40, and transfer the second fluid to second outlet 70. Further, second bore 66 houses components of valve assembly 50. First outlet 68 is an aperture within fluid housing 46 that is configured to transfer the first fluid from first bore 64 to stationary mix chamber 48 when spray valve 24 is in the fluid open position. Further, first outlet 68 is configured to transfer air from air supply 18 to stationary mix chamber 48 when spray valve 24 is in the fluid closed position. Second outlet 70 is an aperture within fluid housing 46 that is disposed opposite first outlet 68 and configured to transfer the second fluid from second bore 66 to stationary mix chamber 48 when spray valve 24 is in the fluid open position. Further, second outlet 70 is configured to transfer air from air supply 18 to stationary mix chamber 48 when spray valve 24 is in the fluid closed position. Contoured cavity 72 is an orifice in fluid housing 46 that is configured to sealingly accept contoured end 52 of stationary mix chamber 48 to prevent fluid and air leakage.

Stationary mix chamber 48 includes spray orifice 28, contoured end 52, first seal groove 54, second seal groove 56, first port 58, second port 60, and mixing bore 62. Stationary mix chamber 48 is positioned in a cavity between fluid housing 46 and air cap 36. More specifically, contoured end 52 of stationary mix chamber 48 is positioned in contoured cavity 72 of fluid housing 46 and the opposite end of stationary mix chamber 48 extends into air cap 36. Air cap 36 is configured to press against surfaces of stationary mix chamber 48 to secure stationary mix chamber 48 within contoured cavity 72. In the embodiment shown, contoured end 52 is a wedge-shaped end that is configured to be pressed into a wedge-shaped cavity 72 in fluid housing 46. It is understood, however, that contoured end 52 can be any geometrical shape, such as conical or frusto-conical (similar to the conical mix chamber 248 shown in FIGS. 6A-6I), that will facilitate sealing between stationary mix chamber 48 and fluid housing 46. Further, contoured cavity 72 can be of any corresponding shape to receive contoured end 52.

Spray orifice 28 is located at one end of stationary mix chamber 48 and is configured to dispense a fluid in a spray pattern onto a substrate. Contoured end 52 is positioned on the opposite end of stationary mix chamber 48 from spray orifice 28. Contoured end 52 is configured to be pressed into contoured cavity 72 of fluid housing 46 to increase fluid sealing between fluid housing 46 and stationary mix chamber 48. Contoured end 52 also includes first seal groove 54 and second seal groove 56. First seal groove 54 and second seal groove 56 are configured to receive a first seal and a second seal, respectively, to seal between contoured end 52 and contoured cavity 72 and prevent leakage of fluid from first outlet 68 and second outlet 70 into fluid housing 46. In the embodiment shown, first seal groove 54 is positioned on a first surface of stationary mix chamber 28 and configured to surround first port 50. Further, second seal groove 56 is positioned on a second surface of stationary mix chamber 28 and configured to surround second port 60. In other embodiments, first seal groove 54 and second seal groove 56 can circumferentially encompass contoured end 52, with first seal groove 54 positioned above first outlet 68 and second outlet 70, such that the first seal groove 54 is between spray orifice 28 and outlets 68, 70, and second seal groove 56 positioned below first outlet 68 and second outlet 70, such that outlets 68, 70 are between second seal groove 56 and spray orifice 28.

First port 58 is an aperture within stationary mix chamber 48 that is fluidly connected to first outlet 68 of fluid housing 46. First port 58 is configured to receive a first fluid from first outlet 68 and transfer the first fluid to mixing bore 62. Second port 60 is an aperture within stationary mix chamber 48, opposite first port 58, that is fluidly connected to second outlet 70 of fluid housing 46. Second port 60 is configured to receive a second fluid from second outlet 70 and transfer the second fluid to mixing bore 62. Mixing bore 62 is an aperture that is fluidly connected to first port 58 and second port 60 and extends from first port 58 and second port 60 to spray orifice 28. Mixing bore 62 is configured to receive a first fluid from first port 58 and a second fluid from second port 60 and to mix the fluids into a plural component fluid mixture that will be dispensed from spray orifice 28 of stationary mix chamber 48. In the embodiment shown, stationary mix chamber 48 is constructed from a metal. In another embodiment, stationary mix chamber 48 can be constructed from a polymer.

Valve assembly 50 includes first fluid needle 76, second fluid needle 78, first valving seal 80, second valving seal 82, first air seal 84, second air seal 86, first fluid seal 88, and second fluid seal 90. First fluid needle 76 includes first needle head 92, first needle neck 94, and first needle shaft 96. Second fluid needle 78 includes second needle head 98, second needle neck 100, and second needle shaft 102. First fluid needle 76 and second fluid needle 78 can be constructed from one of a metal or a polymer.

Valve assembly 50 is disposed at least partially within first bore 64 and second bore 66 of fluid housing 46. Valve assembly 50 is configured to control the flow of fluid and air through fluid housing 46 to stationary mix chamber 48. More specifically, valve assembly 50 is configured to control the flow of the first fluid to first port 58 and the second fluid to second port 60 of stationary mix chamber 48. Pneumatic piston 74 is disposed within body 30 of spray applicator 12 and is configured to use compressed air from air supply 18 to drive first fluid needle 76 and second fluid needle 78 in a linear manner More specifically, pneumatic piston 74 is configured to cause first fluid needle 76 and second fluid needle 78 to translate axially in a linear manner, with respect to axis A. In the embodiment shown, pneumatic piston 74 is utilized to produce the desired linear motion of first fluid needle 76 and second fluid needle 78. In another embodiment, a hydraulic piston, electric piston, or mechanical piston could be used to produce the desired linear motion of first fluid needle 76 and second fluid needle 78.

First fluid needle 76 is disposed at least partially within first bore 64 of fluid housing 46 and attached to pneumatic piston 74, which is configured to control the translating movement of first fluid needle 76. First fluid needle 76 is configured to translate between a first fluid open position and a first fluid closed position. Second fluid needle 78 is disposed at least partially within first bore 64 of fluid housing 46 and attached to pneumatic piston 74, which is configured to control the translating movement of second fluid needle 78. Second fluid needle 78 is configured to translate between a second fluid open position and a second fluid closed position. First fluid needle 76 and second fluid needle 78 are both operatively connected to pneumatic piston 74 for simultaneous actuation. When spray applicator 12 is in the fluid open state, first fluid needle 76 is in a first fluid open position and second fluid needle 78 is in a second fluid open position. Likewise, when spray applicator 12 is in the fluid closed state, first fluid needle 76 is in a first fluid closed position and second fluid needle 78 is in a second fluid closed position.

First valving seal 80 is disposed within first bore 64 of fluid housing 46. First valving seal 80 is configured to provide a fluid and air tight connection between fluid housing 46 and first needle head 92 of first fluid needle 76 when spray applicator 12 is in the fluid closed state. Second valving seal 82 is disposed within second bore 66 of fluid housing 46. Second valving seal 82 is configured to provide a fluid and air tight connection between fluid housing 46 and second needle head 98 of second fluid needle 78 when spray applicator 12 is in the fluid closed state. First air seal 84 is disposed at least partially within fluid housing 46 and configured to provide a fluid and air tight connection between fluid housing 46 and first needle head 92 when spray applicator 12 is in the fluid open state. Second air seal 86 is disposed at least partially within fluid housing 46 and configured to provide a fluid and air tight connection between fluid housing 46 and second needle head 98 when spray applicator 12 is in the fluid open state.

First fluid seal 88 is disposed within first bore 64 of fluid housing 46. First fluid seal 88 is configured to provide a fluid and air tight connection between fluid housing 46 and first needle shaft 96 of first fluid needle 76. Second fluid seal 90 is disposed within second bore 66 of fluid housing 46. Second fluid seal 90 is configured to provide a fluid and air tight connection between fluid housing 46 and second needle shaft 102 of second fluid needle 78. First fluid seal 88 and second fluid seal 90 are both configured to prevent fluid and air from escaping fluid housing 46 into body 30 of spray applicator 12. Each of first valving seal 80, first air seal 84, and first fluid seal 88 are disposed at least partially within fluid housing 46 and each are configured to sealingly engage a portion of first fluid needle 76. Each of second valving seal 82, second air seal 86, and second fluid seal 90 are disposed at least partially within fluid housing 46 and each are configured to sealingly engage a portion of second fluid needle 78.

In operation, the user squeezes trigger 22 to cause pneumatic piston 74 to actuate from the fluid closed position to the fluid open position, resulting in fluid dispensing from spray applicator 12. FIG. 3A illustrates spray applicator 12 in the fluid closed state. When in the fluid closed position, first fluid needle 76 is sealingly engaged with first valving seal 80 and disengaged from first air seal 84, such that first fluid needle 76 is in the first fluid closed position. When in the fluid closed position, second fluid needle 78 is sealingly engaged with second valving seal 82 and disengaged from second air seal 86, such that second fluid needle 78 is in the second fluid closed position. With first fluid needle 76 in the first fluid closed position, fluid is prevented from flowing out of first bore 64 to stationary mix chamber 48 and air is allowed to travel past first air seal 84, through first outlet 68, and into stationary mix chamber 48 through first port 58. Likewise, with second fluid needle 78 in the second fluid closed position, fluid is prevented from flowing out of second bore 66 to stationary mix chamber 48 and air is allowed to travel past second air seal 86, through second outlet 70, and into stationary mix chamber 48 through second port 60. The air that is allowed to travel to stationary mix chamber 48, known as purge air, is configured to be continuously expelled from spray orifice 28 to keep first port 58, second port 60, and mixing bore 62 free of fluid or other debris.

FIG. 3B illustrates spray applicator 12 in an intermediate state in which both fluid and air flows are simultaneously shut off. The plural component sprayer 12 is in a non-spray state during which the sprayer 12 does not emit the plural component material while in the non-spray state. When the user squeezes trigger 22, spray applicator 12 begins to switch from the fluid closed state to the fluid open state. FIG. 3B illustrates the moment in which both the fluid and the air are prevented from entering stationary mix chamber 48. More specifically, FIG. 3B illustrates the moment that first valving seal 80 and first air seal 84 are simultaneously engaged with first needle head 92 of first fluid needle 76, which occurs at an intermediate position between the first fluid open position and the first fluid closed position. First needle head 92 is sized for simultaneous engagement with first valving seal 80 and first air seal 84. Likewise, FIG. 3B also illustrates the moment that second valving seal 82 and second air seal 86 are simultaneously engaged with second needle head 98 of second fluid needle 78, which occurs at an intermediate position between the second fluid open position and the second fluid closed position. Second needle head 98 is sized for simultaneous engagement with second valving seal 82 and second air seal 86. The intermediate state stops both fluid and airflow from flowing in order to prevent fluid from inadvertently entering air paths and air from inadvertently entering fluid paths.

FIG. 3C illustrates spray applicator 12 in the fluid open state. The plural component sprayer 12 is in a spray state in FIG. 3C such that the first and second component materials can flow to the receiving chamber 72 and to the stationary mix chamber 48 to form the plural component material. When in the fluid open state, first fluid needle 76 is disengaged from first valving seal 80 and sealingly engaged with first air seal 84. Further, when in the fluid open state second fluid needle 78 is disengaged from second valving seal 82 and sealingly engaged with second air seal 86. When in the first fluid open state, air is prevented from flowing past first air seal 84 to stationary mix chamber 48 and fluid is allowed to travel past first needle neck 94, through first outlet 68, and into stationary mix chamber 48 through first port 58. More specifically, the first fluid flows around first needle neck 94 when first fluid needle 76 is extended through first valving seal 80. Likewise, when in the second fluid open state, air is prevented from flowing past second air seal 86 to stationary mix chamber 48 and fluid is allowed to travel past second needle neck 100, through second outlet 70, and into stationary mix chamber 48 through second port 60. More specifically, the second fluid flows around second needle neck 100 when second fluid needle 78 is extended through second valving seal 82. The fluid that flows to travel to stationary mix chamber 48 is mixed within mixing bore 62 and then dispensed from spray orifice 28 as a plural component fluid.

Stationary mix chamber 48 and valve assembly 50 within fluid housing 46 remove the need for dynamic metal-to-metal high pressure fluid sealing that is conventionally used in manual spray applicators. Removing the metal-to-metal high pressure fluid sealing reduces manufacturing costs associated with the previous mix chamber design. Further, stationary mix chamber 48 can be constructed from a metal or polymer and can be easily removed from spray applicator 12, which reduces downtime and increases productivity. Stationary mix chamber 48 is a simplified and improved mix chamber because in operation stationary mix chamber 48 remains stationary while valve assembly 50 translates, resulting in less moving components within stationary mix chamber 48.

FIG. 4A is a perspective view of second spray applicator 12′. FIG. 4B is an exploded perspective view of second spray applicator 12′. FIG. 4C is a cross-sectional view of second spray applicator 12′ in a fluid open state. FIG. 4D is a perspective view of a seal within second spray applicator 12′. FIGS. 4A-4D will be discussed together. Second spray applicator 12′ is substantially similar to spray applicator 12 (FIGS. 1-3C), with a few differences described below and shown in FIGS. 4A-4D. Second spray applicator 12′ includes trigger 22′, spray valve 24′ (FIG. 4B), spray orifice 28′, body 30′, grip 32′, cap 34′, retainer cap 36′, first fluid manifold 38′, second fluid manifold 40′, air receiver 42′, air exhaust 44′, fluid housing 46′, and stationary mix chamber 48′.

Body 30′ is the main protective housing that covers the internal components of second spray applicator 12′. Further, body 30′ provides connection points for the other components of second spray applicator 12′. Grip 32′ is connected to body 30′ and provides a handle for the user to hold onto while using second spray applicator 12′. Grip 32′ also provides cover and protection to internal components of second spray applicator 12′. Trigger 22′ is connected to body 30′ and configured to control the spraying of second spray applicator 12′. Cap 34′ is coupled to body 30′ and configured to cover and protect internal components within second spray applicator 12′. Cap 34′ is removable from body 30′, allowing the user access to the internal components of second spray applicator 12′, such as fluid housing 46′ and stationary mix chamber 48′. Retainer cap 36′ is attached to fluid housing 46′ and retainer cap 36′ is configured to secure internal components within second spray applicator 12′. More specifically, retainer cap 36′ is threaded onto mating threads of fluid housing 46′ to secure retainer cap 36′ to fluid housing 46′ and second spray applicator 12′. Retainer cap 36′ is removable from fluid housing 46′, allowing the user access to the internal components of second spray applicator 12′, such as fluid housing 46′ and stationary mix chamber 48′.

First fluid manifold 38′ and second fluid manifold 40′ are each adjacent and connected to body 30′. First fluid manifold 38′ is configured to receive a first fluid from fluid supply 14a (FIG. 1), with pump 16a (FIG. 1) transferring the first fluid from fluid supply 14a to second spray applicator 12′. Second fluid manifold 40′ is configured to receive a second fluid from fluid supply 14b, with pump 16b transferring the second fluid from fluid supply 14b to second spray applicator 12′. In the example shown, first fluid manifold 38′ and second fluid manifold 40′ are formed as a single manifold mounted to second spray applicator 12′. In the embodiment shown, the first fluid and the second fluid can be received by second spray applicator 12′, mixed within second spray applicator 12′, and then dispensed from spray orifice 28′ onto a substrate. In another embodiment, second spray applicator 12′ can receive fluid from a single fluid receiver and dispense a single fluid from spray orifice 28′ onto a substrate.

In the embodiment shown, air receiver 42′ is connected to a rear portion of grip 32′. In another embodiment, air receiver 42′ can be connected to a bottom portion of grip 32′. As such, second spray applicator 12′ can include multiple air receivers 42′, only one of which is connected to air supply 18 (FIG. 1) at any given time. Air receiver 42′ is configured to receive air from air supply 18. In operation, a user connects air supply 18 to air receiver 42′ using a hose, tube, pipe, or other standard connection. Air exhaust 44′ is disposed at a bottom portion of grip 32′. Air exhaust 44′ is configured to expel air from second spray applicator 12′ during the translation of spray valve 24′.

In some cases, second spray applicator 12′ may require disassembly and replacement of parts. More specifically, the pathways within fluid housing 46′ and/or stationary mix chamber 48′ can become clogged due to solidified fluid and/or degradation of the internal components and the parts may need to be replaced. To disassemble second spray applicator 12′, the user removes retainer cap 36′ from fluid housing 46′ and then removes cap 34′ from fluid housing 46′, allowing access to stationary mix chamber 48′. Stationary mix chamber 48′ can then be removed from fluid housing 46′, and more specifically removed from contoured cavity 72′ of fluid housing 46′. With stationary mix chamber 48′ removed, the user can remove fluid housing 46′ from body 30′. Fluid housing 46′ can be removed from body 30′ by unthreading fluid housing 46′ from mating threads on body 30′. Then fluid housing 46′ can be slid over spray valve 24′ and removed from body 30′ of second spray applicator 12′. When removing fluid housing 46′, seals within fluid housing 46′ wipe residue from spray valve 24′, increasing efficiency during disassembly. Second spray applicator 12′ can be assembled by reversing the process. Fluid housing 46′ is slid over spray valve 24′ and threaded into mating threads of body 30′. Stationary mix chamber 48′ is inserted into contoured cavity 72′. Cap 34′ is secured to second spray applicator 12′ and retainer cap 36′ is threaded onto mating threads of fluid housing 46′, further pressing mix chamber 48′ into contoured cavity 72′, enhancing sealing therebetween.

The quick assembly and disassembly of second spray applicator 12′ reduces downtime and increases productivity in the event that fluid housing 46′ and/or stationary mix chamber 48′ need to be removed for repair or removed and replaced. Further, fluid housing 46′ contains the seals that engage spray valve 24′, and containment of the multiple components within fluid housing 46′ increases efficiency of the assembly and disassembly process. In addition, any crossover of fluid is limited to fluid housing 46′ and stationary mix chamber 48′, which can be easily replaced.

FIG. 4C illustrates second spray applicator 12′ in the fluid open state. The internal components of second spray applicator 12′ are substantially similar to the internal components of spray applicator 12 (FIGS. 1-3C). Further, the operation of second spray applicator 12′ is substantially similar to the operation of spray applicator 12. Therefore, to avoid a redundant description of the components and operation of second spray applicator 12′, only the differences between second spray applicator 12′ and spray applicator 12 will be discussed.

As discussed, spray applicator 12 includes first valving seal 80 and first air seal 84, which are configured to sealingly engage with first fluid needle 76. Second spray applicator 12′ combines first valving seal 80 and first air seal 84 into a single first seal cartridge 80′. First seal cartridge 80′ is positioned within fluid housing 46′ and first seal cartridge 80′ is configured to sealingly engage with first fluid needle 76′ to provide both the sealing functions of first valving seal 80 and first air seal 84 of spray applicator 12. When second spray applicator 12′ is in the fluid open state (FIG. 4C), first fluid needle 76′ is disengaged from an upper portion of first seal cartridge 80′ to allow fluid to flow to stationary mix chamber 48′ and first fluid needle 76′ is sealingly engaged with a lower portion of first seal cartridge 80′ to block purge air from flowing to stationary mix chamber 48′. First fluid needle 76′ maintains engagement with first seal cartridge 80′ in each of the fluid open state, the fluid closed state, and the intermediate state. First fluid needle 76′ maintains engagement with first seal cartridge 80′ as first fluid needle 76′ transitions between each of the states. As such, first seal cartridge 80′ of second spray applicator 12′ combines first valving seal 80 and first air seal 84 of spray applicator 12 into a single component. Further, first seal cartridge 80′ of second spray applicator 12′ is configured to provide the same functionality as first valving seal 80 and first air seal 84 of spray applicator 12.

Likewise, spray applicator 12 includes second valving seal 82 and second air seal 86, which are configured to sealingly engage with second fluid needle 78. Second spray applicator 12′ combines second valving seal 82 and second air seal 86 into a single second seal cartridge 82′. Second seal cartridge 82′ is positioned within fluid housing 46′ and second seal cartridge 82′ is configured to sealingly engage with second fluid needle 78′ to provide both the sealing functions of second valving seal 82 and second air seal 86 of spray applicator 12. When second spray applicator 12′ is in the fluid open state (FIG. 4C), second fluid needle 78′ is disengaged from an upper portion of second seal cartridge 82′ to allow fluid to flow to stationary mix chamber 48′ and second fluid needle 78′ is sealingly engaged with a lower portion of second seal cartridge 82′ to block purge air from flowing to stationary mix chamber 48′. Second fluid needle 78′ maintains engagement with second seal cartridge 82′ in each of the fluid open state, the fluid closed state, and the intermediate state. Second fluid needle 78′ maintains engagement with second seal cartridge 82′ as second fluid needle 78′ transitions between each of the states. As such, second seal cartridge 82′ of second spray applicator 12′ combines second valving seal 82 and second air seal 86 of spray applicator 12 into a single component. Further, second seal cartridge 82′ of second spray applicator 12′ is configured to provide the same functionality as second valving seal 82 and second air seal 86 of spray applicator 12.

First seal cartridge 80′ and second seal cartridge 82′ are identical components that provide the same functionality within second spray applicator 12′. The only difference between first seal cartridge 80′ and second seal cartridge 82′ is the fluid needle that each is configured to engage. The following discussion describes first seal cartridge 80′ but the details equally apply to second seal cartridge 80′, the details for each will not be repeated to avoid redundant descriptions. As shown in FIG. 4D, first seal cartridge 80′ is generally cylindrical in shape and includes a plurality of exterior grooves 80A′, a plurality of interior grooves 80B′, and flat surface 104′. More specifically, first seal cartridge 80′ includes a curved exterior surface with a plurality of exterior grooves 80A′ fully surrounding first seal cartridge 80′. Each of the plurality of exterior grooves 80A′ is configured to receive a seal member, such as an O-ring seal. The seal members positioned within the each of the plurality of exterior grooves 80A′ abut both first seal cartridge 80′ and fluid housing 46′ to create a sealing interface between the components, preventing fluid flow between first seal cartridge 80′ and fluid housing 46′. Further, first seal cartridge 80′ includes a plurality of interior grooves 80B′ (FIG. 4C), each of the plurality of interior grooves 80B′ being configured to receive a seal member, such as an O-ring seal. The seal members positioned within each of the plurality of interior grooves 80B′ abut both first seal cartridge 80′ and first fluid needle 76′ to create a sealing interface between the components, preventing fluid flow between first seal cartridge 80′ and first fluid needle 76′.

Flat surface 104′ is positioned on the curved exterior surface of first seal cartridge 80′ and flat surface 104′ is configured to engage a flat surface of fluid housing 46′ to prevent rotation of first seal cartridge 80′ within fluid housing 46′. Further, flat surface 104′ is configured to engage the flat surface of fluid housing 46′ to ensure proper alignment and sealing engagement of first seal cartridge 80′ with fluid housing 46′. More specifically, flat surface 104′ ensures proper sealing alignment of first channel 106′ of first seal cartridge 80′ with first outlet 68′ of fluid housing 46′. First channel 106′ extends through first seal cartridge 80′ from an interior of first seal cartridge 80′ to an outlet aperture formed on flat surface 104′. First seal cartridge 80′ of second spray applicator 12′ simplifies and reduces the number of components within second spray applicator 12′, as compared to spray applicator 12, by combining two components into a single component. The description above regarding first seal cartridge 80′ applies to second seal cartridge 82′, which is identical to first seal cartridge 80′.

As shown in FIG. 4C, second spray applicator 12′ includes puck 110′ positioned adjacent an end of fluid housing 46′. Puck 110′ includes two air passages, with one adjacent an end of first fluid needle 76′ and the other adjacent an end of second fluid needle 78′. The air passages within puck 110′ are configured to direct air, received through air receiver 42′, to stationary mix chamber 48′ to purge any remaining fluid out from stationary mix chamber 48′ when second spray applicator 12′ is de-triggered. Puck 110′ can be constructed from a metal, a polymer, or a composite material. Puck 110′ is a removeable component that can be detached from fluid housing 46′ to access internal components within fluid housing 46′. Further, puck 110′ can be easily removed from fluid housing 46′ and replaced in the event that puck 110′ is damaged due to clogging of second spray applicator 12′.

Stationary mix chamber 48′ and valve assembly 50′ within fluid housing 46′ remove the need for dynamic metal-to-metal high pressure fluid sealing that is conventionally used in manual spray applicators. Removing the metal-to-metal high pressure fluid sealing reduces manufacturing costs associated with the previous mix chamber design. Further, stationary mix chamber 48′ can be constructed from a metal or polymer and can be easily removed from second spray applicator 12′, which reduces downtime and increases productivity. Stationary mix chamber 48′ is a simplified and improved mix chamber because in operation stationary mix chamber 48′ remains stationary while valve assembly 50′ translates, resulting in less moving components within stationary mix chamber 48′.

FIG. 5A is a first isometric view of stationary mix chamber 148. FIG. 5B is a second isometric view of stationary mix chamber 148. FIG. 5C is a third isometric view of stationary mix chamber 148. FIG. 5D is a first plan view of stationary mix chamber 148. FIG. 5E is a first side view of stationary mix chamber 148. FIG. 5F is a second plan view of stationary mix chamber 148. FIG. 5G is a second side view of stationary mix chamber 148. FIG. 5H is a front elevation view of stationary mix chamber 148. FIG. SI is a rear elevation view of stationary mix chamber 148. FIGS. 5A-5I will be discussed together. Stationary mix chamber 148 includes body 150; outlet extension 152; posts 154a, 154b; seal grooves 156a, 156b; outlet orifice 158; inlet orifices 160a, 160b; and projection 162. Body 150 includes first end 164; second end 166; flat sides 168a, 168b; and contoured portion 167 having sloped sides 170a, 170b. Outlet extension 152 includes first portion 172; second portion 174; outlet boss 176; depressions 178a, 178b; recesses 180a, 180b. Post 154a includes outer face 182a and post 154b includes outer face 182b.

Stationary mix chamber 148 is configured to be positioned within a cavity formed by a fluid housing 46 and is retained within the chamber by air cap 36. Stationary mix chamber 148 is configured to receive individual component materials through inlet orifices 160a, 160b. The individual component materials mix within a mixing bore of the mix chamber 148, similar to mixing bore 62. The individual component materials mix to form a plural component material that flows through the mixing bore and is ejected through outlet orifice 158.

Body 150 extends between first end 164 and second end 166. First end 164 is a smallest width portion of body 150. First end 164 can be a smallest width portion of stationary mix chamber 148. Contoured portion 167 is a portion of body formed at and extending from first end 164. Contoured portion 167 extends from first end 164 to increase a width of the body 150. Contoured portion 167 is configured to interface with the contour of the chamber that receives the mix chamber 148 to facilitate sealing at the interface therebetween. More specifically, sloped sides 170a, 170b extend from first end 164 and increase the width of body 150. Sloped sides 170a, 170b are sloped to interface with the contour of the chamber that stationary mix chamber 148 is disposed within. Sloped sides 170a, 170b extend from first end 164 to flats 169a, 169b. Flats 169a, 169b extend between the second end 166 and sloped sides 170a, 170b, respectively. It is understood, however, that in some examples, the sloped sides 170a, 170b can extend the full length between first end 164 and second end 166. Sloped sides 170a, 170b can be considered to form the lateral sides of body 150.

Flat sides 168a, 168b extend between and connect sloped sides 170a, 170b. In some examples, a contour, such as a chamfer, is formed between sloped sides 170a, 170b, and flat sides 168a, 168b to connect the sides. Flat sides 168a, 168b can, in some examples, be the upper and lower sides of stationary mix chamber 148, relative to the orientation of spray gun 12. The body 150 can include sloped portions connecting the first end 164 and the flat sides 168a, 168b.

Projection 162 extends from flat side 168a. Projection 162 is elongate along body 150 from first end 164 towards second end 166. Projection is axially elongate along spray axis A-A. Projection 162 is configured to interface with a slot formed on a component of spray applicator 12, such as on fluid housing 46, to provide a keyed interface. The keyed interface facilitates alignment of stationary mix chamber 148 during installation to provide proper alignment of posts 154a, 154b and ensure that inlet orifices 160a, 160b are positioned to receive the component materials during spraying. While the keyed interface is described as including projection 162 on stationary mix chamber 148, it is understood that projection 162 can be formed on the component of spray applicator 12 and a slot can be formed on stationary mix chamber 148 to receive the projection.

Seal grooves 156a, 156b extend into sloped surfaces 170a, 170b, respectively. Seal groove 156a is an annular groove that extends around post 154a. Seal groove 156a is configured to receive an annular seal, such as an elastomeric seal, such as an o-ring. Inlet orifice 160a is formed through post 154a. Inlet orifice 160a is offset from a centerpoint of outer face 182a such that a width of outer face 182a between inlet orifice 160a and the outer edge of post 154a varies circumferentially about inlet orifice 160a. Outer face 182a of post 154a is sloped such that sloped side 170a and outer face 182a are disposed on a common plane. Seal groove 156b is an annular groove that extends around post 154b. Seal groove 156b is configured to receive an annular seal, such as an elastomeric seal, such as an o-ring. Inlet orifice 160b is formed through post 154b. Inlet orifice 160b is offset from a centerpoint of outer face 182b such that a width of outer face 182b between inlet orifice 160b and the outer edge of post 154b varies circumferentially about inlet orifice 160b. Outer face 182b of post 154b is sloped such that sloped side 170b and outer face 182b are disposed on a common plane. As best seen in FIG. 5I, inlet orifice 160a and inlet orifice 160b can be vertically offset relative each other.

Chamber face 184 is formed at second end 166 of body 150 and is oriented towards outlet extension 152. Chamber face 184 extends fully around the projection of outlet extension 152. Chamber face 184 extends annularly about axis A-A. Chamber face 184 can be formed as a flat surface disposed on a plane orthogonal to the axis A-A. Chamber face 184 provides a surface by which the stationary mix chamber 148 can be compressed within the cavity of the fluid housing 48. For example, an air cap, similar to air cap 36 and/or air cap 36′, can interface with chamber face 184 to drive stationary mix chamber 148 into the receiving cavity.

Outlet extension 152 projects from second end 166 of body 150. First portion 172 of outlet extension 152 is connected to second end 166 and extends between second end 166 and second portion of outlet extension 152. Recesses 180a, 180b are formed on the outer surface of first portion 172. Recesses 180a, 180b provide grips for the user to grasp and manipulate stationary mix chamber 148. In the example shown, recesses 180a, 180b are concave. Recesses 180a, 180b are smoothly contoured. Depressions 178a, 178b are formed on the outer surface of first portion 172. Depressions 178a, 178b provide surfaces at their axial ends that a tool, such as a flathead screwdriver, can interface with to facilitate removal of stationary mix chamber 148 from spray applicator 12. Depressions 178a, 178b can also be referred to as tool interfaces. Depressions 178a, 178b are formed with flat, planar bases and axial sides that provides surfaces for the tool to interface with.

Second portion 174 extends from first portion 172 and between first portion 172 and outlet boss 176. Second portion 174 includes a cylindrical portion having a smaller width than first portion 172 at the interface of first portion 172 and second portion 174. Second portion 174 further includes a frustoconical portion extending from the cylindrical portion. Outlet boss 176 extends from the frustoconical portion of second portion 174. The frustoconical portion reduces the width of outlet extension 152 between the cylindrical portion of second portion 174 and outlet boss 176. Outlet orifice 158 is formed through outlet boss 176. Outlet orifice 158 is configured to emit a spray of the plural component material that is mixed within stationary mix chamber 148. Outlet orifice 158 is configured to emit the spray along the spray axis A-A.

During operation, stationary mix chamber 148 is positioned to receive a first component material though inlet orifice 160a and a second component material through inlet orifice 160b. The first and second component materials mix within a flowpath formed within stationary mix chamber 148. The flowpath extends to outlet orifice 158. The first and second component materials combine in stationary mix chamber 148 to form the plural component material that is emitted as a spray through outlet orifice 158.

FIG. 6A is a first isometric view of stationary mix chamber 248. FIG. 6B is a second isometric view of stationary mix chamber 248. FIG. 6C is a third isometric view of stationary mix chamber 248. FIG. 6D is a first side view of stationary mix chamber 248. FIG. 6E is a first plan view of stationary mix chamber 248. FIG. 6F is a second side view of stationary mix chamber 248. FIG. 6