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Title:
REGULATORS AND POWER SUPPLY SYSTEMS
Document Type and Number:
WIPO Patent Application WO/2010/124036
Kind Code:
A1
Abstract:
Regulators and/or parts or components thereof useful, for example, in systems for powering pneumatic tools. In certain embodiments, dual-stage regulators wherein each stage of the regulators is adjustable and/or tunable. In certain preferred embodiments, tunable and/or adjustable dual-stage regulators which are capable of being used, selectively as desired, in low and/or high pressure applications, shot-type and/or continuous flow delivery applications, and/or low and/or high volume applications (or any combination thereof). In certain additional embodiments, in combination with or separate from the features of other embodiments described herein, regulators which exhibit stable performance regardless of, for example, cylinder supply pressure. In certain embodiments, regulators having an adjustment knob for selecting the pressure which will be delivered to the output port of the regulator (and thus to an attached hose) as well as, optionally, containing a pressure gauge so that the output pressure can be visually monitored and/or utilizing a unique on/off cartridge as a high pressure cartridge or module.

Inventors:
MAUGHAM CHRISTOPHER M (US)
BONTA CARL (US)
TURAN ROBERT L JR (US)
Application Number:
PCT/US2010/031962
Publication Date:
October 28, 2010
Filing Date:
April 21, 2010
Export Citation:
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Assignee:
MAUGHAM CHRISTOPHER M (US)
BONTA CARL (US)
TURAN ROBERT L JR (US)
International Classes:
F04B19/00
Domestic Patent References:
WO2009045229A12009-04-09
Foreign References:
US20070212236A12007-09-13
US6932128B22005-08-23
US6170519B12001-01-09
Attorney, Agent or Firm:
PEQUIGNOT, Matthew, A. (140 Marine View Avenue #22, Solana Beach CA, US)
Download PDF:
Claims:
What is claimed is:

1. A regulator comprising: a main regulator body; a cartridge body including a first end for threadably engaging a high pressure cylinder and a second end for threadably engaging said main regulator body, said first end of said cartridge body having a first, high pressure input aperture for gas flow communication with a high pressure gas source, said second end of said cartridge body having a second aperture for retaining at least a portion of a high pressure piston assembly, and further including a middle aperture located between said first aperture and said second aperture, and a cam shaft located seated in said middle aperture including a cam shaft operating mechanism for rotating said cam shaft within said middle aperture, an off/off stopper located between said first aperture and said cam shaft, said on/off stopper being operable to open and close air flow into said regulator by rotational operation of said cam shaft into first and second rotational positions, respectively; a high pressure piston having a first end extending at least partially into said second aperture, said first end of said high pressure piston having a recessed region carrying a high pressure piston seal and said high pressure piston having a through hole in a side wall joining a centrally disposed gas flow aperture extending the length thereof; said main regulator body including a cartridge chamber threadably engaging said second end of said cartridge body; a second end of said high pressure piston extending at least partially into a portion of said main regulator body and said high pressure piston having a laterally extending annular shoulder portion carrying an o-ring for providing a seal between said annular shoulder portion and an adjacent portion of said regulator; a poppet located generally axially in-line with and opposite said second end of said high pressure piston and having a poppet spring located between said poppet and said annular shoulder portion of said high pressure piston, said poppet having a centrally disposed pin portion extending through an annular poppet seal; a second piston located axially spaced from said poppet proximal said pin portion and having a threaded aperture disposed generally centrally therein; an adjuster shaft threadably engaged with said threaded aperture of said second piston, said adjuster shaft having a generally centrally disposed axial passage for providing air travel there-through, said adjuster shaft having a first end having a bore carrying a relief valve body therein and a second end interlockingly, rotationally engaging an adjuster shaft cap but moveable axially with respect to said adjuster shaft cap; said relief valve body having a detent at a first end for axial communication with said pin portion of said poppet; a spring disposed within said axial passage of said adjuster shaft between a seat portion of said adjuster shaft and said relief valve body; an adjuster spring located disposed about said adjuster shaft and seated at a first end proximal a portion of said second piston; a regulator cap connected to said main regulator body and retaining said adjuster spring at a second end of said adjuster spring; said adjuster shaft cap extending through a bore in said regulator cap and connected to an adjuster knob such that when said adjuster knob is rotated, said adjuster shaft cap rotates said adjuster shaft and said adjuster shaft advances axially farther into or out of said second piston depending on the direction of adjuster knob rotation; an output port for delivering gas to a hose; and wherein rotating said adjuster knob to advance said adjuster shaft farther into said second piston causes said relief valve body to bias against said pin portion of said poppet thereby to at least temporarily axially displace said poppet to allow air flow past a selective air seal between said poppet and said annular poppet seal.

2. A regulator according to any one of the preceding claims wherein said regulator is so structurally configured such that when the cam shaft is rotated such that air flow is turned off, at least one pressure gauge is in air flow communication with a high pressure source such that the pressure of such high pressure source is known.

3. A regulator according to any one of the preceding claims wherein said regulator is so structurally configured such that when the adjuster knob is rotated in a direction to reduce the amount of air pressure to be delivered, the excess air pressure is automatically purged from the regulator via purge structures so that the desired lower air pressure is immediately available for use.

4. A regulator according to any one of the preceding claims wherein said adjuster shaft includes a plurality of adjustment orifices in which pins can be inserted to adjust the maximum output of the regulators.

5. A regulator according to any one of the preceding claims wherein the regulator is structurally configured to allow for a continuous flow at a substantially constant pressure between a low pressure chamber and the outlet port.

6. A regulator according to any one of the preceding claims further including a first gauge for measuring the pressure in the high pressure source and a second gauge for measuring the pressure in the low pressure chamber to be output by the regulator.

7. A regulator according to any one of the preceding claims wherein a hose coupling is connected to the outlet port.

8. A regulator according to any one of the preceding claims wherein the regulator is connected to a tool.

9. A regulator according to any one of the preceding claims wherein the regulator body further includes a fill assembly.

10. A regulator according to any one of the preceding claims wherein said adjuster knob is adjustable to select a desired operational output pressure for delivery by said output port.

Description:
REGULATORS AND POWER SUPPLY SYSTEMS RELATED APPLICATION DATA

This application claims priority to U.S. Provisional Patent Application No. 61/171,449, filed April 21, 2009, entitled REGULATOR, the entirety of which is hereby incorporated by reference. The entireties of U.S. Patent No. 6,932,128, entitled APPARATUS AND METHOD FOR USING A LIGHTWEIGHT PORTABLE AIR/GAS POWER SUPPLY, and PCT Application PCT/US2007/88865, filed December 26, 2008, entitled PNEUMATIC REGULATOR ASSEMBLIES, POWER SUPPLY SYSTEMS, AND METHODS FOR USING THE SAME, are additionally hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to regulators (and/or parts or components thereof) and/or portable pneumatic power supply systems using such regulators. In at least one embodiment, an adjustable regulator attachable to a cylinder fillable with pressurized air/gas. Such an example regulator can be used attached to a high pressure cylinder (pressurized with air/gas) for providing output air/gas pressures (through a hose for example) at specific selected pressures suitable for use in powering pneumatic tools or for filling air bags or tires (or for possible other uses not set forth herein). Specifically, certain embodiments of the regulator have an adjustment knob for selecting the pressure which will be delivered to the output port of the regulator (and thus to an attached hose) as well as, optionally, contain a pressure gauge so that the output pressure can be visually monitored and/or utilize a unique on/off cartridge as a high pressure cartridge or module.

BACKGROUND OF THE INVENTION

A tremendous variety of tool types and the like have been developed over the centuries to address the many numbers of construction and manufacturing arts which have evolved during civilization's technological progress through modern times. For example, in a single industry such as the construction industry, dozens of different tool types may be used on a single construction site. In particular, the number of such tool types which are used has increased due to the various specialties and subspecialties of carpentry and other construction techniques which continue to develop as modern buildings become more complex. Throughout this evolution, substantial efforts have been made to automate tool operation, principally, to improve job efficiencies by improving tool operation speeds and by reducing fatigue of tool operators. In recent decades, such automation efforts have typically involved the development or innovation of compressor powered pneumatic tools or tools powered by electricity. In this regard, due to their improved efficiencies, the use of automated tools has become so commonplace that one would be hard pressed to not find a pneumatic nail gun or an electrically powered drill at a typical construction job site. Nevertheless, conventional pneumatic or electrically operable tools suffer various disadvantages or drawbacks.

For example, pneumatic or electrically powered tools which are directly connected to a compressor via a hose or to an electrical outlet via a power cord are limited in their portability or mobility due to their attachment to their respective power sources (e.g., their portability is limited to the length of the hose or cord and/or they may be difficult or unsafe to carry up a ladder for example). Moreover, the longer the cord or hose, the greater the overall weight as well as the chance that such hose or cord will become entangled or otherwise act as a safety hazard (e.g., as a tripping hazard). Although battery operated tools address some of these disadvantages, such tools are burdened by their own drawbacks such as their increased weight and reliance on the finite charge of a battery (and, after battery depletion, one must wait for the battery to be recharged or have additional batteries available, for example).

Although U.S. Patent No. 6,932,128, entitled APPARATUS AND METHOD FOR USING A LIGHTWEIGHT PORTABLE AIR/GAS POWER SUPPLY has addressed or mitigated some of the above described drawbacks, the present invention is intended to, at least in part, further improve on the apparatus and methods disclosed therein as well as provide other improvements not necessarily addressed towards technologies specifically disclosed in the '128 patent. In particular, the present invention is intended to provide substantial improvements in regulator design for use, for example, with systems such as described in the '128 patent.

For example, certain types of pneumatic tools, such as nail guns, require short bursts of pressurized air ("air" being used generically throughout this application, interchangeably with "gas" or "air/gas", to include atmospheric gases and/or other suitable gases such as nitrogen or helium), while others, such as pneumatic powered screw drivers, require a continuous flow of air, often at high pressures, over the duration of tool operation. Similarly, certain types of pneumatic jobs or projects are best addressed with low pressure, continuous flow air delivery such as the filling of a bicycle tire or a basketball or soccer ball (i.e., employing high pressure bursts or high pressure continuous flow in such applications may damage or burst the tire or ball). Still furthermore, certain more demanding applications, such as the operation of the certain cutting devices such as the "jaws of life" or a lift bag (e.g., each employed by fire departments in emergency operations) or certain impact wrenches, require high volume air delivery in addition to high pressure and continuous flow.

In light of the existence of these numerous applications and job types, each with their own air delivery requirements, it would be desirable to have a single regulator which is capable, because of its configuration or design, of being used in such (or other) alternative application or job types (e.g., with a system such as disclosed in the '128 patent) with or without regulator adjustment or part swapping being required when switching between such applications or job types. In certain optimum designs, it would be desirable, of course, to have a single regulator which is capable of delivering air, alternatively (e.g., selectively, as desired), at both low and high pressures, in bursts (shots) or as continuous flow, and/or in low or high volume (or in any combination of the herein listed delivery types) without requiring part swapping and/or significant regulator adjustment (or no regulator adjustment, other than of the output pressure adjustment mechanism, after an initial adjustment generally temporally proximal the installation of the regulator on the high pressure cylinder or bottle).

Additionally, employing known regulator designs, it is common to experience unwanted pressure variations during regulator operation. As one example of such a deficiency in prior known regulator designs, as the high pressure air source (for example, a steel, aluminum, or carbon fiber cylinder or "bottle") is depleted or the air or gas pressure supplied by the source is reduced, the output pressure delivered by the regulator typically increases (i.e., it is believed that this is because less pressure is initially available in the low pressure chamber to deflect the low pressure piston, and therefore allow regulator seat closure by the regulator pin, to allow air flow delivery to the low pressure chamber to be timely stopped). This unexpected result causes problems in certain types of regulator operation, such as when used with portable air power systems, because, for example, certain tool types will be damaged or will not operate properly if subjected to air pressures above threshold limits or if provided with variable air pressures during operation. In view of the above enumerated drawbacks and/or desires for improvements in the art, it is a purpose of the herein described invention to address one or more of such drawbacks and/or desires as well as, or in the alternative, other needs which will become more apparent to the skilled artisan once given the present disclosure.

SUMMARY OF CERTAIN EMBODIMENTS OF THE INVENTION Generally speaking, the present invention is directed, in certain example embodiments, to regulators (or parts or components thereof) which have configurations which exhibit improved performance (e.g., such as improved gas pressure delivery stability). In other or the same embodiments, adjustable regulators are provided. In such or other example embodiments, regulators are provided which have configurations which exhibit improved operational capabilities (e.g., such as with respect to range of gas pressure delivery, type of gas delivery, and/or volume of delivery). In at least one preferred example embodiment, a regulator is provided which includes two stages with each stage being user adjustable to tune operational performance.

In certain embodiments, the adjustable regulator is connected to an on/off switch or module which is capable of cutting off the supply of pressurized air/gas to the regulator. In some versions of the regulator, when the adjustment knob is turned down to reduce the amount of air/gas pressure to be delivered, the excess air/gas pressure (beyond the pressure desired to be delivered) is automatically purged from the regulator via herein described and illustrated structures (so that the desired lower air/gas pressure is immediately available for use with a tool, for example). Some versions of the regulator have a adjuster shaft with multiple adjustment orifices in which pins can be inserted to adjust the maximum output of the regulators (e.g., from 200 to 300 psi). The same or other versions of the regulator contain a pressure relief port in communication with the high pressure side of the regulator. Having such a pressure relief port allows air/gas to be completely purged from both the regulator and the pressurized cylinder should the need arise to disassemble the regulator or remove it from the bottle and the pressure cannot otherwise be relieved. In some versions of the regulator with the on/off switch (module), the on/off module is specifically structurally configured, in combination with a complementary structure of the regulator, so that even when the on/off switch is turned to the off position, a pressure gauge displays the pressure in the pressurized cylinder (e.g., for safety reasons so you always know the pressure in the cylinder even when the regulator is turned off). Such a pressure gauge may be optionally used in conjunction with a second pressure gauge which displays the pressure which will be output at the output port to a tool or the like (e.g., via a hose). Still other versions of the regulator utilize a pressure adjustment knob guard or cap. Such a guard/cap covers the adjustment knob so that it cannot be inadvertently bumped and the output pressure inadvertently changed. The guard/cap, when used, moreover, reduces the possibility of regulator entanglement. In versions of the regulator which use the on/off switch or module, the high pressure cartridge is not used and the on/off switch/module has a male region which screws into the neck of a cylinder (with the on/off module bolting to the regulator while using o-rings for seals and the like). In versions not connected to or utilizing the on/off module, a high pressure cartridge is used which has a male portion for threading into the neck of a cylinder (for containing pressurized air/gas). In some embodiments which utilize an on/off module, the module has a module body containing a cam-type open/close switching mechanism (e.g., a cam rod) with a lever for switching the module (via the cam mechanism or rod) into flow and non-flow (i.e., on and off) positions as desired. In at least one embodiment there is provided a regulator comprising: a main regulator body; a cartridge body including a first end for threadably engaging a high pressure cylinder and a second end for threadably engaging the main regulator body, the first end of the cartridge body having a first, high pressure input aperture for gas flow communication with a high pressure gas source, the second end of the cartridge body having a second aperture for retaining at least a portion of a high pressure piston assembly, and further including a middle aperture located between the first aperture and the second aperture, and a cam shaft located seated in the middle aperture including a cam shaft operating mechanism for rotating the cam shaft within the middle aperture, an off/off stopper located between the first aperture and the cam shaft, the on/off stopper being operable to open and close air flow into the regulator by rotational operation of the cam shaft into first and second rotational positions, respectively; a high pressure piston having a first end extending at least partially into the second aperture, the first end of the high pressure piston having a recessed region carrying a high pressure piston seal and the high pressure piston having a through hole in a side wall joining a centrally disposed gas flow aperture extending the length thereof; the main regulator body including a cartridge chamber threadably engaging the second end of the cartridge body; a second end of the high pressure piston extending at least partially into a portion of the main regulator body and the high pressure piston having a laterally extending annular shoulder portion carrying an o-ring for providing a seal between the annular shoulder portion and an adjacent portion of the regulator; a poppet located generally axially inline with and opposite the second end of the high pressure piston and having a poppet spring located between the poppet and the annular shoulder portion of the high pressure piston, the poppet having a centrally disposed pin portion extending through an annular poppet seal; a second (low pressure) piston located axially spaced from the poppet proximal the pin portion and having a threaded aperture disposed generally centrally therein; an adjuster shaft threadably engaged with the threaded aperture of the second piston, the adjuster shaft having a generally centrally disposed axial passage for providing air travel there-through, the adjuster shaft having a first end having a bore carrying a relief valve body therein and a second end interlockingly, rotationally engaging an adjuster shaft cap but moveable axially with respect to the adjuster shaft cap; the relief valve body having a detent at a first end for axial communication with the pin portion of the poppet; a spring disposed within the axial passage of the adjuster shaft between a seat portion of the adjuster shaft and the relief valve body; an adjuster spring located disposed about the adjuster shaft and seated at a first end proximal a portion of the second piston; a regulator cap connected to the main regulator body and retaining the adjuster spring at a second end of the adjuster spring; the adjuster shaft cap extending through a bore in the regulator cap and connected to an adjuster knob such that when the adjuster knob is rotated, the adjuster shaft cap rotates the adjuster shaft and the adjuster shaft advances axially farther into or out of the second piston depending on the direction of adjuster knob rotation; an output port for delivering gas to a hose; and wherein rotating the adjuster knob to advance the adjuster shaft farther into the second piston causes the relief valve body to bias against the pin portion of the poppet thereby to at least temporarily axially displace the poppet to allow air flow past a selective air seal between the poppet and the annular poppet seal. In certain example embodiments, the present invention provides: a regulator comprising: a regulator body including an inlet port for connecting to a high pressure gas supply, and the regulator housing a first stage and a second stage; the first stage including a first regulator piston and a first regulator seat for regulating air delivery between a high pressure chamber and a low pressure chamber of the regulator; the second stage including a second regulator piston and a second regulator seat for regulating air delivery between the low pressure chamber and an output pressure chamber; an output port in selective gas flow communication with the output chamber for delivering gas pressure at a desirable output pressure; a first adjuster mechanism in communication with the first stage for adjusting at least one operational parameter of the first stage; a second adjuster mechanism in communication with second stage for adjusting at least one operational parameter of the second stage; and wherein the first adjuster mechanism and the second adjuster mechanism are each adjustable, alone or in combination, to tune performance of the regulator to have desirable operational characteristics. In this or other example embodiments, the second adjuster mechanism is adjustable to select a desired operational output pressure for delivery by said output port (e.g., for use by pneumatically powered tools and the like). In such or other example embodiments, the first and second adjuster mechanisms are adjustable to selectively tune said regulator to be capable of delivering gas, via said outlet, in the alternative or in combination, at low pressures, at high pressures, at low volume, at high volume, in shots, and as continuous flow.

If desired, in any one or combination of the preceding embodiments, the regulator is so designed such that the regulator cap can be removed while the regulator is attached to a pressurized high pressure cylinder without the high pressure cylinder substantially depressurizing.

In certain other contemplated examples, in any one or combination of the preceding embodiments, the regulator is so designed such that the springs (regardless of the type employed) may be selectively removed and replaced with springs of another type or of another "spring bias or strength rating" to thereby change the psi output of the regulator according to a desired selected end use. In certain preferred example embodiments (either as described specifically above or in any combination or sub-combination thereof), the psi output which can be changed is selected from the group comprising: maximum psi output, psi range output, minimum psi output, or some combination of the herein listed output variables. In certain exemplar embodiments, a unique configuration of a high pressure cartridge assembly is provided as a self-contained, removable module. The use of such module, in such example regulator configurations, lends to ease of maintenance and/or repair of the regulator as well as, or in the alternative, ease of manufacture and/or increased reliability.

In some preferred example embodiments, the psi range output can be quickly changed simply by switching out the spring or spring sets. For example, in one embodiment, a regulator may be converted to be capable of switching between 0-150 psi output and 0-300 psi output (in practice, conventionally to 150-300 psi output) by a simple spring (or biasing mechanism pack) switch-out. This is important, in at least one respect, where it is desired to use such regulator (e.g., as part of a portable power supply system) for a variety of end use types ranging from inflating sports balls such as basketballs or soccerballs to more high pressure applications such as for powering impact wrenches or operating emergency lift bags and the like.

In various exemplary embodiments the regulator is designed to connect to a source of pressurized air, such as a portable canister. In such embodiments the canister is preferably small enough to be carried by a user and connects through the regulator to a hose to be operatively coupled to any number of pneumatic tools. In various exemplary embodiments, the flow of the gas from the high pressure chamber to the low pressure chamber may be regulated by a tunable or adjustable high pressure piston assembly (e.g., including a poppet and associated spring). Further, in such example or other embodiments, the flow of gas from the low pressure chamber to the output chamber may be regulated by a tunable or adjustable low pressure piston assembly. In still other embodiments, one or both of the high and low pressure piston assemblies are adjustable and/or tunable to obtain generally predictable, substantially or generally unchanging output pressure regardless of decreases in source pressure (e.g., provided by a high pressure cylinder connected to the regulator).

In some of the herein described embodiments, the longitudinal position of an adjustment shaft within a piston is user adjustable (e.g., for regulator tunability). For example, the regulator may include a knob for user adjustment of the position of the shaft within the low pressure piston.

Further, in some embodiments, the regulator may be capable of receiving air/gas at the air inlet port at a pressure of between at least 0-6000 PSI and stepping down such air/gas pressure, to deliver such air/gas from the air/gas outlet port, in certain preferred example embodiments, at pressures selected between 150-300 PSI, and in more preferred example embodiments, at pressures selected from between 0-300 PSI, and in still further preferred embodiments, at pressures selected from between 0-500 PSI (e.g., at various desirable volume delivery rates). In the most preferred (but still non-limiting) example embodiments, a wide variety of pressures and volumes can be selected and delivered without requiring part swapping and/or substantial regulator adjustment. In certain particularly efficacious embodiments, no adjustment of the regulator is required when switching between end use applications (e.g., other than possibly of the output pressure knob).

In some embodiments, the air/gas outlet is connected via an air/gas hose to a pneumatically operated tool, and the regulator may further include an air fill inlet, which may be connectable via an air hose, for example, to a reservoir or compressor for refilling an air tank connected to the regulator.

In another embodiment, the present invention is directed to a portable pneumatic tool power supply system that includes (a) a two stage regulator that includes a housing having at least a first chamber and a second chamber in fluid communication with the first chamber; a high pressure cartridge assembly and a high pressure piston assembly housed within the first chamber; the high pressure cartridge assembly having an air inlet port, and a low pressure cartridge or other assembly and a low pressure piston or assembly housed within the second chamber, the low pressure cartridge being fluidly connected to an air outlet port; (b) a pressurized air tank; and (c) a hose connected to the air outlet port on one end and to a pneumatic tool on the other end. In certain embodiments described herein, having adjustability at both the first and second stages allows tunability of the regulator so that it can be readily used with a wide range of pneumatic tools (which utilize shot- type gas delivery or continuous flow delivery). In such or other embodiments, having first and second stage adjustability, additionally, or in the alternative, permits tunability so that the regulator delivers a generally or substantially stable output gas pressure regardless of the gas supply pressure (e.g., the pressure of the gas supplied by a high pressure steel, aluminum, or carbon fiber cylinder).

With regard to certain other regulator designs, certain specific drawbacks are present. For example, "droop" may be experienced by air tools that need constant air flow to work such as drills, chisels, grinders, sanders, impact wrenches and the like. When a regulator experiences droop from an air tool being used, the psi provided by a regulator during operation of a tool drops undesirably once the tool has initially started. For instance, if the tool needs 120 psi to run constantly, that means it needs 120 psi for the duration of time in which the tool is being used (e.g., for it to operate efficiently). However, if so-called droop occurs, adequate air pressure (e.g., 120 psi) is not provided (e.g., pressure drops of 30-40 psi may occur which results in less air pressure than is required for a tool to be operated efficiently being provided). This may also result in an attached high pressure cylinder being depleted very quickly thereby using all of the stored air/gas before a job can be fully completed. In certain embodiments of the herein described invention, regulators are provided which can efficiently provide air/gas power to constant air flow tools with significant reductions in droop or substantial or complete elimination of droop. Certain examples of the invention are now below described with respect to certain non- limiting embodiments thereof as illustrated in the following drawings wherein:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a three-dimensional view of one embodiment of a regulator according to the subject invention.

FIG. 2 illustrates a cross-sectional, plan view of the embodiment of the regulator illustrated in FIG. 1.

FIG. 3 illustrates a different cross-sectional, plan view of the embodiment of the regulator illustrated in FIG. 1. FIG. 4 illustrates the embodiment of the regulator illustrated in FIG. 3 with different part shading, certain parts removed for sake of clarity, and the regulator shown in a pressurized mode. FIG. 5 illustrates an exploded, three-dimensional view of the regulator illustrated in FIG. 1.

FIG. 6 illustrates an exploded, three-dimensional view of a removable high pressure cartridge in accordance with one embodiment of the subject invention.

FIG. 7 illustrates an exploded, three-dimensional view of an adjuster shaft, relief valve, and related parts useful in conjunction with at least one regulator embodiment according to the subject invention.

FIG. 8 illustrates an x-ray view of an adjuster shaft useful in conjunction with at least one regulator embodiment according to the subject invention.

FIG. 9 illustrates a cross- sectional view of an adjuster shaft useful in conjunction with at least one regulator embodiment according to the subject invention.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS For a more complete understanding of the present invention, reference is now made to the following description of various illustrative and non-limiting embodiments thereof, taken in conjunction with the accompanying drawings in which like reference numbers indicate like features.

Referring initially to FIGS. 1 and 7, assembled and blown apart views of an example regulator according to the subject invention are illustrated therein. Such figures, in this regard, illustrate regulator 1 as comprising an assembly of four main components or sub-assemblies including a main regulator body 5, a high pressure cartridge or on/off module 3, a regulator cap 47, and a gauge guard 7, each, as assembled together, comprising and/or operatively enclosing regulator l's main functional components.

In this regard, regulator l's high pressure cartridge 3 is generally comprised of a cartridge body 61 having a first end 4 for threadably engaging a high pressure cylinder or other high pressure air source and a second end 6 for threadably engaging main regulator body 5. First end 4, in this regard, includes a high pressure input aperture 74 for gas flow communication with a high pressure cylinder to which it attaches (or is attached). The second end 6 of cartridge body 61 further includes a second aperture for retaining at least a portion of a high pressure piston assembly (including high pressure piston 8 and related parts, as will be described in further detail below) and also includes a middle aperture located between the first aperture and the second aperture which carries a cam shaft or rod 65 therein. Attached to the cam rod 65 is a handle or lever 63 (which serves as a cam shaft operating mechanism) for rotating the cam shaft within the middle aperture. In the illustrated embodiments, cam rod 65 is eccentrically shaped so as to axially bias or move on/off stopper 69, upon cam rod rotation, within a bore in the cartridge body 61 located between first aperture 74 and the cam rod. As illustrated, on/off stopper is retained within the cartridge body employing a hollow set screw 73 which captures or retains a stopper spring 71.

Specifically, by rotating the cam lever 63, cam rod 65 moves on/off stopper 69 between open and closed positions thereby opening and closing high pressure air flow into the regulator (i.e., from a high pressure air source such as a pressurized cylinder) by unblocking or blocking the air pathway which begins at aperture 74 (o-ring 75 is provided around stopper 69 to selectively effect a airtight seal).

As can be seen, high pressure piston 8 is located within the regulator such that its first end extends at least partially into the second aperture of cartridge body 61. The first end of high pressure piston 8 includes a recessed region carrying a high pressure piston seal 9. Moreover, piston 8 has a through-hole 10 in a side wall joining a centrally disposed gas flow aperture 12 extending substantially or entirely the length thereof. The second end of piston 8 extends or resides (in this embodiment) at least partially within a cartridge chamber of main regulator body 5 (e.g., high pressure cartridge 3 being threadably joined to body 5 via its cartridge chamber). At this region, piston 8 includes a laterally extending annular shoulder portion carrying an o-ring 17 for providing a seal between the annular shoulder portion and an adjacent portion of the regulator e.g., via poppet plug 27, installed in a bore of body 5, in this particular, non-limiting embodiment.

Installed within poppet plug 27 is a poppet 23 located generally axially in-line with and opposite the second end of high pressure piston 8 (e.g., near the end with the annular shoulder region). Disposed between poppet 23 and the annular shoulder portion (of piston 8) is a poppet spring 25. Such spring is retained within a bore of poppet 23 at one end and against the shoulder region of piston 8 at its other end. Poppet 23 includes a centrally disposed pin portion extending through an annular poppet seal 29, and poppet spring 25, in certain operational modes, biases poppet 23 against such seal 29 to thereby provide a selective air flow seal between the intermediate pressure chamber and the low pressure chamber (described further below).

Moving further up the regulator body, a second, low pressure piston 39 is located axially spaced from poppet 23 (e.g., proximal its pin portion) and includes a threaded aperture disposed generally centrally therein. Adjuster shaft 37 is threadably engaged with the threaded aperture of piston 39 in a manner such that the axial position of shaft 37 within piston 39 can be adjusted via threading and unthreading. Adjuster shaft 37 includes a generally centrally disposed axial passage for providing air travel there-through. Moreover, the adjuster shaft has a first end having a bore carrying a relief valve body 31 therein and has a second end interlockingly, rotationally engaging an adjuster shaft cap 45. Although shaft 37 is engaged to cap 45 such that they co- rotate with one another, shaft 37 is structurally configured such that it can move axially further into and out of engagement with the female engaging portion of the cap.

Relief valve body 31 includes a detent at a first end for axial communication with the pin portion of poppet 23 and a relief valve spring 33 is disposed within an axial passage of adjuster shaft 37 between a seat portion of the adjuster shaft and relief valve body 31. This, in certain operation modes, biases the relief valve body towards the poppet pin. An adjuster spring 43 is located disposed about adjuster shaft 37 and is seated at a first end proximal or on top of a portion of the second, low pressure piston 39 (e.g., over a raised spring locator portion) and is enclosed or captured at its other end via regulator cap 47. Cap 47 itself is, in this embodiment, connected to main body 5 via threads.

Adjuster shaft cap 45 extends through a bore in regulator cap 47 and is preferably connected to an adjuster knob 49 such that when the adjuster knob is rotated, the adjuster shaft cap rotates adjuster shaft 37 and the adjuster shaft advances axially farther into or out of second, low pressure piston 39 depending on the direction of adjuster knob rotation. More specifically, rotating the adjuster knob in a direction to advance adjuster shaft 37 farther into second (low pressure) piston 39 causes relief valve body 31 to bias against the pin portion of poppet 23 thereby to at least temporarily axially displace the poppet to allow air flow past the selective air seal between poppet 23 and annular poppet seal 29.

Output port 97 is provided in the regulator body for delivering air to a hose, for example, and is in air flow communication with low pressure chamber LPC seen most easily in FIG. 4 (which illustrates the regulator in a pressurized state and low pressure piston 39 raised a distance "d"). Port 97, in this regard, is preferably provided with threaded walls for accepting installation of a quick connect/disconnect type coupler for connecting to an air/gas hose, for example (e.g., for connection, in turn, to a pneumatic tool).

In preferred but not necessarily all embodiments, regulator 1 includes a relief port capable of being used to empty all pressure from the regulator, if desired (e.g., because of need for repair or adjustment or for any other desirable reason). In such embodiments such as shown in FIG. 2, a relief port seal 57 is provided which is held in place to seal the port by relief port plug 59. In the illustrated embodiment, plug 59 has a convex surface so that it provides concentrated pressure proximal the center portion of seal 57. In order to remove plug 59, a hex wrench (for example) can be used to simply unthread it from the regulator body thereby releasing pressure from the regulator (and/or from an attached high pressure cylinder in certain embodiments which include connected air passageways between the relief port and the input aperture 74).

In order to fill an attached high pressure cylinder when regulator 1 is connected to such a cylinder (or similar air storage device), a fill port FP is provided such as illustrated in FIG. 3. As can be seen in this figure, such fill port is connected via air passageways API (with certain portions obstructed in such figure) to passageways AP2 in high pressure cartridge 3 (such connection, for example, being sealed by o-ring 103) which in turn are air path connected to aperture 74 which, when installed, is in communication with the air pressure of a high pressure cylinder. Because of these air path connections, fill port FP can be used to fill a high pressure bottle or cylinder for later use to power pneumatic tools, for example. As a safety feature, a burst disk port 101 (with associated burst disk) is also included connected to such air pathways.

As can be seen in the various figures, high pressure cartridge 3 connects to main regulator body 5, in preferred embodiments, by simply threading thereto employing o-rings such as o-rings 79 and 81, where appropriate, to obtain or achieve necessary seals.

In operation, the two stage regulator which is illustrated is preferably attached to a portable, high pressure air/gas cylinder so that aperture 74 is in air/gas flow communication with a source of pressurized air/gas (e.g., as contained in the connected high pressure air/gas cylinder). In this regard, when cam rod 65 has been operated to the "open" position, pressurized air can enter the regulator and travels past seal 9 when piston 8 is in a retracted position and seal 9 is not biased against seal plug 87. Air pressure which passes seal 9 fills the area or space between piston plug 91 and the exterior circumference of the first end portion of piston 8 and enters through-hole 10 of such piston. After entering through-hole 10, air pressure travels through gas flow aperture 12, out of the piston 8, and into the selectively sealed space above the annular shoulder region of the piston. Once sufficient pressure fills such sealed space sufficient to overcome the upward biasing force of spring 11 (biasing upwardly against the downward facing portion of piston 8's annular shoulder region), such pressure forces high pressure seal 9 against high pressure seal plug 87 and air passage from the high pressure side of the regulator to the intermediate pressure portion (or intermediate pressure chamber IPC) of the regulator is temporarily stopped. It is noted at this juncture that, in certain preferred embodiments (such as shown), an area below the annular shoulder region of piston 8 is exposed to atmospheric or ambient pressure (while otherwise being sealed from exposure to other chambers of the regulator by o-rings such as 17 and 79). This is accomplished by providing ports Pl and P2 such as shown in FIG. 3. Such ports are simply bores in the regulator body which lead to the outside of the regulator. In short, by maintaining low, atmospheric pressure below the annular should region of piston 8, even when such piston is biased downwards (relative to the orientation of the figures), no undesired air pressure resistance results (e.g., such as by air "squeezing") which allows the tuning of the regulator to be consistent and/or predictable by selection of spring values (e.g., for spring 11) rather than relying on the potential additional effect of changing air pressures in such region (the movement of piston 8 being, at least in part, a reflection of the differential of forces (whether applied by springs and/or air pressure) applied to the top and bottom regions of the annular shoulder portion of the piston). In order to select and provide air pressure to the low pressure chamber or output region of regulator 1, adjuster knob 49 is employed to screw adjuster shaft 37 axially farther into low pressure piston 39. When this is done, relief valve 31 is biased downwards against the pin portion of poppet 23. When sufficient downward biasing force has been applied to poppet 23, the upward biasing force provided by spring 25 is overcome and the air seal between poppet seal 29 and poppet 23 is temporarily "broken". In particular, once "broken", air pressure is permitted to travel past seal 29 and into low pressure chamber LPC. As air pressure fills such chamber LPC, air pressure acts on or begins biasing against the lower face of low pressure piston 39. When sufficient air pressure builds in low pressure chamber LPC (i.e., below piston 39) such that it is large enough to overcome the downwardly applied biasing forces of adjuster spring 43 (i.e., being applied against the top region of piston 39), downward biasing pressure on poppet 23 is eased and, with aid of spring 25, poppet 23 once again seats against poppet seal 29 such that the seal between the intermediate pressure chamber IPC and low pressure chamber LPC is restored. Of course, because an output gauge 15 is provided, a user can monitor the pressure supplied to the low pressure chamber LPC and thereby select the pressure which will be delivered to output port 97 (and, thereby, to a connected pneumatic tool, for example). In this regard, by advancing adjuster shaft 37 farther into the regulator and piston 39 (via adjuster knob 49), higher air pressures in the low pressure chamber are achieved. Conversely, by backing shaft 37 farther out of piston 39 (i.e., upwards relative to the orientation of the figures), lower air pressures will be delivered to the low pressure chamber. During operation, of course, when the regulator is pressurized and otherwise open and connected to a high air pressure source, air is evacuated from the low pressure chamber during use (via port 97, possibly connected to a hose or the like). When air is evacuated as such during use (e.g., such as during powering an air wrench), the pressure drop within the low pressure chamber (which results in a lower upward applied biasing force against piston 39) allows the force of spring 43 to temporarily open the seal between poppet 23 and poppet seal 29 again such that additional air pressure enters the low pressure chamber LPC. This, of course, begins a new operating cycle (in which the seal is eventually closed again, etc.).

As an additional improvement in the subject regulator arts, when it is desired to adjust regulator 1 to deliver a lower regulator output pressure, such pressure can be selected by merely turning adjuster knob 49 in the appropriate direction (such as described above) and any pressure in the output side of the regulator which is above the desired selected output pressure will be evacuated via the internal passage within adjuster shaft 37. More specifically, when adjuster shaft 37 is advanced in a direction out of piston 39, the reduced air pressure within the low pressure chamber allows spring 33 to bias relief valve 31 such that its o-ring 21 no longer (temporarily) provides an air seal within the central portion of the shaft. When this seal is broken, air pressure travels out through the central passage of shaft 37 and into the ambient air. Of course, when a sufficient amount of air has been evacuated, relief valve 31 is automatically forced again (by way of differentials of spring and air pressure forces) into a sealing engagement with the internal bore of shaft 37 (by way of its o-ring). Once resealed as such, air no longer evacuates through the adjuster shaft and the desired output pressure has been obtained (e.g., for being delivered to a pneumatic tool).

In at least one embodiment of the invention, adjuster shafts 37 are provided with mechanisms for limiting output pressure delivery. For example, as illustrated in FIGS. 8 and 9, such output shafts are provided with apertures for receipt of blocking pins (not shown). By inserting a pin in one of the respective locations, the travel or axial adjustability of the shaft is physically blocked. The locations of such apertures can be selected, of course, to correspond to particular psi output values such as shown (or as otherwise desired). More specifically, by restricting axial adjustability, the amount of air flow that is permitted into the low pressure chamber by operation of the adjuster knob is limited. This feature may be provided, for example, for safety or to prevent damage to tools (which might be damaged by inadvertently high provided output pressures).

Once given the above disclosure, many other features, modifications, and improvements will become apparent to the skilled artisan. Such features, modifications, and improvements are therefore considered to be part of this invention, without limitation imposed by the example embodiments described herein. Moreover, any word, term, phrase, feature, example, embodiment, or part or combination thereof, as used to describe or exemplify embodiments herein, unless unequivocally set forth as expressly uniquely defined or otherwise unequivocally set forth as limiting, is not intended to impart a narrowing scope to the invention in contravention of the ordinary meaning of the claim terms by which the scope of the patent property rights shall otherwise be determined: