Spray gun/applicator

Abstract

An applicator is provided which through the use of valve assemblies and separate first and second tubing member delivers two separate materials separately to a mixing head. The mixing head is provided with two separate passageways which terminate into an outlet passageway. To help create equal pressure between the materials at the point where the materials meet, an impinger can be placed in one or both of the mixing head passageways. Material flowing into each mixing head passageway first meet and are mixed in the outlet passageway. A tip is attached to the mixing head and a static mixer can be disposed within the tip for further mixing of the combined materials prior to their application out of the tip onto the intended surface. Material is supplied to the valve assemblies by various methods such as hoses. A spray gun embodiment is also disclosed.

Description

[0001] This application is a continuation-in-part of U.S. application Ser. No. 10/072,325, filed Feb. 7, 2002 (which is incorporated by reference).

FIELD OF INVENTION

[0002] This invention relates to spray guns and spray applicators, and more particularly to a spray gun or spray applicator which mixes a plurality of materials just prior to application to a surface.

BACKGROUND OF THE INVENTION

[0003] Spray guns or applicators (“spray guns”) are often used with applicator assemblies for supplying material(s) generated by the assembly to the intended surface (i.e. roof, concrete, pavement, etc.). However, prior spray guns have been relatively heavy and bulky requiring operation in a non-ergonomic correct position, with the result of potential injury to a user, especially after prolonged use. Typical spray guns also incorporate a trigger mechanism, thus, requiring constant pressure by the user to maintain such spray guns in an “on” position. Prior spray guns have also failed to provide superior mixing functions when used with to apply a multiple material composition. Thus, what is needed in the art is a spray applicator which is ergonomically superior to prior spray guns and which also produces a superior mix between the materials of the composition, as compared to the mix generated by previous spray guns. It is, therefore, to the effective resolution of the aforementioned problems and shortcomings of the prior art that the present invention is directed.

SUMMARY OF THE INVENTION

[0004] The present invention preferably comprises an extended pole applicator which can include a manifold having a first valve assembly and a second valve assembly and a handle connected to the valve assemblies. A first tubing is associated with the first valve assembly and a first passageway extending through the valve manifold. A second tubing is associated with the second valve assembly and a second passageway extending through the valve manifold. The opposite end of the first tubing is attached to a mixing head and associated with a first port/passageway in the mixing head, while the opposite end of the second tubing is attached to the mixing head and associated with a second port/passageway in the mixing head. An impinger can be placed in one or both of the mixing head passageways. Both mixing head passageways terminate into and communicate with a mixing head outlet passageway where material flowing into each mixing head passageway first meet and are mixed. A spray tip/nozzle is attached to mixing head and is in communication with the outlet passageway. A static mixer can be disposed within the spray tip/nozzle for further mixing of the combined materials prior to application out of the spray tip/nozzle. Material is supplied to the valve assemblies by various methods such as hoses and heated hoses.

[0005] In use with the user preferably locks the valve handle into an “on” position to open the ball valves which causes a first material to flow from a first hose attached to the first valve into a first manifold passageway and a second material to flow from a second hose attached to the second valve into a second manifold passageway. The first material travels through the first tubing, while the second material travels separately through the second tubing. The first material enters the first mixing passageway, while the second material enters second mixing passageway. The first material enters an aperture of an impinger disposed in the first mixing passageway and exits the impinger from a second aperture into the mixing head's outlet passageway. The second material exits second mixing passageway also into mixing head outlet passageway where it meets the first material. The two materials preferably enter the outlet passageway at essentially the same amount of pressure and begin to mix together. The combined material then begins to travel through the outlet passageway where it preferably confronts the static mixer which further mixes the materials together. After further mixing by the static mixer, the combined material exits out of the tip/nozzle and is applied to its intended surface.

[0006] A further spray gun embodiment which also incorporates the mixing head and static mixer is also disclosed.

[0007] It is therefore an object of the present invention to provide an applicator which provides for superior mixing of materials just prior to application to an intended surface.

[0008] It is another object of the present invention to provide an applicator which is configured and structured to potentially reduce ergonomic related problems found with conventional spray gun applicators.

[0009] It is to be understood that both the foregoing general description and the following detailed description are explanatory and are not restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute part of the specification, illustrate embodiments of the present invention and together with the general description, serve to explain principles of the present invention.

[0010] These and other important objects, advantages, and features of the invention will become clear as this description proceeds.

[0011] The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts that will be exemplified in the description set forth hereinafter and the scope of the invention will be indicated in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:

[0013] FIG. 1 is a right side elevational view of the present invention applicator;

[0014] FIG. 2 is a left side elevational view of the invention shown in FIG. 1;

[0015] FIG. 3 is a top view of the invention shown in FIG. 1;

[0016] FIG. 4 is a sectional view of the mixing head/nozzle portion of the present invention applicator;

[0017] FIG. 5 is an exploded sectional view of the mixing head/nozzle portion of FIG. 4;

[0018] FIG. 6 is an isometric view of the an impinger in accordance with the present invention;

[0019] FIG. 7 is a right side elevational view of the invention shown in FIG. 1 further including a protective guard member;

[0020] FIG. 8 is a top view of the invention shown in FIG. 1 further including the protective guard member;

[0021] FIG. 9 is a perspective view of the invention shown in FIG. 1 in use by a user;

[0022] FIG. 10 is a sectional isometric view of the mixing head portion of the present invention;

[0023] FIG. 11 is a isometric view of the mixing head portion of the present invention;

[0024] FIG. 12 is a side view of the spray gun alternative embodiment of the present invention;

[0025] FIG. 13 is a top view of the spray gun embodiment of FIG. 12 in an “off” position;

[0026] FIG. 14 is a top view of the spray gun embodiment of FIG. 12 in an “on” position;

[0027] FIG. 15 is a top view of a portion of the spray gun embodiment of FIG. 12, with segments of the portion shown in cross-section; and

[0028] FIG. 16 is a perspective view of the spray gun embodiment of FIG. 12 shown in use.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0029] As seen in the drawings the present invention provides a pole gun, sprayer or applicator (collectively referred to as “applicator”) which is generally designated as reference numeral 12. Applicator 12 generally includes a first material passageway 20 having a first end 22 and a second end 24, a second material passageway 30 having a first end 32 and a second end 34, means 40 for restricting material flow into first material passageway 20 and second material passageway 30, and a means 70 for mixing and spraying materials traveling through first material passageway 20 and second material passageway 30.

[0030] First material passageway 20 and second material passageway 30 can be tube-like members, either flexible or rigid. In one embodiment, passageways 20 and 30 are stainless steel tubes or pipes, though such is not considered limiting, and other materials can be used and are considered within the scope of the invention. For purposes of this description and the claims, whether flexible or rigid and regardless of material used for construction, passageways 20 and 30 will be referred to as “tubing” or “material passageways” to collectively refer to all variations. In one embodiment said means for restricting material flow 40 can comprise a valve manifold 42 having a first side 44 and a second side 46 in connection with an on/off valve assembly 43. A first passageway 48 and second passageway 50 can extend through manifold 42 from first side 44 to second side 44. The first ends of tubing 20 and 30 are preferably connected to passageways, 48 and 50, respectively, by conventional means such a pipe connectors or fittings (e.g. compression fittings) which are preferably threaded into, or otherwise attached to manifold 42 to provide fluid or material communication between passageways 48 and 50 and tubing 20 and 30, respectively. Alternatively, the first ends of tubing 20 and 30 can be directly attached to manifold 42 by providing threads at the first ends or by some other conventional connection method (i.e. soldering, welding, etc.). Depending on one or more considerations such as, but not limited to, specific proportions between the materials flowing through tubing 20 and 30 for the final composition sprayed or otherwise outputted out a tip/nozzle 90, flow rates for the materials, viscosity and heat of the materials, pressure, etc., the diameter of tubing 20 and 30 can be the same or different. Thus, as best seen in FIG. 3, the diameter of tubing 20 or 30 can be larger in diameter than the other tubing, though such is not considered limiting.

[0031] On/off valve assembly 43 preferably consist of a first on/off valve 52 and a second on/off valve 54 controlled by a handle 56. On/off valves 52 and 54 can be conventional ball valves, though other valves that can provide on/off characteristics can also be used and are considered within the scope of the invention. Though not preferred, it is possible that manifold 42 can be eliminated and that tubing 20 and 30 are directly connected to on/off mechanisms such as valves 52 and 54. Handle 56 is connected to both valves 52 and 54 and can be positioned such that valves 52 and 54 are open or closed. The nature of handle 56 allows it to lock and automatically maintain its valve open or closed position without continuous pressure or force by the user. Thus, ergonomic concerns found with gun/trigger mechanisms due to the required continuous application of pressure by the user are eliminated. However, it should be recognized that a trigger/mechanism could be substituted for handle 56 to operate valves 52 and 54 though such is not preferred.

[0032] As best seen in FIGS. 4, 5, 10 and 11, means for mixing and spraying 70 preferably consists of a spraying/mixing head 72 and a tip/nozzle member 90. Mixing head 72 can include a first passageway 74, a second passageway 76 and an outlet passageway 78. First mixing passageway 74 is preferably in communication with first material passageway 20 and second mixing passageway 76 is preferably in communication with second material passageway 30. First mixing passageway 74 has a first inlet end associated with tubing 20 and a second outlet end associated with outlet passageway 78. Second mixing passageway 76 has a first inlet end associated with tubing 30 and a second outlet end associated with outlet passageway 78. First mixing passageway 74 and second mixing passageway 76 are in communication with outlet passageway 78. Though not limiting first mixing passageway 74 and second mixing passageway 76 can be partially threaded (e.g. ¼″ pipe thread, etc.) at their first inlet ends for directly mating with tubing 20 and 30 (i.e. where tubing 20 and 30 have one or more threaded ends), respectively, or for mating with connectors or fittings (e.g. conventional plumbing elbows, 45s, compression fittings, etc.) used to attached tubing 20 and 30 to mixing head 72.

[0033] Tip/nozzle member 90 can be any conventional tip or nozzle member such as, but not limited to a Reverse-A-Clean (RAC) Tip made by Graco. Tip member 90 includes an internal passageway 92, which is in communication with outlet passageway 78 for spraying material received and mixed within outlet passageway 78. Preferably, though not limiting, the outer end of outlet passageway 78 is threaded (e.g. pipe thread ¾″, etc.) for mating with threads of tip 90 to removably connect tip 90 to mixing head 72.

[0034] Mixing head 72 can also include a means for controlling a rate of flow of a material within first mixing passageway 74. In one embodiment the means for controlling can be at least one impinger 80 (FIG. 6) having a first end, a second end and an intermediate portion therebetween. Impinger 80 including a first aperture 82 disposed at its second end and a second aperture 84 disposed at its intermediate portion. The body member of impinger 80 defines an internal passageway 86, wherein a first end of internal passageway 86 terminates at first aperture 82. The second end of impinger 80 has a diameter that can be preferably larger that the diameter of impinger 80 at its intermediate portion. Depending on materials used (including heat and viscosity considerations), pressure desired, flow rates, etc., a second impinger (not shown) can be provided for controlling the rate of flow of material entering second mixing passageway 76.

[0035] Mixing head 72 can include a first aperture 75, preferably at least a portion thereof threaded, extending from a first side of mixing head 72 to an intermediate position of first mixing passageway 74. First aperture 75 is in communication with first mixing passageway 74. A second aperture 77, a having at least a portion thereof preferably threaded, can extending from an opposite side of mixing head 72 to an intermediate portion of second mixing passageway 76. Second aperture 77 is in communication with second mixing passageway 76.

[0036] Impinger 80 is preferably disposed within first aperture 75 and a portion of first mixing passageway 74. The diameter of the second end of impinger 80 is chosen such that it effectively seals communication between first mixing passageway 74 and outlet passageway 78. The diameter of the second end of impinger 80 is slightly smaller than a diameter of first mixing passageway 74 at its second end such that a seal is created at the second end of first mixing passageway 74 (See FIG. 4). Any material flowing into first mixing passageway 74 from tubing/first material passageway 20 is directed through second aperture 84 of impinger 80 (due to the smaller diameter of the intermediate portion of impinger 80 as compared to the diameter of its second end) and into internal passageway 86 of impinger 80 and out of first aperture 82 into said outlet passageway 78. Where a second impinger is provided it is similarly disposed within second aperture 77 and a portion of second mixing passageway 76 of mixing head 72. Preferably, a portion of impinger 80 is threaded at 81 for mating with threads of aperture 75 and/or 77. Where no impinger 80 is needed in first mixing passageway 74 or second mixing passageway 76, a cap 87, preferably having threads 89, can be provided at aperture 75 and/or 77, to effectively seal the opening. Where no impinger 80 will ever be needed, then mixing head 72 can be provided without apertures 75 and 77. Impinger 80 can also include a head portion 85 which also acts as a stop member when attaching impinger 80 to mixing head 72.

[0037] The size of first impinger aperture 82 can be chosen, along with other rate of flow considerations, to ensure that the amount of pressure for material flowing into outlet passageway 78 from impinger internal passageway 86 is essentially equal (i.e. substantially balanced) to the amount of pressure for material flowing into outlet passageway 78 from second mixing passageway 76. In one embodiment, impinger aperture 82 can have an orifice diameter of approximately 0.035″, though such is not considered limiting, and other dimensions can be used and are considered within the scope of the invention. The essentially equal or balanced pressure helps to prevent either material from exerting a relatively higher force on the other material which could effect the desired flow of the materials for mixing together in outlet passageway 78. Thus, the area of outlet passageway 78 where first mixing passageway 74 and second mixing passageway 76 terminate provides the first point where materials received from tubing 20 and 30 are mixed together. In one embodiment, the pressure of the materials entering outlet passageway 78 from impinger aperture 82 and second mixing passageway 76 can be anywhere from approximately 500 p.s.i. to approximately 1500 p.s.i., though such range is not considered limiting and other values outside of the above-identified range can be selected and are considered within the scope of the invention.

[0038] The dimensions for first mixing passageway 74, second mixing passageway 76 and outlet passageway 78 are not considered limited to any specific dimensions. In one embodiment, passageways 74 and 76 can provide an approximate orifice diameter of 0.250″, though such is not considered limiting.

[0039] Mixing head 72 can be constructed from various materials such as aluminum, steel, metal, stainless steel, etc. and is not considered limited to any one specific material. Similarly, valve manifold 42 can also be constructed from various materials such as aluminum, steel, metal, stainless steel, etc. and is not considered limited to any one specific material. Tubing 20 and/or 30 can vary in length (such as, but not limited to, approximately 12″ to approximately 48″, though other dimensions are also possible) and in diameter (e.g. ¼″, ½″, ¾″, ⅜″, {fraction (3/16)}″, etc.). Thus, device 12 and/or tubing 20 and/or 30 is not limited to any one specific length and/or size, or any specific range of lengths and/or sizes. The material used to construct tubing 20 and/or 30 can be stainless steel, though other materials can be used and are also considered within the scope of the invention, such as, but not limited to, aluminum, metal, steel, etc.

[0040] A static mixer 100 can be disposed within at least a portion of internal passageway 92 of tip member 90 for further mixing of the materials entering outlet passageway 78 prior to their spraying or otherwise deliver to the intended surface (i.e. roof, concrete, wood, steel, metal, etc.). Static mixer 100 can be constructed from various materials such as steel, metal, stainless steel, aluminum, plastic, etc. and all are considered within the scope of the invention. The specific dimensions for static mixer 100 are not considered limiting. In one embodiment, such dimension can be approximately 0.375″ in diameter and 1.5″ long, though such is given by way of example and not considered limiting.

[0041] It should be understood for purposes of the description and claims, the term “material” when discussing a material flowing through tubing 20 and/or 30 and/or first mixing passageway 74 and/or second mixing passageway 76 is defined to be a single material or a combination of one or more materials previously mixed prior to deliver to tubing 20 and/or 30.

[0042] Applicator 12 can also include a guard member, such as an elongated metal guard 110 which can be attached to tubing 20 and/or 30 be a bridge member (See FIGS. 7 and 8). Guard 110 can be constructed from other materials such as wood, plastic, etc. in addition to metal and all are considered within the scope of the invention. Guard 110 is provided to help prevent contact between tubing 20 and 30 and the user, as tubing 20 and/or 30 may heat to a high temperature based on the temperature of the materials flowing through tubing 20 and/or 30. In lieu of or in addition to guard 110, tubing 20 and/or 30 may be directly covered with a sleeves (not shown) which can withstand and not transfer potential high temperatures of tubing 20 and/or 30.

[0043] As seen in the figures, applicator 12 can also be provided with a handle member 120 which is attached to an intermediate point along tubing 20 and/or 30 for ease in handling applicator 12 by the user. In lieu of or in addition to a handle (not shown) can be formed as an extension of guard 110. Additionally, a handle can be attached to guard 110 instead of tubing 20 and/or 30 by conventional means.

[0044] One or more flush lines 130 can also be provided to help internally clean manifold 42, valves 52 and/or 54, tubing 20 and/or 30, and/or mixing head 72, as well as any connectors or fittings (e.g. compression fittings) used to connect these components together. Each flush line(s) 130 can be preferably attached to valve manifold 42 by a flush valve 132 assembly attached to manifold 42 (e.g. at a side orifice of manifold 42). Each orifice 43 intersects and communicates with one of the manifold passageways 48 or 50. A handle or switch 134 is preferably provided to operate flush valve 132 to either an “on” (open) or “off” (closed) position. Flush line 130 includes a hose 135 connected at one end to flush valve 132. The other end of hose 135 is associated with a cleaning fluid or material, such as a base reactive material and/or mineral spirits supplied at high pressure such as approximately 500 p.s.i., though such value is not considered limiting, and other values can be used and are considered within the scope of the invention.

[0045] Valve assemblies 52 and 54 are each preferably provided with threaded ends 53 and 55, respectively, for mating and connecting of hoses, heated hoses, lines, tubing, pipes, etc. (collectively referred to as “hoses” 140) for receiving material into passageways 48 and 50, respectively. Other devices or methods for attaching hoses to valve assemblies 52 and 54 can be used and are considered within the scope of the invention.

[0046] Applicator 12 can achieve and be used for various ratios and/or flow rates by using or not using impinger 80 and/or cap 87 and/or by the changing of dimensions for impinger 80, mixing passageways 74 and/or 76, and/or tubing 20 and/or 30. Mixing passageways 74 and 76 can be provided with common threads and orifices. Depending on application, such as a spraying application, both or one of mixing passageways 74 and/or 76 can be restricted for high pressure impingement with or without static mixer 100. For applications such as low pressure, high volume injections and/or pour applications, both mixing passageways 74 and 76 can be unrestricted (i.e. no impinger 80, caps 87 only).

[0047] Applicator 12 can be used for a variety of multiple materials and applications for preferably two and three component reactive materials. Other number component reactive materials can also be used with Applicator 12. It is also within the scope of the invention to provide additional material passageway members (tube/pipe), impingers, and/or mixing head passageways to permit the use of an applicator, similar to the concepts and structure of Applicator 12, with larger number of material combinations. Some of the materials that can be transferred, mixed and sprayed by Applicator 12 include, but are not limited to, bituminous materials, asphalts, polyols, polyurethanes, urethanes, isocyanates, elastomers, paints, epoxies, polyesters, foams, resins, etc.

[0048] In use with the user preferably grabbing handle 120 (FIG. 9), handle 56 is locked into an “on” position to open valves 52 and 54 causing a first material to flow from a hose 140 attached to valve 52 into manifold passageway 48 and a second material to flow from a hose 142 attached to valve 54 into manifold passageway 50. The first material continues the solo portion of its journey through tubing 20, while the second material travels separately through tubing 30. The first material enters first mixing passageway 74, while the second material enters second mixing passageway 76. For purposes of illustration only, the remaining discussion of the use of Applicator 12 assumes that an impinger 80 is provided with first mixing passageway 74 and a cap 87 is attached to the side orifice associated with second mixing passageway 76. The first material enters impinger second aperture 84 travels through internal passageway 86 and exits impinger first aperture 82 into mixing head outlet passageway 78. The second materials exits second mixing passageway into mixing head outlet passageway 78 where it meets the first material. The two materials preferably enter outlet passageway 78 at essentially the same amount of pressure and begin to mix together. The combined material then begins to travel through outlet passageway 78 where it preferably confronts static mixer 100 which further mixes the materials together. After further mixing by static mixer 100, the combined material exits out of tip/nozzle 90 and is applied to its intended surface. Though not limiting, the structure of Applicator 12 permits its to apply the combined/mixed material at a distance of approximately 12″-18″ from the intended surface which reduces or minimizes over spraying and increases efficiency.

[0049] As seen in FIGS. 12-16, a spray gun embodiment is illustrated and is generally designated as reference numeral 200. Spray gun 200 generally includes means 210 for mixing and spraying materials and means 250 for restricting material flow into means for mixing and spraying 210. In one embodiment, means for restricting material flow 250 can comprise an on/off valve assembly 252. On/off valve assembly 252 preferably consist of a first on/off valve 254 and a second on/off valve 256 controlled by a handle/lever 258. On/off valves 254 and 256 can be conventional ball valves, though other valves that can provide on/off characteristics can also be used and are considered within the scope of the invention. Handle 258 is connected to both valves 254 and 256 and can be positioned such that valves 254 and 256 are open (FIG. 14) or closed (FIG. 13), though it also within the scope of the invention that the position of handle 258 can be reversed for “open” and “close”. The nature of handle 258 allows it to lock and automatically maintain its valve open or closed position without continuous pressure or force by the user. Thus, ergonomic concerns found with gun/trigger mechanisms due to the required continuous application of pressure by the user are eliminated. However, it should be recognized that a trigger/mechanism could be substituted for handle 258 to operate valves 254 and 256 and considered within the scope of the invention, though such is not preferred. The valves can be positioned opposite to permit an easier connection to handle 258.

[0050] Means for mixing and spraying 210 preferably consists of a mixing head/manifold 214, tube-like member 280 and a tip/nozzle member 240. An adaptor 300 can also be provided. Mixing head 214 is similar to mixing head 72 in structure and operation and can include a first passageway 216, a second passageway 218 and an outlet passageway 220. First mixing passageway 216 is preferably in communication at a first inlet end with said first valve 254 and second mixing passageway 218 is preferably in communication at a first inlet end with second valve 256. First mixing passageway 216 has an second outlet end associated with outlet passageway 220. Second mixing passageway 218 has a second outlet end associated with outlet passageway 220. First mixing passageway 216 and second mixing passageway 218 are in communication with outlet passageway 220. Though not limiting, first mixing passageway 216 and second mixing passageway 218 can be partially threaded (e.g. ¼″ pipe thread, etc.) at their first inlet ends for directly mating with first valve 254 and second valve 256, respectively, or for mating with connectors or fittings used to attached first valve 254 and second valve 256 to mixing head 214.

[0051] Relatively short or small tube-like member 280, can be preferably rigid, can be connected at one end to the output aperture 221 of mixing head 214 (either directly or indirectly through adaptor 300) and at its opposite end to tip/nozzle assembly 240. Once attached to mixing head 214 (directly or indirectly), communication is provided between the output passageway 220 of mixing head 214 and internal passageway 281 extending through tube-like member 280. In one embodiment, tube-like member 280 can be a stainless steel tubes or pipes, though such is not considered limiting, and other materials, preferably at least somewhat rigid, can be used and are considered within the scope of the invention. For purposes of this description and the claims, regardless of material used for construction, term “mixing tube” will be used throughout the disclosure to describe piece 280 and all variations thereof.

[0052] Preferably, mixing tube 280 is connected to mixing head 214 by conventional means such a pipe connectors or fittings (e.g. compression fittings), such as adaptor 300, which can be preferably threaded, which permit fluid or material communication between mixing head output passageway 220 and mixing tube 280. However as mentioned above, it is within the scope of the invention to have the first end of mixing tube 280 directly attached to mixing head 214 by providing external male threads at the first end of mixing tube 280 or by some other conventional connection method (i.e. soldering, welding, etc.).

[0053] Tip/nozzle member 240, can be similar to tip/nozzle member 90 in structure and operation and can be any conventional tip or nozzle member such as, but not limited to a Reverse-A-Clean (RAC) Tip made by Graco. Tip member 240 includes an internal passageway, which is in communication with internal passageway 281 running through mixing tube 280 for spraying material received and mixed and traveling within internal passageway 281 of mixing tube 280. Preferably, though not limiting, the second end 285 of mixing tube 280 can be threaded (e.g. pipe thread ¾″, etc.) for mating with threads of tip 240 to removably connect tip 240 to mixing tube 280.

[0054] Similar to mixing head 72, mixing head 214 can also include a means for controlling a rate of flow of a material within first mixing passageway 216. In one embodiment the means for controlling can be at least one impinger 222, similar to impinger 80 in structure and function, having a first end, a second end and an intermediate portion 225 therebetween. Impinger 222 including a first aperture disposed at its second end and a second aperture 224 disposed at its intermediate portion 225. The body member of impinger 222 defines an internal passageway, wherein a first end of internal passageway terminates at the impinger's first aperture. The second end of impinger 222 has a diameter that can be preferably larger that the diameter of impinger 222 at its intermediate portion. Depending on materials used (including heat and viscosity considerations), pressure desired, flow rates, etc., a second impinger (not shown) can be provided for controlling the rate of flow of material entering second mixing passageway 218. Also similar to mixing head 72, mixing head 214 can include a first aperture 230, preferably at least a portion thereof threaded, extending from a first side of mixing head 214 to an intermediate position of first mixing passageway 216. First aperture 230 is in communication with first mixing passageway 216. A second aperture 232, preferably having at least a portion thereof threaded, can extend from an opposite side of mixing head 214 to an intermediate portion of second mixing passageway 218. Second aperture 232 is in communication with second mixing passageway 218.

[0055] Impinger 222 is preferably disposed within first aperture 230 and a portion of first mixing passageway 216 and the following disclosure regarding the operation of impinger 222 will assume that it is only disposed within first aperture 230. However, it should be recognized that impinger 222 can be disposed within second aperture 232 (See FIG. 14, with cap 234 disposed in first aperture 230) or that two impingers 222 are provided (one for first aperture 230 and one for second aperture 232). Thus, the below discussion also describes how impinger 222 would operate in connection with second mixing passageway 218 if disposed within second aperture 232. It should also be recognized that if two impingers 222 are provided they can be constructed of the same dimensions or of differing dimensions.

[0056] The diameter of the second end of impinger 222 is chosen such that it effectively seals communication between first mixing passageway 216 and outlet passageway 220. The diameter of the second end of impinger 222 is slightly smaller than a diameter of first mixing passageway 216 at its second end such that a seal is created at the second end of first mixing passageway 216. Any material flowing into first mixing passageway 216 from first valve 254 is directed through second aperture 224 of impinger 222 (due to the smaller diameter of the intermediate portion of impinger 222 as compared to the diameter of its second end) and into an internal passageway of impinger 222 and out of the impinger's first aperture 227 into said outlet passageway 220. Where a second impinger is provided it is similarly disposed within second aperture 232 and a portion of second mixing passageway 218 of mixing head 214. Preferably, a portion of impinger 222 is threaded at 223 for mating with threads of aperture 230 and/or 232. Where no impinger 222 is needed in first mixing passageway 216 or second mixing passageway 218, a cap 234, preferably having threads 235, can be provided at aperture 230 and/or 232, to effectively seal the opening. Where no impinger 222 will ever be needed, then mixing head 214 can be provided without apertures 230 and 232. Impinger 222 can also include a head portion 223 which also acts as a stop member when attaching impinger 222 to mixing head 214.

[0057] The size of first impinger aperture 227 can be chosen, along with other rate of flow considerations, to ensure that the amount of pressure for material flowing into outlet passageway 220 from the impinger internal passageway is essentially equal (i.e. substantially balanced) to the amount of pressure for material flowing into outlet passageway 220 from second mixing passageway 218. In one embodiment, the first impinger aperture can have an orifice diameter of approximately 0.035″, though such is not considered limiting, and other dimensions can be used and are considered within the scope of the invention. The essentially equal or balanced pressure helps to prevent either material from exerting a relatively higher force on the other material which could effect the desired flow of the materials for mixing together in outlet passageway 220. Thus, the area of outlet passageway 220 where first mixing passageway 216 and second mixing passageway 218 terminate provides the first point where materials received from material supply hoses 400 and 402 connected to first valve 254 and second valve 256, respectively, are mixed together. In one embodiment, the pressure of the materials entering outlet passageway 220 from the first impinger aperture and second mixing passageway 218 can be anywhere from approximately 500 p.s.i. to approximately 1,500 p.s.i., though such range of values is not considered limiting and other values outside of the above-identified range can be selected and are considered within the scope of the invention.

[0058] The dimensions for first mixing passageway 216, second mixing passageway 218 and outlet passageway 220 are not considered limited to any specific dimensions. In one embodiment, passageways 216 and 218 can provide an approximate orifice diameter of 0.250″, though such is not considered limiting. Mixing head 214 can be constructed from various materials such as aluminum, steel, metal, stainless steel, etc. and is not considered limited to any one specific material. Unneeded portions of mixing head 72 or 214 can be cutaway to reduce the overall weight for spray gun 200 and reduce costs. Mixing tube 280 is not limited to any specific length size or diameter. Thus, spray gun 200 is not limited to any one specific length, diameter and/or size, or any specific range of lengths, diameters and/or sizes. As mentioned above, the material used to construct mixing tube 280 can be stainless steel, though other materials can be used and are also considered within the scope of the invention, such as, but not limited to, aluminum, metal, steel, etc.

[0059] As mentioned above, and intermediate fitting member, such as adaptor 300, can be provided for attaching mixing tube 280 to mixing head 214. Preferably, adaptor 300 is threaded at both ends for mating with outlet aperture 221 of mixing head 214 at one end and first end 283 of mixing tube 280 at its second end. An internal passageway extends through adaptor 300 to permit fluid or material communication between outlet passageway 220 and internal passageway 281 of tubing member 280.

[0060] A static mixer 330, similar in structure and operation to static mixer 100, though possibly longer in length, can be disposed within the internal passageway of adaptor 300 and/or at least a portion of internal passageway 281 of mixing tube 280 for further mixing of the materials exiting out of outlet passageway 220 prior to their spraying or other type of delivery to the intended surface (i.e. roof, concrete, wood, steel, metal, etc.). Static mixer 330 can be constructed from various materials such as steel, metal, stainless steel, aluminum, plastic, etc. and all are considered within the scope of the invention. The specific dimensions for static mixer 330 are not considered limiting. In one embodiment, such dimension can be approximately 0.375″ in diameter and approximately 2″ long, though such is given by way of example and not considered limiting.

[0061] It should be understood for purposes of the description and claims, the term “material” when discussing a material mixing head 214 is defined to be a single material or a combination of one or more materials previously mixed prior to deliver to supply hoses 400 and/or 402, which can be heated or non-heated hoses. Mixing tube 280 can be directly covered with a sleeve (not shown) which can withstand and not transfer potential high temperatures of the material flow therethrough in order to provide protection to the user. Spray gun 200 is particularly useful in spraying areas which may be hard to sufficiently spray with applicator 12, such as, but not limited to, corners of a structure, etc.

[0062] One or more flush line assemblies 350 can also be provided to help internally clean mixing head 214, as well as any connectors or fittings (e.g. compression fittings) used to connect these components together. Each flush line(s) assembly 350 can be preferably attached to mixing head 214 by a flush valve 352 attached to mixing head 214, preferably through one or more fittings 353 (e.g. at an orifice (not shown) in mixing head 214). The orifice intersects and communicates with one or more of the mixing head passageways. A handle or switch 354 can be preferably provided to operate flush valve 352 to either an “on” (open) or “off” (closed) position. Flush line assembly 330 also includes a hose 356 connected at one end to flush valve 352. The other end of hose 356 is associated with a cleaning fluid or material, such as a base reactive material and/or mineral spirits supplied at high pressure such as approximately 500 p.s.i., though such value is not considered limiting and other values can be selected and are considered within the scope of the invention.

[0063] Valve assemblies 52 and 54 and/or 254 and 256 can be each preferably provided with threaded ends 53 and 55 or be connected to fittings having threaded ends, respectively, for mating and connecting of hoses, heated hoses, lines, tubing, pipes, etc. (collectively referred to as “hoses” 400 and 402) for receiving material into passageways 216 and 218, respectively. Other devices or methods for attaching hoses to valve assemblies 52 and 54 and/or 254 and 256 can be used and are considered within the scope of the invention. Preferably, hoses 400 and 402 are connected to their respective valves through elbows 404 and associated fittings, which position hoses 400 and 402 downward (FIG. 16) for extra stability when handling hoses 400 and 402.

[0064] The valve assemblies 52 and 54 and/or 254 and 256 can be connected to their manifolds or mixing heads, respectively, through tapered fitting connections. Adaptor 300 is preferably provided with sloped ends 303 and 305 for mating with sloped portion 229 of outlet aperture 221 and sloped portion 287 of first end 283 of mixing tube 280, respectively. In one embodiment, the degree of angle for the slope is about 37 degrees. However, such value is not considered limiting and a slope from anywhere between about twenty degrees to forty degrees can be chosen and all values are considered within the scope of the invention. The mating relationship of sloped end 303 to portion 229 and sloped end 305 to portion 287 permits a self-sealing connection which is fluid tight without the need of any gaskets. The sloped configuration can also be provided for fittings 409 which are used to connected hoses 400, 402 and/or 356. Where provided the connector portions of hoses 400, 402 and/or 356 would be provided with corresponding sloped portions (preferably internally located). The size of each attachment portion of adaptor 300 can be slightly larger then the corresponding female receiving area (i.e. outlet aperture 221 and first end 283 of mixing tube 280) such that the intermediate nut 301 preferably does not touch mixing head 214 or mixing tube 280. This permits the sloped abutment/connection of end 303 to portion 229 and end 305 to portion 287 to be fully cinched down (i.e. nut portion 301 does not prevent a fully threaded connection between end 303 with aperture 221 and end 305 with first end 283.

[0065] Spray gun 200 can achieve and be used for various ratios and/or flow rates by using or not using impinger 222 and/or cap 234 and/or by the changing of dimensions for impinger 222, mixing passageways 216 and/or 218. Mixing passageways 216 and 218 can be provided with common threads and orifices. Depending on application, such as a spraying application, both or one of mixing passageways can be restricted for high pressure impingement with or without static mixer 330. For applications such as low pressure, high volume injections and/or pour applications, both mixing passageways 216 and 218 can be unrestricted (i.e. no impinger 222, caps 234 only).

[0066] Spray gun 200 can be used for a variety of multiple materials and applications for preferably two and three component reactive materials. Other number component reactive materials can also be used with spray gun 200. It is also within the scope of the invention to provide additional impingers and/or mixing head passageways to permit the use of an spray gun applicator, similar to the concepts and structure of spray gun 200, with larger number of material combinations. Some of the materials that can be transferred, mixed and sprayed by spray gun 200 include, but are not limited to, bituminous materials, asphalts, polyols, polyurethanes, urethanes, isocyanates, elastomers, paints, epoxies, polyesters, foams, resins, etc.

[0067] In use, with the user preferably grabbing hold handle 380 (FIG. 15) attached to mixing head 214 by conventional means, such as but not limited to screws, adhesives, etc. 120, handle 258 is locked into an “on” position to open valves 254 and 256 causing a first material to flow from hose 400 attached to valve 254 into first mixing passageway 216 and a second material to flow from hose 402 attached to valve 256 into second manifold passageway 218. For purposes of illustration only, the remaining discussion of the use of spray gun 200 assumes that an impinger 222 is provided with first mixing passageway 216 and a cap 234 is attached to the side orifice associated with second mixing passageway 218. The first material enters impinger second aperture 224 and travels through the internal passageway of impinger 222 and exits first impinger aperture 227 into mixing head outlet passageway 220. The second materials exits second mixing passageway 218 into mixing head outlet passageway 220 where it meets the first material. The two materials preferably enter outlet passageway 220 at essentially the same amount of pressure and begin to mix together. The combined material then begins to travel through outlet passageway 220 where it preferably confronts static mixer 330, disposed within adaptor 300 and at least a portion of internal passageway 281 of mixing tube 280, which further mixes the materials together. After further mixing by static mixer 330, the combined material finishes its travels through mixing tube 280 and exits out of tip/nozzle 240 and is applied to its intended surface. Though not limiting, the structure of spray gun 200 permits its to apply the combined/mixed material at a relatively close distances to the intended surface which reduces or minimizes over spraying and increases efficiency.

[0068] It will be seen that the objects set forth above, and those made apparent from the foregoing description, are efficiently attained and since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment, and alternative embodiments thereof. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious modifications will occur to a person skilled in the art. It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.

Claims

1. A spray gun comprising:

a mixing head having a body member having a first inlet passageway and a second inlet passageway and an outlet passageway, said first inlet passageway in communication with said outlet passageway, said second inlet passageway in communication with said outlet passageway; and

means for further mixing and spraying materials received from said outlet passageway;

wherein said first inlet passageway adapted for receipt of a first material and said second inlet passageway adapted for receipt of a second material.

2. The spray gun of claim 1 further comprising an on/off assembly for restricting flow of the first material and the second material into their respective inlet passageways.

3. The spray gun of claim 2 wherein said on/off assembly comprising:

a first on/off valve in communication with said first inlet passageway;

a second on/off valve in communication with said second inlet passageway; and

a handle connected to said first on/off valve and said second on/off valve, said handle automatically maintaining said first on/off valve and said second on/off valve in at least either an “on” position or an “off” position.

4. The spray gun of claim 1 wherein said means for further mixing and spraying comprising:

a mixing tube in communication with said outlet passageway; and

a tip member in communication with said mixing tube for spraying mixed material received from said mixing tube.

5. The spray gun of claim 1 wherein said mixing head further comprising a means for controlling a rate of flow of a material within said first inlet passageway, said first inlet passageway having a first end and a second end, said first inlet passageway receiving the first material at said first end, said first inlet passageway in communication with said outlet passageway at said second end.

6. The spray gun of claim 5 wherein said means for controlling comprising:

an impinger having a first end, a second end and an intermediate portion therebetween, said impinger including a first aperture disposed at said second end and a second aperture disposed at said intermediate portion, said impinger defining an internal passageway, wherein a first end of said internal passageway terminates at the first aperture of said impinger, wherein said impinger second end having a diameter larger that a diameter of said impinger intermediate portion;

wherein said mixing head having an aperture extending from a first side of said mixing head to an intermediate position of said first inlet passageway, said aperture in communication with said first inlet passageway;

wherein said impinger is disposed within said mixing head aperture and a portion of said first inlet passageway.

7. The spray gun of claim 6 wherein the diameter of the second end of said impinger is chosen such that it effectively seals communication between said first inlet passageway and said outlet passageway.

8. The spray gun of claim 6 wherein the diameter of the second end of said impinger is slightly smaller than a diameter of said first inlet passageway at its second end such that a seal is created at the second end of the first inlet passageway and any material flowing into said first inlet passageway is directed through said second aperture of said impinger into said impinger internal passageway and out said first aperture of said impinger into said outlet passageway.

9. The spray gun of claim 6 wherein the size of said first impinger aperture is chosen such that an amount of pressure for material flowing into said outlet passageway from said impinger internal passageway is essentially equal to an amount of pressure for material flowing into said outlet passageway from said second inlet passageway.

10. The spray gun of claim 4 wherein said tip member having an internal passageway and said mixing tube having a static mixer disposed within a portion of an internal passageway of said mixing tube for further mixing of material received from said outlet passageway.

11. The spray gun of claim 3 wherein said first on/off valve is a first ball valve and said second on/off valve is a second ball valve.

12. The applicator of claim 3 wherein said first on/off valve adapted for connection to a first hose and said second on/off valve adapted for connection to a second hose.

13. A multiple material spray gun comprising:

a mixing head having a body member having a first inlet passageway and a second inlet passageway and an outlet passageway, said first inlet passageway in communication with said outlet passageway, said second inlet passageway in communication with said outlet passageway;

a first on/off valve in communication with said first inlet passageway;

a second on/off valve in communication with said second inlet passageway;

a handle connected to said first on/off valve and said second on/off valve, said handle being movable to a locked “open” or “closed” position to automatically maintaining said first on/off valve and said second on/off valve in either an “on” position or an “off” position;

a mixing tube in communication with said outlet passageway; and

a tip member in communication with said mixing tube for spraying material received within from said mixing tube.

14. The multiple material spray gun of claim 13 further comprising:

an impinger having a first end, a second end and an intermediate portion therebetween, said impinger including a first aperture disposed at said second end and a second aperture disposed at said intermediate portion, said impinger defining an internal passageway, wherein a first end of said internal passageway terminates at the first aperture of said impinger, wherein said impinger second end having a diameter larger that a diameter of said impinger intermediate portion;

wherein said mixing head having an aperture extending from a first side of said mixing head to an intermediate position of said first inlet passageway, said aperture in communication with said first inlet passageway;

wherein said impinger is disposed within said mixing head aperture and a portion of said first inlet passageway.

15. The multiple material spray gun of claim 14 wherein the diameter of the second end of said impinger is chosen such that it effectively seals communication between said first inlet passageway and said outlet passageway.

16. The multiple material spray gun of claim 14 wherein the diameter of the second end of said impinger is slightly smaller than a diameter of said first inlet passageway at its second end such that a seal is created at the second end of the first inlet passageway and any material flowing into said first inlet passageway is directed through said second aperture of said impinger into said impinger internal passageway and out said first aperture of said impinger into said outlet passageway.

17. The multiple material spray gun of claim 14 wherein the size of said first impinger aperture is chosen such that an amount of pressure for material flowing into said outlet passageway from said impinger internal passageway is essentially equal to an amount of pressure for material flowing into said outlet passageway from said second inlet passageway.

18. The multiple material spray gun of claim 13 further comprising a static mixer disposed within a portion of an internal passageway of said mixing tube for further mixing of material received from said outlet passageway.

19. The multiple material spray gun of claim 13 wherein said first on/off valve is a first ball valve and said second on/off valve is a second ball valve.

20. A method for mixing and applying multiple materials comprising the steps of:

(a) providing a first material into a first inlet passageway of a mixing head;

(b) providing a second material into a second inlet passageway of the mixing head;

(c) directing the first material out of the first inlet passageway into an outlet passageway of the mixing head and directing the second material out of the second inlet passageway into the outlet passageway such that the first material and second material meet and are mixed together; and

(d) spraying the mixed composition consisting of the first material and the second material out of a tip in communication with the outlet passageway through a mixing tube.

21. The method of claim 20 further comprising the step of directing the mixed first and second materials through a static mixer disposed within the mixing tube for further mixing prior to spraying.

22. The method of claim 20 wherein step (c) includes the step of delivering the first material and second material into the outlet passageway at essentially the same pressure.

23. The method of claim 21 wherein step (c) includes the step of delivering the first material and second material into the outlet passageway at essentially the same pressure.

24. A mixing head for use with a spray apparatus, comprising:

a body member having a first inlet passageway and a second inlet passageway and an outlet passageway, said first inlet passageway in communication with said outlet passageway, said second inlet passageway in communication with said outlet passageway.