Abstract:
A system including a spray applicator assembly, including a spray applicator body, a spray applicator component coupled to the spray applicator body, and a spray applicator tool coupled to the spray applicator assembly, wherein the spray applicator tool is configured to adjust one or more parameters of the spray applicator assembly during an operational state, and the spray applicator tool is configured to couple to the spray applicator component and to facilitate removal of the spray applicator component during a non-operational state.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a non-provisional application claiming priority to US Provisional Patent Application No. 62/022,496, entitled “Spray Applicator Tool”, filed Jul. 9, 2014, which is herein incorporated by reference in its entirety for all purposes. 
     
    
     BACKGROUND 
       [0002]    The invention relates generally to spray devices, and more particularly, to a spray applicator tool. 
         [0003]    Spray coating devices, such as spray guns, are used to apply a spray coating (e.g., paint) to a wide variety of target objects. Spray coating devices often include many reusable and/or wear components, such springs, seals, etc. Unfortunately, a considerable amount of time is spent removing portions of a spray coating device in order to access and replace these reusable components. Furthermore, removal of certain parts of the spray coating device may involve the use of external tools that can potentially damage parts of the spray coating device. 
     
    
     
       DRAWINGS 
         [0004]    These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein: 
           [0005]      FIG. 1  is a perspective view of an embodiment of a spray applicator assembly with a spray applicator tool capable of removing a spray applicator piston; 
           [0006]      FIG. 2  is a cutaway perspective view of an embodiment of a spray applicator assembly with a spray applicator tool capable of removing a spray applicator piston; 
           [0007]      FIG. 3  is a partially exploded cutaway perspective view of an embodiment of a spray applicator assembly with a spray applicator tool capable of removing a spray applicator piston; 
           [0008]      FIG. 4  is a cutaway perspective view of an embodiment of a spray applicator assembly with a spray applicator tool coupled to the spray applicator piston; 
           [0009]      FIG. 5  is a cross-sectional view of an embodiment of a spray applicator tool coupling to an external surface of a spray applicator piston; 
           [0010]      FIG. 6  is a cutaway view of an embodiment of a spray applicator tool coupling to a spray applicator piston with a protrusion; 
           [0011]      FIG. 7  is a cross-sectional view of an embodiment of a spray applicator tool with a magnet that couples to a spray applicator piston; and 
           [0012]      FIG. 8  is a side view of an embodiment of a spray applicator tool with a gripping recess. 
       
    
    
     DETAILED DESCRIPTION 
       [0013]    One or more specific embodiments of the present invention will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers&#39; specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure. 
         [0014]    When introducing elements of various embodiments of the present invention, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. 
         [0015]    The present disclosure is generally directed to a spray applicator assembly with a spray applicator tool with multiple purposes. For example, during spraying operations the spray applicator tool may enable adjustment of spraying parameters of the spray applicator assembly. After spraying, the spray applicator tool may facilitate disassembly of a spray applicator assembly. More specifically, the spray applicator tool may include a coupling feature that enables the spray applicator tool to couple to a spray applicator piston within a spray applicator body. Once coupled, the spray applicator tool enables the user to pull the spray applicator piston out of the spray applicator assembly for maintenance (e.g., cleaning, replacement of gaskets, etc.). In some embodiments, the coupling feature may include threads that engage threads on the spray applicator piston. In another embodiment, the coupling feature may include a protrusion that engages a groove on the spray applicator piston. In still another embodiment, the spray applicator tool may include a magnet that enables the spray applicator tool to magnetically couple to the spray applicator piston. Moreover, the spray applicator tool may include any combination of these different coupling features. Finally, in some embodiments, the spray applicator tool may include a gripping feature that enables a user to better grip the spray applicator tool when removing the spray applicator piston. 
         [0016]      FIG. 1  is a perspective view of an embodiment of a spray applicator assembly  10  (e.g., a spray gun assembly) with a spray applicator tool  12  (e.g., a spray gun tool). As explained above, the spray applicator tool  12  may have multiple purposes including removing a spray applicator piston  14  out of a spray applicator  16  (e.g., a spray gun) during maintenance (e.g., gasket replacement, cleaning, etc.) and adjusting spraying parameters. As illustrated, the spray applicator assembly  10  includes a spray tip assembly  18  coupled to a spray applicator body  20  on a first end  22 , and a piston housing cap  24  coupled to the spray applicator body  20  on a second end  26 . Both the spray tip assembly  18  and the piston-housing cap  24  may threadingly couple or otherwise attach to the spray applicator body  20 . In operation, the spray applicator assembly  10  receives fluid flow through fittings  28 . These fittings  28  may include a liquid fitting  30 , an atomization air fitting  32 , and a piston air fitting  34 . The fittings  30 ,  32 , and  34  couple to the respective inlets  36 ,  38 , and  40  in the spray applicator body  20  and to the respective liquid source  42 , compressed air source  44 , and compressed source  46 . Once engaged, the spray applicator assembly  10  produces an atomized spray of a solvent, paint, sealer, stain, etc. with a desired spray pattern and droplet distribution. 
         [0017]      FIG. 2  is a cutaway perspective view of an embodiment of a spray applicator assembly  10  with a spray applicator tool  12  capable of removing a spray applicator piston  14  from the spray applicator body  20  for servicing without the use of additional tools. The spray applicator tool  12  couples to the piston-housing cap  24  with tool threads  60  that engage threads  62  in the cap bore  64 . As illustrated, the spray applicator tool  12  may also include a cavity  66  that receives a valve spring  68  and a portion of a valve  70 . In operation, the spray applicator tool  12  remains on the spray applicator assembly  10  and threads into and out of the piston housing cap  24  to increase and decrease the compression of valve spring  68 , which then increases or decreases the force necessary to unseat the needle valve  70  for spraying. 
         [0018]    As illustrated, the piston housing cap  24  couples (e.g., threads) to the spray applicator body  20 , which houses the spray applicator piston  14 . The spray applicator piston  14  includes a piston body  72  (e.g., cylindrical or annular), an annular lip  74 , a piston counterbore  76  (e.g., cylindrical or annular), and a valve aperture  78  (e.g., cylindrical or annular). The spray applicator piston  14  couples to the spray applicator assembly  10  by inserting the piston body  72  into a cavity  80  (e.g., annular cavity) in the spray applicator body  20 . The piston body  72  passes through the cavity  80  until an end face  82  of the spray applicator body  20  contacts a first counterbore  84  of the spray applicator body  20 . Together, the first counterbore  84  and the spray applicator piston  14  form an airflow chamber  86  (e.g., cylindrical or annular) that contains air entering the spray applicator body  20  through the atomization air fitting  32  (seen in  FIG. 1 ). In order to control the atomization airflow, the spray applicator piston  14  forms a seal around the airflow chamber  86  with the end face  82  and one or more gaskets  88  (e.g., cylindrical or annular). For example, the spray applicator piston  14  may include one or more gaskets  88  (e.g., 1, 2, 3, 4, 5 or more) that rest within cylindrical or annular grooves  90  (e.g., 1, 2, 3, 4, 5 or more) along the piston body exterior surface  92 . In a seated position, the end face  82  and the first counterbore  84  seal the airflow chamber  86  in combination with the gaskets  88 . In some embodiments, the end face  82  and/or the first counterbore  84  may be angled to facilitate contact and sealing. 
         [0019]    In order to open the airflow chamber  86  during spraying operations, the spray applicator piston  14  forms a piston air chamber  94  with the spray applicator body  20 . As illustrated, the annular lip  74  rests within a second counterbore  96  (e.g., cylindrical or annular) of the cavity  80  and includes a gasket  98  (e.g., cylindrical or annular) in a groove  100  (e.g., cylindrical or annular) along an exterior surface  102  of the annular lip  74 . The gaskets  88  and  98  form seals between the spray applicator piston  14  and the spray applicator body  20  enabling piston air  104  to enter the piston air chamber  94  to drive the spray applicator piston  14 . More specifically, as piston air  104  enters the piston air chamber  94  through the piston air fitting  34 , the piston air  104  increases the pressure acting on a first lip surface  106 . As the pressure increases in the piston air chamber  94 , the pressure overcomes the biasing force of a piston spring  108 , enabling the spray applicator piston  14  to move in direction  110 . As the spray applicator piston  106  moves in direction  110 , the spray applicator piston  106  compresses the piston spring  110  a distance  112  until the piston counterbore  76  contacts a valve lip  114 . Further movement of the spray applicator piston  14  in direction  110  enables the spray applicator piston  14  to overcome the biasing force of the valve spring  68  driving the valve  70  in direction  110 , which unseats the valve  70 . 
         [0020]    As illustrated, the valve  70  extends from the first end  22  of the spray applicator body  20  to the second end  26  of the spray applicator body  20 . As the valve  70  extends from the first end  22  to the second end  26 , the valve  70  passes through the valve aperture  78  in the spray applicator piston  14  and through a fluid packing assembly  119 . At the first end  22 , the valve  70  rests within the spray tip assembly  18  to control the flow of liquid through the spray applicator assembly  10 . In a seated position, a tip  116  of the valve  70  blocks the flow of liquid through a liquid delivery tip assembly  118  of the spray tip assembly  18 , while the fluid packing assembly  119  blocks liquid flow around the valve  70  and through the cavity  80  in direction  110 . In the unseated position, the valve  70  enables fluid flow through the liquid delivery tip assembly  118 . As explained above, the valve  70  unseats when piston air  104  enters the piston air chamber  94  driving the spray applicator piston  72  in direction  110  and into contact with the valve lip  114 . In the unseated position, the valve  70  enables liquid to enter the spray applicator body  20  through the liquid fitting  30 . As the liquid passes through the liquid fitting  30 , the liquid enters the liquid deliver tip assembly  118 , which then directs the liquid to a liquid tip aperture  120  where the liquid exits the spray applicator assembly  10 . As the liquid exits, the spray tip assembly  18  atomizes and shapes the liquid with airflow through a spray formation assembly  122 . 
         [0021]    The spray formation assembly  122  couples to the liquid delivery tip assembly  118  and may include a variety of spray formation mechanisms, such as air, rotary, and electrostatic atomization mechanisms. However, the illustrated spray formation assembly  122  comprises an air atomization cap  124 , which is removably secured to the spray applicator body  20  via a retaining nut  126 . The air atomization cap  124  may include a variety of air atomization orifices  128  disposed about the liquid delivery tip assembly  118  enabling atomization of the liquid. The air atomization cap  122  may also have one or more spray shaping air orifices  130 , which use air jets to shape the atomized liquid into a desired spray pattern (e.g., a flat spray). In operation, the spray formation assembly  122  receives airflow through the air atomization fitting  32 . As explained above, when piston air  104  enters the piston air chamber  94 , the pressure drives the spray applicator piston  72  in direction  110 . The movement of the spray applicator piston  14  in direction  110  unseats not only the valve  70 , but also the end face  84  of the spray applicator piston  14  from the first counterbore  82 . As the end face  84  moves in direction  110 , the airflow chamber  86  opens enabling air  132  to flow out of the airflow chamber  86  and into the distribution chamber  134 . In some embodiments, the spray applicator piston  14  may include a gasket  133  (e.g., annular or cylindrical) that rests within a groove  135  (e.g., annular or cylindrical) to block air  132  from flowing around the valve  70  through the spray applicator piston  14 . In the air distribution chamber  134 , the airflow  132  splits between flowing to the air atomization passages  128  or to the shaping air orifices  130  through the fan pattern passage  136 . In some embodiments, the spray applicator assembly  10  may include fan pattern adjustment valve  138  to maintain and regulate the air pressure and flow of the air  132  out of the shaping air orifices  130 . After spraying operations, the piston air  104  is cutoff enabling the piston spring  108  to drive the spray applicator piston  14  in axial direction  140 , which reseats the end face  82  with the first counterbore  84  cutting off airflow into the air distribution chamber  134 . In addition, as the spray applicator piston  14  moves in direction  140 , the spray applicator piston  14  enables the valve spring  68  to reseat the valve tip  116  in the liquid delivery tip assembly  118 . 
         [0022]      FIG. 3  is a partially exploded cutaway perspective view of an embodiment of a spray applicator assembly  10 . As illustrated, the spray applicator removal tool  12  may be disassembled by unthreading the piston removal tool  12  from the housing cap  24  enabling the spray applicator removal tool  12  to couple to the spray applicator piston  14 . After removing the piston removal tool  12 , the valve spring  68  and the valve  70  may be pulled out of spray applicator assembly  10 . The piston-housing cap  24  is also unthreaded from the spray applicator body  20  exposing the piston spring  108  and the spray applicator piston  14 . In the alternative, the piston-housing cap  24  may be unthreaded before removing the valve spring  68  and the valve  70 . In this disassembled state, the piston removal tool  12  may then couple to the spray applicator piston  14  enabling removal of the spray applicator piston  14  for maintenance and cleaning. 
         [0023]      FIG. 4  is a cutaway perspective view of an embodiment of the spray applicator assembly  10  with the spray applicator tool  12  coupled to the spray applicator piston  14 . In some embodiments, the spray applicator tool  12  may be threadingly coupled to the piston counterbore  76  in the piston body  72 . For example, the tool threads  60  (e.g., male coupling) may engage corresponding piston threads  160  on an interior surface  162  of the piston counterbore  76 . After the spray applicator tool  12  is threadingly coupled to the piston body  72 , the spray applicator piston  14  may be easily removed from the spray applicator body  20  by pulling on the spray applicator tool  12  in direction  110 . Once removed the gaskets  88 ,  98 , and  133  may be replaced/inspected and/or other maintenance may be performed on the spray applicator piston  14  and spray applicator body  20  (e.g., cleaning, etc.). 
         [0024]      FIG. 5  is a cross-sectional view of an embodiment of the spray applicator tool  12  coupling to a spray applicator piston  14 . In some embodiments, the spray applicator tool  12  may couple to the external surface  92  of the spray applicator piston  14 . For example, the spray applicator piston  14  may include threads  180  on the exterior surface  92  around the counterbore  76 . The threads  180  on the spray applicator piston  14  may threadingly engage threads  182  (e.g., female coupling) along an interior surface  184  of the spray applicator tool  12  in the cavity  66 . Once coupled, the spray applicator tool  12  may be pulled in direction  110 , enabling easy removal of the spray applicator piston  14  from the spray applicator body  20 . In embodiments, where the spray applicator tool  12  includes threads  182  along an interior surface  184  the piston housing cap  24  may include a larger cap bore  64  that enables the threads  60  to couple to the piston housing cap  24  during operation of the spray applicator assembly  10 . 
         [0025]      FIG. 6  is a cutaway view of an embodiment of a spray applicator tool  12  coupling to a spray applicator piston  14  with a protrusion  200 . As illustrated, the spray applicator tool  12  may include one or more protrusions  200  (e.g., 1, 2, 3, 4, 5, or more) on an exterior surface  202 . The protrusions  200  enable the spray applicator tool  12  to couple to a circumferential groove  204  (e.g., annular groove) in the piston counterbore  76 . In some embodiments, the spray applicator tool  12  is rotated in either direction clockwise direction  206  or counter-clockwise direction  208  until the protrusions  200  align with an axial groove  210  in the interior surface  162  of the piston counterbore  76 . The spray applicator tool  12  is then moved axially in direction  140  until the protrusions  200  enter the circumferential groove  204 . After the protrusions  200  enter the circumferential groove  204 , the spray applicator tool  12  is rotated in either direction  206  or  208  to couple the spray applicator tool  12  to the spray applicator piston  14 . Once coupled, the spray applicator piston  14  may be pulled out of the spray applicator body  20  with the spray applicator tool  12 . In some embodiments, the protrusions  200  may be on an interior surface  184  enabling the pins to couple to a groove  210  on an exterior surface  192  of the spray applicator piston  14 . In another embodiment, the protrusions  200  may be spring-loaded pins (e.g., snap-fit coupling) that compress as the spray applicator tool  12  enters the piston counterbore  76  or as the spray applicator tool  12  extends over the exterior surface  192  of the spray applicator piston  14 , enabling attachment without the axial grooves  210 . As the protrusions  200  slide along the grooves  204  and  210 , the protrusions  200  pop out and couple the spray applicator tool  12  to the spray applicator piston  14 . In still another embodiment, the spray applicator piston  14  may include the protrusions  200  along the interior surface  162  of the piston counterbore that couple to a corresponding groove in the cavity  66  of the spray applicator tool  12 . In this way, the spray applicator tool  12  may couple a groove on the spray applicator tool  12  to the protrusions  200  on the spray applicator piston  14 , enabling removal of the spray applicator piston  14 . 
         [0026]      FIG. 7  is a cross-sectional view of an embodiment of a spray applicator tool  12  with a magnet  220  (e.g., a permanent magnet made of a magnetic material). In some embodiments, the spray applicator tool  12  may include the magnet  220  to enable the spray applicator tool  12  to couple magnetically to the spray applicator piston  14 . As illustrated, the spray applicator tool  12  may include a first section  222  (e.g., annular body) and second section  224  (e.g., annular body). The first section  222  enables the spray applicator tool  12  to couple to the piston-housing cap  24  and to receive the valve  70  and valve spring  68 . The second section  224  may be a user adjustment knob that enables a user to adjust the force on the valve  70  during use and to withdraw the spray applicator piston  14  after use. For example, the second section  224  may include the magnet  220  that magnetically attracts/couples to the spray applicator piston  14 , enabling the spray applicator tool  12  to remove the spray applicator piston  14  from the spray applicator body  20 . In addition, the second section  224  may include a gripping feature  226  that enables a user to better grip the spray applicator tool  12  when removing the spray applicator piston  14 . In some embodiments, the gripping feature  226  may include the lip  228  that extends circumferentially about the entire circumference of the spray applicator tool  12 . In other embodiments, the lip  228  may only extend partially around the spray applicator tool  12 . In still other embodiments, the gripping feature  226  may include a plurality of spaced protrusions or teeth  228 , disposed about the circumference, to enable a user to better grip the spray applicator tool  12  when removing the spray applicator piston  14 . 
         [0027]      FIG. 8  is a side view of an embodiment of a spray applicator tool  12  with a gripping feature  226 . The gripping feature  226  in  FIG. 8  is not a lip but a gripping recess  240 . In some embodiments, the gripping recess  240  may extend circumferentially about the entire circumference of the spray applicator tool  12 . In other embodiments, there may be a plurality of gripping recesses  240  at different axial and/or circumferential positions along the spray applicator tool  12  to facilitate a user&#39;s grip while pulling the spray applicator piston  14  out of the spray applicator assembly  14 . 
         [0028]    Technical effects of the disclosed embodiments include a spray applicator assembly  10  with a multi-purpose spray applicator tool  12 . As explained above, the spray applicator tool  12  enables adjustment of spraying parameters during spraying operations and afterwards facilitates disassembly of the spray applicator assembly  10 . The spray applicator tool  12  includes a coupling feature that enables the spray applicator tool  12  to couple to a spray applicator piston  14  within a spray applicator body  20 . Once coupled, the spray applicator tool  12  enables the user to pull the spray applicator piston  14  out of the spray applicator assembly for maintenance (e.g., cleaning, replacement of gaskets, etc.). 
         [0029]    While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.