REGULATORS, POWER SUPPLY SYSTEMS AND METHODS FOR USING THE SAME

RELATED APPLICATION DATA

[0001] This application claims priority to U.S. Provisional Patent Application No. 60/977,374, filed October 3, 2007, entitled PNEUMATIC REGULATOR ASSEMBLIES, POWER SUPPLY SYSTEMS AND METHODS FOR USING THE SAME, the entirety of which is hereby incorporated by reference. The entirety of U.S. Patent No. 6,932,128, entitled APPARATUS AND METHOD FOR USING A LIGHTWEIGHT PORTABLE AIR/GAS POWER SUPPLY, is additionally incorporated herein by reference.

FIELD OF THE INVENTION

[0002] The present invention relates to regulators (and/or parts or components thereof), portable pneumatic power supply systems using such regulators, and methods of using the same.

BACKGROUND OF THE INVENTION

[0003] 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.

[0004] Throughout the modern evolution of tools, 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. For example, automated tools have become increasingly popular in a number of industries including, the automotive, construction, manufacturing, fire rescue, and racing industries.

[0005] In recent decades, such automation efforts have typically involved the development or innovation of compressor powered pneumatic tools. Pneumatic tools have a number of advantages over electrically powered tools. Pneumatic tools are often easier to maintain, cheaper to manufacture, and more durable than their electrical counter parts.

[0006] Some examples of pneumatic tools commonly found in the industries mentioned above include air hammers, caulk guns, cleaning guns, cutting tools, grinders and sanders, drills, impact wrenches, nail and staple guns, ratchets, screwdrivers, and spray guns. These tools are directly coupled to an air compressor via a hose. Different lengths and sizes of hose are used depending on the job and the compressors are often large machines powered by either electricity or fossil fuels.

[0007]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, to include all 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.

[0008]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 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).

[0009] 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 (e.g., they may drive a nail too deeply) if subjected to air pressures above threshold limits.

[001O]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

[0011] 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 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.

[0012] 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 gas supply and a high pressure chamber of the regulator; the second stage including a second regulator piston and a second regulator seat for regulating air delivery between the high pressure chamber and a low pressure chamber; an outlet in selective gas flow communication with the low pressure 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 outlet (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. In yet a further example embodiment, the first and second stages are housed in a single regulator body (i.e., the regulator is a unibody design).

[0013]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.

[0014]In various exemplary embodiments, the flow of the gas into the high pressure chamber may be regulated by a high pressure piston assembly and a high pressure pin assembly. Further, in such example or other embodiments, the flow of gas into the low pressure chamber may be regulated by a low pressure piston assembly and a low pressure pin assembly.

[0015] In various embodiments, the regulator may further include an air inlet port on the high pressure cartridge assembly for attachment to a hose, which may be a quick disconnect air inlet port, and may further include an air outlet port on the high pressure cartridge assembly for attachment to a hose, which may be a quick disconnect air outlet port.

[0016] Further, in some embodiments, the longitudinal position of the inner piston within the outer piston is user adjustable, and the regulator may further include a knob for user adjustment of the low pressure piston.

[0017] 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 delivering air/gas from the air 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 volumes 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 requiring when switching between end use applications (e.g., other than possibly of the output pressure knob).

[0018] In some embodiments, the air outlet is connected via an air 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 for refilling an air tank connected to the regulator.

[0019] In another aspect, 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 assembly and a low pressure piston assembly housed within the second chamber, the low

pressure cartridge assembly having an air outlet port, the high pressure piston assembly including an outer piston and an inner piston housed at least partially within the outer piston and moveable longitudinally within the outer piston; (b) a pressurized air tank; and (c) a hose connected to the air inlet port on one end and to the pressurized air tank on the other end.

[0020] In some embodiments, the portable pneumatic tools power supply system further includes a pneumatic tool and a hose connected to the air outlet port on one end and to the pneumatic tool on the other end.

[0021] 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 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).

[0022] 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

[0023] FIG. 1 illustrates an exploded, plan view of one embodiment of a regulator according to the subject invention with certain parts shown in x-ray.

[0024] FIG. 2 illustrates an alternative, non-exploded view of the embodiment of a regulator depicted in FIG. 1 (shown with regulator pins in an "open" position).

[0025] FIG. 3 illustrates an alternative, non-exploded view of the embodiment of a regulator depicted in FIG. 1 (shown with regulator pins in a "closed" position).

DETAILED DESCRIPTION OF THE INVENTION

[0026] 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.

[0027] As discussed in certain representative and nonlimiting embodiments herein, the present invention relates, in one example, to a two stage pneumatic regulator wherein each stage of the regulator is user adjustable. The present invention further relates to portable air/gas systems employing such pneumatic regulators, as well as methods for using the same. The regulators of the present invention are user adjustable at both stages (high and low pressure), allowing the them to output air at a wider range of pressures as well as volume flow rates than known regulators, thus permitting them to be used interchangeably with a wide array of pneumatic tools (namely, those requiring relative low pressure to operate - up to about 150 PSI, and those that require relative high pressure to operate - usually 150-300 PSI, but up to 500 PSI or more).

[0028] The regulator body 10 comprises a gas inlet port 12, a high pressure chamber 14, a low pressure chamber 16, and a gas outlet port 18. Gas flow into the high pressure chamber 14 is controlled by a high pressure piston assembly 40 and a high pressure pin assembly 20. Gas flow into the low pressure chamber 16 is controlled by a low pressure piston assembly 80 and a low pressure pin assembly 60. Further, a regulator cap 94 is connected to the regulator body 10. This cap functions to hold the high pressure piston assembly 40 and the low pressure piston assembly 80 in their places.

[0029] Pressurized gas flows into the high pressure chamber 14 from the inlet port 12, and than to the low pressure chamber 16 via a fluid passageway. A source of pressurized gas is connected to the regulator via a gas inlet connector 22. The pressurized gas may be from a number of different sources included various sized canisters of pressurized gas or a compressor. Similarly, the pressurized gas source can be connected either directly to the regulator, via a hose or from

another method. In various exemplary embodiments the source of pressurized gas is a portable canister that is threadably connected to the inlet connector 22 on the regulator body 10.

[0030] The pressurized gas flows through the connector 22 and into a high pressure pin assembly 20 via fluid passageway 29. The high pressure pin assembly 20 includes a pin seat 21, a spring 24, a pin 25 having a shoulder portion 26 and a tip 27, and a high pressure regulator seat 28. In various embodiments the pin seat 21 and the inlet connector 22 are a single cylinder separated by a flange 23. In some embodiments the pin seat may attach to the regulator body via a threaded connection. A spring 24 rests in the pin seat 21 and biases the pin 25 towards the high pressure regulator seat 28. The pin tip 27 contacts the high pressure piston assembly 40 located in the high pressure chamber 14. O-rings 30 are found on both the connector 22 and the high pressure pin assembly 20. These O-rings 30 act to create a fluid tight seal and prevent gas from leaking out of the regulator.

[0031] Two distinct types of adjustable piston assemblies are contemplated by the invention. While described as exemplary, non-limiting embodiments only, it should also be noted that any combination (or variation) of these assemblies could be used. This can include using one type of adjustable piston assembly in both the high and low pressure chambers or switching the high pressure piston assembly and the low pressure piston assembly.

[0032] In various exemplary embodiments the high pressure piston assembly 40 comprises an inner piston 50 and an outer piston 41. The outer piston 41 comprises a shaft having a front portion 42 for interfacing with the high pressure pin 25 and a rear portion 43 for holding a spring 45. These portions are separated by a flange 49, designed to abut an outer face of the regulator body 10 on one side and the spring 45 on the other. In various exemplary embodiments this spring 45 is a Bellville spring. In various exemplary embodiments, the springs 45 may be arranged in a variety of suitable configurations, for example they may be stacked in series on the piston shaft, or they may be stacked in a number of other combinations including, some springs stacked in parallel and/or in series, or all springs stacked in parallel. The center of the outer piston 41 is bored through to create an inner cavity 46. In various exemplary embodiments at

least part of this inner cavity 46 is threaded . O-ring 42 on the outer piston acts to create a fluid tight seal and prevent gas from leaking out of the regulator.

[0033]The inner piston 50 comprises a shaft having a first end 51 and a second end 52. The first end 51 contains a face having a detent designed to interface with the pin tip 27 of the high pressure pin assembly 20. The second end 52 is threaded to mate with the outer piston 41. The inner piston 50 is placed into the outer piston 41 from the rear until the threaded portions of the outer and inner piston meet. The inner piston 50 can than be rotated to adjust its position. The high pressure pin assembly also contains a removable protective cap 53 that is threaded onto the rear of the outer piston 41. This cap 53 covers the inner piston's rear threaded portion 52. To adjust the position of the inner piston 50, the protective cap 53 must first be removed. O-rings 54 on the inner piston act to create a fluid tight seal and prevent gas from leaking into the inner cavity 46.

[0034] The low pressure pin assembly 60 comprises a pin seat 61, a spring 62, a pin 63 having a shoulder portion 64 and a pin tip 65, and a regulator seat 66. The pin seat 61 is connected to the regulator body 10 and secures the pin assembly 60. In various exemplary embodiments the pin seat 61 is threadably connected to the regulator body 10. The spring 64 rests against the pin seat 61 and acts to bias the pin 63 towards the regulator seat 66. O-ring 67 on the piston seat 62 acts to create a fluid tight seal and prevent gas from leaking out of the regulator.

[0035]The low pressure piston assembly 80 comprises a pressure adjuster 90, a piston seat 70, and a piston having a front portion 82 and a rear portion 83. The piston seat 70 contains a detent 72 on one side for interfacing with the pin tip 65 of the low pressure pin assembly 60 and a hollowed out portion 74 on the other side for interfacing with the front portion 82 of the piston shaft. The rear portion 83 of the piston shaft holds a spring element 85. The front potion 82 and the rear portion 83 are separated by a flange 84 which is designed to abut an outer face of the regulator body 10 on one side and spring 85 on the other. In various exemplary embodiments the spring element 85 on the low pressure piston is a Bellville spring. In various exemplary embodiments, the springs 85 may be arranged in a variety of suitable configurations, for example they may be stacked in series on the piston shaft, or they may be stacked in a number of other

combinations including, some springs stacked in parallel and/or in series, or all springs stacked in parallel. The pressure adjuster 90 of the low pressure piston assembly 80 has a shaft portion which is threaded at one end 92 and contains a flange 84 at the other. The flange 84 is designed to interface with the rear portion 83 of the piston while the threaded end 92 mates with threads on the regulator cap 94. A knob 95, located on the outside of the regulator cap, is then threaded to the end of the adjuster 92. This knob 94 allows a user to control the position of the adjuster, and subsequently the piston assembly 80.

[0036] The regulator cap 94 connects to the regulator body 10 and holds the lower pressure piston assembly 80 and the high pressure piston assembly 40 in place. The regulator cap 94 can be connected to the regulator body 10 by any suitable means including fasteners, welding, or an adhesive. In an exemplary embodiment this cap is held in place via a series of screws 96.

[0037]The outlet port 18 is located in fluid communication with the low pressure chamber 16. In various exemplary embodiments the outlet port is designed to connect with a hose of a pneumatic tool. In various exemplary embodiments this is achieved through a quick-connect coupling threadably connected to the outlet port.

[0038] In various exemplary embodiments the regulator is also provided with a fill assembly. This assembly includes a fill chamber 32, a fill connector 34 and a one-way valve 33. The oneway valve is placed in the fill chamber 32 and the fill connector 34 is placed over it. In various exemplary embodiments the fill connector 34 includes a threaded portion 36 for connecting to the regulator body 10. O-ring 35 acts to create a fluid tight seal and prevents gas from escaping the regulator.

[0039] In various exemplary embodiments the regulator body 10 is machined out of a single piece of metal or metal alloy. To create the fluid passageways between the high pressure chamber 14 and the low pressure chamber 16 a series of through channels are machined into to regulator body 10. To close the holes made by this process, screws 68 are attached to the regulator body 10. These screws 68 include O-ring 69 to create a fluid tight seal and prevent gas from escaping the regulator.

[0040] FIGS. 2 & 3 show an embodiment of the regulator in operation. FIG. 2 shows the chambers of the regulator in an open position while FIG. 3 shows the chambers of the regulator in a closed position.

[0041] In operation, the two stage regulator is connected to a source or pressurized gas via the gas inlet connector 22. In various exemplary embodiments the gas source is pressurized to at least 4500 psi. In other embodiments the pressure is between 4500 psi and 6000 psi. The regulator is then connected to a pneumatic tool via the gas outlet 18.

[0042] Initially, the high pressure piston assembly 142 presses against the high pressure pin 127, forcing the pin 127 away from the regulator seatl28. This open position allows the pressurized gas to flow through the fluid passageway 129 in the inlet connector 122 and into the high pressure chamber. The gas then flows from the high pressure chamber to the low pressure chamber. As in the high pressure chamber, the low pressure piston assembly 182 initially presses against the low pressure pin 165, forcing the pin 165 away from the regulator seat 166.

[0043] As the pressure in the low pressure chamber builds, the force will press against the low pressure piston 182, compressing the springs 185. As the low pressure piston 182 moves away from the pin 165, the spring 162 in the pin assembly will force the shoulder portion 164 of the pin 165 against the regulator seat 166, preventing more gas from entering the low pressure chamber. The amount of pressure it takes to accomplishes this can be adjusted by moving the pressure adjuster 90 laterally with respect to the low pressure piston. As the adjuster 90 moves, it will push the piston assembly towards or away from the pin assembly. As the piston assembly 80 moves towards the pin assembly 60, the piston springs 185 will require a greater amount of compression to enable the shoulder portion 164 to abut the regulator seat 166, and thus a higher pressure will be maintained in the low pressure chamber. As the piston assembly 80 moves away from the pin assembly 60, the piston springs 185 will require less compression to enable the pin shoulder 164 to abut the regulator seat 185, and thus a lower pressure will be maintained in the low pressure chamber. In various exemplary embodiments the adjuster 90 is connected to a knob 95. By turning the knob 95 the distance between the low pressure piston 80 and the low

pressure pin assembly 60 can be increased or decreased. In various exemplary embodiments the knob 95 is of sufficient size to permit a user wearing gloves to accurately adjust the pressure.

[0044] In various exemplary embodiments the regulator body 10 is provided with a passageway 13 for connecting a pressure gauge for the low pressure chamber. This gauge allows a user to accurately determine the amount of pressure in the low pressure chamber, thus facilitating efficient adjustments.

[0045]When the low pressure chamber is closed, the high pressure chamber will experience a rise in pressure. The force of the building pressure will compress the springs 145 of the outer piston, moving the high pressure piston assembly 40 away from the high pressure pin assembly 20. When the springs 145 of the outer piston are compressed to a certain amount the pin shoulder 126 will abut the regulator seat 128, closing off the high pressure chamber from the pressurized gas source. The amount of pressure it takes to close the high pressure chamber is controlled by the high pressure piston assembly 40, specifically by adjusting the position of the inner piston. In various exemplary embodiments the inner piston is threadably connected to the outer piston. Therefore the inner piston may be adjusted by rotating it with respect to the outer piston. In some embodiments this is accomplished by using a tool, such as a screwdriver, alien wrench, or a hex wrench. By adjusting the position of the inner piston, the distance that the piston assembly must travel to close off the high pressure chamber from the pressurized gas source can be lengthened or shortened. As the travel distance is increased the amount the springs must be compressed increases, thus raising the amount of pressure that will be held in the high pressure chamber. As the travel distance is decreased the amount the springs must be compressed also decreases, thus lowering the amount of pressure that will be held in the high pressure chamber.

[0046] In various exemplary embodiments a removable protective cap is attached to the outer piston, over the threaded end of the inner piston. This cap must therefore be removed before adjustment to the high pressure piston assembly can be made.

[0047] In various exemplary embodiments the regulator body 10 is provided with a passageway 11 for connecting a pressure gauge for the high pressure chamber. This gauge allows a user to accurately determine the amount of pressure in the high pressure chamber, thus facilitating efficient adjustments.

[0048] By adjusting the high pressure piston assembly 40 and the low pressure piston assembly 80 a wide range of output pressure can be achieved. In various embodiments the output pressure is between 0 and 300 psi. In other embodiments the output pressure is between 150 and 300 psi.

[0049] The regulator can also be used to fill an empty canister. In various exemplary embodiments the regulator is connected, via the inlet port 12, to a portable canister. This canister, which can be easily carried by the user, holds a pressurized gas. If more gas is needed to complete a job than can be held in a single canister it may be necessary to refill the canister. This is facilitated by the regulator's fill assembly. The portable canister is left attached to the regulator while the fill assembly is connected to a separate source of pressurized gas via connection 34. This source may be a compressor, a large tank, or other source of pressurized gas. The pressurized gas will pass through a one-way valve 33 and through the inlet port 12 into a canister. As the gas enters through the fill assembly, the high pressure chamber 14 remains closed, preventing the gas from passing through the regulator. This allows the canister to fill with pressurized gas and be used over again.

[005O]In various exemplary embodiments the gas source is pressurized to at least 4500 psi. In other embodiments the pressure is up to approximately 6000 psi. The regulator may be connected to the gas source via a threaded connection or connected via a hose and coupling. In some instances the coupling is a quick connect type coupling commonly found amongst pneumatic tools.

[0051] 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: