Abstract: A spray applicator for particulate material includes a unitary powder passageway sized to be particularly useful with dense phase material flow. An external electrode assembly is provided that is keyed to an air cap that is used to provide atomizing and pattern shaping air to the dense phase material that exits the powder passageway. In this manner a nozzle is not required. A manual and automatic version of the applicator are provided, including a pattern shaping trigger that can be used by the operator to dynamically adjust the spray pattern. An automatic gun version has the multiplier located at a mounting location to reduce bending moments of the elongated gun.

Abstract: A nozzle assembly for a material application device includes an expansion chamber for slowing down the velocity of powder fed to the nozzle from a dense phase pump. The nozzle assembly includes a nozzle insert that forms the expansion chamber and provides air assist function. The nozzle includes an integral deflector, and further includes a passageway for a charging electrode so that the electrical path is routed away from the powder path, while permitting the electrode tip to be centered in the powder spray pattern from the nozzle. The nozzle also includes air wash for the electrode. The nozzle outlet orifice has a cross-sectional area that is equal to or greater than the inlet cross-sectional area so that a slow moving dense phase powder cloud is produced by the nozzle.

Abstract: A material supply for a material application system such as a powder coating application system includes a feed hopper in the form of a duct. The duct is connectable to negative pressure during a color change process and is disconnected from the negative pressure during a spray application process. The negative pressure can be provided from a powder overspray recovery system such as an after filter blower. Dampers are provided to control air flow through the hopper duct and to allow the duct to be at ambient pressure during a supply mode of operation. The hopper duct also includes a suction interface for pumps, in the form of a siphon ring, as well as a fluidizing function. A removable sieve is provided with an optional vibration feature. Powder may be added to the duct via an access door or transfer pumps for new powder and/or reclaimed powder overspray.

Abstract: Apparatus and methods are provided for removing powder overspray from the exterior surfaces within a spray booth, especially the exterior surfaces of a spray gun assembly. These surfaces may include the spray gun housing and nozzle, a tube mount housing for the tube mount configurations, and in some embodiments the various hoses and lines that are coupled to the spray gun in a bar mount configuration. In one embodiment, powder overspray is removed from such surfaces or other surfaces within the spray booth by applying a cleaning or powder removal agent/article in contact with the surfaces to knock off, wipe, blow or otherwise remove the powder overspray. The cleaning agent/article may take many forms, including but not limited to fluids including air or liquid, negative pressure or suction, charged ions, positive pressure within the spray gun assembly, or any number and variety of cleaning devices such as but not limited to brushes, cloth, sponges, wipers and so on.