Spray gun with simultaneously removable valve tip and valve seat

Abstract: A coating dispenser such as a spray gun which is adapted for the application of a protective coating material onto metal can bodies, comprises a gun body (12) formed with a liquid passageway (14) which carries the valve stem (20) of a needle valve (18). The lowermost end or valve tip (22) of the needle valve (18) and a valve seat (6) are carried within a valve seat block (24) which is secured to the base of the gun body (12). A threaded connection is provided between the valve tip (22) in the valve seat block (24), and the valve stem (20) within the gun body (12), so that the valve tip (22), valve seat (60) and valve seat block (24) can be removed and replaced as a unit when the valve tip (22) and/or valve seat (60) becomes worn. Pins (40,58) connected to the valve stem (20), and to the valve tip (22), are carried within slots (42,44,48,50) in the gun body (12) and valve seat block (24), respectively. These pins (40,58) prevent rotation of the valve stem (20) relative to the gun body (12) and the valve tip (22) relative to the valve seat block (24) when they are threaded into and out of engagement with one another.

Description: This invention relates to a coating dispenser for use in applying coating material in high speed production lines having a valve tip and valve seat which are removable as a unit or separately for repair or replacement without disturbing the coating supply line, electric and/or pneumatic lines and the mounting structure associated with coating dispenser. A variety of products produced on high speed production lines require the application of coating material to form a protective layer thereon. For example, the production of metal cans involves dispensing a thin film of lacquer or other protective coating onto the can ends or can bodies to protect the contents of the can against metal contaminants. Commercially available lines for the production of metal cans run at speeds on the order of about 400 to 700 cans per minute, and for some applications a coating dispenser such as a spray gun must be turned on and off at the frequency of the cans moving past the spray gun. Spray guns for coating the ends and/or interior of metal cans are disclosed, for example, in documents US-A-4886013 and US-A-4430886. Spray guns of this type have proven to be effective in applying the desired protective coating onto the ends and/or interior of metal cans, even at high line speeds, but the valve mechanism associated with such spray guns which starts and stops the flow of coating material to the cans eventually wears out after a large number of cycles. Periodically, the valve tip, valve seat, seals and other elements of the valve mechanism of the spray gun must be replaced because of wear. Maintenance of the spray guns employed in high speed production lines such as can coating lines has been a problem in the past. The downtime required to repair or replace worn elements of spray guns is costly, particularly considering the high speed of operation of the production lines in which the spray guns are utilised. One solution to this problem has been to employ spray guns which are modular in construction to reduce the time required for the repair or replacement of various components of the coating apparatus, particularly the valve mechanism and associated seat which turns on and off the flow of coating material discharged from the gun. US-A-3490701 discloses a valve assembly which may be disassembled quickly so that the various components may be cleaned when necessary and which is effective to prevent clogging of the material being sprayed. One problem with spray guns of this type is that such repairs must be effected "off line", i.e. with the spray gun removed from the production line. This requires the coating supply lines, electric lines and/or air lines associated with the gun to be disconnected, as well as the mounting structure which retains the spray gun in position with respect to the object such as metal cans moving therepast. After the spray gun is repaired, it must then be reattached to the mounting structure and to the various supply lines before operation of the can production line can be resumed. These delays are costly and there is a need for reducing the time required for the repair or replacement of various parts of spray guns used in metal can manufacturing lines and other high volume production lines. A spray gun valve in accordance with the invention comprises a valve seat block having a discharge bore with a valve seat at the outlet thereof, the valve seat block being releasably connected to the spray gun body so that the discharge bore is in communication with a passageway in the spray gun body, and a reciprocable valve stem carried within the passageway, the valve stem having a valve tip which is engageable with the valve seat for controlling the flow of material through the discharge bore, characterised in that the valve tip is releasably connected to the valve stem and in that means are provided for retaining the valve tip within the valve seat block so that the valve tip and the valve seat block can be simultaneously connected to, or disconnected from, the valve stem and the spray gun body respectively. The valve stem may comprise upper and lower portions having matchingly threaded ends by which the upper and lower portions may be connected. The upper end of the valve tip and the lower end of the valve stem, or of the lower portion thereof, may have matching threads by which the valve stem and the valve tip may be connected. In such an arrangement the valve tip and the valve seat can be removed and replaced as a unit when either element becomes worn. Conveniently, a first pin may be mounted to the valve stem and is engageable with at least one longitudinal slot formed in the spray gun body and a second pin may be mounted to the valve tip and is engageable with at least one longitudinal slot formed in the valve seat block, the first pin being effective to substantially prevent rotation of the valve stem relative to the spray gun body and the second pin being effective to substantially prevent rotation of the valve tip relative to the valve seat block during connection or disconnection of the valve stem and the valve tip. The valve seat block may incorporate means adapted to engage the second pin so as to retain the valve tip within the valve seat block. Appropriately the spray gun body and the valve seat block maybe provided with means to prevent rotation of the valve seat block relative to the spray gun body. The valve tip may comprise a section having a first ball at one end and a second ball at the opposite end, the second ball being shaped to mate with the valve seat, and the means for releasably connecting the valve tip and the valve stem comprises a hollow collet mounted to the lower end of the valve stem and having an aperture which is at least partially elastically deflectable so as to receive the first ball of the valve tip within the hollow interior of the collet. This arrangement permits the needle valve stem extension and valve seat to be separately removed from the gun body without disturbing the placement of the gun body or remainder of the spray gun. This invention is therefore predicated upon the concept of permitting repair and/or replacement of the valve tip and associated valve seat of the spray gun, as a unit, without disturbing the remainder of the spray gun during the replacement process. The coating supply lines, electric or pneumatic lines and mounting structure for the spray gun can all remain in place as the valve tip and valve seat are removed and replaced. It has been found that the valve tip and valve seat elements are among the parts of the spray gun which are most susceptible to wear and/or failure, and thus it is desirable to permit their repair or replacement as quickly as possible and with the least amount of disruption to the production line. The invention will now be described by way of example with reference to the accompanying drawings, wherein: Fig. 1 is an elevation view, in partial cross section, of a spray gun employing the removable valve seat block in accordance with the invention; Fig. 2 is a cross section view along line 2-2 of Fig. 1; Fig. 3 is a cross section view along line 3-3 of Fig. 1; Fig. 4 is a disassembled, elevation view in partial cross section of the lowermost portion of the coating dispenser shown in Fig. 1; Fig. 5 is a plan view along line 5-5 of Fig. 4; Fig. 6 is an elevation view, in cross section, of a spray gun similar to that in Figure 1 but having a different connection means between the valve stem and the valve tip. Referring to Fig. 1, a spray gun 10 comprises a gun body 12 formed with a liquid passageway 14 which discharges liquid coating material through a nozzle 16 communicating with the body 12. A needle valve 18 is axially movable within the liquid passageway 14 to control the flow of liquid to the nozzle 16. This invention is directed to the construction of the lower portion of the spray gun 10, and to the needle valve 18. The needle valve 18 is formed with a two-piece valve stem 20 carried within the liquid passage-way 14 of dispenser body 12, and a valve tip 22 carried within a valve seat block 24 as described below. The valve stem 20 includes an upper portion 26 and a lower portion 28 which are axially movable along the liquid passageway 14, as described in more detail below. The upper portion 26 of valve stem 20 has a flange 30 mounted to its top end, a threaded lower end 32 and a sleeve 34 located intermediate the flange 30 and threaded lower end 32. The lower portion 28 of valve stem 20 is tubular in shape having an internally threaded upper end 36 and a lower end which mounts a threaded extension 38. The upper and lower portions 26, 28 of the valve stem 20 are removably interconnected to one another by threading the lower end 32 of upper portion 26 into the internally threaded upper end 36 of the lower portion 28. A roll pin 40 is fixedly mounted to the lower portion 28 of valve stem 20. A pair of opposed, longitudinally extending slots 42 and 44 are formed in the dispenser body 12 on either side of the liquid passageway 14, each of which receive one end of the roll pin 40 mounted to the valve stem 20. The roll pin 40 is axially movable within the slots 42, 44 as the valve stem 20 is reciprocated within the liquid passageway 14, as described below. But rotation of the valve stem 20 with respect to the dispenser body 12 is substantially prevented by engagement of the ends of the roll pin 40 with the edges of slots 42, 44, for purposes to become apparent below. Referring now to the lower portion of Fig. 1, and Figs. 2-5, the construction of the valve seat block 24 of this invention is illustrated in detail. The valve seat block 24 is formed with a stepped throughbore 46 and a pair of longitudinally extending slots 48 and 50 on either side of the throughbore 46. The valve tip 22 of the needle valve 18 is located within the stepped throughbore 46 and is formed with an internally threaded bore 47 at its upper end which is mateable with the threaded extension 38 of valve stem 20, as described below. The lower end of valve tip 22 which comprises the needle valve end is ball-shaped and is engageable with a correspondingly formed valve seat 60. A roll pin 58 is fixedly mounted to the valve tip 22, and the opposed ends of this roll pin 58 extend within the slots 48, 50 adjacent to the stepped throughbore 46. The roll pin 58 permits axial movement of the valve tip 22 along the stepped throughbore 46 with respect to a valve seat 60 mounted to or integrally formed with the valve seat block 24 at the base of throughbore 46. Rotation of the valve tip 22 relative to the valve seat block 24 is substantially prevented, however, by engagement of the roll pin 58 with the edges of the slots 48, 50 in valve seat block 24. The valve tip 22 is retained within the stepped throughbore 46 by an O-ring 61 which is interposed between an overhanging, annular flange 62 formed at the top of the valve seat block 24, and the roll pin 58. The flange 62 is formed with opposed slots 63, 64 which permit insertion of the ring 61 within the interior of the valve seal block 24, in between the flange 62 and roll pin 58. In the event of an upward movement of the valve tip 22, the ring 61 engages the overhanging flange 62 and the roll pin 58 contacts the ring 61, thus retaining the valve tip 22 within the valve seat block 24. The lower portion of the wall of valve seat block 24 is formed with external threads which are adapted to mate with the internal threads of a nozzle nut 65. The upper portion of the wall of valve seat block 24 is formed with flats 66 adapted to receive a tool such as a wrench, and an annular shoulder 68 which provides a seat for the lower flange 70 of a retaining nut 72. This retaining nut 72 has internal threads which engage the external threads of a dispenser body extension 74 projecting downwardly from the base of dispenser body 12. Preferably, the extension 74 has a recess which carries an 0-ring 76 engageable with the top surface of valve seat block 24. At least two locking pins 78 project downwardly from the extension 74 which are engageable with slots 80 formed at the top end of the valve seat block 24. See Figs. 4 and 5. The valve seat block 24, including the valve tip 22 and valve seat 60, can be assembled and disassembled as a unit from the dispenser body 12 quickly and easily and without disturbing the remainder of the spray gun 10. With reference to Figs. 1 and 4, an assembly operation proceeds as follows. Initially, a new O-ring 76 is inserted within the recess at the base of the dispenser body extension 74 to ensure a fluid-tight seal is created between the extension 74 and the valve seat block 24. The valve tip 22 is then threaded onto the valve stem 20 of needle valve 18 by engagement of the threaded extension 38 of the lower portion 28 of valve stem 20 with the internally threaded bore 47 at the top end of the valve tip 22. The flats 66 on the outside of valve seat block 24 can be utilised to assist in threading the valve tip 22 and valve stem 20 together using a tool such as a wrench (not shown). As described above, the valve stem 20 is substantially prevented from rotating within the gun body 12 because of the engagement of roll pin 40 with the edges of slots 42, 44 in the gun body 12, and valve tip 22 is substantially prevented from rotating within the valve seat block 24 because of the engagement of roll pin 58 with the slots 48, 50 in the valve seat block 24. With the valve stem 20 and valve tip 22 thus maintained rotatably fixed relative to the gun body 12 and the valve seat block 24, the interconnection of the valve stem 20 and valve tip 22 can proceed until the top surface of the valve tip 22 engages the bottom surface of valve stem 20. In this position, the top of valve seat block 24 is located adjacent the dispenser body extension 74, with the O-ring 76 interposed therebetween. As viewed in Fig. 1, the extension 38 of the valve stem 20 is allowed to bottom out against the base of the threaded bore 47 in the valve tip 22, before the valve seat block 2 contacts the dispenser body extension 74, due to the axial movement of the valve stem 20 which is permitted within the liquid passageway 14. As viewed in Figs. 2 and 3, the slots 42,44 in the gun body 12, and, to a lesser extent, the slots 48, 50 in the valve seat block 24, are larger in dimension than the diameter of the roll pins 40 and 58, respectively. That is, the dimension or distance between the opposed edges 110 and 112 of each slot 42, 44 in gun body 12 is greater than the diameter of roll pin 40, and the distance between the opposed edges 114 and 116 of each slot 48, 50 in the valve seat block 24 is greater than the diameter of roll pin 58. Limited rotation of the roll pin 40 within slots 42 and 44 in the gun body 10, and limited rotation of the roll pin 58 within slots 48 and 50 in the valve seat block 24, is thus permitted so that the locking pins 78 at the base of dispenser body extension 74 can be inserted within the slots 80 formed in the top of valve seat block 24. In order to mount the valve seat block 24 onto the dispenser body extension 74, the retaining nut 72 is threaded onto the dispenser body extension 74 so that the lower flange 70 at the base of retaining nut 72 engages the annular shoulder 68 in the valve seat block 24. As the retaining nut 72 is tightened, the locking pins 78 prevent rotation of the valve seat block 24 relative to the dispenser body 12 thus allowing the valve seat block 24 to firmly seat against the dispenser body extension 74 and O-ring 76. Assembly is completed by affixing the nozzle 16 to the base of valve seat block 24 by engagement of the nozzle nut 65 with the external threads along the lower portion of valve seat block 24. As viewed in Figs. 1 and 4, the nozzle 16 is formed with a shoulder 17 which engages an annular flange 81 at the base of the nozzle nut 65 to retain the nozzle 16 upon the base of valve seat block 24. Disassembly of the valve seat block 24 from the gun body 12 is accomplished by essentially reversing the above-described operation. The nozzle nut 65 is first disconnected from the valve seat block 24 which disengages the nozzle 16 therefrom. The retaining nut 72 is then unthreaded from the dispenser body extension 74 which exposes the flats 66 formed in the valve seat block 24. In order to disengage the alignment pins 78 from the alignment slots 80 at the top of the valve seat block 24, the valve seat block 24 and needle valve 18 is pulled downwardly a short distance by hand. Using the flats 66 and a wrench, the valve seat block 24 can be rotated to unthread the valve tip 22 from the valve stem 20 and thus disengage the valve seat block 24 from the gun body 12. With reference to Fig. 6, a spray gun 10A is illustrated which is similar in many respects to that shown in Figs. 1-5 except for the removal and replacement of the valve seat and valve tip. As described in connection with Figs. 1-5, repair or replacement of the valve tip 22 and valve seat 60 is accomplished by unthreading the valve tip 22 from the valve stem 20 so that the valve seat block 24, valve tip 22 and valve seat 60 can be removed as a unit from the remainder of the gun body 12. In the spray gun 10A shown in Fig. 6, such repair or replacement of the valve seat and valve tip is accomplished somewhat differently, but with the same objective of permitting repair and replacement thereof while the dispenser body 12 is on-line. As illustrated in Fig. 6, the upper portion of the spray gun 10A, the solenoid 82 and housing 84 are identical to that disclosed in connection with Figs. 1-5 and the same reference numbers are utilised in Fig. 6 to identify the same structure. The valve stem 20A of Fig. 6 is secured to the lower end 32 of sleeve 34 in the same manner as described above in Fig. 1, but the lower portion of valve stem 20A has a shoulder 120 and a threaded end 122 which mates with internal threads formed in a collet 124. The collet 124 is threaded onto the end 122 of valve stem 20A until it engages the shoulder 120. The collet 124 has a hollow interior 126 and a radially inwardly extending flange 128 at the entrance to the interior 126. This flange 128, and the walls of collet 124, are at least partially elastically deformed to receive a large ball end 130 of a needle valve extension 132. Preferably, the collet 124 is formed of a plastic material which exhibits sufficient elasticity to deform and receive the ball end 130, but retain it in place on the lower end of valve stem 20A. The opposite end of the needle valve extension 132 is formed with a smaller ball 134 which engages a mating seat 136 mounted at the outlet 135 of a passageway 137 formed in a valve seat block 138. The valve seat 136 includes a bore 139 and an upstanding collar 140 having an internal diameter which is greater than the diameter of ball 134. In the course of extension and retraction of plunger 20A, as described above, the collar 140 guides the ball end 134 so that it remains axially aligned with the valve seat 136. The valve seat block 138 is mounted to the gun body 12A against an O-ring 142 by a retaining nut 72 in the same manner as valve seat block 24 described in connection with Fig. 1, so that the inlet 141 of its passageway 137 communicates with the passageway 14 in gun body 12A. A nozzle 16 is mounted to the valve seat block 138 with a nozzle nut 65 as also described above. The above described construction of the embodiment of Fig. 6 permits easy, on-line removal of both the valve seat 136 and needle valve extension 132 for repair or replacement as required. It can be appreciated that both the assembly and disassembly operations can be accomplished without disturbing the mounting structure which positions the gun body 12 relative to a metal can production line (not shown), or requiring disconnection of any fluid or electrical lines to the gun body 12 or 12A. Repair or replacement of the valve tip 22 and valve seat 60, or valve tip extension 132 and valve seat 136, is accomplished with the dispenser body 12 or 12A on-line, and thus a minimum amount of disruption to the can coating or other production line is created. The remaining portions of the spray gun 10 form no part of this invention per se, and are thus described only briefly hereinafter for purposes of illustrating the means for reciprocating needle valve 18 with respect to the valve seat 60 or 136. A detailed discussion of the structure and operation of spray gun 10 can be found in US-A-4430886. As shown in Fig. 1 and Fig. 6, the gun body 12 mounts a solenoid 82 having a housing 84 which contains a coil 86 retained therein by a cap 88 and nut 90. The lowermost end of the housing 84 has a reduced diameter armature sleeve 85 which at its lower end is threaded into a bore formed in the gun body 12 with an O-ring 87 located between. The upper portion of armature sleeve 85 extends through housing 84 and has a threaded top end which mounts nut 90 so that the housing 84 can be tightened against the gun body 12. The solenoid housing 84 is formed with a bore 92 which receives an armature 94 extending at least partially into the coil 86. The armature 94 is tubular in shape and has a throughbore 96 which receives the upper portion 26 of valve stem 20. A radially inwardly extending flange 98 is formed at the base of armature 94 which is engageable with the sleeve 34 on the upper portion 26 of valve stem 20. A compression spring 100 is located between a shoulder 102 formed at the top of bore 92 and a seat 104 formed into the armature 94. A second compression spring 106 extends between a counterbore 108 formed in the solenoid housing 84 at the top of bore 92, and the flange 30 at the top of the upper portion 26 of valve stem 20. When power is supplied to the coil 86 of solenoid 82, the armature 94 is pulled upwardly as the armature 94. A second compression spring 106 extends between a counterbore 108 formed in the solenoid housing 84 at the top of bore 92, and the flange 30 at the top of the upper portion 26 of valve stem 20. When power is supplied to the coil 86 of solenoid 82, the armature 94 is pulled upwardly as viewed in Fig. 1 or Fig. 6 so that its lower flange or lip 98 engages the sleeve 34 in the upper portion 26 of valve stem 20 or 20A to pull the valve stem 20 or 20A upwardly therewith. In turn, the valve tip 22 or needle valve extension 132 is pulled upwardly with the valve stem 20 or 20A so that the valve tip 22 or extension 126 disengages the valve seat 60 or 136. This permits the flow of liquid from the liquid passageway 14 in the gun body 12, through the valve seat 60 or 136 into the nozzle 16 for discharge onto the interior of a can body or the like. De-energisation of the solenoid 82 allows the compression springs 100 and 106 to return the armature 94 and needle valve 18 to a valve closed position in which the valve tip 22 or needle valve extension 136 engages the valve seat 60 or 136 and thus prevents the flow of liquid to the nozzle 16. Movement of the needle valve 18 within the dispenser body 12 and valve seat block 24 is permitted by the roll pins 40 and 58 as they move within slots 42, 44 and 48, 50 respectively.

Claims: A spray gun comprising a valve seat block having a discharge bore with a valve seat at the outlet thereof, the valve seat block being releasably connected to the spray gun body so that the discharge bore is in communication with a passageway in the spray gun body, and a reciprocable valve stem carried within the passageway, the valve stem having a valve tip which is engageable with the valve seat for controlling the flow of material through the discharge bore, characterised in that the valve tip (22) is releasably connected to the valve stem (20) and in that means (58, 61) are provided for retaining the valve tip (22) within the valve seat block (24) so that the valve tip (22) and the valve seat block (24) can be simultaneously connected to, or disconnected from, the valve stem (20) and the spray gun body (12) respectively. A spray gun according to Claim 1 characterised in that the valve stem (20) comprises upper and lower portions (26, 28) having matchingly threaded ends by which the upper and lower portions (26, 28) may be connected. A spray gun according to Claim 1 or 2 characterised in that the upper end of the valve tip (22) and the lower end of the valve stem (20), or of the lower portion (28) thereof, have matching threads by which the valve stem (20) and the valve tip (22) may be connected. A spray gun according to Claim 1, 2 or 3 characterised in that a first pin (40) is mounted to the valve stem (20) and is engageable with at least one longitudinal slot (42, 44) formed in the spray gun body (12), and in that a second pin (58) is mounted to the valve tip (22) and is engageable with at least one longitudinal slot (48, 50) formed in the valve seat block (24), the first pin (40) being effective to substantially prevent rotation of the valve stem (20) relative to the spray gun body (12) and the second pin (58) being effective to substantially prevent rotation of the valve tip (22) relative to the valve seat block (24) during connection or disconnection of the valve stem (20) and the valve tip (22). A spray gun according to any preceding Claim characterised in that the spray gun body (12) and the valve seat block (24) are provided with means (78, 80) to prevent rotation of the valve seat block (24) relative to the spray gun body (12). A spray gun according to Claim 1 or 2 characterised in that the valve tip (132) comprises a section having a first hall (130) at one end and a second ball (134) being shaped to mate with the valve seat (136). A spray gun according to Claim 6 characterised in that the means for releasably connecting the valve tip (132) and the valve stem (20A) comprises a hollow collet (124) mounted to the lower end of the valve stem (20A) and having an aperture which is at least partially elastically deflectable so as to receive the first ball (130) of the valve tip (132) within the hollow interior (126) of the collet (124). A spray gun according to any preceding Claim characterised in that means are provided to move the valve stem (20) and the valve tip (22) between a position in which the valve tip (22) is disengaged from the valve seat (60) to permit the flow of material through the valve seat block (24) and a position in which the valve tip (22) is engaged with the valve seat (60) to prevent the flow of material through the valve seat block (24).

Inventors: LOPARO THOMAS A, WARYU JOSEPH C, LOPARO, THOMAS A., WARYU, JOSEPH C.
Applicants: NORDSON CORP, NORDSON CORPORATION
Application year: 1991
Main classification: B05B1
IPC codes: B05B1