Abstract:
A single stage regulator is disclosed wherein a cartridge valve, and built in accumulator configuration are utilized to regulate an input or supply pressure such as about 5,000 PSI, to an output or delivery pressure range from about 50 to about 150 PSI. The single stage regulator can be used in the construction and mechanical assembly industries. The regulator can power such devices as pneumatic nailing equipment, impact wenches, and other air driven devices.

Description:
RELATED APPLICATIONS  
       [0001]     This application claims the benefit of U.S. Provisional Application Ser. No. 60/486,942, filed on Jul. 14, 2003, and herein incorporated by reference. This application also claims the benefit of U.S. Provisional Application Ser. No. ______ (To Be Determined), having attorney docket no. 5709 P006, filed concurrently with this application, and herein incorporated by reference. 
     
    
     TECHNICAL FIELD  
       [0002]     The present invention relates to a regulator apparatus and method for regulating the output delivery pressure from a pressure vessel or the like.  
       SUMMARY OF THE INVENTION  
       [0003]     A single stage regulator is disclosed wherein a cartridge valve and built-in accumulator configuration are utilized to regulate an input or supply pressure as high as about 5,000 PSI, to an output or delivery pressure in an adjustable range from about 50 PSI to about 150 PSI. As an example, and without limitation thereto, the single stage regulator can be used in the construction and mechanical assembly industries. The regulator can be used to power devices such as pneumatic nailing equipment, impact wrenches, and other air driven devices.  
         [0004]     Other features and advantages of the invention will be apparent from the following specification taken in conjunction with the following drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0005]      FIG. 1  is an elevation view of an adjusting knob for a regulator in accordance with the present invention;  
         [0006]      FIG. 2  is a top view of the adjusting knob of  FIG. 1 ;  
         [0007]      FIG. 3  is a bottom view of the adjusting knob of  FIG. 1 ;  
         [0008]      FIG. 4  is a side elevation view of an output or delivery pressure adjustment shaft for a regulator in accordance with the present invention;  
         [0009]      FIG. 5  is an end view of the adjustment shaft of  FIG. 4 ;  
         [0010]      FIG. 6  is a cross sectional side elevation view of a regulator body for a regulator in accordance with the present invention;  
         [0011]      FIG. 7  is a side elevation view of the regulator body of  FIG. 6 , wherein cavities and passages within the regulator are depicted with broken lines;  
         [0012]      FIG. 8  is an end view of the regulator body of  FIG. 7 ;  
         [0013]      FIG. 9  is an opposite end view, from that shown in  FIG. 8 , of the regulator body of  FIG. 7 ;  
         [0014]      FIG. 10  is an extrusion profile of the regulator body of  FIGS. 6-9 ;  
         [0015]      FIGS. 11-12  are side elevation views of a regulator cap for a regulator in accordance with the present invention, wherein cavities and passages within the regulator cap are depicted with broken lines;  
         [0016]      FIG. 13  is a bottom view of the regulator cap of  FIGS. 11-12 ;  
         [0017]      FIG. 14  is a top view of the regulator cap of  FIGS. 11 and 12 , wherein cavities and passages within the regulator are depicted with broken lines;  
         [0018]      FIG. 15  depicts various measurements for the regulator cap of  FIGS. 11-14 ;  
         [0019]      FIG. 16  depicts a cross sectional side elevation view of a piston for a regulator in accordance with the present invention;  
         [0020]      FIG. 17  depicts a side elevation view of the piston of  FIG. 16 , wherein passages within the piston are depicted with broken lines;  
         [0021]      FIG. 18  depicts an end view of the piston of  FIGS. 16-17 ;  
         [0022]      FIG. 19  depicts an opposite end view, from that shown in  FIG. 18 , of the piston of  FIGS. 16-17 ;  
         [0023]      FIG. 20  is a cross sectional side elevation view of another embodiment of a piston for a regulator in accordance with the present invention;  
         [0024]      FIG. 21  depicts a side elevation view of the piston of  FIG. 20 , wherein passages within the piston are depicted with broken lines;  
         [0025]      FIG. 22  depicts an end view of the piston of  FIGS. 20-21 ;  
         [0026]      FIG. 23  depicts an opposite end view, from that shown in  FIG. 22 , of the piston of  FIGS. 20-21 ;  
         [0027]      FIG. 24  is a cross sectional side elevation view of a vessel or bottle adaptor in accordance with the present invention;  
         [0028]      FIG. 25  depicts a side elevation view of the vessel or bottle adaptor of  FIG. 24 , wherein passages within the adaptor are depicted with broken lines;  
         [0029]      FIG. 26  depicts an end view of the bottle adaptor of  FIG. 25 ;  
         [0030]      FIG. 27  depicts an opposite end view, from that shown in  FIG. 26 , of the bottle adaptor of  FIG. 25 ;  
         [0031]      FIGS. 28-30  depict various views of an alternative embodiment of a regulator main body in accordance with the present invention, wherein the regulator main body has an accumulator that accumulates oil or the like;  
         [0032]      FIGS. 31-34  depict various views of an end or regulator body cap for use with the regulator main body of  FIGS. 28-30 ;  
         [0033]      FIG. 35  depicts a cosmetic cut profile view of the regulator body cap of  FIGS. 31-34 ;  
         [0034]      FIGS. 36-39  depict various views of a high pressure piston for use with the regulator main body of  FIGS. 28-30 ;  
         [0035]      FIGS. 40-42  depict various views of an low pressure adjuster knob for use with the regulator main body of  FIGS. 28-30 ;  
         [0036]      FIGS. 43-45  depict various views of a high pressure valve pin for use with the regulator main body of  FIGS. 28-30 ;  
         [0037]      FIGS. 46-47  depict various views of an oiler piston for use with the regulator main body of  FIGS. 28-30 ;  
         [0038]      FIGS. 48-49  depict various views of a gauge adapter for use with the regulator main body of  FIGS. 28-30 ;  
         [0039]      FIGS. 50-54  depict various views of an oil fill nipple for use with the regulator main body of  FIGS. 28-30 ;  
         [0040]      FIGS. 55-57  depict various views of an oil fill strut for use with the regulator main body of  FIGS. 28-30 ;  
         [0041]      FIGS. 58-61  depict various views of an on/off rotary valve for use with the regulator main body of  FIGS. 28-30 ;  
         [0042]      FIGS. 62-63  depict various views of a shoulder screw for use with the regulator main body of  FIGS. 28-30 ;  
         [0043]      FIGS. 64-66  depict various views of a high pressure adjuster for use with the regulator main body of  FIGS. 28-30 ;  
         [0044]      FIGS. 67-69  depict a high pressure regulator seat for use with the regulator main body of  FIGS. 28-30 ;  
         [0045]      FIGS. 70-72  depict an air fill adapter for use with the regulator main body of  FIGS. 28-30 ; and,  
         [0046]      FIGS. 73-75  depict a fill strut for use with the regulator main body of  FIGS. 28-30 . 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0047]     While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments 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 the embodiments illustrated.  
         [0048]     Turning to  FIGS. 1-3 , an output pressure adjustment knob  10  is depicted. The knob  10  is attached to an end  12  of an output pressure adjustment shaft  14  depicted in  FIG. 4 . The shaft  14  is installed into a regulator main body  16  depicted in  FIGS. 6-9 . Preferably, a urethane o-ring (not shown) or the like is mounted about a groove  20  in the shaft  14 .  
         [0049]     The main body  16  includes a threaded output port  40 , and accumulation chamber  42 , a threaded safety poppet port  44 , a threaded burst disk port  46 , a threaded plug fill nipple ports  48  and  52 , a threaded bottle adapter port  50 , and a piston bore  54 .  
         [0050]     Attached to a planar end surface  22  of the regulator main body  16  is a regulator cap  24  depicted in  FIGS. 11-13 . Also, mounted within the piston bore  54  within the regulator main body  16  is a piston  26  as depicted in  FIGS. 16-19 . Alternatively, the piston  28  as depicted in  FIGS. 20-23  is mounted within the piston bore  54  formed within the regulator main body. Preferably, each piston  26  and  28  has a groove  30  with an o-ring (not shown) mounted therein. Moreover, each piston preferably includes a bore  29  with a ball plunger (not shown) installed therein. The ball plunger provides a “ratchet” feel when adjustments or turns are made to the adjustment shaft  14 . The “ratchet” feel results from the ball plunger engaging the knurl on the adjustment shaft  14 .  
         [0051]     Turning to  FIGS. 24-26 , a vessel or bottle adapter  32  is depicted for attaching and receiving input or supply pressure from a vessel, bottle, or the like. Preferably, urethane o-rings (not shown) or the like are mounted about grooves  33  in the adapter  32 . Preferably, all components shown within the FIGURES are made from a metal or metal alloy such as an aluminum alloy.  
         [0052]     Turning back to  FIGS. 6-9 , the output port  40  provides an output for the regulated gas, such as air, provided by the device. Accordingly, the regulated gas, such as air, is stored within the accumulation chamber  42 .  
         [0053]     In an embodiment, a safety poppet (not shown) is installed within the safety poppet port  44 . Preferably, but not necessarily, the poppet releases or vents pressure from the accumulator chamber  42  if the pressure within the chamber exceeds about 200 PSI. The poppet can be the resealing type, wherein pressure is not vented from the accumulator chamber once the pressure within the chamber drops below about 200 PSI.  
         [0054]     In an embodiment, a burst disk (not shown) is installed within the burst disk port  46 . The burst disk provides for high pressure safety by bursting if the pressure within the input supply port  50  becomes too great. Accordingly, for example, the burst disk will rupture if a gas tank (i.e., gas supply) provides too much supply pressure to the device.  
         [0055]     In an embodiment, a pressure gauge (not shown) and fill nipple (not shown) can be installed within the ports  48  and  52 . In an embodiment, the pressure gauge provides a pressure reading from about 0 PSI to about 5000 PSI. Moreover, the fill nipple provides for attaching the device to a gas pressure supply such as an air tank.  
         [0056]     As will be appreciated by those having ordinary skill in the art, additional ports, similar to ports  48  and  52 , can be provided by the device. Preferably, any unused ports are plugged.  
         [0057]     In an embodiment, the cartridge or bottle adapter  32  of  FIGS. 24-27  is installed within the bottle adapter port  50 . The bottle adapter  32  provides for attaching the device to a gas pressure supply such as a gas bottle providing, for example, a pressure of about 5000 PSI or less. The bottle adapter  32  can retain a spring (not shown), valve pin (not shown), and a valve seat (not shown). In an embodiment, the seat is preferably constructed of urethane and has a {fraction (3/8)} inch outer diameter, {fraction (1/8)} inch inner diameter, and is {fraction (1/8)} inch thick. The valve seat can be pressed into the bottle adapter  32 , which is installed into the bottle adapter port  50  by compressing the seat and creating a seal.  
         [0058]     In an embodiment, the piston  26  as shown in  FIGS. 16-19 , or the piston  28  as shown in  FIGS. 20-23 , is installed within the piston bore  54 . The piston is preferably forced within the bore  54  by a spring (not shown). Moreover, the distal end  15  of the adjustment shaft  14  ( FIGS. 4 and 5 ) is inserted through the bore within the piston. Also, threads  17  about the adjustment shaft  14  engage like threads  21  about a bore in the regulator cap  24 .  
         [0059]     The adjustment shaft  14 , via the piston, pushes on the valve pin (not shown) seated on the valve seat (not shown) wherein, as stated previously, the bottle adapter  32  retains both the valve pin and the valve seat. As the valve pin seated on the valve seat is pushed, it allows high pressure gas into the piston bore  54  opposing the piston and sending the piston up off of the valve pin to thus provide regulated pressure into the accumulator via path  72  from the piston bore  54  to the accumulator chamber  42 .  
         [0060]     While the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention, and the scope of protection is only limited by the scope of the accompanying claims.