Multi-component spraying system

A plural component spraying system, comprising:

• a first source of first component;
• a second source of second component;
• spraying means for directing mixed first and second components at a substrate;
• liquid delivery means for providing a flow of said first component from said first source to said spraying means and for providing a flow of said second component from said second source to said spraying means;
• a source of compressed air;
• air delivery means for providing a flow of compressed air from said compressed air source to said spraying means;
• and
• mixing means for mixing said first and second components to provide a mixture of said first and second components for atomization,
• said spraying means including an airless liquid nozzle for forming the mixture of first component and second component into a fan-like film with edges extending from a liquid orifice, and a nozzle assembly for directing a first flow of compressed air to impinge on the fan-like film closely adjacent to the airless liquid nozzle and assist in the formation of a particle spray and for further directing a second flow of compressed air to substantially confine the particle spray downstream of the impingement of the first flow of compressed air, said first and second flows of compressed air interacting with the fan-like film of mixed first and second components to assist atomization and capture the particles of the mixture.

A method of forming a coating form a plurality of mixed components, comprising:

• delivering a flow of a first component to a spraying means;
• delivering a flow of compressed air to said spraying means;
• introducing a second component into the flow of compressed air to said spraying means;
• forming the first component flow into a fan-like film with expanding edges extending from the spraying means;
• directing the flow of compressed air and second component at the fan-like film of said first component in the absence of a directed flow of compressed air between said fan-like film and said flow of compressed air and second component;
• atomizing the first component and mixing the first component and second component with the flow of compressed air;
• and
• directing the atomized and mixed first and second components at a substrate where the first and second mixed components harden to form a coating.

A method of forming a coating from a plurality of mixed components, comprising:

• delivering a flow of a first component to a spraying means;
• delivering a flow of second component to said spraying means;
• delivering a flow of compressed air to said spraying means;
• mixing said first component and said second component and forming the mixture of first and second component into a fan-like film with expanding edges extending from the spraying means;
• dividing the flow of compressed air into two air flows having greater width than depth and directing said two air flows at the fan-like film of said mixture from opposite sides of the film within a fraction of an inch of the spraying means;
• further dividing the flow of compressed air into two substantially parallel air jets directed at the expanding edges of the fan-like film downstream of intersection of the expanding air flows, said mixture being formed into a spray pattern with particles of mixed first and second components substantially contained in said spray pattern;
• and
• directing the spray particles at a substrate where the first and second mixed components harden to form a coating.

Means for forming an article from a catalyzed, resinous material, comprising:

• a first source of resin;
• a second source of catalyst for said resin;
• spraying means to mix said catalyst with said resin and to direct mixed catalyst and resin at an article-forming substrate;
• liquid delivery means to provide a flow of resin from said first source to said spraying means;
• air delivery means to provide a flow of compressed air to said spraying means;
• and
• injection means for introducing catalyst into said flow of compressed air comprising a fluid valve and mixing assembly coupled to said second source of catalyst and to said air delivery means for introducing catalyst into said compressed air, said air delivery means comprising means for coupling said fluid valve and mixing assembly to said spraying means to deliver a flow of compressed air and catalyst particles to said spraying means,
• said spraying means comprising a liquid nozzle for forming the resin flow into a fan-like resin film with expanding edges extending from a liquid orifice, and a nozzle directing compressed air and catalyst particles at the fan-like resin film,
• said liquid nozzle and said nozzle being adapted so that the compressed air and catalyst particles interact with the fan-like resin film and its expanding edges to provide a spray pattern with mixed catalyst and resin particles uniformly distributed throughout the spray pattern.

A method of forming a coating from a plurality of mixed components, comprising:

• delivering a flow of a first component to a spraying means;
• delivering a flow of a second component to said spraying means;
• delivering a flow of compressed air to said spraying means;
• mixing said first component and said second component and forming the mixture of said first and second components into a fan-like film with expanding edges extending from the spraying means;
• directing a first flow of compressed air having greater width than depth to intersect the fan-like film of said mixture within a fraction of an inch of the spraying means to assist in the formation of a particle spray;
• further directing a second flow of compressed air to substantially confine the particle spray downstream of intersection of the expanding air flow and fan-like film, said particle spray of mixed first and second components being substantially confined in a spray pattern of reduced size;
• and
• directing the spray particles at a substrate where the first and second mixed components harden to form a coating.