Single stage regulator with surge reducing valve

In a single stage regulator as used in conjunction with a high pressure vessel, a surge reducing valve is positioned within the outlet from the regulator and just at its low pressure side of the regulator in order to reduce any surge or jump in the gas flow during sustained gas consumption or when it is shut off.

BACKGROUND OF THE INVENTION 
This invention relates generally to gas regulators, and more particularly 
pertains to a surge reducing valve used in conjunction therewith. 
The construction and usage of single stage regulators in conjunction with 
high pressure gas, as contained within a vessel, is well known and 
understood within the art. For example, such regulators normally include a 
housing that incorporates an intake side, and which usually connects with 
the high pressure vessel, and an outlet conduit that conveys the now 
reduced and low pressure gas to its point of usage, whether it be to an 
acetylene welding torch, or any oxygen delivery system such as used for 
patient treatment within a hospital. And, such type regulators further 
usually incorporate a handle or adjusting screw that cooperates with a 
spring that applies pressure upon a diaphragm and cooperating disc for 
effecting that rather precise reduction in the pressure of the gas being 
delivered from the high pressure vessel to its point in consumption. 
Normally, the gas pressure within such a vessel may be within a range of 
2,000 to 2,500, or more, psi, whereas, gas pressure at its point of usage 
may preferably and desirably be within the range and vicinity of 2 to 4 
psi, and normally less than 10 psi. Precision in the regulation of the 
pressure of this delivered gas is rather critical, since, for example, in 
the torch technology it is desirable that the welder or steel worker be 
able to adjust the torch flame to that required length as desired and 
needed for the particular job being performed. Furthermore, and of more 
criticality, the delivery of, for example, oxygen to the patient must be 
at a rather precise level, and the technician must be assured that once 
the pressure regulator is adjusted to effect delivery of this gas at a 
defined critical level, that such will be maintained. Any variation in the 
quantity or volume of gas being delivered may have injurious effects on 
the patient being treated, and therefore, precise control in this specific 
usage is significantly critical. 
But, even in view of the foregoing, and particularly during gas flow 
control through the use of single stage regulation, the industry has 
constantly been plagued by what is generally defined in the art as a jump 
in the gas flow, generally comprising either a momentary or gradual rise 
as the gas from the vessel is being consumed. Furthermore, such jump can 
more dramatically occur when the gas flow from the vessel is curtailed, as 
through a shutoff of its regulator, and when this occurs a surge in the 
gas pressure is significantly increased until it finally drops after a few 
seconds of terminal flow to its required zero level. An analysis of this 
predicament will be subsequently reviewed in detail. 
Various prior art structures for regulating pressurized gas flow have been 
devised, generally for the purpose of providing a reduction in the gas 
flow from that high pressure maintained in the vessel, particularly when a 
new bottle of gas is tapped for usage. For example, the two U.S. Pat. to 
Amlong, No. 4,008,716 and No. 3,976,067, probably disclose the more 
current type of gas dispensing assemblies now in use, and from these two 
particular patents one can see the concept of utilizing a pair of valves, 
but in this particular instance, in demand valves, being used at the 
outlet part of the gas storage vessel and to either side of its pressure 
gauge for attaining a particular and desired result. The valve shown in 
these two designs, as previously explained, are of the demand valve type, 
and function mainly to regulate the flow of oxygen during the specific 
inhalation cycle of the patient being tested or treated. Their 
specifications do not describe the use of the valves for the specific 
purpose of finely regulating or eliminating the surge of any gas dispensed 
from the vessel, and particularly at its outlet assembly, but rather, are 
simply to provide the means for retaining particular dispension of oxygen 
only when a demand is made, as specifically during the inhalation breath 
cycle of the patient. 
The U.S. Pat. to McClelland, No. 1,939,509, recognizes that a problem may 
be inherent in the usage of pressure indicating gauges for detecting flow 
rates, and that vibrations or pulsations of the indicating pointer of such 
a gauge may be an existing problem. Thus, to solve that problem, this 
prior art disclosure shows the usage of a baffle having a fine bore 
therethrough, as the means for controlling exposure of the pressurized 
material to the gauge indicating means. This has a minor relationship to 
the invention under consideration, in that it does disclose the usage of 
some form of a small bore baffle for regulating flow, but in this 
instance, the flow is directed only towards the indicator, and not within 
the main line transfer of any pressurized fluid, such as the gas, to an 
outlet, and to its location of usage, and more specifically for preventing 
gas surge during such operation. 
The patent to Koppleman, U.S. Pat. No. 2,855,926, discloses an oxygen 
dispensing machine wherein a couple of valves are provided for regulating 
gas flow to the mask. In addition, a demand regulator is also provided for 
authorizing the dispensing of gas only upon demand, as previously 
explained, as when the user inhales. But, there is nothing shown within 
this disclosure relating to any dampening of any gas surge as when the 
main valve is shut off, or while the gas flow is maintained desirably at a 
regulated amount over a sustained period of time. 
The U.S. Pat. to Flint, No. 4,006,742, simply discloses another form of 
control valve for use in the administration of gases such as oxygen, or 
the like. The pressure relief in this particular control functions by way 
of a disc valve, which just allows for the exhausting of any high pressure 
when release is needed. But, there is nothing in this disclosure relating 
to the dampening of any surge during gas flow or shut off. 
Finally, the U.S. Pat. to Price, No. 1,622,843, discloses the use of a 
stabilizer for preventing rapid fluctuations in the pressure of a gas 
within the main air line, and which may have an effect upon gas flow, with 
this accomplishment being achieved from this prior art design for use as a 
restricting means, such as by means of a small opening nozzle, which 
functions as an inverted Venturi for dampening the pressurized liquid 
pulsation within the main line. Apparently this type of a restriction 
within the outlet line of a regulator still encounters the surging problem 
when the main supply of gas is shut off, whereas, with the current 
invention, this problem has been significantly eliminated through the 
usage of a supplemental surge reducing valve which constricts passage of 
the pressurized gas immediately as it leaves the regulator and to a point 
of usage. 
In view of the foregoing, it is the principal object of this invention to 
provide a particular style of surge reducing valve in a regulator as the 
high pressure gas is reduced for usage from a single stage regulator in 
order that a constant flow of gas at a particular pressure is maintained 
throughout its consumption. 
A further object of this invention is to provide means for furnishing a 
precisely regulated flow of gas from a high pressure vessel. 
Yet another object of this invention is the provision of means for 
providing a constriction to the flow of pressurized gas so as to attain 
its regulation to a desired pressure, and to within a range of a constant 
value. 
Still another object of this invention is the structure of the surge 
reducing valve for use in conjunction with the single stage regulator for 
precisely controlling the flow of gas under pressure. 
Another object of this invention is the furnishing of means to minimize the 
risk of damage or harm to one working with highly pressurized and 
flammable gases. 
Another object of this invention is to prevent an immediate surge in gas 
flow after a regulator has been shut off. 
Still a related object of this invention is to provide means for preventing 
a jump in the flow of gas as the pressure of the gas within a vessel is 
gradually depleted. 
These and other objects will become more apparent to those silled in the 
art upon reviewing the summary of this invention and upon undertaking a 
study of its preferred embodiment in view of the drawings. 
SUMMARY OF THE INVENTION 
This invention contemplates the locating of particularly styled surge 
reducing valve within the flow path of pressurized gas passing through the 
single stage regulator and from a pressurized vessel of gas. Essentially, 
the valve means comprises a cylindrical member that has an aperture or 
channel therethrough, being of a relatively small diameter dimension, and 
which acts as a constriction against the onrush of the pressurized gas to 
flow from its vessel and into and through the regulator wherein its 
pressure may be dropped from the 2,000 psi range down to a significantly 
reduced value of approximately less than 10 psi, which is the pressure of 
the gas as normally used in conjunction with other equipment as previously 
described. This surge reducing valve fits within the outlet line of the 
regulator, or at least in some conduit that leads between the regulator 
and the point of its usage, with said valve having a shoulder formed 
therein so as to provide for its snug seating within an inset of the 
outlet conduit. Furthermore, said valve may incorporate a taper from its 
formed shoulder to its inlet side so as to aid in the installation of the 
valve within the particular conduit leading from the high pressure vessel. 
In addition, the opposite end of the surge reducing valve means has a 
slight chamfer provided thereon in order to furnish clearance for insuring 
the snug insertion and fitting of the valve when installed. 
An example of the attributes to be obtained from usage of this invention 
may be observed from the charts disclosed in FIGS. 4 and 5 of the 
drawings. For example, in FIG. 4, this particular graph discloses the 
functioning of a single stage regulator in conjunction with a pressurized 
vessel of gas, and shows just how the low pressure flow meter of the 
regulator when adjusted to provide for a discharge of 4 psi gas from the 
gas vessel, during the continuing discharge of the gas from the same, over 
a prolonged period of time, gradually increases in pressure up to 
approximately 9.5 psi, without any further adjustment having been made to 
the regulator, before it drops off to a zero pressure as attained upon 
emptying of the said vessel. Thus, without the use of the surge reducing 
valve of this invention, the pressure significantly increases from the 
desired and usable 4 psi and up to and approximating 10 psi just through a 
normal discharge of the said gases through the adjusted and single valve 
set regulator. The detriments to be obtained from such a functioning 
regulator can be readily determined where the gas being dispensed from the 
pressure vessel may be used in conjunction with an oxygen mask, as for 
example, when applied to a patient in a hospital or related facility, 
which under normal operating conditions through the usage of the current 
regulator technology, significantly increases in the gas discharge level 
and to a level that may be harmful to the patient. Whereas, the 
recommended dosage of the oxygen delivered to the mask may be at the 4 psi 
level, after a few hours of discharge, or perhaps over a night's 
application to the sleeping patient, the gas discharge may more than 
double that amount as can be readily determined from the chart line shown 
in FIG. 4. 
On the other hand, and as can be determined from FIG. 5, wherein the 
medical regulator is provided with the surge reducing valve restriction in 
its outlet as applied through the teachings of this invention, once the 
regulator is set to dispense, as for example as shown at a 4 psi of 
pressurized oxygen, as the vessel discharges, and even when it approaches 
a zero capacity, the regulator, with the installed inventive valve, has 
prevented the gas discharge from rising above approximately 5 psi. Thus, 
level gas flow is approximately maintained. The patient will not be 
damaged or harmed from the regulator that incorporates the valve of this 
invention. 
As to why the foregoing occurs it is not completely understood, but it is 
believed that in a single stage regulator, that does not incorporate one 
of the valves of this invention, the theory of pressurized gas flow called 
jump occurs, and which probably can be theorized as an indication of the 
true difference between the gas pressure at the regulator outlet when gas 
is flowing and its pressure when the gas is not flowing, or when reduced, 
particularly when this increase in pressure is gauged when the regulator 
has been shut off, or as the gas pressure reduces. And, the type of 
increase in pressure shown in FIG. 4 of the drawings apparently occurs due 
to the pressure on the low pressure side of the regulator rising until the 
diaphragm is moved far enough to compensate for the reduction in pressure 
entering into the intake line from the pressure vessel as a result of the 
depleting gas supply contained therein.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
In FIG. 1 of the drawings, there is disclosed the regulator of this 
invention having its handle conveniently disposed for opening or shutting 
off gas flow through said regulator. The high pressure gauge 2 is provided 
for furnishing an ever present indication of the amount of pressurized gas 
yet remaining within the pressure vessel (not shown) from which a quantity 
of gas is dispensed through this regulator and to the instrument of its 
usage. In addition, an intake line 3 is associated with the regulator and 
is disposed for connecting to a conduit that couples with the pressure 
vessel, while an outlet line 4 attaches with the other side of the 
regulator, or its low pressure side, for transferring low pressure gas to 
its source of usage, whether it be an acetylene torch, oxygen mask, or any 
other instrumentation which requires a low pressure gas in its operation. 
Furthermore, a low pressure indicator 5 is coupled with the outlet conduit 
of the regulator, as aforesaid, so as to provide a prompt indication of 
the amount of low pressure gas passing through the regulator, and which 
may be set anywhere from zero up to 15 psi depending upon the adjustment 
made to the regulator handle 1. In addition, within the outlet of the 
regulator, there may be contained a valve 6 so as to provide for some 
continuity of the flow of the gas through the regulator, and out of the 
outlet and to provide means for providing a fine operation of the gauge 5. 
The nut 7 as shown provides means for connecting this regulator with the 
conduit leading to the instrument of gas usage, as previously explained. 
The essence of this invention is the provision of the surge reducing valve 
8 within the regulator, or at least leading towards the entrance into the 
outlet line for the same, and this valve is positioned in the manner as 
shown to effect and accomplish the various attributes from this invention 
as previously summarized and explained in this disclosure. 
This valve 8, as can be further seen in greater detail in FIGS. 2 and 3, 
incorporates a cylindrical portion 9 which is chamfered, as at 10, so as 
to furnish clearance for the snug seating of the valve within the position 
as shown in FIG. 1. Furthermore, a shoulder 11 is formed at approximately 
the midposition of the cylindrical portion of the valve, and this shoulder 
communicates with a tapered area of the cylindrical portion up to the 
intake side 12 of the valve. An aperture or channel, as of 13, is provided 
through the length of the valve, and furnishes a significant reduction in 
the volumetric capacity for flow of the pressurized gas, as at its lower 
pressure side from the regulator and through to the outlet of the same, 
and further furnishes the continuity of the gas flow so as to 
approximately sustain the gas volume and velocity to that quantity 
previously set upon adjustment of the regulator handle 1, and which 
setting has been visually observed by means of the low pressure gauge 5. 
The desired dimension for the diameter of the aperture 13 provided through 
the cylindrical portion of the valve is preferably set at less than twenty 
thousandths of an inch, or more specifically, a diameter of approximately 
0.0135 inch has been found to provide the consistency in gas flow at the 
adjusted level as exhibited through the experimentation that was used to 
derive the graph of FIG. 5. In addition to the foregoing, the passage 
through the valve 6 is customarily somewhere set within the range of 0.023 
inch, and generally acts as a means for providing some constancy to the 
gas flow for the benefit of the gauge 5, but when used individually 
without the valve 8 of this invention has given rise to the inaccuracies 
in regulator operation as shown upon the graph 4 as constructed from the 
experimentations made upon such a regulator. 
Variations in the construction and fabrication of the regulator 
incorporating the valve of this invention may occur to those skilled in 
the art upon reviewing the subject matter of this invention. Such 
variations, as for example, changing the shape of the portion of the 
cylindrical body 9 or the valve 8 itself may occur to those skilled in the 
art upon reviewing the subject matter of this disclosure. Any such 
variation or modification, if within the spirit of this invention, are 
intended to be encompassed by the scope of any claims to patent protection 
issuing hereon. The subject matter of this detailed analysis is set forth 
for illustrative purposes only, and is not meant to be limiting of the 
contents of the invention provided herein.