CROSS-REFERENCE TO RELATED APPLICATION(S)
-
This application claims priority to
U.S. Provisional Application No. 63/744,909 filed January 14, 2025 and entitled "FLUID SPRAYER," the disclosure of which is hereby incorporated by reference in its entirety.
BACKGROUND
-
This disclosure relates generally to fluid sprayers. More specifically, this disclosure relates to fluid sprayers for generating and applying a spray fluid onto a substrate.
-
Fluid sprayers include a pump that pressurizes a spray fluid and outputs the pressurized spray fluid to a spray gun. The spray gun includes a nozzle configured to atomize the spray fluid into a fluid spray that is applied to a target substrate. The spray gun includes a trigger that can be pulled by the user to open a valve to cause spraying by the spray gun. The trigger is released to cause the valve to close and stop spraying by the spray gun. The pump is powered by a motor of the fluid sprayer.
SUMMARY
-
According to an aspect of the disclosure, a pump module for a spray system for spraying paint includes a chassis; a piston pump; an electric motor which outputs rotational motion; a drive at least partially located within the chassis, the drive converting the rotational motion output by the electric motor into linear reciprocating motion that operates the piston pump; and a cover mounted to the chassis, the cover covering at least a portion of the drive, wherein the cover includes a side extension that extends further rearward on a first side of the cover than on a second side of the cover disposed opposite the first side.
-
According to an additional or alternative aspect of the disclosure, a pump module for a spray system for spraying paint includes a chassis; a piston pump supported by the chassis; an electric motor which outputs rotational motion; a drive at least partially located within the chassis, the drive converting the rotational motion output by the electric motor into linear reciprocating motion that operates the piston pump; a shroud that at least partially encloses the electric motor; and a power cord configured to provide electrical power to the pump module, the power cord including a collar clamped between the shroud and the chassis.
-
According to another additional or alternative aspect of the disclosure, a pump module for a spray system for spraying paint includes a chassis; a piston pump supported by the chassis; a filter manifold; an electric motor which outputs rotational motion; a drive at least partially located within the chassis, the drive converting the rotational motion output by the electric motor into linear reciprocating motion that operates the piston pump; a shroud that at least partially encloses the electric motor; and a transfer hose that routes paint output from the pump into the filter manifold, wherein the shroud defines a passage through which the transfer hose extends between the pump and the filter manifold.
-
According to yet another additional or alternative aspect of the disclosure, a pump module for a spray system for spraying paint includes a chassis; a piston pump; an electric motor which outputs rotational motion; a drive at least partially located within the chassis, the drive converting the rotational motion output by the electric motor into linear reciprocating motion that operates the piston pump; and a board mount on which a capacitor board is mounted, the board mount mounted on a housing of the electric motor.
BRIEF DESCRIPTION OF THE DRAWINGS
-
- FIG. 1A
- is an isometric view of a sprayer.
- FIG. 1B
- is a partial isometric view of the sprayer showing a cover exploded away from a chassis of the sprayer.
- FIG. 1C
- is a partial top view of the sprayer.
- FIG. 2
- is an isometric view showing a front end of the sprayer with the cover removed.
- FIG. 3
- is an isometric view of a cover.
- FIG. 4A
- a first isometric cross-sectional view showing an interface between a shroud and a chassis.
- FIG. 4B
- is a second isometric cross-sectional view showing the interface between the shroud and the chassis.
- FIG. 5A
- is an isometric view of a sprayer.
- FIG. 5B
- is a rear view of the sprayer.
- FIG. 6
- is an isometric view showing internal components of a sprayer.
- FIG. 7A
- is a first isometric view of a board mount.
- FIG. 7B
- is a second isometric view of the board mount.
DETAILED DESCRIPTION
-
The present disclosure relates to fluid sprayers. The fluid sprayers can be used to spray a variety of fluids. Paint will be used herein as the main example of a type of fluid that can be sprayed, but it will be understood that the teachings of the present disclosure can relate to spraying of other types of fluids, such as lacquers, stains, finishes, coatings, textures, and adhesives, among other options.
-
A spray system, which can also be referred to as a fluid sprayer, includes a pump module and a spray gun fluidly connected to the pump module. Pump modules according to aspects of the disclosure include a chassis configure to support a pump. An electric motor outputs rotational motion. A drive that converts the rotational output from the motor to a linear input to the pump is at least partially located in the chassis.
-
Pump modules according to aspects of the disclosure include a front cover that mounts to the chassis. The front cover covers at least a portion of the drive. The front cover includes a side extension that extends from at least one side of the front cover. The side extension extends further rearward than other portions of the front cover.
-
According to some aspects of the disclosure, the side extension of the front cover extends further rearward on a first side of the front cover than on a second side of the front cover opposite the first side. The first side can be a top side of the front cover. The first side can be a lateral side of the front cover. The side extension can, in some examples, be formed partially on a top side and partially on a lateral side of the front cover. The side extension can include a corner between the top and lateral sides of the front cover.
-
According to some additional or alternative aspects of the disclosure, a gap can be formed between the chassis and a shroud of the pump module. The shroud can enclose various electrical components of the pump module, such as a motor, a controller, etc. The gap can be disposed laterally between the chassis and the shroud, among being at other locations. The side extension of the front cover can extend rearward towards the shroud to cover the gap. The side extension can be aligned with an edge of the shroud. The side extension can be spaced outward from the chassis to align with the shroud and cover the gap. The side extension covering the gap can prevent ingress of contaminants, such as falling paint particles among others.
-
Pump modules according to aspects of the disclosure include a shroud that at least partially encloses various components of the pump module. For example, the electric motor, a controller, among other components can be covered by the shroud. According to various aspects of the disclosure, a power cord that supplies electrical power for electronic components of the pump module can be clamped between the chassis and the shroud. The chassis and the shroud can engage with a collar of the power cord to locate the power cord relative to other components of the pump module. The collar can engage with the chassis and/or the shroud to secure the power cord in place.
-
According to some aspects of the disclosure, the collar can extend into one or both of the shroud and chassis, the chassis and/or shroud can extend into the collar, or a combination of such interfaces can clamp the power cord to the chassis and shroud. In some examples, the collar interfaces with one or both of the chassis and the shroud at a tongue-and-groove interface.
-
Pump modules according to some aspects of the disclosure include a transfer hose that connects between the pump and a filter manifold. The pump can output fluid through the transfer hose to the filter manifold. The hose that extends to a spray gun in a fluid sprayer including the pump module can extend between the filter manifold and the spray gun. The filter manifold can house a filter that filters the paint upstream of the spray gun.
-
The transfer hose can extend from within to outside of a shroud of the pump module. The transfer hose can be routed through a passage to exit from an interior of the pump module. The passage can be at least partially defined by the shroud. Three of four sides of the passage can be defined by the shroud, though it is understood that not all examples are so limited. The passage can be at least partially defined by a stand of the pump module. In various examples, the transfer hose is not fixed in place by the shroud. The transfer hose can pass through the shroud without being engaged and held in place by the shroud.
-
Pump modules according to aspects of the disclosure include a board mount that is configured to support a capacitor board. The board mount can be mounted in an interior of the pump module. One or more capacitors can be mounted on the capacitor board. The board mount can engage with a housing of the electric motor to mount within the pump module. The board mount can, in some examples, engage with a tie rod that supports the electric motor.
-
FIG. 1A is an isometric view of sprayer 10. FIG. 1B is a partial isometric view of sprayer 10 showing cover 30 exploded away from chassis 32. FIG. 1C is a partial top view of sprayer 10. FIGS. 1A-1C are discussed together. Pump module 12, supply hose 14, intake hose 16, and spray gun 18 of sprayer 10 are shown. Module body 20, stand 22, pump 24, filter manifold 26, shroud 28, cover 30, chassis 32, module handle 34, transfer hose 36, and drive 38 of pump module 12 are shown. Trigger 40, valve 42, gun handle 44, and spray tip 46 of spray gun 18 are shown.
-
It is understood that sprayers of other embodiments can take different forms. FIG. 1A includes directional arrows showing respective front direction, backward direction, leftward direction, rightward direction, upward direction, and downward direction. Synonyms for these directions can be used, such as rearward for the back direction, top for upwards, and bottom for downward, amongst other options. It is assumed that these directions are part of a three axis Cartesian coordinate system radiating out from the center of pump module 12, such that the front and back, right and left, and top and bottom, are respective opposite directions along the respective axes of the three axis Cartesian coordinate system. The rightward and leftward directions can also be referred to as lateral directions, the forward and backward directions can also be referred to as longitudinal directions, and the upward and downward directions can also be referred to as vertical directions.
-
Sprayer 10 is configured to receive spray fluid (e.g., paint among other options) from a reservoir (e.g., a bucket) (not shown) via intake hose 16. The sprayer 10 outputs the paint through a spray nozzle of spray gun 18. The spray nozzle is part of a spray tip 46 inserted into the spray gun 18. The spray nozzle can be integrated into a barrel of the spray tip 46. In some examples, the spray tip 46 is a rotatable spray tip 46. The rotatable spray tip 46 can be rotated to reverse the direction of flow of paint through the spray nozzle to unclog the spray nozzle in the event of formation of a clog in the spray nozzle. The rotatable spray tip 46 can be replaced with a variety of other rotatable spray tips 46, typically of different sizes and/or shapes of nozzle which produce different spray patterns (e.g., different fan sizes, spray shapes (cone, fan, etc.), etc.).
-
Pump module 12 is configured to pressurize the fluid from the reservoir and output a pressurized flow of the fluid to the spray gun 18. The spray gun 18 receives spray fluid through supply hose 14. The supply hose 14 can be a single segment of a hose or can be multiple hose segments serially connected to each other by fittings. The supply hose 14 connects to pump module 12 at outlet 48. The outlet 48 is part of pump module 12.
-
The pump module 12 includes module body 20. The pump module 12 includes stand 22. The stand 22 includes a plurality of legs 50 which rest on the ground to support the module body 20. The stand 22 can include at least two legs. The stand 22 can include more than two legs 50. In the example shown, the stand 22 includes four legs 50 formed by two tubes. The entirety of the module body 20 can be supported by the stand 22.
-
In the example shown, the stand 22 includes a base plate 52. The legs 50 are connected to the base plate 52. The module body 20 can be connected to the base plate 52 to be supported by the base plate 52. In various examples, the module body 20 can be supported on a ground surface by the base plate 52 and legs 50. The module body 20 can be supported by the legs 50 via the base plate 52, though it is understood that not all examples are so limited.
-
The pump module 12 includes pump 24. The pump 24 is configured to draw paint from the reservoir and put the paint under pressure. The pump 24 is configured to drive the paint under pressure to the spray gun 18 for spraying on a target substrate. The pump 24 can be a piston pump which includes a piston that reciprocates inside of cylinder 54 to put paint or other spray fluid under pressure. Pump 24 can be removably mountable to the module body 20.
-
The pump 24 can connect to other portions of pump module 12 via a static interface and a dynamic interface. The static interface holds the pump 24 to the body 20. The dynamic interface drives reciprocation of the piston of the pump 24. In the example shown, the static interface is formed between pump 24 and module body 20. The pump 24 can be at least partially disposed within a mount chamber 56 of the module body 20 with the pump mounted to the module body 20.
-
The pump module 12 includes filter manifold 26. The filter manifold 26 receives paint output from the pump 24 via transfer hose 36. The transfer hose 36 extends between an outlet of the pump 24 and an inlet of the filter manifold 26. A filter is contained inside of the filter manifold 26 which filters the paint before outputting the paint via the outlet 48. The outlet 48 can be a fitting of the filter manifold 26. Such a fitting connects to the supply hose 14. The paint can thus flow from the pump 24 to the filter manifold 26 via transfer hose 36 and then from filter manifold 26 to spray gun 18 via supply hose 14.
-
Pump module 12 includes chassis 32 that supports other components of pump module 12. The chassis 32 can be mounted to the stand 22. For example, the chassis 32 can be mounted to the base plate 52 of the stand 22. The chassis 32 can form a frame of the module body 20.
-
Chassis 32 may be formed from metal. Chassis 32 may be formed from multiple pieces of metal. The chassis 32 can structurally support the electric motor, the pump 24, the shroud 28, the cover 30, the filter manifold 26, and various other components of the pump module 12. The chassis 32 can contain at least part or all of drive 38, and as such can be considered to form a drive housing. The drive 38 converts rotational motion output from the motor of pump module 12 into linear reciprocating motion that operates the pump 24, such as by reciprocating a piston of the pump 24.
-
The pump module 12 includes shroud 28. Shroud 28 forms a portion of the module body 20. The shroud 28 can enclose various other components of pump module 12 in an interior of the pump module 12. The shroud 28 can be formed as a single piece. Shroud 28 can be formed from polymer, among other options. Shroud 28 is a hollow structure which can house an electric motor, a controller, and/or other parts of the pump module 12.
-
In the example shown, the shroud 28 is a monolithic component that is formed as a single part. The shroud 28 is not formed from multiple components, such as a clamshell, in this example. It is understood, however, that in some examples the shroud 28 can be formed from multiple parts, such as in a clamshell configuration. In some examples, the shroud 28 can be formed from metal. Shroud 28 can mount to chassis 32.
-
The pump module 12 further includes cover 30. The cover 30 can be mounted on the front side of the pump module 12. Cover 30 can be referred to as a front cover. The cover 30 can form a front facing exterior surface of the module body 20. The cover 30 can connect to the chassis 32. Cover 30 can at least partially cover a part of the drive 38. The cover 30 can extend over a portion of the drive 38 to enclose that portion of the drive 38, such as to cover the drive 38 to prevent contaminants from reaching the drive 38 and to protect the user from inadvertent contact with the drive 38 during operation.
-
The pump module 12 includes module handle 34. At least part of the module handle 34 can be formed from the same metal parts that form the chassis 32. In various examples, module handle 34 is connected directly to the chassis 32. Module handle 34 can be formed separately from and connected to the chassis 32, such as by one or more fasteners (e.g., bolts among other options). Module handle 34 extends from a chassis top side 58 of chassis 32. Pump module 12 can be carried by a user grasping module handle 34 and carrying pump module 12 by the module handle 34.
-
Cover 30 includes a cover front side 60, a cover top side 62, a cover lateral side 64a, and a cover lateral side 64b. In various examples, cover lateral side 64a is on a right side of the pump module 12 and cover lateral side 64b is on a left side of the pump module 12.
-
Cover 30 includes side extension 66. The side extension 66 is a part of the cover 30 which extends beyond the rest of the cover 30. In the example shown, the side extension 66 extends rearward relative to the rest of the cover 30.
-
Cover 30 includes cover base 68 that is formed by the cover rim 70 of the cover 30. The cover base 68 is oriented towards the chassis 32 with the cover 30 mounted on chassis 32. Side extension 66 extends rearward of cover base 68. The side extension 66 extends outward of the cover base 68 to project further in the rearward direction than the cover base 68.
-
Cover 30 is laterally asymmetric in this example shown. In this example, cover lateral side 64a includes the side extension 66 whereas cover lateral side 64b does not include any side extension 66. It is understood that not all examples are so limited, however. In some examples, both cover lateral side 64a and cover lateral side 64b can include side extensions. In one such example, the side extension 66 may be longer than a relatively shorter side extension on cover lateral side 64b.
-
Window 81 is formed by the chassis 32. The window 81 exposes the drive 38 when the cover 30 is removed. The window 81 is formed by an extension 72 of the chassis 32 that projects longitudinally forward. The chassis 32 can define a drive chamber 83 within which a portion of the drive 38 is disposed. The extension 72 can form one or more sides of the drive chamber 83. For example, the extension 72 can define a top side, lateral sides, a bottom side, etc. of the drive chamber 83. In the example shown, the window 81 opens into the drive chamber 83. The extension 72 extends in the forward direction from other portions of the chassis 32.
-
In the example shown, chassis 32 includes base portion 82 (best seen in FIGS. 4A and 4B) and upper portion 84. Base portion 82 can interface with stand 22 to connect chassis 32 to stand 22. Upper portion 84 extends vertically from base portion 82. The drive chamber 83 can be formed in the upper portion 84. The extension 72 can project from wall 86 of upper portion 84. The upper portion 84 and base portion 82 can be formed monolithically such that chassis 32 is formed as a single component. In some examples, extension 72 can be formed separately from and connected to wall 86 to form chassis 32.
-
Cover 30 fits partially or fully around the extension 72 (e.g., top, bottom, and lateral sides of the extension 72) of the chassis 32 that forms the window 81. The cover 30 can mount to the chassis 32 such that the chassis 32 is at least partially received within the cover 30. As such, the cover 30 can overlap with chassis 32.
-
Along the side extension 66 the cover 30 overlaps the chassis 32 to greater degree than the rest of the cover 30 extending rearward from the cover front side 60. Only a single side extension 66 may be present as part of the cover 30, though it is understood that not all examples are so limited.
-
Chassis 32 includes chassis side 74 and chassis side 74. Between the chassis side 74 and the chassis top side 58 (or formed by the chassis side 74 and/or the chassis top side 58) is a chassis corner 76. In various examples, the chassis side 74 and chassis top side 58 can be formed by or at least partially by the extension 72 that at least partially defines the drive chamber 83.
-
The chassis corner 76 is curved between the chassis side 74 and the chassis top side 58. The chassis side 74 can be considered to form a lateral side of the chassis 32. The side extension 66 also forms an extension corner 78 between cover lateral side 64a and cover top side 62. Extension corner 78 can be curved between cover lateral side 64a that is oriented laterally and cover top side 62 that is oriented vertically. The extension corner 78 can be considered to comprise part of cover lateral side 64a (right side in this embodiment) and part of cover top side 62. The extension corner 78 is configured to extend over and cover the chassis corner 76.
-
In the example shown, the side extension 66 extends further rearward on one side of the cover 30 than on an opposite side of the cover 30. Side extension 66 can extend further rearward on cover lateral side 64a than on the opposite cover lateral side 64b. Side extension 66 can additionally or alternatively extend further rearward on cover top side 62 than on a bottom vertical side of cover 30 opposite the cover top side 62. The side extension 66 can be considered to extend further rearward on a first side of cover 30 and/or on a third side of cover 30, which first side is disposed opposite a second side of cover 30 and which third side is disposed opposite a fourth side of cover 30. For example, the first side can be formed by cover lateral side 64a and the third side can be formed by cover top side 62.
-
Cover 30 can be fixed to chassis 32. Cover 30 can be mounted to chassis 32 by fasteners 80, among other options. The fasteners 80 can be threaded fasteners (e.g., screws, bolts, etc.) which extend through respective holes in the cover 30 and thread into threaded holes of the chassis 32 to secure the cover 30 to the chassis 32.
-
In the example shown, a gap 90 is disposed between chassis 32 and shroud 28 with shroud 28 mounted to chassis 32. The gap 90 is disposed on a lateral side of the module body 20. In the example shown, the gap 90 is disposed on a right side of the module body 20. In the example shown, the gap 90 is formed between an outer side of the chassis 32 and an inner side of the shroud 28. The gap 90 can be open longitudinally and can expose an interior of the module body 20 within shroud 28. The gap 90 can be a lateral gap between the shroud 28 and the chassis 32.
-
The gap 90 may otherwise allow the ingress of wet or dry paint sprayed from the spray gun 18, except that the side extension 66 of the cover 30 extends to cover up the gap 90. As such, the asymmetric side extension 66 can cover a particular gap 90. The gap 90 is not present on the other lateral (left) side of the pump module 12 in this example.
-
FIG. 2A is a partial front view of sprayer 10. Cover 30 is omitted in FIG. 2A to show a closer view of the gap 90. FIG. 2B is a partial top view of sprayer 10 showing cover 30 mounted to chassis 32.
-
Gap 90 is formed between chassis 32 and shroud 28. In the example shown, various internal components of the sprayer 10 are exposed through gap 90. The exposed internal components can be electronic components. In the example shown, portions of controller 88 can be viewed through the gap 90. Controller 88 is configured to control the electrical system of the pump module 12. Contact of wet spray fluid with the electrical components of controller 88 should be avoided. Side extension 66 extending over and covering the gap 90 can prevent ingress of the wet fluid into the interior of the module body 20 to help avoid such contact with the wet fluid.
-
Controller 88 can be of any desired configuration for controlling operation of electrical components of pump module 12 (e.g., an electric motor, among other components) and can include control circuitry (e.g., one or more of a processor, a microprocessor, a controller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), a graphics processing unit (GPU), a system-on-module (SOM), or other equivalent discrete or integrated logic circuitry) and computer-readable memory.
-
Controller 88 is configured to store executable code, implement functionality, and/or process instructions. Controller 88 is configured to perform any of the functions discussed herein, including controlling operation of any components referenced herein. Controller 88 can be of any suitable configuration for controlling operation of electrical components, gathering data, processing data, etc. Controller 88 can include hardware, firmware, and/or stored software. Controller 88 can be of any type suitable for operating in accordance with the techniques described herein. It is understood that controller 88 can be entirely or partially mounted on one or more circuit boards. In some examples, controller 88 can be implemented as a plurality of discrete circuitry subassemblies.
-
Cover 30 is mounted such that chassis 32 is at least partially disposed within cover 30. In various examples, the rim 70 of the cover 30 can extend rearward of the leading edge of the chassis 32 and fully around the chassis 32. The side extension 66 extends further rearward than other portions of the cover 30.
-
In the example shown, the side extension 66 is spaced laterally outward of the chassis 32. Cover lateral side 64a is spaced laterally outward of the chassis side 74 such that a spacing gap 92 is disposed therebetween. The side extension 66 being spaced away from the chassis side 74 allows the side extension 66 to project outward to cover the gap 90 formed between chassis 32 and shroud 28.
-
In the example shown, the gap 90 between chassis 32 and shroud 28 extends laterally. The side extension 66 being disposed laterally outward of the chassis side 74 positions the cover 30 to overlap longitudinally with the gap 90. The side extension 66 can further extend to laterally and/or vertically overlap with the gap 90.
-
Distal end 94 of side extension 66 is an end of side extension away from base 68 of cover body 96. Distal end 94 is formed by rim 70 in the example shown. The distal end 94 of side extension 66 is a portion of side extension 66 that extends furthest in the rearward direction in the example shown.
-
The side extension 66 can be aligned with shroud 28 to cover the gap 90. In some examples, distal end 94 of side extension 66 can be aligned with shroud rim 98 of shroud 28. The rim 70 on side extension 66 can align with the shroud rim 98. The shroud rim 98 is spaced away from chassis 32 by the gap 90. The side extension 66 aligning with the shroud rim 98 can minimize the size of any opening to the gap 90 by preventing a lateral or vertical opening from being formed between the shroud rim 98 and the side extension 66. Such longitudinal overlap between the side extension 66 and shroud 28 can thereby inhibit ingestion of contaminants through the gap 90.
-
FIG. 3 is a rear isometric view of cover 30. The view of FIG. 3 shows an internal, backside of the cover 30. Cover front side 60, cover top side 62, cover lateral side 64a, cover lateral side 64b of cover 30 are shown. Cover 30 includes cover body 96, side extension 66, and notch 100. Cover 30 includes cover base 68 that is formed by rim 70 of the cover 30. The rim 70 extends on a back side of the cover 30 to defines the opening into the cover 30. The rim 70 can form the cover base 68 and the edges of the side extension 66. The rim 70 can form the notch 100.
-
In the example shown, the cover body 96 is configured to extend over and enclose one or more components of pump module 12. Cover body 96 can cover the window 81 of the chassis 32. Side extension 66 projects from cover body 96. Side extension 66 projects longitudinally from the cover body 96. Side extension 66 extends rearward from cover body 96 in the example shown.
-
Rim 70 extends around the open end of the cover 30. The cover base 68 of cover 30 is formed by a portion of rim 70. The cover base 68 forms an end of the cover body 96. The side extension 66 projects rearward relative to the cover base 68. The side extension 66 is configured to extend towards the shroud 28 to be positioned closer to the shroud 28 than the cover body 96 of the cover. The side extension 66 extends closer to the shroud 28 than the cover base 68 of the cover 30. The side extension 66 extends to a distal end 94 that is spaced longitudinally from the cover base 68 of the cover 30. The distal end 94 can form a portion of the side extension 66 closest to the shroud 28.
-
Cover 30 includes notch 100. Notch 100 extends into cover body 96. Notch 100 extends in the forward direction from the cover base 68 of the cover body 96 in the example shown. Notch 100 extends forward while side extension 66 extends rearward. The notch 100 is formed on an opposite side of cover 30 from the side extension 66 in this example, the side extension 66 being at least partially on cover top side 62 and notch 100 being formed on a bottom side of cover 30.
-
The notch 100 is configured to accept part of the chassis 32 with the cover 30 mounted. The notch 100 is formed by the rim 70 of the cover 30. It is the rim 70 that forms the side extension 66, with the rim 70 being longer along the side extension 66 relative to the rest of the rim 70. In the example shown, the cover 30 is configured such that cover top side 62 extends further rearward than a bottom side of the cover 30, with the notch 100 formed in the bottom side.
-
FIG. 4A is a cross-sectional isometric view showing a portion of sprayer 10 with the shroud 28 mounted. FIG. 4B is a cross-sectional isometric view showing a portion of sprayer 10 with the shroud 28 partially exploded away from chassis 32. A portion of the interior of the pump module 12 is shown in FIGS. 4A and 4B.
-
Portions of controller 88 are shown within the interior of the pump module 12. The controller 88 is covered by the shroud 28 with the shroud 28 mounted to the chassis 32. Power cord 102 extends into the interior of the pump module 12. Power cord 102 is configured to provide electrical power to components of sprayer 10. Power cord 102 can connect to controller 88. Power cord 102 can be a standard electrical cord with a plug on its far end that connects to an electrical socket to provide power to the controller 88 to drive the electric motor to operate the pump 24 via the drive 38.
-
Power cord 102 is clamped between chassis 32 and shroud 28 to secure the power cord 102. In particular, the power cord 102 is clamped between the chassis 32 on a front side of the power cord 102 relative to pump module 12 and the shroud 28 on a rear side of the power cord 102 relative to pump module 12. Clamping the power cord 102 between shroud 28 and chassis 32 maintains the location and orientation of the power cord 102 relative to those components. As shown, the power cord 102 is clamped and wires 104 can extend to components of pump module 12 out of a sheath of the power cord 102 at a location internally within the pump module 12. The power cord 102 is configured to not be removable once clamped.
-
Power cord 102 includes collar 106. Collar 106 of power cord 102 is the portion of power cord 102 clamped between the chassis 32 and the shroud 28. Collar 106 can contact both chassis 32 and shroud 28 to be clamped between chassis 32 and shroud 28. Collar 106 interfaces with both chassis 32 and shroud 28.
-
Collar 106 can be formed as an enlarged portion of the power cord 102 relative to a portion of the power cord 102 adjacent to the collar 106 and outside of an interior of the pump module 12. The collar 106 can be formed as an enlarged sleeve. The wires 104 can extend through the collar 106 from outside of pump module 12 in an interior of pump module 12.
-
Collar 106 includes cord interface 108 which can interface with shroud interface 110 of the shroud 28. The cord interface 108 can additionally or alternatively interface with chassis interface 112 of chassis 32. Such interfaces can be a tongue and groove type interface to help secure the power cord 102 from being pulled out from its clamped position. As shown, the collar 106 includes a groove into which respective projections of the chassis 32 and/or the shroud 28 extend. The groove 114 forms the cord interface 108.
-
In the example shown, the shroud 28 includes shroud projection 116 that forms the shroud interface 110. The shroud projection 116 is formed as a shelf that can extend into the groove 114. In the example shown, the shroud projection 116 wraps at least partially around the collar 106. The shroud projection 116 can extend into the groove 114 on a rear side of the collar 106 and on one or both lateral sides of the collar 106.
-
In some examples, chassis interface 112 is formed by a surface of the chassis 32. The collar 106 can be pressed against the surface of the chassis 32 by the shroud 28. In some examples, the chassis 32 includes a projection that extends into the groove 114 to interface with the collar 106 within the groove 114. It is understood, however, that not all examples are so limited. In some examples, the chassis 32 can abut the collar 106 without having a projection that extends into the groove 114.
-
In examples in which both shroud 28 and chassis 32 include projections, the respective projections of the shroud 28 and the chassis 32 can be at the same vertical level. As such, the one or more projections of the shroud 28 and the one or more projections of the chassis 32 can both extend into the same groove 114 forming the cord interface 108. It is understood, however, that in various other examples the projections forming the shroud interface 110 and the chassis interface 112 can be at different vertical levels and extend into different grooves of the collar 106.
-
While collar 106 can be configured to receive a portion of chassis 32 and a portion of shroud 28, it is understood that not all examples are so limited. In some examples, the chassis interface 112 can be formed as one or more projections and the chassis interface 112 and shroud interface 110 can be formed as grooves. In some examples, the chassis interface 112 can be formed as a combination of groove and projection, with one of shroud interface 110 and chassis interface 112 formed as a groove to receive the projection of the cord interface 108, and the other one of the shroud interface 110 and the chassis interface 112 formed as a projection to be received by a groove of the cord interface 108. As such, in various examples, the collar 106 can extend into one or the other or both of the chassis 32 and the shroud 28 to mount the power cord 102.
-
In various examples, the collar 106 can receive or be received by one of shroud 28 and chassis 32 while abutting the other one of shroud 28 and chassis 32. For example, one of shroud 28 and chassis 32 can include a projection that extends into the groove 114 of the collar 106. The collar 106 can be tightly held between and by chassis 32 and shroud 28 to secure power cord 102. The collar 106 can abut the other one of chassis 32 and shroud 28, such as by abutting against a flat surface of the other one of chassis 32 and shroud 28.
-
Collar 106 being clamped between chassis 32 and shroud 28 provides significant advantages. The power cord 102 is held in place relative to components in the interior of pump module 12 by the clamping. Such a configuration prevents damage to the internal connections by power cord 102 such as due to pulling or tugging on power cord 102. The power cord 102 being clamped between shroud 28 and chassis 32 provides for ease of assembly and reduces part count as the power cord 102 is directly held by portions of the module body 20.
-
Power cord 102 does not pass through a portion of the stand 22 in this example. Power cord 102 does not pass through base plate 52 of stand. The power cord 102 is instead held directly between and by the shroud 28 and the chassis 32. Such a configuration provides for a simpler configuration that is easier to assemble and that provides sturdy holding of the power cord 102.
-
FIG. 5A is a partial isometric view or pump module 12 showing a back side of pump module 12. FIG. 5B is a rear elevational view showing a portion of pump module 12. As shown, transfer hose 36, which extends between pump 24 and filter manifold 26, extends out from within the shroud 28 when traveling between the pump 24 and the filter manifold 26. Specifically, transfer hose 36 extends out from an interior of pump module 12 through passage 118. The passage 118, in various examples, fully surrounds the transfer hose 36 as the transfer hose 36 extends through the passage 118.
-
In the example shown, shroud 28 defines a top side and both lateral (left and right) sides of the passage 118. Stand 22 defines a lower side of the passage 118. In this way, the passage 118 surrounds the transfer hose 36 on top, bottom, left, and right sides. The top, left, and right sides of the passage 118 are formed by a shroud notch 120 in the shroud 28. The shroud notch 120 is U-shaped in the example shown, though it is understood that various other shapes are possible.
-
In the example shown, a bottom side of the passage 118 is defined by the stand 22 and the shroud 28 defines the other sides of the passage 118.
-
The bottom side of the passage 118 is formed by base plate 52 of the stand 22. The legs 50 of the stand 22 can be connected to the base plate 52. In various examples, the chassis 32 is mounted on the base plate 52 to connect to stand 22. For example, the base portion of the chassis 32 can mount to the base plate 52. In some examples, the stand 22 includes two tubes forming four legs 50 that are joined together in their middles by being respectively connected (e.g., by welding) to the base plate 52.
-
As shown, the passage 118 surrounds, but does not contact, the transfer hose 36. The transfer hose 36 is not fixed in place by the shroud 28. The passage 118 can protect the transfer hose 36. The transfer hose 36 is not clamped by the shroud 28 and/or the stand 22 but those structures can nevertheless surround and help protect the transfer hose 36. As such, the transfer hose 36 remains flexible between the pump 24 and the filter manifold 26.
-
FIG. 6 is an enlarged isometric view showing a portion of the interior of the pump module 12. The shroud 28 is removed for clarity. FIG. 7A is a first isometric view of board mount 122. FIG. 7B is a second isometric view of board mount 122. FIGS. 6-7B are discussed together. Shroud 28 attaches to the backside of the chassis 32 with fasteners, such as threaded bolts that extend through parts of the shroud 28 and into threaded holes of the chassis 32.
-
Board mount 122 is disposed in an interior of the pump module 12. Capacitor board 124 is mounted to board mount 122. Capacitor board 124 can be a circuit board, such as a printed circuit board. At least one capacitor 126 is mounted on the capacitor board 124. Such a capacitor board 124 may be needed in only some geographies such that is not ideal to integrate the capacitor 126 into the controller 88 for all units manufactured. The capacitor board 124 can be installed for the geographies requiring such a capacitor 126.
-
Board mount 122 facilitates the modular mounting of the capacitor board 124 for those embodiments that need such a capacitor 126. The board mount 122 is mounted on the top of the motor 127 and can contact a cylindrical housing 128 of the motor 127. Board mount 122 is disposed vertically above the motor 127 in the example shown. The board mount 122 can be disposed directly vertically above the motor 127. In the example shown, the board mount 122 is disposed over the motor 127 such that the board mount 122 radially overlaps with the motor 127 relative to an axis of rotation of a rotor of the motor 127. Board mount 122 can be formed from polymer, among other options.
-
In the example shown, tie rod 130 assists in supporting the motor 127 within the pump module 12. The tie rod 130 can help secure the motor 127 within the pump module 12. Tie rod 130 can be connected to chassis 32. The tie rod 130 can be connected to an end of motor 127 opposite an end of the motor 127 oriented towards the chassis 32. The tie rod 130 can be connected to an end of motor 127 opposite an end of the motor 127 providing the rotational output to drive 38. The tie rod 130 can span lengthwise along the motor 127.
-
The board mount 122 at least partially surrounds tie rod 130. In the example shown, the tie rod 130 can extend fully longitudinally through board mount 122. In some examples, tie rod 130 extends outward from board mount 122 in the rearward longitudinal direction. In some examples, tie rod 130 can extend outward from board mount 122 in both the rearward and forward longitudinal directions.
-
In the example shown, part of the board mount 122 extends between the tie rod 130 and the housing 128 of the motor 127. A portion of the board mount 122 can be disposed directly between the tie rod 130 and the housing 128 of the motor 127. Part of the board mount 122 can extend longitudinally forward beyond the motor 127. Part of the board mount 122 can extend longitudinally forward of an end face of the housing 128.
-
Board mount 122 includes a mount body 132, grip 134, lock 136, receiver 138, and board interfaces 140. Mount body 132 is a main body portion of the board mount 122. Mount body 132 includes board portion 142 and mount portion 144. The board portion 142 is spaced vertically from the mount portion 144. In the example shown, receiver 138 is formed as a notch between the mount portion 144 and the board portion 142.
-
Lock 136 is formed on mount portion 144 in the example shown. The lock 136 can include a tab 146 which can flex when the board mount 122 is being slid longitudinally relative to the cylindrical housing 128 of the motor 127 and then can spring inward after having passed the front end of the motor 127 housing 128 such that an end of the tab engages the front side of the housing 128 to lock the board mount 122 in place. The tab 146 of the lock 136 is configured to be manually pushed in (e.g., by a finger of a user) to disengage from the front side of the electric motor 127 to allow the board mount 122 to slide relative to the electric motor 127 to be removed.
-
A portion of chassis 32 can be received by the board mount 122 in various examples. The chassis 32 can extend into the receiver 138 of the board mount 122 with the board mount 122 installed in the pump module 12. The receiver 138 can be formed as a slot disposed between the mount portion 144 and the board portion 142 of the board mount 122.
-
Board portion 142 of the board mount 122 is configured to support the capacitor board 124. Board interfaces 140 are formed on one side of the board portion 142. The board interfaces 140 are formed on a side of board portion 142 oriented away from motor 127 with the board mount 122 installed. Capacitor board 124 is mounted to board mount 122 at board interfaces 140. Board interfaces 140 can be formed as bores, such as threaded bores, threaded projections, a combination thereof, or other structure that connects between board mount 122 and capacitor board 124.
-
Grip 134 is formed on board portion 142. Grip 134 is configured to interface with tie rod 130 to mount board mount 122 on tie rod 130. In the examples shown, grip 134 includes fingers 148 and positioners 150. Fingers 148 are configured to wrap at least partially around tie rod 130 to hold onto the tie rod 130. Positioners 150 are configured to interface with tie rod 130 and can provide support between tie rod 130 and board portion 142. Positioners 150 can include a curved base in which a curved exterior of the tie rod 130 is disposed. The positioners 150 can rest on the tie rod 130. The positioners 150 can be disposed on a top side of the tie rod 130 while the fingers 148 wrap around a bottom side of the tie rod 130.
DISCUSSION OF NON-EXCLUSIVE EXAMPLES:
-
The following are non-exclusive descriptions of possible examples of the present invention.
-
Example 1. A pump module for a spray system for spraying paint, the pump module comprising: a chassis; a piston pump; an electric motor which outputs rotational motion; a drive at least partially located within the chassis, the drive converting the rotational motion output by the electric motor into linear reciprocating motion that operates the piston pump; and a cover mounted to the chassis, the cover covering at least a portion of the drive, wherein the cover includes a side extension that extends further rearward on a first side of the cover than on a second side of the cover disposed opposite the first side.
-
Example 2. The pump module of example 1, wherein the cover is formed as a single piece of molded plastic.
-
Example 3. The pump module of any one of examples 1 and 2, wherein the first side is a first lateral side of the cover and the second side is a second lateral side of the cover.
-
Example 4. The pump module of any one of examples 1-3, wherein the first side is on a right side of the paint sprayer and the second side is on a left side of the paint sprayer with the piston pump disposed at a front end of the paint sprayer.
-
Example 5. The pump module of any one of example 1-4, wherein the first side is a top side of the cover and the second side is a bottom side of the cover .
-
Example 6. The pump module of any one of examples 1-4, the side extension extends further rearward on a third side of the cover than on a fourth side of the cover.
-
Example 7. The pump module of example 6, wherein the third side is a top side of the cover and the fourth side is a bottom side of the cover.
-
Example 8. The pump module of any example 1, wherein the side extension forms a corner of both of a top side of the cover and a lateral side of the cover.
-
Example 9. The pump module of any one of examples 1-8, wherein the cover includes a notch on a bottom side of the cover, the notch accepting part of the chassis when the front cover is mounted on the chassis.
-
Example 10. The pump module of any one of examples 1-9, wherein the chassis includes a window that opens into a chamber within which the drive is at least partially, the window defined by an extension of the chassis that projects from a main body portion of the chassis, the drive at least partially exposed though the window with the cover dismounted from the chassis.
-
Example 11. The pump module of example 10, wherein the cover wraps around the extension to at least partially overlap with the extension on each of a top side of the extension, a bottom side of the extension, a first lateral side of the extension, and a second lateral side of the extension.
-
Example 12. The pump module of any one of examples 1-11, further comprising: a shroud that at least partially encloses the electric motor; wherein a gap is formed laterally between a first lateral side of the chassis and a first lateral side of the shroud such that an interior of the pump module is exposed through the gap; and wherein the side extension projects over the chassis and towards the shroud to at least partially cover the gap.
-
Example 13. The pump module of example 12, wherein a distal end of the side extension is aligned with a shroud rim of the shroud such that the distal end and the shroud rim longitudinally overlap.
-
Example 14. The pump module of example 13, wherein a rim of the cover at the distal end longitudinally overlaps with the shroud rim.
-
Example 15. A paint sprayer comprising: the pump module of any one of examples 1-14; and a spray gun fluidly connected to the pump to receive paint output by the pump.
-
Example 16. A pump module for a spray system for spraying paint, the pump module comprising: a chassis; a piston pump supported by the chassis; an electric motor which outputs rotational motion; a drive at least partially located within the chassis, the drive converting the rotational motion output by the electric motor into linear reciprocating motion that operates the piston pump; a shroud that at least partially encloses the electric motor; and a power cord configured to provide electrical power to the pump module, the power cord including a collar clamped between the shroud and the chassis.
-
Example 17. The pump module of example 16, wherein the collar is enlarged relative to a portion of the power cord adjacent the collar and outside of an interior of the pump module.
-
Example 18. The pump module of any one of examples 16 and 17, wherein the collar receives a portion of the shroud.
-
Example 19. The pump module of example 18, wherein a projection of the should extends into a groove of the collar.
-
Example 20. The pump module of example 19, wherein the projection wraps at least partially around the collar.
-
Example 21. The pump module of any one of examples 19 and 20, wherein the projection extends around a rear side of the collar and at least one lateral side of the collar.
-
Example 22. The pump module of any one of examples 19 and 20, wherein the projection extends around a rear side of the collar, a first lateral side of the collar, and a second lateral side of the collar.
-
Example 23. The pump module of any one of examples 18-22, wherein the collar is disposed between a shroud interface of the shroud that interfaces with the collar and the piston pump.
-
Example 24. The pump module of any one of examples 16-23, wherein the collar receives a portion of the chassis.
-
Example 25. The pump module of any one of examples 16-24, wherein the shroud is mounted to the chassis and is not mounted directly to the electric motor.
-
Example 26. The pump module of example 16, wherein the collar is an enlarged sleeve having a cord interface that mates with one or both of a shroud interface of the shroud and a chassis interface of the chassis.
-
Example 27. The paint sprayer of example 26, wherein the mating between the collar and the one or both of the shroud interface and the chassis interface comprises a tongue and groove interface.
-
Example 28 A paint sprayer comprising: the pump module of any one of examples 16-27; and a spray gun fluidly connected to the pump to receive paint output by the pump.
-
Example 29. A pump module for a spray system for spraying paint, the pump module comprising: a chassis; a piston pump supported by the chassis; a filter manifold; an electric motor which outputs rotational motion; a drive at least partially located within the chassis, the drive converting the rotational motion output by the electric motor into linear reciprocating motion that operates the piston pump; a shroud that at least partially encloses the electric motor; and a transfer hose that routes paint output from the pump into the filter manifold, wherein the shroud defines a passage through which the transfer hose extends between the pump and the filter manifold.
-
Example 30. The pump module of example 29, wherein the shroud defines at least three sides of the passage.
-
Example 31. The pump module of example 30, wherein the at least three sides includes an upper side, a first lateral side, and a second lateral side.
-
Example 32. The pump module of any one of examples 29-31, wherein the transfer hose is not fixed in place by the shroud.
-
Example 33. The pump module of any one of examples 29-32, wherein the shroud includes a shroud notch, the shroud notch extending upward from a bottom edge of the shroud, the shroud notch defining the passage.
-
Example 34. The pump module of any one of examples 29-33, further comprising: a stand having at least two legs, wherein the stand forms at least one side of the passage.
-
Example 35. The pump module of example 34, wherein the at least one side is a lower side of the passage.
-
Example 36. The pump module of any one of examples 34 and 35, wherein the stand comprises a plate that connects with each of the at least two legs and which forms the at least one side of the passage.
-
Example 37. The pump module of example 36, wherein the chassis is directly mounted to the plate.
-
Example 38. A paint sprayer comprising: the pump module of any one of examples 29-37; and a spray gun fluidly connected to the pump to receive paint output by the pump.
-
Example 39. A pump module for a spray system for spraying paint, the pump module comprising: a chassis; a piston pump; an electric motor which outputs rotational motion; a drive at least partially located within the chassis, the drive converting the rotational motion output by the electric motor into linear reciprocating motion that operates the piston pump; and a board mount on which a capacitor board is mounted, the board mount mounted on a housing of the electric motor.
-
Example 40. The pump module of example 39, wherein the board mount comprises a lock that fixes a position of the board mount on the electric motor, the lock engaging with the housing of the electric motor.
-
Example 41. The pump module of example 40, wherein the lock engages a longitudinal end of the housing oriented towards an end of the pump module at which the pump is mounted.
-
Example 42. The pump module of any one of examples 40-41, wherein the lock includes a tab that engages the housing of the electric motor.
-
Example 43. The pump module of any one of examples 39-42, further comprising: a tie rod that secures the electric motor, wherein the board mount is mounted on the tie rod.
-
Example 44. The pump module of example 43, wherein the board mount includes a grip that engages the tie rod.
-
Example 45. The pump module of example 44, wherein the grip includes at least one finger that wraps at least partially around the tie rod.
-
Example 46. The pump module of any one of examples 44 and 45, wherein the grip includes at least one positioner having a curved face that interfaces with a curved exterior of the tie rod.
-
Example 47. The pump module of any one of examples 39-46, wherein a portion of the board mount is disposed directly between the tie rod and the housing of the electric motor.
-
Example 48. The pump module of any one of examples 39-47, wherein the board mount radially overlaps with the housing of the electric motor and the board mount axially overlaps with the housing of the electric motor.
-
Example 49. The pump module of any one of examples 39-48, wherein a portion of the chassis is disposed in a slot formed between a mount portion of the electric motor and a board portion of the electric motor, the mount portion interfacing with the housing of the electric motor and the capacitor board mounted on the board portion.
-
Example 50. A paint sprayer comprising: the pump module of any one of examples 39-49; and a spray gun fluidly connected to the pump to receive paint output by the pump.
-
Components that are described as connected are not necessarily in contact with each other without an intermediary component, unless it is specified that they are directly connected, in which case the two components are in contact with each other. Although not necessarily stated, any two materials that are contacting in any of the figures can be described (e.g., specifically claimed) as directly connected, and any two components described herein as being connected can be described (e.g., specifically claimed), optionally, as directly connected.
-
Optional language is used herein describing what "can" or "may" be present, or what "various" embodiments or examples may include, not what is or must necessarily be present. Therefore, if in reference to an embodiment or example, it is stated that an aspect "may" or "can" be present, then that option can be included, or left out, of the embodiment or example, particularly in a claim. Each sentence or paragraph can refer to multiple, independent aspects. A claim can be amended with a select word or phrase from a sentence or paragraph without taking the whole sentence or paragraph.
-
The present disclosure uses multiple examples to demonstrate various inventive aspects. The inventive scope of this disclosure is not necessarily limited to any one of these embodiments, nor to all of them in just the manner shown and/or described. Rather, the inventive aspects demonstrated herein can be implemented in various other manners. One aspect or feature shown or described from one embodiment could be implemented on another embodiment in this disclosure even if not shown or described for that embodiment, or various embodiments not illustrated herein. The embodiments illustrated and/or discussed are intended to be illustrative and not limiting, and the described and/or illustrated features can be mixed and matched between different embodiments while including and excluding various features amongst the embodiments.
-
Components with common reference numbers can be structurally and functionally equivalent except to the limited extent specifically shown and/or described to be different. As such, aspects discussed and/or shown in connection with one embodiment can be present in another embodiment even if not discussed and/or shown for the other embodiment, particularly when common reference numbers are used.
-
While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.