Abstract:
A regulator assembly for a paintball marker includes a body having an inlet orifice for connecting to the compressed fluid source, an outlet orifice for connecting to the marker, and a cavity formed therein having a first chamber proximate the outlet orifice, a second chamber proximate the inlet orifice and providing a fluid pathway between the inlet and outlet orifices, a poppet valve functionally positioned within the outlet orifice, and a pneumatic valve actuator positioned within the cavity of the body and supportively coupled to the poppet valve. The pneumatic valve actuator comprises a piston, a spring pack and an adjustment strut. The spring pack is modular to allow interchanging and includes a plurality of Belleville springs properly oriented and secured in place by a washer and O-ring to create a predefined pressure threshold.

Description:
RELATED APPLICATIONS 
     The present application claims the filing priority of U.S. Provisional Application Nos. 61/680,594 filed Aug. 7, 2012 and titled “Pneumatic Valve And Regulator,” and 61/706,843 filed Sep. 28, 2012 and titled “Pneumatic Valve and Regulator.” 
    
    
     TECHNICAL FIELD OF THE INVENTION 
     The device of this application relates to a pneumatic valve and regulator which regulates the output delivery pressure from a pressure vessel. More particularly, the device relates to a pneumatic-type regulator containing a pressure activated demand valve configured to be attached to, for example, a paintball gun or BB gun. 
     BACKGROUND OF THE INVENTION 
     Pressure regulators that deliver discrete charges of fluid are employed in a wide variety of industries for a wide variety of purposes—e.g., to activate controls, provide control, fire projectiles, provide feedstock—and uses—e.g., as a diluent, catalyst, carrier, or fuel to processes. The relevant industries share in common a need for a regulator that reliably delivers accurately metered amounts of fluid at a controlled pressure and at scheduled times or on demand. One such industry that requires such discrete charges on demand is the paintball game industry. 
     The popularity of paintball games has grown immensely, and with that growth there has been a proliferation of different types of paintball guns (hereafter “markers”) and the devices that are used in conjunction with these markers, such as regulators and compressed gas canisters. Improvements in markers and related devices have become necessary due to the increased level of play as players improve and hone their skills. Improvements in paintball equipment encourages improvements in the players abilities and skills, which in turn requires further improvements in the equipment. The early types of markers and related devices provided an adequate level of play. However, the onset of more experienced players, along with challenging paintball gun tournaments, now provides an arena where better markers and peripherals are required to sufficiently compete. 
     Safety is a serious concern with any system where pressurized gas is confined or handled in the equipment. Canisters typically confine gas under several thousand pounds of pressure. Regulators that are in gas receiving communication with such canisters are sometimes exposed to the pressure that is in the canister. Regulators generally function to regulate the pressure that associated applications are exposed to. Often such associated applications are not capable of withstanding the gas pressure that is in the canisters. Unexpected spikes in gas pressure are sometimes encountered by such canisters and associated regulators. Regulators must be designed to reliably prevent excessive gas pressure from reaching the associated applications. Regulators are typically designed with sufficient strength to confine and regulate pressurized gas with a safety factor of at least twice the maximum anticipated pressure. This safety requirement dictates that the regulator be constructed with sufficient mass to provide the required strength. This can make a regulator heavier and larger than desired in many systems. 
     In general, a marker is used to fire or shoot a paintball at an intended target. A discrete charge (as opposed to continuous flow) of compressed gas is delivered from a canister through a regulator to a paintball marker to propel a paintball towards the intended target. The marker or paintball gun is attached directly or indirectly through a suitable conduit to a regulator, which is in turn attached to the source of compressed gas, such as a canister. The regulator meters the volume and controls the pressure of the gas charge that is delivered to the marker. 
     The overall marker-regulator-canister system in a paintball gun application is sometimes awkward and heavy to handle, especially for smaller game participants. Even a small reduction in size and/or weight is significant in increasing the usability and enjoyment of using the system. Also, any increase in the number of shots that may be reliably obtained from a given system without recharging the canister significantly improves the play of the user. 
     Many paintball guns operate on compressed gas such as air, nitrogen, other suitable gases or mixtures of gases. The players typically carry a supply of compressed gas with them as they compete. This supply is depleted after a certain number of cycles. Typically, the players have no means of replenishing this supply of compressed gas without returning to some central station removed from the playing field. Compact lightweight systems that extend the number of cycles that are available from one canister full of gas are much sought after by players. 
     Any regulator in a marker-regulator-canister system that safely provides a reduced size and weight advantage and extends the period of play or other use while remaining reliable and consistent would be uniquely advantageous. As such, there is a great need in the field of paintball systems and other systems for such regulators. 
     Further, while many experienced and top-level players own and maintain high-end markers, facilities exist which appeal to all levels of players, including the novice. Accordingly, such facilities often rent equipment, including markers and marker assemblies, to players who do not have or do not want to use their own equipment. This equipment (like most rental equipment) is subjected to an inordinate amount of wear without the requisite cleaning and care to operate effectively. The rental market possess a unique market opportunity in the industry. 
     Regulators for regulating pressurized gas that is delivered from a canister to a paintball gun or a marker are illustrated in Colby U.S. Pat. No. Des. 357,967, Colby U.S. Pat. No. 6,543,475, Colby U.S. Pat. No. 6,405,722, Carroll U.S. Pat. No. 6,851,447, Carroll U.S. Pat. No. 6,363,964, Gabrel U.S. Pat. No. 7,004,192, Gabrel U.S. Pat. No. 7,188,640, Gabrel U.S. Pat. No. 6,722,391, and Gabrel U.S. Pat. No. 6,478,046, each of which is hereby incorporated by reference as if fully set forth herein. 
     Accordingly, there exists a need for a regulator for compressed gas that is safe, light-weight, compact, and reliable. There is a need for the combination of these features in one regulator. 
     SUMMARY OF THE INVENTION 
     A paintball marker assembly including an improved regulator which avoids the disadvantages of prior devices while affording additional structural and operating advantages is described. Generally, the marker assembly includes a marker, a compressed fluid source, and a regulator to safely couple the marker and fluid source. 
     An improved regulator is also described. Generally, the regulator includes a body having an inlet orifice for connecting to the compressed fluid source, an outlet orifice for connecting to the marker, and a cavity formed therein having a first chamber proximate the outlet orifice, a second chamber proximate the inlet orifice and providing a fluid pathway between the inlet and outlet orifices, a poppet valve functionally positioned within the outlet orifice, and a pneumatic valve actuator positioned within the cavity of the body and supportively coupled to the poppet valve. 
     In an embodiment, the pneumatic valve actuator comprises an adjustable air delivery shaft for regulating airflow from the fluid source through the inlet orifice and into the cavity, the shaft comprising a passageway there through having a volume and a nozzle fluidly coupled to the passageway, a reciprocating piston having a polymeric seat at one end for blocking the nozzle, the piston being configured to open and close a passage between the first chamber and the second chamber of the cavity, and a spring pack positioned about the piston and secured thereon to bias the piston to close the passage. In use, a positive pressure differential in the first chamber of the cavity moves the piston to open the passage and block the nozzle. 
     In a particular embodiment of the pneumatic regulator assembly the body comprises a first body portion threadably engaged to a second body portion. Alternatively, the body may be a single, unitary construction. Either embodiment may include a detachable flange portion at the outlet orifice, wherein the detachable flange portion houses the poppet valve and excess of the piston and spring pack. 
     In a particular embodiment of the pneumatic regulator assembly the adjustable air delivery shaft is comprised of brass and the polymeric seat is comprised of “TEFLON”, chemically known as polytetrafluoroethylene (PTFE). The nozzle also preferably comprises a plenum to increase volume of the passageway for greater output. 
     In another particular embodiment, the spring pack has a predefined pressure threshold, typically one of either 250 lbs, 550 lbs, 850 lbs or 1150 lbs. Thus, the spring pack may be replaceable to allow quick and easy upgrading and downgrading of output pressure. 
     These and other aspects of the invention may be understood more readily from the following description and the appended drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For the purpose of facilitating an understanding of the subject matter sought to be protected, there are illustrated in the accompanying drawings, embodiments thereof, from an inspection of which, when considered in connection with the following description, the subject matter sought to be protected, its construction and operation, and many of its advantages should be readily understood and appreciated. 
         FIG. 1  is a side view of a marker assembly including a marker, regulator and pressure vessel; 
         FIGS. 2A-C  are engineering drawings of a first embodiment of a regulator in accordance with the present disclosure; 
         FIGS. 3A-C  are engineering drawings of a second embodiment of a regulator in accordance with the present disclosure; 
         FIGS. 4A-F  are engineering drawings of an embodiment of the body of the regulator of  FIG. 3A ; 
         FIG. 5  is an engineering drawing of an embodiment of a poppet valve; 
         FIG. 6  is an engineering drawing of an embodiment of a piston; 
         FIG. 7  is an engineering drawing of an embodiment of the gland nut used in the regulator of  FIG. 3A ; 
         FIG. 8  is an engineering drawing of an embodiment of an adjustment shaft; and 
         FIG. 9  is a partial cross section of an embodiment of a nozzle on an adjustment shaft showing the metering orifice. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail at least one preferred embodiment of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to any of the specific embodiments illustrated. 
     Further, there is illustrated embodiments of the disclosed regulator in conjunction with a paintball gun (aka, marker). In fact, while all the embodiments illustrated or described may specifically reference use for a paintball gun, it should be understood that the principles of the invention may be more broadly applied to other uses as well, as would be known and understood by those skilled in the art. 
     As used herein “canister” includes all manner of pressure vessels, including, but not limited to small portable bottles or tanks, large stationary tanks, tanks connected to compressors, metallic containers, composite plastic containers, single or plural use pressure vessels, or other sources of compressed gas, and the like. 
     As shown in  FIG. 1 , a complete paintball marker assembly includes a single stage regulator system  10  in accordance with the present invention, attached to a high-pressure vessel  12 , and a marker  14 . The pistol grip  16  on the marker  14  is typically where the regulator assembly  10  is connected. The regulator assembly  10  is described in more detail below. 
     Generally speaking, the present regulator assembly is a single stage regulator, designed to accept input working pressures up to 4,500 pounds-per-square-inch (PSI), and designed to regulate an output pressure in the range of between about 250 and about 1,150 PSI. The various embodiments of the present regulator assembly  10  are considered to be compatible with many of the Paintball guns or markers currently used in the sport of Paintball. 
     A preferred embodiment of the assembly  10  incorporates advantages over prior devices, including considerably reduced size and weight, resulting in material cost savings, utilizing common round stock instead of customized square stock, a smaller, more efficient profile, elimination of high points that may impede ease of screwing regulator into marker, reduced labor cost on assembly by using a simple threaded screw attachment method, and improved safety and all-around ease of use. 
     The regulator assembly  10  is first attached to the vessel  12  via a threaded fitting  15  at the inlet end of the regulator assembly  10 , as is well-known in the art. The regulator assembly  10  is semi-permanently connected to the high-pressure bottle or vessel  12 , and is not intended to be removed. When the compressed air/gas falls below the operational pressure level the pressure vessel  12  can be refilled through a port on the regulator assembly  10 . 
     To fill the vessel  12 , a form of compressed air/gas compatible with those normally used in conjunction with the sport of Paintball is used. The vessel  12  is filled through a rated fill nipple and one-way check valve  17  ( FIG. 2 ). Once the vessel  12  is filled and ready to go, the regulator  10  is screwed into the marker  14 , by screwing the male CGA portion of the regulator  10  into a female adapter (of the same thread design) either located remotely or on a marker  14 . The regulator  10  and vessel  12  system will fill the marker  14  and the marker lines to a factory set preset output pressure, in the preferred embodiment, of about 250, 550, 850 and 1150 PSI, though other preset values are possible. 
       FIGS. 2 and 3  shows alternate embodiments of the regulator assembly  10  as a two-piece construction ( FIG. 2 ) and a one-piece construction ( FIG. 3 ). The two-piece regulator assembly ( FIG. 2 ) is a high-performance regulator suited for top-level players. The one-piece regulator assembly ( FIG. 3 ) is aimed at the rental market. By “two-piece” it is meant that the body of the regulator has two sections which are fastened together (threadably attached, as shown). Another distinction in the two embodiments illustrated is the use of a removable gland nut  19  which treadably engages the body of the one-piece configuration. The removable gland nut  19  allows the internals of the regulator to be positioned within the body  20 . While this component is necessary for the one-piece configuration, it may also be used on the two-piece configuration, if desired. 
     Preferably the internals (described below) of the one-piece “rental market” regulator include a stainless steel adjustment shaft/strut  28  with a V-cut face nozzle and a urethane seat, which is far more tolerant of dirt and debris entering the air cavity. This rugged combination may also be used in the two-piece internals, but the brass adjustment shaft/strut with plenum and a TEFLON seat (described below) is preferred. As will be more fully described below, the remaining general components and operation of the two regulators are substantially identical. 
     For example, each one- and two-piece regulator assembly  10  includes a body  20  having an internal cavity  18 , a piston  22  biased by a spring pack  24  (an arrangement of Belleville disk springs) toward a poppet valve  26 , and an adjustable shaft  28  for regulating airflow at an inlet opening. 
     As previously disclosed, the regulator assembly  10  may also include a high-pressure inlet fill nipple and valve  17  used for filling the pressure vessel  12 . The male valve  17  attaches to the regulator  10  and can be used with a fill station containing a suitably rated female fitting. When the pressure vessel  12  falls below the operational levels, the filling station containing the female fitting is connected to the regulator assembly  10  at the high-pressure inlet male fitting, and high pressure gas, air or nitrogen is transferred from the filling station through the regulator assembly  10  and into the high-pressure bottle  12 . 
     Both the two- and one-piece configurations have a hex-shaped body  20  which preferably includes tool flats  30  ( FIG. 2 ) to allow a wrench or similar device to be used for tightening the regulator  10  to the vessel  12 . The body  20  conceals an internal cavity  18  which can be divided into two chambers, an inlet side chamber  18 A and an outlet side chamber  18 B. The body  20  also houses the regulator internal systems, including a pneumatic valve actuator  40  positioned within the cavity  18  of the body and supportively coupled to the poppet valve  26 . The pneumatic valve actuator  40  comprises the adjustable air delivery shaft  28  for regulating airflow from the fluid source (i.e., the vessel  12 ) through inlet orifice  21  and into the cavity  18  via a nozzle  29 , the reciprocating piston  22  having a polymeric seat  23  at one end for blocking the nozzle  29 , and a spring pack positioned about the piston  22  and secured thereon to bias the piston  22  to close a passage connecting the two cavity chambers,  18 A and  18 B. 
     The piston  22  is preferably configured to open and close the passage between the inlet or first chamber  18 A and the outlet or second chamber  18 B of the cavity  18 . The piston  22  acts as an air manifold to direct air between the two chambers of the cavity  18 , as is known in the art. At the inlet end of the piston a polymeric seat  23  is used to seal against the nozzle  29  of the adjustment shaft  28 . The adjustment shaft  28  comprises a passageway there through which has a volume, and the nozzle  29  is fluidly coupled to the passageway. As shown in  FIG. 9 , the nozzle  29  is cut to create a plenum  42  which increases the volume of the passageway. This provides an increased upper end output pressure. Further, as opposed to the V-cut rim of typical stainless-steel shafts which use a softer urethane seat, a brass shaft is preferred with a TEFLON (PTFE) polymeric seat  23  on the piston  22 . In special situations, the TEFLON and urethane seats may be used in either. 
     The poppet valve  26  is seated within the body  20  as well directly coupling to the pneumatic valve actuator  40  instead of being contained in a separate compartment. This saves considerable time and cost in manufacturing over prior devices. The poppet pin engages and disengages the transfer of regulated (output) pressure, while the poppet spring ensures the return of the poppet pin to a closed position. 
     The Belleville disk springs of the spring pack  24  are configured such that a determined amount of spring energy can build to offset compressed gas pressure energy. A key feature of the present regulator assembly  10  is that it has a modular component. Specifically, an O-ring and washer on the piston  22  secure the Belleville disk springs in place to create a unitary component. This spring pack  24  is readily removable from the pneumatic actuator  40  and can be quickly replaced with a greater or lesser output rated spring pack, each of which is created by varying the number and/or orientation of the Belleville disk springs. The regulator assembly  10  can go from a 250 PSI output up to a 1150 PSI output and then back down to a 550 PSI output in just a few minutes time by merely changing out the modular spring pack  24 . 
     As described above, the regulator  10  and vessel  12  are usually combined together and not intended to be separated. When the vessel  12  is empty, filling of the pressure vessel  12  can take place through the regulator assembly  10 . The compressed gas will pass through the body  20 , across the ports of the adjustment shaft  28  and down into the pressure vessel  12  for storage. Once the pressure vessel  12  filled, the system is ready to go. 
     First, the regulator assembly  10  and vessel  12  are attached to the marker  14  by screwing the male CGA portion of the regulator  10  into a female adapter (of the same thread design) either located remotely or on a Paintball marker  14 . Once attached, the vessel  12  and regulator system  10  will fill the marker  14  and the lines to a factory set preset output pressure, in the preferred embodiment about 250 to 1,150 PSI. The marker  14  is now ready for firing. 
     When the user pulls the trigger on the marker  14 , a demand is created for the propellant gas. The gas travels from the regulator assembly  10  into the marker  14 , and forces or expels the paint ball (not shown) from the marker  14 . 
     Once the propellant exits the regulator assembly  10 , the pressure therein is reduced. This reduction in pressure forces the seat  23  to unseal at the nozzle  29 , thereby allowing the regulator assembly  10  to again fill and regulate an amount of propellant. 
     In particular, once the marker  14  is connected to the regulator assembly  10 , compressed gas travels from the vessel  12  up through the adjustment shaft  28 , which is set at a predetermined depth for the desired system output pressure within design parameters. The gas (and pressure) crosses the regulator seat  23  utilizes the piston  22  as an air manifold and makes contact with the top of the piston  22 . As the gas flows through to the piston  22 , pressure is applied to the top of the piston  22 . The pressure applied to the top of the piston  22  is transferred to the spring pack  24  (i.e, the array of Belleville disk springs). The energy developed by the compressed gas is applied to the energy generated by the spring pack  24 . The balance of these two forces along with the gap between the regulator seat  23  and the adjustment shaft nozzle  29  acts to regulate airflow and pressure. The flow can be increased or decreased by altering the gap between the regulator seat  23  and the adjustment strut nozzle  29  based on compressed gas/spring energy. Hence, the pressure on the backside of the poppet valve  26  is regulated. The poppet valve  26  remains in a closed position thereby sealing off the outlet or second chamber  18 B and the regulated gas is prohibited from passing to ambient air. 
     When the regulator system  10  is screwed into a female CGA thread equipped with a depressor pin, as those found in a standard marker  14 , the depressor pin will engage the exposed portion of the poppet valve  26  and depress the poppet pin against the poppet spring. Once the poppet valve  26  is forced to the open position, regulated compressed gas will begin to flow into the female adapter, creating a pressure drop. 
     The introduction of a pressure drop to the “low side” of the regulator  10  causes the spring pack  24  energy to overcome low side compressed gas pressure, thereby forcing the piston  22  upward. The gap between the regulator seat  23  and adjustment shaft nozzle  29  increases. As described above, an increase in gap creates additional gas flow, which applies additional force to the topside of the piston  22 . The piston  22  is driven back down against spring energy and closes the gap between the adjustment strut nozzle  29  and the regulator seat  23 . 
     While the embodiments of the present regulator assembly may have structural similarities to that of prior regulators, e.g., the pneumatic regulator illustrated in U.S. Pat. No. 6,543,475, the following is a non-exhaustive list of body design changes to the regulator assembly of the present invention which distinguish it from all other regulators in the industry, including that of the &#39;475 patent. Specifically, the present regulator assembly  10  has:
         a smaller round body design which replaces the bulky four (4) bolt square body design;   two sets of safety set screws which replace the use of four long-drilled and tapped 10/32×¾ bolts used to hold the two body halves together;   wrench flats added to the bonnet design for ease of removal; and   safety bleed grooves which have been added to the regulator stem, to allow for safe venting of the pressure canister in the event the regulator begins to separate from the canister.       

     Additionally, internal part changes, specifically as compared to the regulator of the &#39;475 patent, include:
         removal of the independent stainless steel poppet and poppet spring, and removal of the stainless steel poppet retainer secured and torqued in with Loctite® or similar material, replaced with a simple spring inserted into the back end of the piston pushing up against a brass poppet and sealing element;   changed interior design of poppet assembly to eliminate the need for custom matching;   changed parameters of the spring pack, using larger Belleville washer in order to increase the stability and provide better air flow;   uses an adjustment shaft to eliminate need for fixed metering orifice and allowing for quick changing of the metering orifice to provide almost unlimited options, including more range of firing.       

     The changed interior design which eliminates the need for custom matching provides a significant cost savings on both production and assembly labor. Further, the options provide by the use of the adjustment shaft are a feature today&#39;s paintballers are looking for with the new electric markers. The adjustability allows the present regulator to keep up with special demands the gun/marker manufacturers are requiring of air delivery, including different out pressures needed to be competitive. This feature eliminates the need to make a different regulator each time a different application is needed. 
     At first use, the pressure in the canister is typically several times the output pressure of the regulator. For example, the pressure in the canister may be as much as 4,500 pounds per square inch (psi), and the designed output pressure from the regulator in paintball systems may be approximately 800 psi, more or less. For other systems the output pressure may range from as little as approximately 5-10 psi to as much as approximately 1,150 psi or more. The regulator delivers gas to the marker at a predetermined maximum pressure one discrete charge at a time. The regulator accepts pressurized gas from a canister until the pressure within the regulator reaches a predetermined value and then shuts off the flow into the regulator. In paintball games the charge of gas is held in the regulator for an indefinite period of time until the player fires the marker. That is, the charge is available instantaneously for on demand use. For some applications charges are released at previously scheduled regular or irregular intervals. Releasing the charge immediately exhausts the charge from the regulator and delivers it to the marker or other application. The regulator then seals itself from outputting gas to the marker and opens its inlet to receive another charge of gas from the canister, and the cycle of fill, hold, and discharge starts over. 
     Cycle rates (the maximum number of complete fill-hold-discharge cycles per second) should generally be in the range of at least 2 to 20 cycles per second. Reliable cycle rates in excess of this may be required or desired for other applications. 
     The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. While particular embodiments have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the broader aspects of applicants&#39; contribution. The actual scope of the protection sought is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.