create an annular seal which blocks pressurized gas coming from the gas port 112 through the inner channel 128 of the outer needle 88, along axial grooves 130 of the inner needle 86, and further passing by the inner needle seat 126 and out the downstream port 116 to the mix chamber 16 only when the inner needle head 120 is disengaged from the inner needle seat 126. Engagement between the inner needle head 120 and the inner needle seat 126 shuts off flow of compressed gas to the downstream port 116.

Outer needle 88 is disposed within main bore 78. Outer needle 88 includes outer needle head 132 at a downstream end of outer needle 88 and outer needle body 134 extending in the upstream direction UD from outer needle head 132. Outer needle head 132 of the outer needle 88 can engage the outer needle seat 136 to develop an annular seal which blocks flow of the constituent material coming from the material port 114 and flowing to the component chamber 138 from flowing further downstream to the downstream port 116. The component chamber 138 is formed in a portion of the main bore 78 axially between the outer needle seat 136 and the bushing 90. The component chamber 138 is pressurized with constituent material during operation, with the cartridge 14 in each of the purge state, transition state, and spray state.

In the example shown, the component chamber 138 is disposed axially between the gas port 112 and the downstream port 116. The multi-fluid valve 76 is configured such that the compressed gas passes through the component chamber 138 but is fluidly isolated from the constituent material within the component chamber 138. In the example shown, the outer needle 88 fluidly isolates the constituent material contacting an exterior of the outer needle 88 from the compressed gas contacting the interior of the outer needle 88. As such, the multi-fluid valve 76 can route the pressurized gas through the component chamber 138 that is pressurized with constituent material while isolating the compressed gas from the constituent material.

In the example shown, outer needle seat 136 is disposed within main bore 78. It is understood that in various other examples the outer needle seat 136 can be formed by cartridge body 28. Constituent material can pass by the outer needle seat 136 only when the outer needle head 132 disengages from the outer needle seat 136, allowing the constituent material under pressure within the component chamber 138 to pass by the outer needle seat 136 and through the downstream port 116 into the mix chamber 16. In the example shown, the outer needle seat 136 is formed by a seat disposed within the cartridge body 28, however the outer needle seat 136 may be formed by additional components or by the cartridge body 28 in various other examples. As shown, the engaging surfaces of the outer needle seat 136 and the outer needle head 132 have tapered surfaces which engage to develop the annular seal.

Outer needle body 134 extends in the upstream direction UD from outer needle head 132. Outer needle body 134 extends within bushing 90. Outer needle body 134 can extend fully axially through bushing 90. Bushing 90 is configured to guide outer needle 88 along valve axis VA to maintain outer needle 88 aligned on valve axis VA. An exterior surface inner needle 86, such as of inner needle body 122, can engage with an interior surface of outer needle 88 defining needle channel 128 to maintain inner needle 86 coaxial with outer needle 88. In the example shown, axial grooves 130 are formed in inner needle body 122 to facilitate passage of compressed gas through outer needle 88 and between inner needle 86 and outer needle 88 while inner needle 86 still engages with outer needle 88 to maintain coaxial alignment therebetween.

Bushing 90 is not fixed directly to cartridge body 28, such as by interfaced threading. Instead, bushing 90 is configured to mount to cartridge body 28 and dismount from cartridge body 28 as a portion of valve assembly 74. As best seen in FIG. 5, each multi-fluid valve 76 supports at least one valve seal 140. In the example shown, each multifluid valve 76 includes a valve seals 140a, 140b, 140c, 140d. Valve seals 140a, 140b are disposed around an exterior of bushing 90 and mounted on seal body 142 of bushing 90. Valve seals 140a, 140b are configured to interface with a surface of main bore 78 and with bushing 90 to prevent constituent material and compressed gas from leaking therebetween. Valve seals 140c, 140d are disposed between bushing 90 and outer needle 88. Valve seal 140c is disposed on a downstream side of bushing 90 and is configured to prevent upstream leakage between outer needle 88 and bushing 90. Valve seal 140d is disposed on an upstream side of bushing 90 and is configured to prevent downstream leakage between outer needle 88 and bushing 90. It is understood that valve seals 140 can be of any desired configuration, such as o-rings, u-cups, etc. In the example shown, the valve seals 140a, 140b are formed as o-rings and the valve seals 140c, 140d are formed as u-cups. In some examples, one or both of valve seals 140c, 140d can be configured as wiper seals that wipe residue from the exterior of outer needle 88. For example, as outer needle 88 displaces in the upstream direction UD, valve seal 140c can wipe constituent material from outer needle 88, preventing outer needle 88 from carrying the constituent material upstream, such as into portions of cartridge body 28 fluidly connected to gas port 112 throughout operation.

Braces 144a, 144b are disposed on opposite axial ends of bushing 90. Braces 144a, 144b are disposed on opposite axial sides of seal body 142. Braces 144a, 144b can maintain the valve seals 140c, 140d in desired positions during operation. Brace 144a provides a bearing surface for the valve spring 92. The brace 144b provides a bearing surface between the bushing 90 and mount plate 104. The bushing 90 can be considered to be clamped between the valve spring 92 and the mount plate 104 by the valve spring 92 biasing the bushing 90 towards the mount plate 104.

Valve spring 92 engages with outer needle 88 to bias outer needle 88 in the downstream direction DD. Valve spring 92 is disposed around outer needle 88 and is in the component chamber 138 between bushing 90 and outer needle seat 136. As such, valve spring 92 is exposed to the constituent material within and flowing through component chamber 138. Valve spring 92 braces against bushing 90 and engages an upstream side of outer needle head 132. In the example shown, bushing 90 braces against mount plate 104 of valve assembly 74. Bushing 90 can be biased towards mount plate 104 by valve spring 92. Valve spring 92 is configured to bias outer needle 88 to a closed state as shown in FIGS. 4A and 4B.

Check valve 72 is disposed at a downstream end of mixer supply channel 60. Check valve 72 is a one-way valve that is configured to allow flow in the downstream direction DD and to prevent flow in the upstream direction UD. Check valve 72 is a ball valve in the example shown, though it is understood that other configurations are possible. A ball cage 146 of check valve 72 is connected to cartridge body 28, such as by interfaced threading among other options. The ball 148 is configured to seat on cartridge body 28 in the example shown, though it is understood that the seat of check valve 72 can, in some examples, be formed separately from cartridge body 28 and mounted within cartridge body 28. A spring biases the ball 148 into engagement with the seat of check valve 72 such that check valve 72 is normally closed.

Mix chamber 16 is mounted to dispense end 84 of cartridge body 28. In the example shown, the dispense end 84 includes exterior threading that is configured to interface with interior threading of the cartridge body 28. At least a portion of the cartridge 14 is received within the mix chamber housing 52 of the mix chamber 16 with the mix chamber 16 mounted to the cartridge 14.

Static mixer 54 is disposed within mix chamber housing 52. Static mixer 54 is fluidly connected to the mixer supply channel 60 through cartridge body 28. Static mixer 54 interfaces with cartridge 14 to receive compressed gas output from cartridge 14. Static mixer 54 interfaces with the ball cage 146 of check valve 72 in the example shown. It is understood however, that in various other examples the static mixer 54 can interface directly with the cartridge body 28 to fluidly connect to the mixer supply channel 60. Mixer gas channel 62 is fluidly connected to the mixer supply channel 60.

Mixer gas outlet 150 extends through static mixer 54 and provides a pathway for compressed gas to flow out of mixer gas channel 62 and into the passages formed between static mixer 54 and mix chamber housing 52. The compressed gas may be always released from the mixer gas outlet 150, regardless of the state of actuation of the trigger 18. For example, the check valve 72 can be configured such that the compressed gas has sufficient pressure to open the check valve 72 both when the compressed gas is flowing through each multi-fluid valve 76a, 76b and through downstream ports 116a, 116b (e.g., with spray gun 10 in the purge state) and when inner needle 86 is engaged with inner needle seat 126 to block the flow of compressed gas to the downstream ports 116a, 116b (e.g., with spray gun 10 in the transition state and in the spray state). The compressed gas being output from static mixer 54 can help agitate liquids to mix and react within the mix chamber 16 before being expelled from the nozzle 26 during spraying, and such flow can purge residue when not spraying and can also prevent any liquid being purged from inadvertently being flowed into the mixer gas channel 62. Such compressed gas can also provide energy to drive out the mix fluid from the mix chamber 16 and out the nozzle 26 during spraying.

Piston 36 is at least partially disposed in piston chamber 50. Piston head 64 is disposed in piston chamber 50. Piston shaft 66 from piston head 64, out of piston chamber 50, and into mount cavity 48. In the example shown, piston shaft 66 extends to radially overlap with portions of cartridge body 28 with cartridge 14 mounted to gun body 12. Piston mount 68 extends into yoke mount 108 of yoke 70. The yoke mount 108 is formed as a cavity within yoke 70. The piston mount 68 interfaces with the yoke 70 within the yoke mount 108 such that piston 36 can exert driving forces on the yoke 70 to displace yoke 70 in both the upstream direction UD and the downstream direction DD.

During operation, the cartridge 14 is mounted to the gun body 12. As discussed above, the mount end 80 of the cartridge 14 is inserted into mount cavity 48 of gun body 12. Mount end 80 is interfaced with gun body 12 to form the static connection. Yoke 70 is interfaced with piston 36 to form the dynamic connection. For example, cartridge 14 can be shifted axially into mount cavity 48 and then rotated relative to gun body 12, the relative rotation securing both the static interface and the dynamic interface.

Spray gun 10 is initially in the purge state shown in FIG. 4A. Return spring 38 biases piston 36 in downstream direction DD. Piston 36 pushes yoke 70 in the downstream direction DD such that inner needle head 120 is spaced from inner needle seat 126. Valve spring 92 biases the outer needles 88 in downstream direction DD such that outer needle head 132 engages with outer needle seat 136 and provides a fluid seal between component chamber 138 and downstream port 116.

Compressed gas is provided to spray gun 10 through gas fitting 22. A portion of the compressed gas flows through actuation passage 44b (FIG. 3) to bias piston 36 in downstream direction DD, maintaining the multi-fluid valves 76 in the open state for compressed gas flow and in the closed state for constituent material flow.

A portion of the compressed gas flows to mount cavity 48 and pressurizes mount cavity 48. The compressed gas to mount cavity 48 is provided through gas passage 42 (FIG. 3), which is fluidly connected to the incoming flow of pressurized gas throughout operation. The compressed gas flows through the multi-fluid valves 76a, 76b and to the downstream ports 116a, 116b. In the example shown, the compressed gas flows from a location upstream of the component chamber 138, through the component chamber 138 while within outer needle 88, and then downstream within main bore 78 to the downstream port 116.

The compressed gas exits from cartridge 14 along the valve axes VA. The compressed gas exits from cartridge 14 through the end face 102a and enters into mix chamber 16 after fully exiting from cartridge 14. The compressed gas enters into mix chamber 16 at a location that is not radially overlapped by structure of cartridge body 28. The compressed gas fully exits from cartridge body 28 to enter into mix chamber 16. The compressed gas is downstream from cartridge body 28 when the compressed gas enters into the mix chamber 16. The compressed gas is downstream from all portions of the main bores 78 when the compressed gas enters into mix chamber 16. A portion of the compressed gas can also flow through mixer supply channel 60 and to mixer gas channel 62 and out from mixer gas outlet 150.

The trigger 18 is actuated, redirecting the compressed gas from flowing to piston chamber 50 through actuation passage 44b to flowing to piston chamber 50 through actuation passage 44a (FIG. 3). The compressed gas drives the piston 36 in upstream direction LID and piston pulls yoke 70 and thus inner needles 86 in the upstream direction UD. The inner needles 86 shift such that the inner needle heads 120 engage with the inner needle seats 126. The spray gun 10 is thus placed in the transition state shown in FIG. 4B.

With the spray gun 10 in the transition state, the multi-fluid valves 76 are in the closed state for compressed gas flow and in the closed state for constituent material flow. The flow of compressed gas through the multi-fluid valves 76 is shut off prior to the constituent material flow being started. Engagement of the inner needle heads 120 with the inner needle seats 126 increases the pressure of the gas flowing through mixer supply channel 60, accelerating the flow through mixer supply channel 60, mixer gas channel 62, and mixer gas outlet 150.

The piston 36 continues to shift in the upstream direction UD. Engagement between the inner needle head 120 and the inner needle seat 126 can exert an axial force on outer needle 88 to pull the outer needle 88 rearward. The inner needle 86 engaging with and exerting axial force on outer needle 88 overcomes the spring force of valve spring 92 such that inner needle 86 can drive the outer needle 88 in the upstream direction UD to disengage the outer needle head 132 from the outer needle seat 136. The outer needle head 132 disengaging from the outer needle seat 136 opens a flowpath for the constituent material to flow to downstream port 116. Spray gun 10 is thereby placed in the spray state shown in FIG. 4C.

With spray gun 10 in the spray state, the flowpaths for the constituent materials are open through cartridge 14. The constituent material flows through the gap between outer needle 88 head and outer needle seat 136 and exits from cartridge 14 through downstream ports 116. The constituent materials enter into the mix chamber 16 and are mixed to form the plural component material. The constituent material enters into mix chamber 16 at a location that is not radially overlapped by structure of cartridge body 28. The constituent material fully exits from cartridge body 28 to enter into mix chamber 16. The constituent material is downstream from cartridge body 28 when the constituent material enters into the mix chamber 16. The constituent material is downstream from all portions of the main bores 78 when the constituent material enters into mix chamber 16. The cartridge outputs the constituent material axially along the valve axes VA of the multi-fluid valves 76. The constituent materials do not combine at any location that is radially overlapped by structure of cartridge body 28. The cartridge 14 is configured such that the first constituent material and the second constituent material exit from the cartridge body 28 to locations not radially overlapped by structure of the cartridge body 28 prior to the first constituent material mixing with the second constituent material.

The constituent materials are mixed by static mixer 54 at a location downstream of the cartridge 14. In examples including a static mixer 54 having mixer gas channel 62 and mixer gas outlet 150, compressed gas is output from static mixer 54 and into the mixture within mix chamber 16. The constituent materials combine to form the plural component material that is driven downstream and emitted through nozzle 26.

To stop spraying, trigger 18 is released and returns to the detriggered state. The trigger valve 34 (FIG. 3) shifts from directing compressed gas to actuation passage 44a to directing compressed gas to actuation passage 44b. Compressed gas through gas passage 42 maintains mount cavity 48 in a pressurized state as trigger valve 34 shifts to redirect the compressed gas flow. The compressed gas drives piston 36 in the downstream direction DD. The piston 36 drives yoke 70 and thus inner needles 86 in the downstream direction DD. The valve springs 92 drive the outer needles 88 in the downstream direction DD causing the outer needle heads 132 to reseat on the outer needle seats 136. Spray gun 10 is thus returned to the transition state shown in FIG. 4B.

In the example shown, the spring force exerted by the valve springs 92 is of sufficient strength such that the outer needle 88 and inner needle 86 are engaged to maintain closure of the compressed gas flowpaths through multi-fluid valves 76 as valve assembly 74 displaces in the downstream direction DD. The inner needles 86 remain seated on the outer needles 88 while the piston drives the inner needles 86 forward and the valve springs 92 drive the outer needles 88 forward. The outer needles 88 seat on the outer needle seats 136 shutting off flow of the constituent materials and stopping displacement of outer needles 88 in the downstream direction DD, returning to the transition state. With the spray gun 10 in the transition state, the multi-fluid valves 76 are closed for both compressed gas and constituent material flow.

The piston 36 continues to displace in the downstream direction DD. The inner needle heads 120 unseat from the inner needle seats 126, restarting flow of the compressed gas through the multi-fluid valves 76. The spray gun 10 is thus returned to the purge state shown in FIG. 4A. The compressed gas flowing through multi-fluid valves 76 exits cartridge 14 through downstream ports 116 and flows through mix chamber 16 and out through nozzle 26, purging residue from within cartridge 14 and mix chamber 16.

Spray gun 10 provides significant advantages. Multi-fluid valves 76 control flow of both compressed gas and constituent material to mix chamber 16. Moving components of multi-fluid valves 76 shift together in a first common axial direction to shut off gas flow and start constituent material flow. The moving components shift together in a second common axial direction opposite the first axial direction to shut off constituent material flow and start compressed gas flow. The multi-fluid valves 76 are sequenced such that the compressed gas flow is shut off before the constituent material flow begins and the compressed gas flow is turned on after the constituent material flow is shut off. Such a configuration prevents constituent material from flowing into the gas pathways of cartridge 14. Such a configuration protects gas pathways in cartridge 14 and prevents undesirable constituent material flow to portions of cartridge 14 in which constituent material is not desirable.

Cartridge 14 connects to spray gun 10 at a static interface and at a dynamic interface. The static interface supports cartridge 14 on gun body 12. The dynamic interface shifts the multi-fluid valves 76 between various flow states. Cartridge 14 is configured such that the static and dynamic interfaces can be simultaneously formed and broken, providing for simple, quick, and efficient mounting and dismounting.

The mix chamber 16 is disposed downstream of the cartridge 14 and is supported by cartridge body 28. The constituent materials and compressed gas exit from within the cartridge 14 to enter into the mix chamber 16. The mix chamber 16 does not receive constituent materials from cartridge 14 at locations that are within cartridge 14. Instead, the mixing of the constituent materials occurs at locations downstream of cartridge 14, preventing undesirable cross-over or curing within cartridge 14.

The mix chamber 16 can be easily dismounted and changed for another mix chamber 16, such as for a mix chamber 16 having a differently shaped nozzle 26 or if mix chamber 16 experiences clogging. The mix chamber 16 can be removed from cartridge 14 without having to first remove any other components from cartridge 14 or spray gun 10. For example, both cartridge 14 and manifold 20 can remain mounted during removal and replacement of mix chamber 16. Such a configuration provides for simple and quick changing of mix chambers 16. The constituent materials are output axially along the valve axes VA from the cartridge 14. The axial flows of the constituent materials into the mix chamber 16 facilitates mixing by the static mixer 54. The axial flows maintain fluid velocity, assisting in generating turbulent flow that facilitates mixing and maintaining a desired flowrate out through nozzle 26. Such a configuration provides for high quality plural component material that is well mixed and has desired properties.

FIG. 6A is a first isometric view of cartridge 14. FIG. 6B is a second isometric view of cartridge 14. FIG. 6C is a third isometric view of cartridge 14. FIGS. 6A-6C are discussed together and with continued reference to FIGS. 1-5. Cartridge body 28 and valve assembly 74 of cartridge 14 are shown. Cartridge mounts 30; mount end 80; main body portion 82; dispense end 84; main bores 78a, 78b; material ports 114a, 114b; downstream ports 116a, 116b; body chamber 118; manifold mount bore 154; and ridge 156 of cartridge body 28 are shown. A portion of an inner needle 86 and yoke 70 of valve assembly 74 are shown. Ball cage 146 of check valve 72 is shown.

Cartridge 14 is mountable and dismountable as a single unit. Mounting of cartridge 14 mounts the flow control components (e.g., multi-fluid valves 76a, 76b) of the spray gun 10 to the gun body 12. Removal of cartridge 14 removes the flow control components from the gun body 12. Removal and replacement of cartridge 14 replaces the flow control components.

Cartridge body 28 supports other components of cartridge 14. Cartridge body 28 at least partially defines flowpaths for both compressed gas and constituent material. Mount end 80 is disposed at one end of cartridge body 28 and dispense end 84 is disposed at an opposite end of cartridge body 28. The mount end 80 is configured to connect to gun body 12 to form the static interface between cartridge 14 and gun body 12. Cartridge mounts 30 project radially outward from an exterior surface of mount end 80. Dispense end 84 is configured to interface with mix chamber 16 to support mix chamber 16 on cartridge 14. In the example shown, threading is formed on the exterior of dispense end 84 to form a threaded interface that supports the mix chamber 16 on the cartridge body 28.

End face 102a is disposed at a downstream end of the cartridge body 28. End face 102a is formed at a distal end of dispense end 84 of cartridge body 28. The main bores 78a, 78b are open through the end face 102a. The downstream ports 116a, 116b of main bores 78a, 78b are formed through end face 102a. Both downstream ports 116a, 116b are exposed on end face 102a such that compressed gas and constituent materials are output from cartridge 14 through end face 102a. The flows of the constituent materials are output from cartridge 14 as separate flows that combine at locations downstream of cartridge 14, such as within the mix chamber 16. The flows of the constituent materials do not combine at any location that is radially overlapped by structure of cartridge body 28. The flows of compressed gas controlled by the multi-fluid valves 76a, 76b do not recombine downstream of the multi-fluid valves at any location that is radially overlapped by structure of the cartridge body 28.

In the example shown, a portion of check valve 72 projects in the downstream direction DD relative to end face 102a. Specifically, the ball cage 146 projects downstream relative to cartridge body 28. In the example shown, the cartridge 14 thus outputs a first, mixer portion of compressed gas at a location spaced axially downstream from the locations where the cartridge 14 outputs the flows of compressed gas regulated by the multi-fluid valves 76. It is understood, however, that not all examples are so limited. The cartridge 14 can be configured such that the cartridge 14 continuously outputs a single flow (e.g., the compressed gas through mixer supply channel 60) throughout operation. The cartridge 14 can selectively outputs additional flows depending on the operating state of cartridge 14. The cartridge 14 outputs compressed gas from main bores 78a, 78b in the purge state, outputs neither compressed gas nor constituent material in the transition state, and outputs constituent material in the spray state. The cartridge 14 thereby continuously outputs one flow of compressed gas while selectively outputting two additional flows of compressed gas, two flows of constituent material, or no additional flows. It is understood that in various other examples the static mixer 54 may not convey compressed gas to output at a location downstream of cartridge 14. In such an example, the cartridge 14 may not include mixer supply channel 60 or check valve 72.

End face 102b is disposed at an upstream end of cartridge body 28. End face 102b is formed at a distal end of mount end 80 of cartridge body 28. End face 102b is oriented axially relative to the spray axis SA. Body chamber 118 is formed within cartridge body 28 and is open to an exterior of cartridge body 28. Body chamber 118 is open through end face 102b. The cartridge 14 is configured to receive compressed gas into the cartridge body 28 through end face 102b.

Valve assembly 74 is at least partially disposed within cartridge body 28. As shown, inner needles 86 can connect to yoke 70 via a slotted interface between a yoke arm 158 of the yoke 70 and the inner needle tail 124 of the inner needle 86. The yoke aperture 110 extends fully axially through the yoke 70. Yoke mount 108 is formed as a chamber within yoke 70. As best seen in FIG. 5B, an opening into the cavity forming yoke mount 108 is non-circular. The opening into the yoke mount 108 is oblong in the example shown. The configuration of the opening into yoke mount 108 facilitates piston mount 68 entering into yoke mount 108 by relative axial movement between cartridge 14 and piston 36 along the spray axis SA. Relative rotation between cartridge 14 and piston 36 then causes the piston mount 68 to axially overlap with the structure of yoke 70 defining yoke mount 108 such that piston 36 can exert axial driving force on yoke 70 in both the upstream and downstream axial directions.

In the example shown, the opening through end face 102b into body chamber includes mount lobes 160 and yoke lobes 162. The yoke 70 is at least partially disposed within the yoke lobes 162. The yoke lobes 162 can interface with yoke 70 to prevent rotation of yoke 70 on the spray axis SA. The yoke lobes 162 can be considered to axially guide yoke 70 to limit yoke 70 to axial movement. The mount lobes 160 are oriented orthogonal to the yoke lobes 162 in the example shown, though it is understood that other configurations are possible. Portions of the mount plate 104 of valve assembly 74 are configured to enter into cartridge body 28 through mount lobes 160. Mount lobes 160 provide access for mounting and dismounting of valve assembly 74 on cartridge body 28. In the example shown, fasteners that secure mount plate 104 to cartridge body 28 can be accessed through the mount lobes 160.

Material ports 114a, 114b are formed through a bottom side of cartridge 14. The material ports 114 are configured to receive constituent material into cartridge 14 from manifold 20. As shown, manifold seals 164 are supported by cartridge body 28 annularly around the material ports 114a, 114b. It is understood that, in some examples, the manifold seals 164 can be supported by the manifold.

Ridge 156 is formed by a portion of cartridge body 28. In the example shown, the ridge 156 is formed on main body portion 82 of cartridge body 28. Ridge 156 is disposed between the material ports 114a, 114b such that one material port 114 is on one lateral side of the ridge 156 and the other material port 114 is on an opposite lateral side of the ridge 156. Ridge 156 can extend into a slot on manifold 20 to locate cartridge 14 and manifold 20 relative to each other. Such a configuration prevents relative rotation between cartridge 14 and manifold 20 assisting in maintaining the fluid connections therebetween.

Manifold mount bore 154 extends into cartridge body 28. In the example shown, manifold mount bore 154 extends into ridge 156. Manifold mount bore 154 is configured to receive a fastener, such as a bolt or other threaded fastener, among other options, that secures manifold 20 to cartridge 14. In the example shown, manifold mount bore 154 is formed as a threaded bore that is configured to interface with a threaded fastener to secure the manifold 20 to the cartridge 14.

FIG. 7 is a cross-sectional view of a cartridge 14'. Cartridge 14' is substantively similar to cartridge 14 (best seen in FIGS. 5-6C) except that portions of main bores 78a, 78b are angled relative to the valve axes VA. In the example shown, each main bore 78a, 78b includes a downstream portion 115. The downstream portions 115 extend downstream to the downstream ports 116a, 116b. Downstream portions 115 are angled relative to the valve axes VA. In the example shown, the downstream portions 115 are angled to converge towards each other. In other examples, the downstream portions 115 can be angled to diverge away from each other. In the example shown, the downstream portions 115 are canted such that the downstream ports 116a, 116b are radially offset from the valve axes VA and are not disposed coaxially with the valve axes VA.

The downstream portion 115 of main bore 78a is angled to extend towards the spray axis SA. The downstream portion 115 of main bore 78b is angled to extend towards the spray axis SA. The main bores 78a, 78b converge towards each other in the example shown. While the main bores 78a, 78b converge towards each other, the main bores 78a, 78b do not cross-over or fluidly connect at any location within the cartridge 14'. Instead, each main bore 78a, 78b still extends to a downstream port 116a, 116b that is open on the downstream end face 102a. Angling the downstream portions 115 towards each other such that main bores 78a, 78b converge towards the centerline of the cartridge 14' can assist in mixing of the constituent materials after the constituent materials are output from cartridge 14'. Angling the downstream portions 115 to converge as the downstream portions 115 extend to the downstream ports 116a, 116b can encourage mixing and impingement of the multiple constituent materials once output from the cartridge 14'. Such a configuration can thus assist in mixing and formation of high quality plural component material.

FIG. 8A is an isometric view of valve assembly 74. FIG. 8B is a cross-sectional view of valve assembly taken along line B-B in FIG. 8A. FIG. 9A is an isometric view of a multi-fluid valve 76. FIG. 9B is a sectional view taken along line B-B in FIG. 9A. FIGS. 8A-9B are discussed together with continued reference to FIGS. 1-7.

Valve assembly 74 includes multi-fluid valves 76a, 76b; mount plate 104; yoke 70; and yoke spring 106. Each multi-fluid valve 76 includes an inner needle 86, outer needle 88, valve spring 92, bushing 90, and valve seals 140a-140d. Inner needle 86 includes inner needle head 120, inner needle body 122, and inner needle tail 124. Inner needle tail 124 includes mount shoulder 166, mount neck 168, and mount head 170. Outer needle 88 includes outer needle head 132 and outer needle body 134. The bushing 90 includes seal body 142 and braces 144a, 144b. The mount plate 104 includes plate body 172 and plate tabs 174. The yoke 70 includes yoke mount 108, yoke bore 110, yoke arms 158, and mount slots 176.

Valve assembly 74 is a single unit that contains the movable valving components for controlling flows of compressed gas and constituent material downstream through cartridge 14 and to the mix chamber 16. The valve assembly 74 can be installed in cartridge 14 as a single unit and can be removed from cartridge 14 as the single unit. Removal and replacement of a valve assembly 74 replaces all moving valving components for control of the constituent material and compressed gas through the main bores 78a, 78b of cartridge 14.

Yoke 70 is configured to connect to piston 36 by receiving a piston mount 68 of piston 36 within the chamber forming yoke mount 108. Yoke bore 110 extends fully axially through yoke 70 and provides a flowpath for compressed gas to flow through yoke 70. Yoke 70 is disposed on an opposite axial side of mount plate 104 from the bushings 90, valve springs 92, and outer needles 88. The yoke 70 does not radially overlap with any of the bushing 90, valve spring 92, or outer needle 88 in the example shown.

Inner needle 86 extends through mount plate 104 to interface with yoke 70. Inner needle 86 radially overlaps with each of outer needle 88, mount plate 104, and yoke 70. In the example shown, the inner needle tail 124 is connected to yoke 70 to secure inner needle 86 to yoke 70. More specifically, mount neck 168 of the inner needle 86 is slid into mount slot 176 of yoke 70. The mount shoulder 166 and mount head 170 of the inner needle tail 124 are disposed on opposite axial sides of the yoke arm 158. The yoke 70 can exert driving force on inner needle 86 in the downstream direction DD by pushing against mount shoulder 166. The yoke 70 can exert driving force on inner needle 86 in the upstream direction UD by pushing against mount head 170.

Inner needle 86 extends fully axially through yoke 70, mount plate 104, and outer needle 88. The inner needle 86 is axially longer than the outer needle 88. The inner needle 86 and outer needle 88 are nested. Inner needle head 120 is disposed at an opposite axial end of inner needle 86 from inner needle tail 124. Inner needle head 120 is spaced from inner needle seat 126, which is formed by outer needle 88 in the example shown, in the downstream direction DD to open flow of compressed gas through the multi-fluid valve 76. The inner needle 86 is actuated in the upstream direction UD relative to outer needle 88 to engage inner needle head 120 with inner needle seat 126 to close the flowpath for compressed gas through the multi-fluid valve 76. The outer needle 88 actuates opposite the inner needle 86 to open and close flowpath for the constituent materials. In the example shown, the outer needle 88 shifts in the upstream direction UD to disengage outer needle head 132 from outer needle seat 136 and open the flowpath of the constituent material. The outer needle 88 can be pulled in the upstream direction UD by the inner needle 86 exerting a driving force on the outer needle 88. The outer needle 88 shifts in the downstream direction DD to engage the outer needle head 132 with the outer needle seat 136. As such, the inner needle 86 shifts upstream to stop flow of compressed gas and the outer needle 88 shifts upstream to open flow of constituent material. The inner needle 86 shifts downstream to open flow of the compressed gas and the outer needle 88 shifts downstream to stop flow of the constituent material.

For each multi-fluid valve 76, the valve spring 92 is braced between outer needle 88 and bushing 90. Valve spring 92 biases outer needle 88 in the downstream direction DD. The valve spring 92 is configured to maintain the outer needle 88 seated on the outer needle seat 136 until the spray gun 10 is actuated to the spray state.

Bushing 90 is disposed between mount plate 104 and valve spring 92. Valve spring 92 can bias bushing 90 into mount plate 104 such that bushing 90 is clamped between valve spring 92 and mount plate 104. Seal body 142 of bushing 90 supports the valve seals 140a- 140d. The seal body 142 is disposed between braces 144a, 144b. Brace 144a provides a bearing surface for valve spring 92. Brace 144b is disposed between seal body 142 and mount plate 104. Brace 144b interfaces with mount plate 104 in the example shown.

Yoke spring 106 is configured to interface with yoke 70 and exert a biasing force in the upstream direction UD. In the example shown, the yoke spring 106 interfaces with yoke 70 and with the brace 144b of each bushing 90. The yoke spring 106 extends axially through the mount plate 104 in the example shown. The yoke spring 106 is configured to bias the yoke 70 in the upstream direction UD such that yoke 70 is properly positioned for forming of the dynamic interface with piston 36 during mounting of cartridge 14.

Mount plate 104 is disposed between yoke 70 and bushings 90. The mount plate 104 is configured to support other components of valve assembly 74. Plate body 172 is dispose directly axially between portions of yoke 70 and braces 144b. Plate body 172 includes openings through which the inner needles 86 extend to mate with the yoke 70. The movable valving components of valve assembly 74 (e.g., inner needle 86 and outer needle 88) move relative to but do not contact the mount plate 104. The inner needle 86 extends through but does not contact mount plate 104. In some examples, the outer needle 88 can extend into mount plate 104 to radially overlap with mount plate 104, e.g., when in the spray state, but outer needle 88 may not contact mount plate 104 even when radially overlapping mount plate 104. In some examples, the outer needle 88 does not radially overlap with mount plate 104 during operation.

Plate tabs 174 extend outward from plate body 172. Plate tabs 174 include openings therethrough that are configured to receive fasteners that extend through the mount plate 104 and into the cartridge body 28 to mount the valve assembly 74 to the cartridge body 28.

Valve assembly 74 provides significant advantages. Valve assembly 74 includes the flow control components that move to turn on and shut off flows of compressed gas and constituent material downstream out of cartridge 14. Valve assembly 74 is a single unit that can be installed on and removed from cartridge body 28. The valve assembly 74 provides a single part that can be removed and replaced to replace all movable flow control components of the cartridge 14, simplifying such replacement and reducing part count.

Multi-fluid valves 76 provide significant advantages. The multi-fluid valves 76 control flows of both constituent material and compressed gas out of cartridge 14. The inner needle 86 and outer needle 88 are disposed coaxially on a valve axis VA. Such coaxial positioning provides for simple operation. Such coaxial movement also facilitates closure of the gas pathways prior to opening of the constituent material pathways. The yoke 70 is not directly connected to the outer needle 88. Instead, the inner needle 86 seats on the outer needle 88, closing the compressed gas flowpaths, and then axial driving force is exerted on the outer needle 88 by the inner needle 86. The inner needle 86 seating on outer needle 88 to displace outer needle 88 to open the constituent material flowpath ensures that the compressed gas flowpaths through the multi-fluid valves 76 are closed prior to opening of the constituent material flowpaths.

FIG. 10 is an isometric view of an inner needle 86. Inner needle 86 includes inner needle head 120, inner needle body 122, inner needle tail 124, mount shoulder 166, mount neck 168, mount head 170, and axial grooves 130.

Inner needle body 122 is disposed axially between and connects inner needle head 120 and inner needle tail 124. Inner needle head 120 is configured to mate with inner needle seat 126 to shut off flows of compressed gas through a multi-fluid valve 76. Inner needle tail 124 is configured to interface with yoke 70. Mount neck 168 extends between mount shoulder 166 and mount head 170. Mount neck 168 is configured to mount within a slot of yoke 70 (e.g., mount slot 176). The mount neck 168 and mount slot 176 are sized such that mount head 170 and mount shoulder 166 axially overlap with structure of the yoke 70 with mount neck 168 disposed within the mount slot 176. The yoke 70 can thus exert driving force on the inner needle 86 to displace the inner needle 86 axially in either the upstream or downstream directions. Mount shoulder 166 can be considered to be formed by inner needle body 122 in some examples.

Axial grooves 130 are formed along inner needle body 122. In the example shown, inner needle body 122 has a non-circular cross-section orthogonal to the valve axis VA along which the inner needle 86 is configured to extend. The axial grooves 130 provide passageways between the exterior surface of inner needle 86 and the interior surface of outer needle 88 to allow compressed gas to flow therebetween. In the example shown, the axial grooves 130 extend along portions of the inner needle body 122 that have a triangular cross-section orthogonal to the valve axis VA, though it is understood that other configurations are possible. Outer surface 178 of inner needle body 122 is a radially outermost portion of the inner needle body 122. The outer surface 178 can engage with the interior surface of the outer needle 88 to guide inner needle 86 along outer needle 88 and maintain concentricity therebetween, though not all examples are so limited.

FIG. 11 is a partial isometric view of spray gun 10 showing an interface between manifold 20 and gun body 12. In the example shown, manifold 20 includes body slot 180. Body slot 180 is configured to receive projection 182 of the gun body 12. The projection 182 extending into the body slot 180 prevents manifold 20 from rotating about the spray axis SA. As discussed above, the manifold 20 is fixed to the cartridge body 28. As such, the interface formed by projection 182 extending into body slot 180 also prevents relative rotation between cartridge 14 and gun body 12 during operation of spray gun 10.

FIG. 12 is an isometric view of spray gun 210. Spray gun 210 is substantively similar to spray gun 10 (FIGS. 1-4C and 11). Reference number for similar components of spray gun 210 as for spray gun 210 are the same except increased by “200” (e.g., spray gun 10 and spray gun 210).

The spray gun 210 includes a gun body 212. The gun body 212 can be formed of polymer and/or metal. The gun body 212 can form the structural frame of the spray gun 210. The spray gun 210 further includes a handle 224. The handle 224 can be part of the gun body 212 or may be formed from a different material be attached to the gun body 212. The handle 224 permits the spray gun 210 to be held and operated by a single hand. The spray gun 210 includes a trigger 218. Actuation of the trigger 218 by one or multiple fingers may cause spraying from the spray gun 210 and release of the trigger 218 may cease spraying from the spray gun 210.

Material sprayed from the spray gun 210 is released from the nozzle 226, typically as a stream or pattern such as a cone. In this example, the nozzle 226 is integrated with the mix chamber 216 (specifically, a mix chamber housing), however in various other embodiments they may be separate. Constituent components are combined in the mix chamber 216 into a mixed fluid which is sprayed from the nozzle 226.

Spray gun 210 includes a manifold 220. Manifold 220 can mount to the gun body 212 and/or to the cartridges 214, amongst other options. Manifold 220 can include fittings or other types of connector for a first constituent component, a second constituent component, and compressed gas. Compressed gas can be used for several functions including purging, mixing, and propelling, amongst other options. Compressed gas can be compressed air, amongst other options such as nitrogen gas. The constituent materials and the compressed gas can be combined in the mix chamber 216 to develop reactant (i.e., the plural component material) which is sprayed out of the nozzle 226 for foaming and/or curing on a substrate.

The spray gun 210 includes at least one cartridge 214. In the example shown, the spray gun 210 includes multiple cartridges 214. In the example shown, the spray gun 210 includes two cartridges 214a and 214b; however, in alternative examples the spray gun 210 may include a single cartridge (e.g., cartridge 14 (best seen in FIGS. 1-6C) and/or cartridge 14' (FIG. 7)). Whether as one or two cartridges, the cartridge 214 manages the flow of one or both of the constituent materials, in which at least two valves must be present, the valves located in the cartridges 214a and 214b or dual valves can be included in a single cartridge (e.g., cartridge 14) if the spray gun 210 includes only a single cartridge.

The cartridges 214a, 214b may be mounted to and detached from the gun body 212, and/or from the mix chamber 216. Each of the cartridges 214a and 214b can be separately mounted and attached, such that one cartridge 214a can be replaced while another cartridge 214b is left in place. As such, a single valve can be swapped while leaving the other valve in place. In the example shown, the cartridges 214a, 214b are configured to mount laterally relative to the gun body 212. Lateral movement of a cartridge 214a, 214b towards the spray axis SA, along which the nozzle 226 is oriented and the plural component material is output, can establish both static connections for supporting the cartridge 214a, 214b on the gun body 212 and dynamic connections for actuation of the valve within the cartridge 214a, 214b. Actuation of the trigger 218 opens and closes the valves in the cartridges 214a, 214b to control release or blocking of flow of the constituent materials to the mix chamber 216. Actuation of the trigger 218 can also control release or blocking of compressed gas to the mix chamber 216. The valves within the cartridges 214a, 214b are discussed herein.

FIG. 13 shows a sectioned view of an isolated multi-fluid valve 276. FIGS. 14A- 14C show dual multi-fluid valves 276a, 276b within the cartridges 214a, 214b during different actuation states of the trigger 218. The cartridges 214, mix chamber 216, manifold 220, and portion of gun body 212 on which cartridges 214 are mounted is shown in FIGS. 14A and 14C. An additional rearward portion of the gun body 212, a portion of the trigger 218, and a return spring 238 are shown in FIG. 14B. The portions of the gun body 212 and trigger 218 not shown in FIGS. 14A and 14C are removed for clarity. It is understood that the rear portion of gun body 212 (shown in FIG. 14B), which can include handle 224, and the forward portion of gun body 212 can be formed together as a single piece (e.g., monolithically) or as separate components mounted together.

FIG. 14A shows the multi-fluid valves 276a, 276b in a purge state in which the trigger 218 is not actuated and the multi-fluid valves 276a, 276b are positioned such that compressed gas is routed to the mix chamber 216 through the multi-fluid valves 276a and 276b as purge gas to remove residual constituent materials and/or the resultant plural component material. The constituent materials themselves are not routed to the mix chamber 216. The purge state can also be referred to as a non-spray state. FIG. 14B shows the multi-fluid valves 276a, 276b in a transition state in which the trigger 218 is partially actuated such that the multi-fluid valves 276a, 276b are positioned such that compressed gas is no longer routed to the mix chamber 216 through the multi-fluid valves 276a, 276b while the constituent materials are also not routed to the mix chamber 216. The transition state can also be referred to as a pre-spray state. FIG. 14C shows the multi-fluid valves 276a and 276b in a spray state in which the trigger 218 is actuated such that the multi-fluid valves 276a, 276b are positioned such that compressed gas is not routed to the mix chamber 216 through the multi-fluid valves 276a, 276b. The constituent materials are routed to the mix chamber 216 through the multi-fluid valves 276a, 276b for mixing to form the plural component material and spraying.

The structure of each multi-fluid valve 276 will be discussed in connection with FIG. 13. The multi-fluid valve 276 of FIG. 13 is intended to represent both multi-fluid valves 276a and 276b such that the following discussion and structure shown in FIG. 13 is applicable to both multi-fluid valves 276a and 276b. It is noted that both multi-fluid valves 16& and 276b are actuated in synchrony, being that they are attached to the same trigger 218 and intervening mechanical structure to go through the phases shown and discussed in connection with FIGS. 14A-14C.

The cartridge 214 is sectioned in FIG. 13. The cartridge 214 is formed in substantial part by cartridge housing 384. Cartridge housing 384 can be polymer or metal, such as in the form of a block. Retainer 386 is connected to cartridge housing 384 at an upstream end of cartridge housing 384, such as by interfaced threading, among other options. Retainer 386 can brace and/or retain other components of cartridge 214 within cartridge housing 384. The cartridge housing 384 and retainer 386 can be considered to form a cartridge body 228 of the cartridge 214. Within the cartridge housing 384 is formed a main bore 278. The main bore 278 may comprise annular steps and/or ramps or other structures which changes its diameter along its axial length. The main bore 278 may also be accessed by ports, such as gas port 312 which can feed compressed gas to the multi-fluid valve 276, and the material port 314 which can feed the constituent material to the multi-fluid valve 276. The material port 314 can also be referred to as a component liquid port. The cartridge 214 further includes downstream port 316. The downstream port 316 in this embodiment is formed as the termination of the main bore 278 and is formed in the cartridge housing 384, however not all embodiments are so limited and the downstream port 316 may be formed from other materials or components.

Within the main bore 278 is an inner needle 286 located at least partially within an outer needle 288. This being a multi-fluid valve 276, multiple fluids can be mediated. In this case, the mediation is done by having two flow controllers, the inner needle 286 and the outer needle 288. The inner needle 286 and the outer needle 288 are nested. In this example, the inner needle 286 extends axially beyond the outer needle 288 in both the upstream direction UD and the downstream directions DD such that the inner needle 286 is axially longer than the outer needle 288. The inner needle 286 can be coaxial with the outer needle 288 (along valve axis VA). Each of the inner needle 286 and the outer needle 288 can move linearly coaxial with respect to each other along valve axis VA.

Generally speaking, movement and sealing of the inner needle 286 alternately blocks and passes compressed gas from the gas port 312 to the mix chamber 216. Such compressed gas flow can purge the portions of main bore 278 downstream of the multifluid valve 276 and further flows to mix chamber 216 to purge the mix chamber 216 for removal residual constituent material through the nozzle 226 to prevent reacting and curing within the spray gun 210. Generally speaking, movement and sealing of the outer needle 288 alternately blocks and passes constituent material from the material port 314 to the mix chamber 216.

The inner needle 286 includes an inner needle head 320. The inner needle head 320 can be wider than an upstream portion of the inner needle 286. The inner needle head 320 can seat within a channel formed within the outer needle 288 at inner needle seat 326, the inner needle head 320 being narrower than inner needle seat 326 at the points of engagement between the inner needle head 320 and the inner needle seat 326. As shown, both inner needle seat 326 and the inner needle head 320 are tapered, such that their engagement can create an annular seal which blocks pressurized gas coming from the gas port 312 through the inner channel of the outer needle 288, along axial grooves 330 of the inner needle 286, and further passing by the inner needle seat 326 and out the downstream port 316 to the mix chamber 216 only when the inner needle head 320 is disengaged from the inner needle seat 326.

Engagement between the inner needle head 320 and the inner needle seat 326 shuts off flow of compressed gas to the downstream port 316. Engagement between the inner needle head 320 and the inner needle seat 326 can exert an axial force on outer needle 288 to pull the outer needle 288 rearward as cartridge 214 is actuated from the purge state to the spray state. Valve spring 292 located within the main bore 278 can urge the outer needle 288 in the downstream direction DD. The inner needle 286 engaging with and exerting axial force on outer needle 288 overcomes the spring force of valve spring 292 such that inner needle 286 can drive the outer needle 288 to disengage the outer needle head 332 from the outer needle seat 336, opening a flowpath for the constituent material to flow to downstream port 316. Valve spring 292 can return outer needle 288 to a seated state to shut off constituent material flow as the cartridge 214 transitions from the spray state and back to the purge state.

An outer needle head 332 of the outer needle 288 can engage the outer needle seat 336 to develop an annular seal which blocks flow of the constituent material coming from the material port 314 and flowing to the component chamber 338 from flowing further downstream to the downstream port 316. Such constituent material can pass by the outer needle seat 336 only when the outer needle head 332 disengages from the outer needle seat 336, allowing the constituent material under pressure within the component chamber 338 to pass by the outer needle seat 336 and through the downstream port 316 into the mix chamber 216. In the example shown, the outer needle seat 336 is formed by the cartridge housing 384, however the outer needle seat 336 may be formed by other components in various other embodiments. As shown, the engaging surfaces of the outer needle seat 336 and the outer needle head 332 have tapered surfaces which engage to develop an annular seal.

In a purge or non-actuated state, corresponding to FIG. 14A, a driver directly or indirectly pushes the inner needle 286 in the downstream direction DD to unseat the inner needle head 320 from the inner needle seat 326. Multi-fluid valve 276 is configured such that without trigger 218 actuation compressed gas flows from the gas port 312, through the multi-fluid valve 276, and out the downstream port 316 into the mix chamber 216. For example, the driver can be formed by or include a spring (e.g., return spring) for biasing the inner needle 286 in the downstream direction DD.

When the trigger 218 begins to be actuated, corresponding to FIG. 14B, the inner needle 286 is pulled in an upstream direction to seat the inner needle head 320 against the inner needle seat 326 closing off such flow of compressed gas past the multi-fluid valve 276 and through the downstream port 316. Further pulling of the trigger 218 , corresponding to FIG. 14C, causes the inner needle head 320 to apply a force on the inner needle seat 326 in the downstream direction DD such that the outer needle 288 overcomes the valve spring 292 to unseat the outer needle head 332 from the outer needle seat 336. Outer needle head 332 disengaging from outer needle seat 336 starts the flow of constituent material from the material port 314, through the component chamber 338 past the outer needle seat 336, and out the downstream port 316 to the mix chamber 216 for mixing and flow out the nozzle 226. Release of the trigger 218 causes the outer needle head 332 to engage the outer needle seat 336 to reestablish the annular seal to block flow of constituent material past the outer needle seat 336 before the inner needle head 320 disengages from the inner needle seat 326. Further release of the trigger 218 causes the inner needle head 320 to disengage from the inner needle seat 326 to resume the flow of compressed gas from the gas port 312 along the axial grooves 330 and past the inner needle seat 326 and out the downstream port 316 to the mix chamber 216, to purge residue material.

It is noted that valve seals 340a, 340b, 340c, 340d, 340e, 340f and 340g are within and/or supported by the cartridge 214. The valve seals 340a-340g are collectively referred to herein as “valve seal 340” or “ valve seals 340”. Such valve seals 340 can be O-rings or U cups, amongst other options. Such valve seals 340 can seal the downstream port 316, the material port 314, the gas port 312, the downstream port 316, and/or around or within the inner needle 286 and/or the outer needle 288. In the example shown, valve seal 340a is disposed about the downstream port 316 and is configured to engage with a plate 390. Valve seal 340b is disposed about the material port 314 and is configured to seal with the manifold 220. Valve seal 340f is disposed about the gas port 312 and is configured to seal with a portion of gun body 212, in the example shown. Valve seal 340g is disposed between retainer 386 and cartridge housing 384 to form a fluid seal therebetween and prevent upstream flow between retainer 386 and cartridge housing 384. Valve seal 340e is disposed between inner needle 286 and cartridge body 228. In the example shown, valve seal 340e is disposed between inner needle 286 and retainer 386 to form a fluid seal therebetween and prevent upstream flow between inner needle 286 and retainer 386. Valve seals 340e, 340g prevent compressed gas from flowing upstream and out of main bore 278. Valve seals 340c and 340d are configured to seal against outer needle 288 and cartridge housing 384. Valve seals 340c and 340d are configured to prevent constituent material from flowing upstream around outer needle 288 and to prevent compressed gas from flowing downstream around outer needle 288. Valve seal 340c is oriented towards component chamber 338 and is configured to prevent upstream flow of constituent material between cartridge body 228 and outer needle 288. Valve seal 340d is configured to prevent downstream flow of compressed gas between cartridge body 228 and outer needle 288. In some examples, one or both of valve seals 340c, 340d can be configured as wiper seals that wipe residue from the exterior of outer needle 288. For example, as outer needle 288 displaces in the upstream direction UD, valve seal 340c can wipe constituent material from outer needle 288, preventing outer needle 288 from carrying the constituent material upstream, such as portions of cartridge body 228 fluidly connected to gas port 312 throughout operation.

Bushing 290 is disposed around the outer needle 288 can align the outer needle 288 to foster linear translation along the axis VA. Bushing 290 is disposed between and can support seals 340c, 340d. Bushing 290 can be considered to form a seal body that supports the seals 340c, 340d. Bushing 290 can be cylindrical, among other options.

Gas channeling 388 is within the gun body 212. Such gas channeling 388 can be one or more passages for the flow of compressed gas. Such gas channeling 388 can both feed the gas ports 312a, 312b of the cartridges 214a, 214b and can also flow the compressed gas through a mixer gas channel 262 and out a mixer gas outlet 350 within the mix chamber 216. Such gas may be always released from the mixer gas outlet 350, regardless of the state of actuation of the trigger 218, because there is no valve which blocks such flow and such gas can help agitate liquids to mix and react within the mix chamber 216 before being expelled from the nozzle 226 during spraying, and such flow can purge residue when not spraying and can also prevent any liquid being purged from inadvertently being flowed into the mixer gas channel 262. Such compressed gas can also provide energy to drive out the mix fluid from the mix chamber 216 and out the nozzle 226 during spraying.

It is noted that when the inner needle head 320 seats with the inner needle seat 326 to prevent the flow of compressed gas passing the multi-fluid valves 276a, 276b, this increases the pressure within the gas channeling 388 such that more and/or higher pressure gas flows through the gas channeling 388 and out the mixer gas outlet 350 to mix the constituent materials. Then when the multi-fluid valves 276a, 276b are closed for constituent material to flow but opened for flow of compressed gas during release of the trigger 218 (e.g., with the spray gun 210 in the purge state), the flow and/or pressure of compressed gas through the gas channeling 388 decreases as part of the compressed gas is now rerouted to go through the multi-fluid valves 276a, 276b. As such, triggering and detriggering changes the flow and/or pressure of mixing gas introduced into the mix chamber 216.

Within the mix chamber 216 is a static mixer 254. The static mixer 254 can include a helix or other structure which projects radially within a mix chamber 216 to break up the direct flow of liquids and forces turbulence to foster mixing.

In the example shown, plate 390 interfaces with the downstream ports 316 of the cartridges 214a, 214b. Such interfacing can be an axial face seal. Such interfacing can pinch the cartridges 214a, 214b axially to both seal with cartridges 214a, 214b as well as trap them in position. The plate 390 can be part of the static mixer 254 as shown in this example or may be a separate structure. In this example, a downstream plate 392 axially pinches the cartridges 214a, 214b from the upstream side. In the example shown, the downstream plate 392 is part of the gun body 212, but in various other examples can be a separate structure.

Yoke 270 indirectly connects the trigger 218 to the inner needle 286 of each multifluid valve 276a, 276b. As shown, the yoke 270 may include slots to accept or otherwise connect with the inner needles 286a, 286b. A drive stem 394 can be connected to yoke 270 and extend axially from yoke 270. The drive stem 394 can be connected to the yoke 270 such that the drive stem 394 can displace yoke 270 in either the upstream direction UD or the downstream direction DD. The drive stem 394 can interface with trigger 218 and return spring 238. The return spring 238 can push directly or indirectly on the yoke 270 to urge the yoke 270 forward (e.g., in the downstream direction DD) such that the trigger 218 must be actuated to overcome the return spring 238 and move the inner needles 286a, 286b rearward (e.g., in the upstream direction UD) which eventually moves the outer needles 288a, 288b rearward as discussed previously. Release of the trigger 218 allows the return spring 238 to displace yoke 270 in the downstream direction DD while the outer needles 286 are displaced in the downstream direction by valve springs 292.

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. 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 cartridge for use in a plural component spray gun, the plural component spray gun having a mix chamber and configured to be supplied with a compressed gas, a first constituent material, and a second constituent material, the cartridge comprising: a cartridge body having a mount end and a dispense end; a first multi-fluid valve disposed at least partially within the cartridge body, the first multi-fluid valve actuatable along a first valve axis between a first spray state which permits flow of the first constituent material to the mix chamber and a first non-spray state which blocks flow of the first constituent material to the mix chamber; a second multi-fluid valve disposed at least partially within the cartridge body and actuatable along a second valve axis between a first spray state which permits flow of the first constituent material to the mix chamber and a first non-spray state which blocks flow of the first constituent material to the mix chamber; a first downstream port is open on the cartridge body and fluidly connected to the first multi-fluid valve, wherein the first constituent material is output from the cartridge body through the first downstream port; and a second downstream port open on the cartridge body and fluidly connected to the first multi-fluid valve, wherein the second constituent material is output from the cartridge body through the second downstream port; wherein the first downstream port is spaced from the second downstream port such that the first constituent material and the second constituent material fully exit from within the cartridge body as separate flows.

2. The cartridge of claim 1, wherein the first downstream port is disposed coaxially with the first valve axis.

3. The cartridge of any one of claims 1 and 2, wherein the second downstream port is disposed coaxially with the second valve axis.

4. The cartridge of any one of claims 1-3, wherein the first multi-fluid valve is operable in the first spray state which permits flow of the first constituent material to the mix chamber and blocks flow of the compressed gas through the first multi-fluid valve to the mix chamber, and in the first non-spray state which blocks the flow of the first constituent material through the first multi-fluid valve and permits the flow of the compressed gas through the first multi-fluid valve to the mix chamber.

5. The cartridge of claim 4, wherein the second multi-fluid valve is operable in the second spray state which permits flow of the second constituent material to the mix chamber and blocks flow of the compressed gas through the second multi-fluid valve to the mix chamber, and in the second non-spray state which blocks the flow of the second constituent material through the second multi-fluid valve and permits the flow of the compressed gas through the second multi-fluid valve to the mix chamber.

6. The cartridge of any one of claims 4 and 5, wherein the first multi-fluid valve is operable in a first transition state in which the first multi-fluid valve blocks the flow of the first constituent material to the mix chamber and blocks the flow of the compressed gas to the mix chamber.

7. The cartridge of claim 6, wherein the second multi-fluid valve is operable in a second transition state in which the second multi-fluid valve blocks the flow of the second constituent material to the mix chamber and blocks the flow of the compressed gas to the mix chamber.

8. The cartridge of any one of claims 1-7, wherein the first multi-fluid valve is configured to receive the compressed gas through a first gas port disposed coaxially with the first valve axis.

9. The cartridge of claim 8, wherein the second multi-fluid valve is configured to receive the compressed gas through a second gas port disposed coaxially with the second valve axis.

10. The cartridge of any one of claims 1-9, wherein the first multi-fluid valve comprises a first inner needle and a first outer needle, the first inner needle located at least partially within the first outer needle, and one or both of the first inner needle and the first outer needle is moveable relative to the other of the first inner needle and the first outer needle.

11. The cartridge of claim 10, wherein the first inner needle translates to alternately unseat and seat to permit and block the flow of the compressed gas through the first multi-fluid valve to the mix chamber.

12. The cartridge of any one of claims 10 and 11, wherein the first outer needle translates to alternately unseat and seat to permit and block the flow of the first constituent material through the first multi-fluid valve to the mix chamber.

13. The cartridge of any one of claims 10-12, wherein the first inner needle extends downstream of the first outer needle.

14. The cartridge of any one of claims 10-13, wherein the first inner needle extends entirely through the first outer needle such that the first inner needle extends beyond the first outer needle in both an upstream direction and a downstream direction.

15. The cartridge of any one of claims 10-14, wherein the first inner needle is coaxial with the first outer needle.

16. The cartridge of any of claims 10-15, wherein the first inner needle engages the first outer needle to convey force to move the first outer needle and unseat the first outer needle.

17. The cartridge of any one of claims 10-16, wherein the first inner needle seats on the first outer needle to block flow of the compressed gas and unseats from the first outer needle to permit flow of the compressed gas.

18. The cartridge of claim 17, wherein the first inner needle comprises a first inner needle head and the first outer needle comprises a first inner channel, wherein the first inner needle head is wider than the first inner channel and seats at a downstream end of the first inner channel to block flow of the compressed gas and unseats from the downstream end of the first inner channel to permit flow of the compressed gas.

19. The cartridge of claim 18, wherein the outer needle includes an outer needle head that is wider than the inner needle head.

20. The cartridge of claim 19, wherein the outer needle head engages with the inner needle head to seat the first inner needle and wherein the outer needle head engages with an outer needle seat to seat the first outer needle.

21. The cartridge of any one of claims 10-20, wherein the inner needle comprises one or more axial grooves that permits the compressed gas to flow along the inner needle.

22. The cartridge of any one of claims 10-21, wherein the first inner needle and a second inner needle of the second multi-fluid valve are connected to a yoke such that the yoke can exert an axial driving force on the first inner needle and the second inner needle.

23. The cartridge of any one of claims 10-21 , wherein the first multi-fluid valve further comprises a first valve spring interfacing with the first outer needle and biasing the first outer needle towards the first downstream port.

24. The cartridge of any one of claims 1-23, wherein the first valve axis is disposed parallel to the second valve axis.

25. The cartridge of any one of claims 1-24, wherein the cartridge further comprises a mixer supply bore disposed within the cartridge and open through the dispense end, the mixer supply bore configured to convey the compressed gas to a mixer gas channel within a static mixer of the mix chamber.

26. The cartridge of claim 25, wherein the mixer supply bore is disposed between the first multi-fluid valve and the second multi-fluid valve.

27. The cartridge of any one of claims 25 and 26, further comprising a check valve configured to allow flow of the compressed gas downstream through the mixer supply bore and to prevent flow upstream through the mixer supply bore.

28. The cartridge of claim 27, wherein a ball cage of the check valve is disposed partially within the cartridge body and partially outside of the cartridge body.

29. The cartridge of any one of claims 25-28, wherein each of the first downstream port, the second downstream port, and the mixer supply bore are open through a downstream end face of the cartridge body.

30. The cartridge of any one of claims 1-29, wherein the first multi-fluid valve and the second multi-fluid valve are connected for simultaneous actuation.

31. The cartridge of any one of claims 1-30, wherein the dispense end includes exterior threading configured to interface with a mix chamber housing of the mix chamber to connect the mix chamber to the cartridge.

32. The cartridge of any one of claims 1-31, wherein the second multi-fluid valve includes a second inner needle disposed at least partially within a second outer needle, wherein one or both of the second inner needle and the second outer needle is moveable relative to the other of the second inner needle and the second outer needle.

33. The cartridge of any one of claims 1-32, wherein the first multi-fluid valve is at least partially disposed within a first main bore within the cartridge body, the first main bore extending to the first downstream port.

34. The cartridge of claim 33, wherein a first material port is open to the first main bore to provide the first constituent material to the first main bore, wherein the first material port is disposed axially between a first gas port providing the compressed gas to the first main bore and the first downstream port.

35. The cartridge of any one of claims 33 and 34, wherein the first main bore has a variable radial width.

36. The cartridge of claim 1, wherein the first downstream port is not disposed coaxially with the first valve axis.

37. The cartridge of claim 1, wherein: the first multi-fluid valve is at least partially disposed within a first main bore formed in the cartridge body; the second multi-fluid valve is at least partially disposed within a second main bore formed in the cartridge body; the first main bore includes a first downstream portion extending between the first multi-fluid valve and the first downstream port; the second main bore includes a second downstream portion extending between the second multi-fluid valve and the second downstream port; and the first downstream portion and the second downstream portion are canted.

38. The cartridge of claim 37, wherein the first downstream portion and the second downstream portion converge towards a centerline of the cartridge body.

39. The cartridge of claim 37, wherein the first downstream portion extends towards the second downstream portion and the second downstream portion extends towards the first downstream portion.

40. The cartridge of claim 37, wherein the first downstream portion and the second downstream portion are canted to diverge away from each other.

41. The cartridge of claim 37, wherein the first downstream portion and the second downstream portion are canted to converge towards each other.

42. A cartridge for use in a plural component spray gun, the plural component spray gun having a mix chamber and configured to be supplied with a compressed gas, a first constituent material, and a second constituent material, the cartridge comprising: a cartridge body; a first main bore formed in the cartridge body; a first multi-fluid valve disposed at least partially within the first main bore, the first multi-fluid valve actuatable along a first valve axis between a first spray state which permits flow of the first constituent material to the mix chamber and a first non-spray state which blocks flow of the first constituent material to the mix chamber; a first gas port configured to provide compressed gas to the first multi-fluid valve; and a first material port configured to provide the first constituent material to the first multi-fluid valve; wherein the first material port is disposed downstream from the first gas port.

43. The cartridge of claim 42, wherein the first material port extends through a side wall of the first main bore.

44. The cartridge of any one of claims 42 and 43, wherein the first gas port is disposed coaxially with the first valve axis.

45. The cartridge of any one of claims 42-44, wherein the first main bore extends to a first downstream port open on the cartridge body, wherein the flow of the first constituent material and the flow of the compressed gas are output from the cartridge body through the first downstream port.

46. The cartridge of claim 45 , wherein the first gas port and the first downstream port are disposed coaxially.

47. The cartridge of any one of claims 42-46, wherein the first main bore includes a first component chamber fluidly connected to the first material port with the first multi-fluid valve in both the spray state and the non-spray state such that the first component chamber is pressurized by the first constituent material with the first multi-fluid valve in both the spray state and the non-spray state.

48. The cartridge of claim 47, wherein the multi-fluid valve routes the compressed gas through the first component chamber while fluidly isolating the compressed gas from the first constituent material with the multi-fluid valve in the non- spray state.

49. The cartridge of any one of claims 42-48, wherein the first gas port is disposed at an upstream end of the first main bore, the first downstream port is disposed at a downstream end of the first main bore, and the first material port is disposed between the upstream end and the downstream end, such that the compressed gas flows within the first main bore for greater portion of a length of the first main bore to reach the first downstream port than the first constituent material flows to reach the first downstream port.

50. The cartridge of any one of claims 42-49, further comprising: a second main bore formed in the cartridge body; a second multi-fluid valve disposed at least partially within the second main bore, the second multi-fluid valve actuatable along a second valve axis between a second spray state which permits flow of the second constituent material to the mix chamber and a second non-spray state which blocks flow of the second constituent material to the mix chamber; a second gas port configured to provide compressed gas to the second multifluid valve; a second material port configured to provide the second constituent material to the second multi-fluid valve; wherein the second material port is disposed downstream from the second gas port.

51. The cartridge of claim 50, wherein the first valve axis is parallel to the second valve axis.

52. The cartridge of any one of claims 50 and 51, wherein a body chamber is formed in the cartridge body, wherein the first gas port and the second gas port are open to the body chamber to receive compressed gas from the body chamber.

53. The cartridge of any one of claims 42-52, wherein the first multi-fluid valve comprises a first inner needle and a first outer needle, the first inner needle located at least partially within the first outer needle, wherein the first inner needle is configured to seat and unseat to control flow of the compressed gas downstream to the first downstream port and the outer needle is configured to seat and unseat to control flow of the first constituent material to the first downstream port.

54. The cartridge of claim 53, wherein the first inner needle extends through the first gas port.

55. A cartridge for use in a plural component spray gun, the plural component spray gun having a mix chamber and configured to be supplied with a compressed gas, a first constituent material, and a second constituent material, the cartridge comprising: a cartridge body having a mount end and a dispense end; a first main bore formed within the cartridge body and extending to a first downstream port open through the dispense end; a first multi-fluid valve disposed at least partially within the first main bore, the first multi-fluid valve actuatable along a first valve axis between a spray state which permits flow of the first constituent material to the mix chamber and blocks flow of compressed gas to the mixing chamber, a transition state which blocks flow of the first constituent material and the compressed gas to the mix chamber, and a purge state which blocks flow of the first constituent material and allows flow of the compressed gas to the mix chamber; a second main bore formed within the cartridge body and extending to a second downstream port open through the dispense end; and a second multi-fluid valve disposed at least partially within the second main bore and actuatable along a second valve axis to control flows of the second constituent material and the compressed gas to the mix chamber through the second downstream port; wherein the first downstream port is spaced from the second downstream port such that flows controlled by the first multi-fluid valve exit the cartridge body separately from flows controlled by the second multifluid valve.

56. The cartridge of claim 55, wherein the first downstream port is disposed coaxially with the first valve axis.

57. The cartridge of any one of claims 55 and 56, wherein the second downstream port is disposed coaxially with the second valve axis.

58. The cartridge of any one of claims 55-57, wherein the first valve axis is parallel to the second valve axis.

59. The cartridge of any one of claims 55-58, wherein the first main bore is open for fluid flow in both an upstream direction and a downstream direction.

60. The cartridge of claim 59, wherein the second main bore is open for fluid flow in both the upstream direction and the downstream direction.

61. A valve assembly for use in a cartridge for use in a plural component spray gun, the plural component spray gun having a mix chamber and the cartridge configured to be supplied with a compressed gas, a first constituent material, and a second constituent material, the valve assembly comprising: a mount plate; a yoke; a first multi-fluid valve connected to the yoke and configured to shift along a first valve axis, wherein at least a portion of the first multi-fluid valve extends through the mount plate to connect to the yoke; and a second multi-fluid valve connected to the yoke and configured to shift along a second valve axis, wherein at least a portion of the second multi-fluid valve extends through the mount plate to connect to the yoke.

62. The valve assembly of claim 61, wherein the first multi-fluid valve comprises: a first outer needle; a first inner needle at least partially disposed within the first outer needle and connected to the yoke, wherein one or both of the first outer needle and the first inner needle is movable relative to the other one of the first inner needle and the first outer needle.

63. The valve assembly of claim 62, wherein the first inner needle extends fully axially through the first outer needle.

64. The valve assembly of any one of claims 62 and 63, wherein the first inner needle includes an inner needle tail disposed within a mount slot of the yoke to connect the first inner needle to the yoke.

65. The valve assembly of any one of claims 62-64, wherein the first inner needle includes an inner needle head configured to engage with an inner needle seat to close a flowpath between the inner needle head and the inner needle seat.

66. The valve assembly of claim 65, wherein the inner needle seat is formed by the outer needle.

67. The valve assembly of any one of claims 62-66, further comprising: a first valve spring interfacing with the outer needle and configured to bias the outer needle away from the yoke.

68. The valve assembly of claim 67, further comprising: a first bushing disposed between the first valve spring and the mount plate, wherein the first outer needle is at least partially disposed within the first bushing.

69. The valve assembly of claim 68, wherein the first bushing supports a plurality of valve seals.

70. The valve assembly of claim 69, wherein the first bushing includes a seal body configured to support the plurality of valve seals and the first bushing includes a first brace interfacing with the first valve spring and the seal body.

71. The valve assembly of claim 70, wherein the first bushing further includes a second brace disposed on an opposite side of the seal body from the first brace, the second brace configured to interface with the mount plate and the seal body.

12. The valve assembly of claim 71, further comprising: a yoke spring interfacing with the yoke and the second brace, the yoke spring configured to bias the yoke away from the first outer needle.

73. The valve assembly of any one of claims 61-71, further comprising: a yoke spring interfacing with the yoke and configured to bias the yoke away from the mount plate.

74. The valve assembly of any one of claims 61-73, wherein the mount plate includes a plate body at least partially axially overlapping with the first multi-fluid valve and the second multi-fluid valve, and the mount plate includes at least one plate tab extending away from the plate body.

75. The valve assembly of any one of claims 61-74, wherein the yoke includes a yoke bore extending fully through the yoke.

76. The valve assembly of any one of claims 61-74, wherein the second multifluid valve comprises: a second outer needle; a second inner needle at least partially disposed within the second outer needle and connected to the yoke, wherein one or both of the second outer needle and the second inner needle is movable relative to the other one of the second inner needle and the second outer needle.

77. A plural component spray gun configured to be supplied with compressed gas, a first constituent material, and a second constituent material and to output a plural component material formed by mixing of the first constituent material and the second constituent material, the plural component spray gun comprising: a gun body; a cartridge mountable to and dismountable from the gun body as a single unit, the cartridge comprising: a cartridge body having a dispense end and a mount end; a first multi-fluid valve disposed at least partially within the cartridge body, the first multi-fluid valve actuatable along a first valve axis between a first spray state which permits flow of the first constituent material to a first downstream port and out of the cartridge body and a first non-spray state which blocks flow of the first constituent material to the first downstream port; and a second multi-fluid valve disposed at least partially within the cartridge body, the second multi-fluid valve actuatable along a second valve axis between a second spray state which permits flow of the second constituent material to a second downstream port and out of the cartridge body and a second non-spray state which blocks flow of the second constituent material to the second downstream port; and a mix chamber mounted to the dispense end such that the mix chamber is supported by the cartridge body.

78. The plural component spray gun of claim 77, wherein the dispense end is received within a mix chamber housing of the mix chamber to mount the mix chamber to the cartridge body.

79. The plural component spray gun of any one of claims 77 and 78, wherein the mix chamber is mounted to the cartridge body by interfaced threading.

80. The plural component spray gun of any one of claims 77-79, wherein the mix chamber includes a static mixer having projections configured to redirect flow of the first constituent material and the second constituent material within the mix chamber.

81. The plural component spray gun of any one of claims 77-80, wherein the first downstream port is open through a first end face formed at a distal end of the dispense end and wherein the second downstream port is open through the first end face.

82. The plural component spray gun of any one of claims 77-81, wherein the cartridge is configured such that the first constituent material and the second constituent material exit from the cartridge body to locations not radially overlapped by structure of the cartridge body prior to the first constituent material mixing with the second constituent material.

83. The plural component spray gun of any one of claims 77-82, wherein the mount end includes a plurality of cartridge mounts, the gun body includes a plurality of body mounts, and the cartridge mount axially overlap with the body mounts with the cartridge mounted to the gun body.

84. The plural component spray gun of any one of claims 77-83, wherein the mount end is at least partially disposed within the gun body with the cartridge mounted to the gun body.

85. The plural component spray gun of any one of claims 77-84, further comprising: a manifold configured to provide the first constituent material and the second constituent material to the cartridge, the manifold directly connected to the cartridge.

86. The plural component spray gun of claim 858, wherein a projection of the gun body extends into a body slot formed in the manifold, the projection and body slot interfacing to prevent relative rotation between the cartridge and the gun body.

87. A method of spraying, the method comprising: shifting a first inner needle of a first multi-fluid valve in an upstream direction and along a first valve axis of the first multi-fluid valve; contacting a first inner needle head of the first inner needle with a first outer needle through which the first inner needle at least partially extends, thereby shutting off a flow of compressed gas through the first multifluid valve; and displacing the first outer needle in the upstream direction by the first inner needle to unseat the first outer needle from a first outer needle seat, thereby opening a flow of a first constituent material through the first multi-fluid valve and downstream to a mix chamber.

88. The method of claim 87, further comprising: shifting the first inner needle and the first outer needle in a downstream direction opposite the upstream direction such that the outer needle seats on the outer needle seat thereby shutting off the flow of the first constituent material; and further shifting the first inner needle in the downstream direction such that the first inner needle head disengages from the first outer needle thereby opening the flow of the compressed gas through the multifluid valve.

89. The method of any one of claims 87 and 88, further comprising: shifting a second inner needle of a second multi-fluid valve in the upstream direction and along a second valve axis of the second multi-fluid valve; contacting a second inner needle head of the second inner needle with a second outer needle through which the second inner needle at least partially extends, thereby shutting off a flow of compressed gas through the second multi-fluid valve; and displacing the second outer needle in the upstream direction by the second inner needle to unseat the second outer needle from a second outer needle seat, thereby opening a flow of a second constituent material through the second multi-fluid valve and downstream to the mix chamber.

90. The method of claim 89, further comprising: simultaneously shifting the first inner needle and the second inner needle in the upstream direction.

91. The method of any one of claims 87-90 further comprising: outputting the first constituent material from a cartridge supporting the first multi-fluid valve to the mix chamber such that the first constituent material does not interact with the second constituent material at a location radially overlapped by structure of the cartridge.

92. A cartridge for use in a plural component spray gun, the plural component spray gun having a mixing chamber, the plural component spray gun configured to be supplied with a compressed gas and a first constituent material, the cartridge comprising: a first cartridge body; and a first valve located at least partially within the first cartridge body operable in a spray state which permits flow of the first constituent material to the mix chamber and in a non-spray state which blocks flow of the first constituent material to the mix chamber; wherein the first cartridge body is configured to mount to the plural component spray gun.

93. The cartridge of claim 92, wherein the first valve is a first multi-fluid valve located at least partially within the first cartridge body operable in the spray state which permits flow of the first constituent material to the mix chamber but blocks flow of the compressed gas through the first multi-fluid valve to the mix chamber, and in the non-spray state which blocks flow of the first constituent material through the first multi-fluid valve and permits the flow of the compressed gas through the first multi-fluid valve to the mix chamber.

94. The cartridge of claim 93, wherein the first multi-fluid valve comprises a first inner needle and a first outer needle, the first inner needle located at least partially within the first outer needle, one or both of the first inner needle and the first outer needle moveable relative to the other of the first inner needle and the first outer needle.

95. The cartridge of claim 94, wherein the first inner needle translates to alternately unseat and seat to permit and block the flow of the compressed gas through the first multi-fluid valve to the mix chamber.

96. The cartridge of any one of claims 94 and 95, wherein the first outer needle translates to alternately unseat and seat to permit and block the flow of the first constituent material through the first multi-fluid valve to the mix chamber.

97. The cartridge of any one of claims 94-96, wherein the first inner needle extends downstream of the first outer needle.

98. The cartridge of any one of claims 94-97, wherein the first inner needle extends entirely through the first outer needle such that the first inner needle extends beyond the first outer needle in both upstream and downstream directions.

99. The cartridge of any one of claims 94-98, wherein the first inner needle is coaxial with the first outer needle.

100. The cartridge of any one of claims 94-99, wherein the first inner needle engages the first outer needle to convey force to move the first outer needle.

101. The cartridge of any one of claims 94-100, wherein the first inner needle engages the first outer needle to unseat the first outer needle.

102. The cartridge of any one of claims 94-101, wherein the first inner needle seats on the first outer needle to block flow and unseats from the first outer needle to permit flow.

103. The cartridge of claim 102, wherein the first inner needle comprises a head and the first outer needle comprises an inner channel, wherein the head is wider than the inner channel and seats at a downstream end of the inner channel to block flow and unseats from the downstream end of the inner channel to permit flow.

104. The cartridge of any one of claims 94-103, wherein the first multi-fluid valve can be in a pre-spray state in which both of the first inner needle and the first outer needle are both respectively seated to block flow of the compressed gas and the first constituent material.

105. The cartridge of any one of claims 94-104, wherein the inner needle comprises one or more axial grooves that permits gas flow along the inner needle.

106. The cartridge of any of claims 94-105, wherein the cartridge does not contain, even in part, any valve other than the first multi-fluid valve.

107. A plural component spray gun that accepts the cartridge of any one of claims 94-106.

108. The plural component spray gun of claim 107, wherein the cartridge is axially pinched by the mix chamber to form a seal between the mix chamber and the cartridge.

109. The plural component spray gun of any one of claims 107 and 108, further comprising a manifold which is bolted to a body of the plural component spray gun but is not bolted to the cartridge.

110. The plural component spray gun of claim 109, wherein the manifold abuts the cartridge to retain the cartridge.

111. The plural component spray gun of one of claims 107-110, wherein the plural component spray gun accepts the cartridge of any one of claims 94-106 to control flow of the first constituent material and further accepts another cartridge to control flow of a second constituent material to the mix chamber.

112. The plural component spray gun of claim 111, wherein the other cartridge comprises a similar arrangement of components as the cartridge to operate similarly to the cartridge but with the second constituent material in place of the first constituent material.