Dispenser with air mixing

A method of dispensing a plural component material, the method comprising:

• receiving a first material and a second material at an inlet of a mixing channel, the mixing channel having upstream and downstream ends defining a first flow direction through the mixing channel, and the mixing channel comprising a housing wall defining a flow passage, wherein the housing wall includes an inlet portion disposed at the upstream end and configured to receive the first material and the second material and a tip orifice disposed at the downstream end of the mixing channel and configured to emit a plural component material from the mixing channel;
• flowing the first material and the second material through a mixer disposed within the mixing channel to produce a plural component material;
• and
• flowing nucleation air through an aerator projecting from outside of the mixing channel and into the flow passage and into the plural component material at a location downstream of a downstream end of the mixer and upstream of the tip orifice such that the plural component material flows around a portion of the aerator disposed in the flow passage and such that the nucleation air is emitted into the flow of plural component material to form an aerated plural component material prior to the plural component material exiting the flow channel through the tip orifice.

A nozzle assembly comprising:

• a mixing channel having upstream and downstream ends defining a flow direction through the mixing channel, the mixing channel comprising:
• a housing wall defining a flow passage, the housing wall comprising:
• an inlet portion disposed at the upstream end and configured to receive a first material and a second material;
• and
• a tip orifice disposed at the downstream end, the tip orifice configured to emit a plural component material from the mixing channel;
• a static mixer disposed within the mixing channel, the mixer configured to mix the first material and the second material into the plural component material;
• and
• an aerator extending into the flow passage and configured to flow nucleation air into the flow passage at a location downstream of an upstream end of the mixer and upstream of the tip orifice such that the nucleation air is emitted into a flow of the plural component material prior to the plural component material exiting the flow channel through the tip orifice, the aerator configured to flow a stream of the nucleation air into the plural component material in an upstream direction relative to the flow of the plural component material.