Abstract:
The integrated air tool and pressure regulator assembly allows several air tools to operate from a single air compressor, using a simplified air hose distribution system. An operator may independently adjust the regulated pressure of the integrated air tool and pressure regulator assembly to compensate for varying working conditions. A greater air hose supply pressure may be used, as regulation of air pressure is accomplished at the integrated air tool and pressure regulator assembly. The increased air transport efficiency allowed by the integrated air tool and pressure regulator assembly of the present invention may provide for the use of smaller diameter hose, which may be lighter, more flexible, less costly, and the like.

Description:
CROSS REFERENCE  
       [0001]     The present application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Ser. No. 60/491,792, entitled: Integrated Air Tool and Pressure Regulator, filed on Jul. 31, 2003, which is hereby incorporated by reference in its entirety. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates generally to the field of pressure regulators, and more particularly to a pneumatic tool including a pressure regulator assembly wherein a pressure regulator is integrated in the body of a pneumatic tool.  
       BACKGROUND OF THE INVENTION  
       [0003]     Pneumatic tools utilizing compressed air (air tools) are frequently operated by groups or teams of air tool users sharing a single air compressor assembly and pressure regulator. Supplying several air tools with compressed air from a single air compressor assembly and pressure regulator may be desirable for minimizing equipment costs, reducing the amount of equipment needed in a work area, and the like. For example, a team of workers may use several pneumatic fasteners such as pneumatic fasteners powered by a single air compressor assembly. When working conditions, air tool types, or the like differ between members of a team doing different jobs, however, air pressure requirements may vary for different team members. For instance, a worker using a pneumatic hammer drill may have different air pressure requirements from workers using pneumatic fasteners. As a result, workers utilizing the same compressor may be forced to select a single pressure for all the pneumatic tools operated from the compressor. When team members sharing a single air compressor assembly have differing air pressure requirements, the team may have to add an additional air compressor assembly, an additional pressure regulator and separate air hoses between the air compressor assembly and the work area, and the like. Additional equipment may require additional cost as well as the added expense in time and effort of transporting the additional equipment to and from a job site each day.  
       SUMMARY OF THE INVENTION  
       [0004]     Consequently, the present invention is directed to a pneumatic tool including a pressure regulator assembly. The integrated pneumatic tool of the present invention allows several air tools to operate from a single air compressor using a simplified distribution system. An operator may independently adjust the regulated pressure of the pneumatic tool to compensate for varying conditions. In an exemplary embodiment, a higher air hose supply pressure may be used, as regulation of air pressure is accomplished at the point of use. Higher pressures may allow the system to deliver air with less pressure loss over a lower pressure system. In addition, the increased air transport efficiency allowed by the pneumatic tool of the present invention may provide for the use of smaller diameter hose, which may be lighter, more flexible, less expensive, promote mobility and the like.  
         [0005]     In a first aspect of the invention, a pneumatic tool includes a pneumatic device for performing a task upon application of compressed air. A regulator and coupling are integrated into a tool housing encompassing the pneumatic device such that compressed air entering the pneumatic device is regulated to a pre-selected pressure at the point of use of the pneumatic device.  
         [0006]     In a further aspect of the invention, a pneumatic fastener, such as a pneumatic nail gun or a pneumatic staple gun, includes a pneumatic driver for driving a fastener into a workpiece. An adjustable regulator is included in a housing encompassing the pneumatic driver. The regulator is coaxially arranged with a coupling for connecting to a supply of compressed air such as a pneumatic hose connected to a compressor. In an embodiment, the regulator is adjustable via a dial having a set of inwardly extending gear teeth configured to contact with a planet gear which is engagement with a sun gear for operating a valve to change the pressure of air operating the pneumatic driver.  
         [0007]     It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not necessarily restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention and together with the general description, serve to explain the principles of the invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]     The numerous advantages of the present invention may be better understood by those skilled in the art by reference to the accompanying figures in which:  
         [0009]      FIG. 1  is a side view of a pneumatic fastener including an integrated pressure regulator assembly;  
         [0010]      FIG. 2  is a partial isometric view of an integrated pressure regulator for utilization with a pneumatic fastener;  
         [0011]      FIG. 3  is a partial side view of a pneumatic fastener including pressure regulator assembly;  
         [0012]      FIG. 4  is a partial end view of a pneumatic fastener including a pressure regulator;  
         [0013]      FIG. 5  is a partial cross-sectional view of a pressure regulator in accordance with an aspect of the present invention;  
         [0014]      FIG. 6  is a side view of a pneumatic fastener including a coaxially configured pressure regulator assembly;  
         [0015]      FIG. 7  is a partial isometric view of a coaxial integrated pressure regulator for utilization with a pneumatic fastener;  
         [0016]      FIG. 8  is a partial cross-sectional view of a coaxial pressure regulator in accordance with an aspect of the present invention;  
         [0017]      FIG. 9  is a partial cross-sectional view of a coaxial pressure regulator in accordance with an aspect of the present invention;  
         [0018]      FIG. 10  is a partial exploded view of a coaxial pressure regulator assembly in accordance with an embodiment of the present invention;  
         [0019]      FIG. 11  is a partial exploded view illustrating a coaxial pressure regulator assembly; and  
         [0020]      FIG. 12  is an exploded view of a pneumatic fastener including a coaxial pressure regulator assembly. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0021]     Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings.  
         [0022]     Referring generally to  FIGS. 1 through 5 , an integrated pneumatic tool and pressure regulator assembly in accordance with an exemplary embodiment of the present invention is described. The integrated pneumatic tool and regulator assembly includes a pneumatic device, a regulator assembly threadably connected to the pneumatic device, and a coupling threadably connected to the regulator assembly for connecting pipes, pressure hoses, tubes, and the like. Suitable pneumatic tools for performing a task include staplers, nailers, sanders, drills, hammering devices, paint guns, impact wrenches, and the like. In the present embodiment, the regulator assembly includes a housing for integrating with the pneumatic device such as by connecting the coupling to the pneumatic device, a plunger which forms a seal to retain a regulated pressure and a bleed-off port, a knob threadably connected to the housing, and a spring compressed between the knob and the plunger. For example, a regulator may be configured to be connected into the pneumatic device/tool housing encompassing the pneumatic device. The plunger abutting the spring may be affixed to a pressure control valve abutting a spring, for maintaining the regulated pressure in proportion to the rotational position of the knob.  
         [0023]     Referring generally to  FIGS. 1 through 4 , a pneumatic fastener  100  in accordance with an embodiment includes a pneumatic fastener driver  102 , a pressure regulator assembly  200  threadably connected to the pneumatic driver  102 , and a coupling  104  threadably connected to the regulator assembly  200  for coupling to pipes, pressure hoses, tubes, or the like. Those of skill in the art will appreciate a variety of pneumatic devices may be implemented. For example, a pneumatic motor may be utilized for operating a pneumatic random orbit sander. A knob for biasing a pressure control valve of the regulator assembly  200  may include a scale with fixed settings  300 . A stop such as a pin  302  may be inserted into a housing of the regulator assembly  200  to limit the rotational range of the knob thereby limiting the obtainable pressure of the valve. Those of skill in the art will appreciate that a wide variety of stop configurations for defining a maximum allowed or acceptable pressure for the power tool. It is the intent of this disclosure to encompass and include such variation.  
         [0024]     Referring to  FIG. 5 , a pneumatic fastener  100  in accordance with an exemplary embodiment of the present invention includes a pneumatic driver  102 ; a pressure regulator assembly  200  threadably integrated into the pneumatic driver  102 ; and a coupling  104  threadably (i.e. a threaded connection) connected to the pressure regulator assembly  200  and sealed with an O-ring  106 , for connecting to pipes, pressure hoses, tubes, and the like. The regulator assembly  200  may include a housing  202  having an intake port  204  and an exhaust port  206 , for connecting the coupling  104  and the pneumatic driver  102  respectively; a plunger  208  which forms a seal to retain a regulated pressure and includes a bleed off port  212 ; a knob  220  threadably connected to the housing  202 ; and a spring  222  compressed between the knob  220  and the plunger  208 . The knob  220  may include a scale with fixed settings  300  (as may be observed in  FIGS. 2 and 3 ). In the current embodiment, a shoulder  304  is connected between the housing  202  and the plunger  208  for limiting the travel range of the plunger  208 . In an advantageous example, the plunger  208  abutting the spring  222  is affixed to a pressure control valve  209  abutting a small spring  223  (relative to spring  222 ). The pressure control valve  209  connected between the small spring  223  and the spring  222  (via the plunger  208 ) maintains the regulated pressure  210  in proportion to the rotational position of the knob  220 . In further embodiments, various pressure regulating devices may be implemented, such as a diaphragm type valve assembly, or the like for regulating the flow of air.  
         [0025]     A crank knob  220  or handle may be implemented in substantially the same manner as the knob  220  of the present embodiment. Those of skill in the art will further appreciate that the regulator assembly  200  may include a lever assembly for biasing the pressure control valve  209 , the lever being pivotally attached to the housing  202  for compressing the spring  222 . In further embodiments, a non-adjustable pressure regulator assembly is utilized. For instance, a fixed regulator for providing a predefined fixed pressure is implemented, in order to minimize ware, for cost effectiveness, and the like. In further embodiments, the pressure adjustment device may be configured to prevent inadvertent adjustment or unauthorized adjustment, such a through utilization of a set screw, a key system, or the like for preventing inadvertent or unauthorized pressure adjustment.  
         [0026]     Referring generally now to  FIGS. 6 through 12 , pneumatic fastener including an integrated pressure regulator assembly in accordance with an embodiment is described. The pneumatic fastener includes a pneumatic driver and a pressure regulator assembly. The pneumatic fastener includes a pressure cap having a coupling device for connecting to pipes, pressure hoses, tubes, and the like. The regulator assembly includes a manifold connected between the pressure cap and the pneumatic device. In exemplary embodiments, the manifold includes components for regulating the pressure of high flow compressed air supplied to the pneumatic fastener. For instance, the manifold may include a sleeve for enclosing high flow pressure regulator components, a plunger which forms a seal to retain a regulated pressure and includes a bleed off port, a screw threadably connected to the sleeve, and a spring compressed between the screw and the plunger. The screw may be coupled with a dial rotationally connected to the manifold via a set of planetary gears or the like, for adjusting the rotational position of the screw by twisting the dial. The plunger abutting the spring may be affixed to a pressure control valve abutting a small spring, for maintaining the regulated pressure in proportion to the rotational position of the dial.  
         [0027]     Referring to  FIGS. 6 and 7 , an integrated pneumatic fastener and regulator assembly  400  in accordance with an exemplary embodiment of the present invention includes a pneumatic fastener assembly  402  and a regulator assembly  500 . The pneumatic fastener  402  includes a pressure cap  404  having a coupling device  410  for connecting pipes, pressure hoses, tubes, and the like. A dial  520  for biasing a pressure control valve included in regulator assembly  500  may include a label scale  600  for indicating pressure settings. In exemplary embodiments of the present invention, a setting indicator  606  which may include a decal, a pin, a notch, a ridge, a marking, or the like is affixed to the regulator assembly  500  and paired with the label scale  600  for indicating pressure settings of the dial  520 . Alternately, the regulator assembly  500  may include the label scale  600  and the dial  520  may include the setting indicator  606 . Those of skill in the art will appreciate that the regulator assembly  500  may include one or more retention pieces including pins, screws, and the like to limit or fix the rotational range of the dial  520  without departing from the scope and intent of the present invention. For example, a pull-out knob may be utilized to prevent inadvertent pressure adjustment.  
         [0028]     Referring generally now to  FIGS. 8 through 12 , a pneumatic fastener including an integrated pressure regulator assembly in accordance with an exemplary embodiment of the present invention includes a pneumatic driver  402  and a pressure regulator assembly  500 . The pneumatic fastener includes a pressure cap  404  having a coupling for connecting pipes, pressure hoses, tubes, and the like. For example, the coupling is a male quick connect pneumatic coupler  410 . Those of skill in the art will appreciate that a variety of coupling devices may be utilized such as a female quick connect pneumatic coupler, threaded couplers, and the like for pneumatically connecting a pneumatic tool to an air source. The pressure regulator assembly  500  includes a manifold  502  including an intake port  504  and an exhaust port  506  (as may be seen in  FIG. 12 ), connected between the pressure cap  404  and the pneumatic driver  402 . An intermediate plate  408  for receiving the intake port  504  is connected between the manifold  502  and the pressure cap  404 . The intermediate plate  408  is sealed against the pressure cap  404  with an O-ring seal or the like, for supplying an inlet pressure to the intake port  504 . The intake port  504  is sealed against the intermediate plate  408  with an O-ring seal  406  or the like, for supplying the inlet pressure to the regulator assembly  500 .  
         [0029]     In exemplary embodiments, the manifold  502  includes components for regulating the pressure of high flow compressed air supplied to the pneumatic driver  402 . For instance, the manifold  502  may include a sleeve  516  for enclosing high flow pressure regulator components, a plunger  508  which forms a seal to retain a regulated pressure  510  and includes a bleed off port  512 , a screw  518  threadably connected to the sleeve  516 , and a spring  522  compressed between the screw  518  and the plunger  508 . The screw  518  may be coupled with a dial  520  rotationally connected to the manifold  502  via a set of planetary gears or the like, for adjusting the rotational position of the screw  518  by rotation of the dial  520 .  
         [0030]     The plunger  508  abutting the spring  522  may be affixed to a pressure control valve  509  abutting a small spring  523 , for maintaining the regulated pressure  510  in proportion to the rotational position of the dial  520 . Those of skill in the art will appreciate that the intermediate plate  408 , the manifold  502 , and/or the dial  520  may include one or more stops such as interference protrusions, teeth, or the like to limit the rotational range of the dial  520  as well. The small spring  523  may be compressed between the pressure control valve  509  and a stop  524  for supporting the small spring  523 . The housing  502  may include a plug  526  for sealing one end of the intake port  504 , if the intake port  504  is formed generally as an L-shaped passageway through the manifold  502  or the like.  
         [0031]     Referring generally to  FIGS. 10 and 11 , the dial  520  is coupled with the valve screw  518  via a sun gear  528  and a planetary gear  530  in an exemplary embodiment of the present invention. Those of ordinary skill in the art will appreciate that while the screw  518  is threadably connected to the sleeve  516  and rotates in concert with the sun gear  528 , the sun gear  528  may be connected to the screw  518  fixedly, slidably, or the like, for remaining substantially in contact with the planet gear  530 . For instance, the screw  518  may include a square protrusion upon which the sun gear  528  is slidably mounted, relative to an axis of rotation of the screw  518  and the sun gear  528 . In this arrangement, the sun gear  528  may be supported between the intermediate plate  408  and the sleeve  516  for remaining in contact with the planetary gear  530 . Alternately, the sun gear  528  may be fixedly connected to the screw  518 , and the planetary gear  530  may be of a sufficient thickness for remaining in contact with the sun gear  528  throughout a linear range of travel, relative to an axis of rotation of the screw  518  and the sun gear  528 .  
         [0032]     The planetary gear  530  is connected between the sun gear  528  and the dial  520 , which includes a set of inwardly extending gear teeth about its interior circumference. Rotation of the dial  520  causes rotation of the planetary gear  530  and corresponding rotation of the sun gear  528 . In exemplary embodiments of the present invention, the planetary gear  530  is supported between the intermediate plate  408  and the housing  502  with a pin  532  or the like. Alternately the pin  532  may be integrally formed with the housing  502 , the intermediate plate  408 , or the like. Those of skill in the art will appreciate that various springs having various sizes, spring rates, and stresses; and gears having various ratios; threads having various pitches; and the like may be implemented for varying the magnitude of pressure regulation changes accomplished through rotation of the dial  520 , providing mechanical advantage for rotating the screw  518 , allowing for finer or coarser adjustment of the screw  518 , and the like.  
         [0033]     In exemplary embodiments of the present invention, a pneumatic fastener having an integrated pressure regulator assembly  400  may include an indicator for providing signals, such as an audible signals, a tactile signals, a visual signals, or the like (or a combination thereof), for indicating adjustment of the dial  520 . Such an indicator may also be used for indicating unwanted movement of the dial  520 , for providing a number of discrete incremental adjustment steps for the pressure regulator assembly  500  via the dial  520 , for limiting the rotational range of the dial  520 , and the like. For instance, a leaf spring  534  including a raised portion for contacting the set of gear teeth about the interior circumference of the dial  520  may be employed for providing audible and/or tactile signals for indicating adjustment of the dial  520 , preventing unwanted movement of the dial  520 , and providing a number of discrete incremental adjustment steps for the pressure regulator assembly  500  via the dial  520 . The leaf spring  534  may be connected between the intermediate plate  408  and the housing  502 . Those of skill in the art will appreciate that many various devices for providing signals including audible signals, tactile signals, visual signals, and the like; for preventing unwanted movement of the dial  520 ; for providing a number of discrete incremental adjustment steps for the pressure regulator assembly  500  via the dial  520 ; for limiting the rotational range of the dial  520 ; and the like may be implemented as desired.  
         [0034]     Referring to  FIG. 12 , a pneumatic fastener including an integrated pressure regulator assembly  400 , in accordance with an exemplary embodiment, includes threaded pins  412  for connecting the pressure regulator assembly  500  with the pneumatic fastener assembly  402 . The threaded pins  412  may extend from the pressure cap  404  through the intermediate plate  408  and the manifold  502 , being threadably received by the pneumatic fastener assembly  402 . Those of skill in the art will appreciate that a variety of securing devices may be implemented for connecting the regulator assembly  500  with the pneumatic driver  402 . For example, the pneumatic driver  402  may threadably receive the regulator assembly  500 , the regulator assembly  500  may threadably receive the pneumatic driver  402 , the pneumatic driver  402  and the pressure regulator assembly  500  may be connected with bolts or screws, the pneumatic fastener assembly  402  and the pressure regulator assembly  500  may be formed as an integral unit or assembly, and the like.  
         [0035]     Further, the pressure regulator assembly  500  may be removably attached to the pneumatic fastener assembly  402 . For example, it may be desirable to include the pressure regulator assembly  500  when working with high flow compressed air and to remove the pressure regulator assembly  500  when working with air at a lower pressure. The ability to remove the pressure regulator assembly  500  from the pneumatic fastener assembly  402  may provide for a more flexible tool. It should also be noted that more than one pressure regulator assembly may be provided with an integrated air tool and pressure regulator assembly, in accordance with exemplary embodiments of the present invention. For example, it may be desirable to include a high flow pressure regulator assembly when working with high flow compressed air and to remove the high flow pressure regulator assembly and replace it with a lower flow pressure regulator assembly when working with air at a lower pressure.  
         [0036]     Those of skill in the art will appreciate that a plurality of pneumatic tools having integrated regulators may be incorporated into a high pressure system. For example, a system having multiple tools may have a delivery pressure set to at least the pressure requirement for the highest pressure tool. For instance, a system including a first tool having a pressure requirement of 90 psi (pounds per square inch), a second tool having a 125 psi requirement, and a third tool having a 135 psi requirement may have a compressor, or distributed pressure of at least 135 psi. Moreover, a higher delivery pressure (i.e. the pressure delivered to the tool) may minimize air loss during delivery, minimize the size of hose required, promote mobility, and the like.  
         [0037]     It is believed that the integrated air tool and pressure regulator assembly of the present invention and many of its attendant advantages will be understood by the foregoing description, and it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely an explanatory embodiment thereof, it is the intention to encompass and include such changes. It is the intention of the following claims to encompass and include such changes.