First stage scuba regulator

A first stage pressure regulator for use with a high pressure source of breathable gas includes a housing and either a yoke arrangement for connection to the conventional U.S. high pressure gas source or a DIN connection for coupling to a European-type gas source. First and second presure-regulated outlets are provided and independently regulated in order to provide from a single high pressure source dual intermediate pressure air for delivery to second stage regulators. In combination with second stage regulators, a system is provided which has enhanced safety features.

The present invention is addressed to self-contained breathing systems, 
such as those used in SCUBA diving equipment, and more particularly 
relates to a first stage pressure regulator and a SCUBA regulator system 
having enhanced safety features. 
Typically, SCUBA divers utilize a high pressure source of breathable gas at 
a relatively high pressure which may exceed 3,000 psi. 
The breathable gas, or air, is typically reduced in pressure by a first 
stage regulator at a constant intermediate pressure of about 140 psi. The 
first stage regulator is mounted directly on the high pressure source of 
air and the intermediate pressure air is applied to a second stage 
regulator which provides air to the diver at a useable pressure. 
For safety purposes, the first stage regulator commonly may have two 
intermediate pressure air outlets which are in turn coupled to two 
separate second stage regulators and associated mouthpiece. The two 
outlets are both dependant on a single regulator valve system for a common 
supply of intermediate pressure air. Second stage SCUBA regulators for use 
in combination with the first stage regulator, in accordance with the 
present invention, are generally well known and described, for example, in 
U.S. Pat. No. 5,259,375 entitled Second Stage SCUBA Regulator with 
Balanced Piston Volume Control. This U.S. patent is incorporated herewith 
by specific reference thereto for the purpose of describing suitable 
second stage regulators which may be used in unique combination with the 
first stage regulator of the present invention in order to achieve a novel 
SCUBA regulator system. 
As is pointed out in U.S. Pat. No. 5,097,860, a disadvantage of present day 
regulators arises from the fact that they are susceptible to icing and 
corrosion from the impurities contained in ambient water, and that 
decreases the useful life of the regulators and increases the maintenance 
cost thereof. Further, since only one first stage regulator is commonly 
used in a SCUBA regulator system, such icing may prevent proper regulation 
of the high pressure air which may cause serious problems to the diver. 
As hereinabove pointed out, often more than one second stage regulator is 
utilized; however, both of the second stage regulators heretofore have 
been connected to the single valve first stage regulator and hence the 
redundancy of second stage regulators is of no avail should the first 
stage regulator malfunction. 
U.S. Pat. No. 5,097,860 utilizes a diaphragm in order to prevent internal 
mechanisms of the regulator from being exposed to ambient water. However, 
despite these precautions, should the first stage regulator become 
inoperative and the supply of air provided to the second stage regulator 
is jeopardized, serious injury or distress may be encountered by the SCUBA 
diver. 
The first stage regulator in the system provided by the present invention 
provides a degree of safety heretofore never provided by a single first 
stage regulator. An independent dual output is provided by the first stage 
regulator in accordance with the present invention so that if one side or 
portion of the first stage regulator becomes inoperative, the other side 
is fully operative in providing a reliable new source of intermediate 
pressure air to one or more second stage regulators. 
SUMMARY OF THE INVENTION 
In accordance with the present invention, a first stage pressure regulator 
for use with a high pressure source of breathable gas generally includes a 
housing and means for attaching the housing to the high pressure source of 
breathable gas. 
A first pressure-regulated outlet is provided along with a second 
pressure-regulated outlet. 
Importantly, first means disposed within the housing is provided for 
delivering to the first pressure regulator outlet a supply of breathable 
gas at a pressure lower than the high pressure source and second means, 
disposed within the housing and operationally independent from the first 
means, is provided for delivering to the second pressure-regulated outlet 
a supply of breathable gas at a pressure lower than the high pressure 
source. 
Because the first and second means for delivering regulated air to the 
outlets are operationally independent from one another, the single stage 
pressure regulator, in accordance with the present invention provides a 
safety level unobtainable from heretofore developed first stage 
regulators. If the first means, or the second means, becomes inoperative 
for any reason, regulated breathable gas is still provided by the first 
stage pressure regulator in accordance with the present invention. 
More particularly, the first stage pressure regulator, in accordance with 
the present invention, may comprise a single valve seat member fixed 
within the housing and first means may comprise a first piston having a 
hollow center in fluid communication with the first pressure-regulated 
outlet and open end means for sealing the first piston against one side of 
the fixed valve seat member. 
In addition the second means may comprise a second piston having a hollow 
center in fluid communication with the second pressure regulated outlet 
and open end means for sealing the second piston against another side of 
the fixed valve seat member. 
First spring means may be provided for biasing the first piston in order to 
effect a first regulated valve opening between the first piston open end 
means and the fixed valve seat member, and second spring means may be 
provided for biasing a second piston in order to effect a second regulated 
valve opening between the second piston open end means and the fixed valve 
seat member. 
It is important to appreciate that the valve seat member is fixed within 
the housing and, unlike prior art devices, no movement is necessary in 
order to regulate the pressure of the breathable air delivered to the 
first and second outlets. 
Regulation of the intermediate air pressure to both the first and second 
pressure-regulated outlets is provided by first and second secondary 
spring means for adjusting the amount of bias provided by the first and 
second spring means, respectively. 
In addition, first and second body means, each rotatably mounted to the 
housing, may be provided for supporting first and second 
pressure-regulated outlets, respectively and screw means may be provided 
which is accessible from outside of the first and second body means, 
respectively, for changing the compression of the first and second 
secondary spring means. 
A plurality of first pressure-regulated outlets may be disposed in the 
first body means and a plurality of second pressure-regulated outlets may 
be disposed in the second body means to enable the use of more than two 
second stage regulators with the first stage regulator, in accordance with 
the present invention. 
In addition, at least one high pressure outlet may be provided and attached 
to the housing in direct fluid communication with the high pressure source 
of breathable air in order to prevent the volume of air in the high 
pressure source and may be monitored. 
A SCUBA regulator system, in accordance with the present invention, for use 
with a single high pressure source of breathable gas generally includes a 
single stage pressure regulator having first and second independently 
operating pressure-regulated outlets, as hereinabove set forth, and 
adapted for being connected to the single high pressure source of 
breathable gas. 
Means are provided for independently delivering to first and second 
pressure-regulated outlets a supply of breathable gas at an intermediate 
pressure lower than the pressure of the single high pressure source of 
breathable gas. 
Two second stage regulator means are provided for receiving the 
intermediate pressure breathable air from the first and second 
pressure-regulated outlets and delivering breathable to at least one 
mouthpiece at a pressure suitable for a SCUBA diver. 
In one embodiment of the present invention, means are provided for 
connecting one of the two second stage pressure regulator means to the 
first pressure-regulated outlet and another of the two second stage 
pressure-regulated outlets to the second pressure-regulated outlet. 
Alternatively, means may be provided for connecting both of the two second 
stage pressure regulator means to both the first and second 
pressure-regulated outlets. In this manner, if one of the first and second 
pressure-regulated outlets from the first stage regulator fails to deliver 
the intermediate pressure, both of the second stage pressure regulator 
means remain operative.

DETAILED DESCRIPTION 
Turning now to FIG. 1, there is generally shown a first stage pressure 
regulator 10, in accordance with the present invention, having a housing 
12 with a yoke 14 and nut 16 threaded thereto which provides a means for 
attaching the housing 12 to a high pressure source 20, as shown in FIG. 2, 
and O-ring 22 provides a seal and a filter 24 prevents contamination from 
passing between the high pressure breathable gas source 20 and a central 
chamber 28 of the housing 12. The yoke 14 configuration shown in FIGS. 1 
and 2 is conventional for U.S. configured supply tank 20. 
A plurality of first pressure-regulated outlets 32, 34, 36, 38 may be 
rotatably disposed in a first body 42 which is mounted to the housing 12 
and sealed thereto by O-rings 46, 50. 
The multiple outlets 32, 34, 36, 38 enable a plurality of second stage 
regulators (not shown) to be supplied with breathable air of intermediate 
pressure. As shown in FIG. 1, only one line 52 is interconnected to outlet 
32 by a conventional coupling 54. Rotation of the body 42 in opposite 
directions as indicated by the arrow 56 enables the line 52 to be 
conveniently positioned with respect to the diver. 
A second body 58 is provided with outlets 62, 64 with a second line 66 
being attached to the outlet 64 by a conventional coupling 68. While only 
two outlets 62, 64 are shown in the figures, it should be appreciated that 
the second body 58 may include four outlets symmetrically disposed around 
the body 58 as is the case with the first body 42. Similar to the first 
body 42, the second body 58 is rotatably attached to the housing 12 and 
sealed thereto by the O-rings 46, 50 for enabling rotation of the body as 
indicated by the arrow 78. 
Turning now to FIG. 2, first and second pistons 82, 84 having hollow 
centers 86, 88 and a single valve seat 94 provide first and second means 
disposed within the housing 12 for delivering to the first 
pressure-regulated outlets 32, 34, 36, 38 and second pressure-regulated 
outlets 62, 64, respectively, a supply of breathable gas at a pressure 
lower than the high pressure source. 
More specifically, the pistons 86, 88 include open ends 96, 98 for sealing 
the first and second pistons 82, 84 respectively against opposite sides 
102, 104 of the seat 94. 
As shown in FIG. 3, the seat 94 is affixed to the inside sidewall 108 of 
the chamber 28 and is preferably fabricated from a solid plastic material 
or the like having sufficient stiffness to prevent movement when engaged 
by the piston open ends 96, 98, but yet enables seating, or sealing, of 
the pistons 82, 84 thereagainst. 
Turning again to FIG. 2, the first and second springs 112, 114 compressed 
between end walls 118, 120 of the first and second bodies 42, 58 
respectively, and shoulders 124, 126 of bushings 128, 130 threadably 
engaging the pistons 82, 84, respectively, provide a means for biasing the 
first and second pistons 82, 84 in order to effect regulated valve 
openings between the first pistons and open end 96 and the one side 102 of 
the seat 94 and between the open end 98 and another side 104 of the seat 
94. 
In operation, the springs 112, 114 balance the pistons 82, 84 such that 
when air is drawn through one of the outlets 32, 34, 36, 38, or 62, 64, 
the springs 112, 114 respectively urge the pistons 82, 84 away from the 
seat member 94 to enable high pressure air in the chamber 28 from the high 
pressure source 20 to enter the hollow center portions 86, 88 to be 
delivered and removed through the outlets 32, 34, 36, 38 and 62, 64. When 
the removed air is replenished, the piston returns to a sealed engagement 
with the seat member 94. 
It should be obvious that each of the pistons 82, 84 operate independently 
from one another and therefore a malfunction of one piston, for example 
piston 82, will not affect the performance of the second piston 84. This 
provides an inherent safety system which can be utilized with second stage 
regulators as will be discussed thereinafter in greater detail. 
The bushings 128, 130 are slidably disposed within the bodies 42, 58 
respectively with O-rings 140, 142 providing a seal therebetween. 
In order to provide a means for adjusting the amount of bias provided by 
the first and second springs 112, 114 in order to regulate the pressure of 
the supply of breathable gas available from a first outlet 32 and a second 
outlet 64, secondary springs 146, 148 are disposed respectively within the 
first and second bodies 42, 58 between the bushings 128, 130 and retainers 
150, 152 respectively. Caps 156, 158 are respectively threaded to the 
bodies 42, 58 in order to seal the bodies 42, 58 and to capture the 
springs 112, 114, 146, 148 along with the bushings 128, 130 and retainers 
150, 152, all respectively within the bodies 42, 58. Threaded plugs 162, 
164 provide a screw means accessible from outside the first and second 
bodies 42, 58 for changing the compression of the first and second 
secondary springs 146, 148. Each plug 162, 164 includes a hex-shaped 
depression 168, 170 to facilitate rotation thereof for changing the spring 
146, 148 compression, as hereinabove noted. 
O-rings 172, 374 provide a seal between the plugs 162, 164 and the caps 
156, 158, respectively. O-rings 176, 178 provide a means for sealing the 
caps 156, 158 to the bodies 42, 58 upon screwing up the caps 156, 158 to 
the bodies 42, 58 respectively. Outlets 32, 36 and 64, 70 are either 
coupled to lines 52, 66 or are sealed by caps 182, 184. 0-rings 188, 190, 
192 and 194, respectively provide the seals for the outlets 32, 36, 64, 70 
and caps 82, 84, respectively. Hex-shaped cavities 196, 198 are provided 
for enabling removal and insertion of the caps 182, 184 respectively. 
Turning again to FIGS. 1 and 2, a swivel cap 202 is rotatably mounted to 
the housing 12 and sealed thereto by O-ring 204. The swivel cap carries a 
plurality of high pressure outlets 208, 210, which communicate with the 
high pressure chamber 28 of the housing 12. Removal of plugs 214, 216 
threadably engaging swivel cap 202 by means of hex openings 218, 220 
enables the attachment of the high pressure gauge as indicated in FIGS. 5 
and 6. Access to the retainer 224 is provided by a plug cover 226. 
In order to reduce the possibility of icing or corrosion of the springs 
112, 114 and pistons 82, 84, body volumes 230, 232 may be filled with an 
antifreeze type fluid, such as alcohol. 
Accordingly, in order to equalize the pressure within the body volumes 230, 
232, with ambient water pressure, pressure equalizers 236, 238 are 
provided as shown in FIGS. 1 and 7. As detailed in FIG. 7, the pressure 
equalizer 236 includes a body portion 240 screwed into a housing wall 242 
with a cap 244 threadably engaging an upper portion 246 of the body 240 
with an O-ring 248 providing a seal between the housing wall 242 and body 
240 and an O-ring 250 providing an inner seal. A piston 252 disposed 
within the body 240 enables the balance of ambient water pressure with the 
body volume 230. 
Shown in FIG. 4 is an alternative embodiment 258 of the present invention 
utilizing a single body 42. Like numbers on FIG. 4 correspond to the 
already-described mechanism shown in the left side of FIG. 2. It should be 
appreciated that the embodiment 158 may be converted at a later time to 
the embodiment 10 by the removal of a cover 260 and insertion of a second 
body 58 (not shown in FIG. 4), a seal between the cover 260 or the second 
body 58 being provided by O-ring 262. This feature enables the embodiment 
258 to be "upgraded" at a later time at the convenience of the user. Also 
shown in FIG. 4 is a DIN European-type coupling 264. Accordingly, the 
housing 12 is appropriately fitted with threads 266 for engagement 
therewith. 
Turning now to FIG. 5, there is shown a SCUBA regulator system which 
generally includes the first stage regulator 10, as hereinabove described, 
interconnected through lines 270, 272 to second stage regulators 134, 136, 
thereinabove referred to. The two second stage pressure regulators 134, 
136 receive intermediate pressure breathable air at about 125 to 150 psi 
and deliver breathable air to at least one mouthpiece at a pressure 
suitable for a SCUBA diver in a conventional manner. 
Importantly, as hereinabove described, the regulator 10 provides two 
separate and independent sources of such intermediate pressure breathable 
air from a single high pressure source 20, and hence any malfunction of 
one of the pistons 82, 84 will not result in a failure of the system in 
supplying intermediate breathable air to the second stage regulator. 
Prior art systems have utilized dual second stage regulators; however, they 
are both connected to a single first stage regulator and hence failure of 
the latter results in total failure of the system. An alternative 
embodiment 278 of a SCUBA regulator system, in accordance with the present 
invention, includes the first stage regulator 10 as hereinabove described, 
along with second stage regulators 134, 136, as hereinabove noted. 
Importantly, T-connectors 282, 284 provide a means for connecting both of 
the two second stage pressure regulators 134, 136 to both the first and 
second pressure-regulated outlets 32, 64 via lines 288, 290, 292, 294, 
296, 298. 
This interconnection enables either of the second stage regulators 134, 136 
to operate from either of the first stage independent outlets 32, 64. 
Thus, failure of one of the pistons 82, 84 will enable either of the 
second stage regulators 134, 136 to remain operative. This may be 
important should one of the second stages 334, 136 malfunction. It also 
provides additional safety for buddy diving operations. Also shown in 
FIGS. 5 and 6 is a representation of a high pressure gauge 302 
interconnected by a line 304 to the high pressure outlet 208 on the first 
stage regulator 10. 
Although there has been hereinabove described a first stage regulator and 
SCUBA regulator system in accordance with the present invention, for the 
purpose of illustrating the manner in which the invention may be used to 
advantage, it should be appreciated that the invention is not limited 
thereto. Accordingly, any and all modifications, variations, or equivalent 
arrangements which may occur to those skilled in the art, should be 
considered to be within the scope of the present invention as defined in 
the appended claims.