SPRAY GUN APPLICATOR

A plural component applicator including a nozzle attached to a gun body, wherein the gun body comprises a manifold configured to receive a plurality of components based on operation of a trigger assembly, wherein the manifold is configured to separately deliver the plurality of components to a static mixer within the nozzle based on operation of the trigger assembly.

TECHNICAL FIELD

The present system relates in general to Applicator Spray Guns, and in particular to Applicator Spray Guns used for spraying two component sprays such as spray-on insulation foams and adhesives.

BACKGROUND OF THE INVENTION

Spray-on building insulation foams and adhesives are typically applied onto a roof using a spray gun (also known as an “applicator”). In the applicator two separate fluid streams meet and mix before they're sprayed onto the roof. Common problems with these conventional spray guns are that they often don't produce a consistent bead spacing or splatter coverage on the roof. As a result, some foam or adhesive is always wasted and more foam or adhesive is sprayed onto the roof than would be desirable.

It would instead be desirable to build systems that provide an even, predictable and uniform distribution of the spray foam or adhesive onto the roof. Such a system would increase efficiencies and permit faster installation with increased final quality. In addition, it would also be desirable to provide a spray foam or adhesive application onto a plurality of parallel locations simultaneously since spray foams and adhesives are typically applied in parallel lines along the roof. In addition, wind across the surface of the roof can cause problems with spray foam application. It would instead be desirable to dispense the spray foam or adhesive much closer to the roof's surface than is currently being done in the industry. This would allow for less material loss and a cleaner and more consistent application, thereby resulting in improved spray quality. It would also be desirable to gather time and motion information from one spray gun application that could be used with other spray gun applications in future. Recording such information (preferably including spraying times and corresponding spray gun movements) could be used to improve spray quality and aid in system troubleshooting.

As will be explained herein, the present system addresses these above concerns and provides solutions to remedy these problems.

SUMMARY OF THE INVENTION

In preferred aspects, the present system relates to a plural component spray gun applicator that can include a nozzle attached to a gun body. The gun body preferably comprises a manifold configured to receive a plurality of components based on operation of a trigger assembly, and the manifold is also configured to separately deliver the plurality of components to a static mixer located within the nozzle based on operation of the trigger assembly.

In other preferred aspects, the present system provides a spray applicator, comprising: (a) a fluid manifold having a first fluid chamber and a second fluid chamber; (b) a first valve permitting fluid flow into the first fluid chamber; (c) a second valve permitting fluid flow into the second fluid chamber, wherein both the first and second valves are received into the fluid manifold; (d) a handle assembly; (e) a nozzle attached to the handle assembly, wherein fluid flows out of the first and second fluid chambers and into the nozzle; and (f) a trigger assembly, wherein movement of the trigger assembly opens and closes the first and second valves; and wherein the handle assembly and trigger assembly are connected together around the manifold.

In preferred aspects, the manifold is snap-fit together and the manifold is in turn snap fit into the handle assembly and into the trigger assembly. The manifold is specifically configured to burst in an overpressure situation. The manifold is pressurized by fluid flow therethrough, but the handle and trigger assemblies are not pressurized by fluid flow therethrough. The advantage of this design approach is that the manifold can be designed and built to higher precision, whereas the handles and trigger assemblies can be manufactured with more relaxed tolerances, such that they can be built more cheaply. As such, only the manifold itself (which is a small component of the system in terms of material requirements) has to be built to precision high tolerances.

In preferred aspects, the present system also includes an accelerometer to detect movement of the spray applicator and an internal control unit. The internal control unit can be configured to power down the spray applicator after a predetermined passage of time with no detected movement, and/or it can log movement data of the spray applicator over time which can be downloaded for future use.

In other preferred aspects, a third fluid chamber can be added to the manifold such that air can be introduced into the mixture that is sprayed out of the applicator.

In yet other preferred aspects, the nozzle is connected to an elongated spray tube such that the operator can apply spray at a distance closer to the roof as (s)he walks across the roof. Optionally, this spray tube may be forked to terminate in dual streams. In addition, the spray tube may also terminate with a fan-shaped outlet to give a more desired spray pattern (or two fan-shaped outlets in the case of a dual stream embodiment).

DETAILED DESCRIPTION OF THE DRAWINGS

As shown inFIGS.1-10, a plural component applicator10can include a nozzle13attached to a gun body16, wherein the gun body16comprises a manifold19configured to receive a plurality of components22based on operation of a trigger assembly25, wherein the manifold19is configured to separately deliver the plurality of components22to a static mixer28within the nozzle13based on operation of the trigger assembly25.

In some embodiments, the plural component applicator10can provide that the gun body16comprises a rear hood31and handle34. In certain embodiments, the plural component applicator10can further provide that the manifold19is configured to snap fit into the handle34and rear hood31. In some embodiments, the plural component applicator10can provide that the rear hood31is configured to snap fit into the handle34as well.

In certain embodiments, the plural component applicator10can further include at least one temperature sensor37for sensing the temperature or the fluid(s) or for sensing ambient air temperature, or both.

In certain embodiments, the plural component applicator10can further provide that the trigger assembly25comprises a cam40configured to rotate against a rear external surface43of the manifold19. The cam face rotates against a bearing surface in a manner that moves the fulcrum to increase trigger lever moment as the trigger assembly25is actuated. This counteracts the increasing force of the needle valve springs as they are compressed, resulting on trigger forces that are more constant than would be encountered by a fixed trigger point.

Preferably, a position indicator that is integral to the trigger will tell the operator how far to pull the trigger based upon the level of fluid in the pressurized tanks. This prevents premature exhaustion of propellant from the tanks. In some embodiments, the plural component applicator10can provide that the trigger assembly25comprises a trigger46configured to increase a lever moment49based on actuation of the trigger46. According to some embodiments, the plural component applicator10can include a trigger lock mechanism64configured to prevent accidental actuation and dispensing. Specifically, trigger lock mechanism64may auto-engage such that the user is required to grasp fully around the handle to unlock the device. In some embodiments, the plural component applicator10can provide that the applicator comprises an integral hook70. According to some embodiments, the plural component applicator10can include a hand grip73, a finger shelf76, and surface texturing79.

In certain embodiments, the plural component applicator10can further include a plurality of needle valves52and springs55, wherein the lever moment49is configured to counteract an increasing force of the springs58based on actuation of the trigger46to thereby operate the needle valves52.

According to some embodiments, the plural component applicator10can include at least one optical indicator61, wherein the at least one optical indicator61is configured to optically transmit information related to battery power, trigger46actuation, fluid temperature conditions of both components, pressure conditions of both components, or combinations thereof. In preferred embodiments, temperature sensor37can be used to determine if fluid temperatures are within specified environmental ranges. This is important as spray application can typically not be carried out at excessively high or excessively low temperature ranges.

According to certain embodiments, the plural component applicator10can include a plurality of hoses67, wherein the hoses67are configured to enter the manifold19through the handle34. In some embodiments, the plural component applicator10can provide that the manifold19is configured to sacrificially and deterministically burst based on a material overpressure situation as described further below. In one embodiment, the manifold wall thickness is designed to fail at predetermined pressures. Preferably as well, the manifold fails in a manner that the fluid escapes forwards out of the nozzle, or out the rear of the manifold19.

For example, in certain embodiments, the plural component applicator10can provide that the manifold19comprises an internal pressure, and wherein the manifold19is configured to sacrificially and deterministically burst if an internal pressure of the manifold19reaches a pressure of 200 to 220 pounds per square inch or up to 300 pounds per square inch. In certain embodiments, the plural component applicator10can provide that the manifold19comprises a dividing wall154on a forward external surface103of the manifold19configured to segregate the first fluid91from the second fluid before contact with a static agitator of the static mixer28. In some embodiments, the plural component applicator10can include an o-ring seal15attached to the forward external surface103of the manifold19.

In preferred aspects, the manifold19is snap-fit together, and the handle assembly34and trigger assembly25are connected together around the manifold. Preferably, the handle and trigger assemblies25and35are snap-fit together around manifold. Only the manifold19is actually pressurized by fluid flow therethrough, whereas the handle assembly25and trigger assembly35are not pressurized by fluid flow therethrough. As a result, the manifold can be designed and built to higher precision, whereas the handles and trigger assemblies35and25can be manufactured with more relaxed tolerances, such that they can be built more cheaply. As such, only the manifold itself (which is a small component of the overall system in terms of material requirements) has to be built to precision high tolerances.

The plural component applicator10can include a first fluid chamber82configured to receive a first fluid91from a first fluid source88through a first fluid hose68based on operation of a trigger46; a second fluid chamber85configured to receive a second fluid from a second fluid source89through a second fluid hose69based on operation of the trigger46; a static mixer28configured to receive the first fluid91from the first fluid91chamber82and second fluid92from the second fluid chamber85and form a third fluid100, wherein the third fluid100is a mixture of the first and second fluid, a reaction product of the first and second fluid, or a combination thereof; and a nozzle tip14configured to output the third fluid100. In some embodiments, the plural component applicator10can include a nozzle13, wherein the nozzle13consists of a single piece nozzle13body comprising the nozzle tip14and the static mixer28. In some embodiments, the plural component applicator10can include a manifold19, wherein the manifold19comprises the first fluid91chamber82and second fluid chamber85. In further optional embodiments, additional chambers with additional fluids and gasses can also be added.

According to some embodiments, the plural component applicator10can include an internal control unit80housed within the gun body16configured to reduce a battery drain (from battery81) when the applicator is not in use and to store performance information. In other embodiments, internal control unit80further comprises an accelerometer configured to detect movement of the spray applicator. Preferably, internal control unit80is configured to power down the spray applicator after a predetermined passage of time with no detected movement. Preferably as well, the internal control unit logs movement data of the spray applicator over time and such movement data can be downloaded from the internal control unit (for example for quality control and training purposes). Other data may also optionally be logged, including product temperature data, pressure data, or other data as well. In addition, such other data may be read by an external LED reader.

In some embodiments, the plural component applicator10can include an internal control unit80and a gun body16, wherein the internal control unit80is removably attached to a top external surface106of the manifold19and within the gun body16. In certain embodiments, the plural component applicator10can provide that the internal control unit80comprises a first sensor38and a second sensor39. According to certain embodiments, the plural component applicator10can provide that the first sensor38is a temperature sensor37, pressure sensor, or combination thereof. In certain embodiments, the plural component applicator10can provide that the second sensor39is a temperature sensor37, pressure sensor, or combination thereof, wherein the first sensor38is configured to detect a first condition of the first fluid chamber82, and the second sensor39is configured to detect a second condition of the second fluid chamber85. In certain embodiments, the plural component applicator10can provide that the internal control unit80is a printed circuit assembly, wherein the printed circuit assembly comprises a button battery space109. According to certain embodiments, the plural component applicator10can provide that the internal control unit80comprises memory, wherein the memory is configured to store data received from the first sensor38and second sensor39. According to certain embodiments, the plural component applicator10can provide that the internal control unit80comprises I/O port109, wherein the I/O port109is configured to interface with an external computer system to output data from the memory to the computer system. According to certain embodiments, the plural component applicator10can provide that the internal control unit80comprises an accelerometer115. In certain embodiments, the plural component applicator10can provide that the accelerometer115is configured to power down the plural component applicator10based on a predetermined passage of time with no detected movement. According to certain embodiments, the plural component applicator10can provide that the accelerometer115is configured to store changes in motion in the memory. According to certain embodiments, the plural component applicator10can provide that the internal control unit80further comprises a plurality of optical indicators61. In some embodiments, the plural component applicator10can include comprising a rear hood31, wherein the rear hood31comprises grooves118for each of the plurality of optical indicators61.

The plural component applicator10can include a gun body16; a nozzle13; a handle34; a first hose configured to deliver a first fluid to a first chamber in a manifold19based on actuation of a trigger assembly25; and a second hose configured to deliver a second fluid to a second chamber in a manifold19based on actuation of the trigger assembly25; wherein actuation of the trigger assembly25is configured to rotate a cam40against a rear external surface43of the manifold19, thereby acting with a force against that of a first needle valve spring56and a second needle valve spring57.

In certain embodiments, the plural component applicator10can provide that the rear external surface43of the manifold19comprises a notch portion121, wherein the cam40comprises a perpendicular end portion124, wherein the perpendicular end portion124is configured to fit within the notch portion121based on the trigger46being fully actuated against the handle34. In certain embodiments, the plural component applicator10can provide that the cam40is directly connected to a trigger lock mechanism64. According to some embodiments, the plural component applicator10can provide that the cam40and trigger lock mechanism64form an integral piece127. In some embodiments, the plural component applicator10can provide that the trigger lock mechanism64comprises a fork portion130configured to slide within the handle34based on actuation of the trigger lock mechanism64. According to some embodiments, the plural component applicator10can provide that the trigger assembly25comprises a trigger46, wherein actuation of the trigger46is prevented by the trigger lock mechanism64when the trigger lock mechanism64is not actuated, and wherein actuation of the trigger46is enabled by actuation of the trigger lock mechanism64. In certain embodiments, the plural component applicator10can provide that rotation of the cam40against the external surface of the manifold19increases a trigger46moment directly with increasing opposite force from the first and second needle valve springs55.

According to some embodiments, the plural component applicator10can provide that the first hose is circumscribed by the handle34and connects to a manifold19bottom surface through a first hose fitting97and first hose o-ring94, wherein the second hose connects to the manifold19bottom surface through a second hose fitting98and second hose o-ring95. Preferably, a twist-fit connection is used to secure the hoses to the manifold.

In certain embodiments, the plural component applicator10can provide that the gun body16comprises a front face with a plurality of gun body front face notches139, wherein the manifold19comprises a corresponding set of protrusions142configured to fit through the gun body front face notches139. In some embodiments, the plural component applicator10can provide that the nozzle13comprises at least one alignment guide145and the gun body16comprises a visual indicator of an unlocked position149of the nozzle13relative to the gun body16, wherein the alignment guide145can be attached and removed from the gun body16when the alignment guide145is aligned with the visual indicator of the unlocked position148. In certain embodiments, the plural component applicator10can provide that the gun body16comprises a visual indicator of a locked position149of the nozzle13relative to the gun body16, wherein the alignment guide145can be moved from the unlocked position149to the locked position149to attach the gun body16. In some embodiments, the plural component applicator10can provide that the nozzle13comprises a nozzle back face151comprising nozzle notches159corresponding to the set of protrusions142, wherein when the nozzle13guide is in the unlocked position149, the nozzle notches159align with the protrusions142, wherein movement of the nozzle13guide from the unlocked to the locked position149moves the nozzle notches159away from the protrusions142and locks the nozzle13to the gun body16by placing the nozzle back face151between the protrusions142and the gun body front face136.

FIGS.11A and11Bare simplified perspective and elevation views of a three fluid component manifold100. In this embodiment, the same trigger assembly described above can be used to now simultaneously open flow into three separate internal chambers101A and101B and102. As illustrated, chamber101A is connected to liquid hose67A, chamber101B is connected to liquid hose67B and chamber102is connected to air hose110. This operation is similar to how needle valves52opened to allow fluid into the first and second fluid chambers described above in the embodiment ofFIGS.1to10. In preferred embodiments, a third valve is now included to open the third chamber102. This valve may been a needle valve as described above, a spool valve, or any other suitable type of valve. In this three component embodiment of the manifold, air can be entering the third chamber through air hose110, and each of the two components of the spray-on insulation or adhesive can enter manifold100through fluid hoses67A and67B. The advantage of this three component spray is that the addition of air may be used to increase bubbling or splattering of the spray-on application. It is to be understood that chambers101A,101B and102are illustrated conceptually inFIGS.11A and11Band that the sizes and placements of the chambers may be varied. In addition, the chamber102may meet chambers101A and101B at any location within the spray gun, including at the end of the manifold itself. The size of the third chamber102may also be adjustable and its size may be set to best correspond to the particular chemical components that are passing through the adapter spray gun. The addition of air into the sprayed mixture leaving the gun is that it will create more of a splatter thereby increasing material coverage area.

FIG.12Ais a perspective view of an elongated spray tube150attached onto the nozzle13of the applicator10. This spray tube150is preferably made from a semi-rigid piece of plastic tubing. The advantage of spray tube150is that it better defines the pattern of material dispensed. As such, an operator can dispense material along well defined lines. Another advantage of spray tube150is that the mixed spray exits applicator10at a location much closer to the roof surface. This permits the operator to walk upright without having to bend over during the spraying. Also, directing the spray from a location closer to the roof itself prevents accidental splatter in unwanted locations. This is especially beneficial when working in the wind on top of a building.

FIG.12Bis a perspective view of an elongated spray tube160terminating in dual streams at its ends162and164. Spray tube160operates similar to spray tube150described above, however, the dual ends permits the operator to walk over the roof surface applying spray in two parallel lines. This saves considerable time. An optional spacer166can be used to hold ends162and164a preferred distance apart. This is beneficial because spray lines are preferred distances apart (with the spacing being dependent upon the particular components being sprayed). In optional preferred embodiments, spacer166is adjustable such that the preferred spacing between ends162and164can be set at the start of the job. In various embodiments, the spray tubes160,162and164can have different or similar lengths, all depending upon user preference. The dual streams highly improves consistency of bead spacing and helps improve the quality of the installation. Tube160may be a disposable or non-disposable component, as desired.

FIG.13is a perspective view of a fan-shaped outlet180at the end of spray tube150or160. The advantage of fan-shaped outlet180is that by moving fan tip outlet180closer to the applied surface reduces the material waste due to environmental conditions. In addition, it provides a more ergonomic application method so the individual applying the material does not need to bend over to move the applicator closer to the surface on which the material is applied.

FIGS.14A and14Bschematically illustrate a spool valve200suitable for use in the present manifold in place of the needle valves52. Spool valve200has a laterally moveable plunder202and a pair of disks204and206. Plunger202is preferably moved electrically, pneumatically or manually. When the plunger202holds disks204and206as shown inFIG.14A, the flow is closed.FIG.14Bshows plunger202moved to the left such that disks202and204no longer block the flow paths, such that the fluid components passing through hoses67are directed into the first and second fluid chambers101A and101B in the applicator (such that they will mix in the applicator and are then directed out of the nozzle13of the spray gun applicator). Lastly,FIG.14Ccorresponds to the three chamber embodiment of the present system, showing air passing into the air chamber. As can be seen, plunger202now opens all three chambers101A,101B and102by moving disks204,206and205. It is to be understood that the spool valve ofFIGS.14A,14B and14Cis only exemplary and that other embodiments of spool valves (and other valves) are all encompassed by the present invention.