Safety paintball gun regulator

Paintball regulators of the present invention receive higher pressure gas from a gas canister, output lower pressure gas to a gun body, but resist violent separation if inadvertently disassembled. The paintball regulators include a hollow valve body, a plug seat fixed in the valve body, a piston subassembly removably secured to the valve body, a plug, a first coacting member on the plug and a second coacting member on the piston subassembly. The valve body defines an open end for receiving the piston subassembly and a gas supply opening. A plug seat is set in the valve body such that the plug seat and the valve body together define a fluid pathway between the supply opening and the open end. The piston subassembly is removably secured to and engageable with the open end. The plug is positioned in the pathway and complementary to the plug seat. The first member, which is on the plug, and the second member, which is on the piston subassembly, coact such that the plug is offset from the plug seat when the paintball regulator is fully assembled and that the plug is received at the plug seat when the paintball regulator is less than fully assembled.

FIELD OF THE INVENTION

This invention relates to a pressure regulator suitable for use with paintball marking guns and other pressurized-gas powered devices.

BACKGROUND OF THE INVENTION

Paintball marking guns are used in a variety of targeting and simulated battle games (e.g., capture the flag). These guns launch a ball of paint with a frangible shell that is designed to hold the ball shape until striking an object after firing. Upon striking the object, the ball is set to break open leaving a paint spot.

Paintball guns typically employ a firing system powered by compressed gas such as air. Compressed air is supplied from a canister which is mounted to or carried with the gun. The gun systems also include a gun body, a paintball hopper and one or more pressure regulators which receive gas from the tank at a relatively high pressure and deliver gas at a reduced, more consistent pressure to the gun body for propelling the paintball.

The pressure regulators are modular and typically include at least two major components interconnected with threaded portions. One well-accepted type of gun system design calls for a pressure regulator to be threaded directly into the supply canister.

It is preferred, safe practice to fully discharge gas canisters before disassembling any part of the gun system. Paintball players are known to remove the regulator-canister portion of the system from the gun body without discharging the gas canister, however. Players may wish to make adjustments at remote locations or avoid the cost of a gas recharge.

Although modular paintball regulator designs are preferred for performance and maintenance, it is a concern that paintball regulator parts may be inadvertently separated when a paintball player attempts to remove a canister. If such parts are disassembled before the canister is discharged, the ultimate separation can be violent and therefore unsafe.

One approach to addressing this safety concern is the placement of special alignment markings on threaded fittings. A change in the alignment of the markings serves as a warning to the paintball player that the wrong parts are separating. Although well accepted, this approach relies on the paintball player to monitor the markings while removing the paintball regulator or canister from the gun body.

There would be several advantages to a paintball regulator system that prevents violent separation of components when inadvertently disassembled.

SUMMARY OF THE INVENTION

Paintball regulators of the present invention receive higher pressure gas from a gas canister, output lower pressure gas to a gun body, but resist violent separation if inadvertently disassembled. The paintball regulators include a hollow valve body, a plug seat fixed in the valve body, a piston subassembly removably secured to the valve body, a plug, a first coacting member on the plug and a second coacting member on the piston subassembly. The valve body defines an open end for receiving the piston subassembly and a gas supply opening. A plug seat is fixed in the valve body such that the plug seat and the valve body together define a fluid pathway between the supply opening and the open end. The piston subassembly is removably secured to and engageable with the open end. The plug is positioned in the pathway and complementary to the plug seat. The first member (on the plug) and the second member (on the piston subassembly) coact such that the plug is offset from the plug seat when the paintball regulator is fully assembled but the plug is received at the plug seat when the paintball regulator is less than fully assembled. In a preferred embodiment, the first member is a spacer integral with the plug and the second member is a land on the piston subassembly.

An embodiment of the present invention can be described as follows. The paintball regulator comprises a body and an actuator subassembly removably secured to the body. The actuator subassembly includes an actuator housing. The body has a gas source coupling portion at one end and an open opposite end. The body defines a fill port, an output port, an inlet opening in the coupling portion and an axial flow pathway in communication between the inlet opening and the open end. The coupling portion is adapted for connection to a compressed gas tank or canister. A plug is positioned in and axially movable within the pathway. A plug seat is positioned between the fluid pathway and the open end. The piston subassembly is movable between a secured assembled position in which the plug is offset from the retainer by the spacer and a secured disassembly position in which the plug is responsive to the high pressure gas to block the fluid pathway.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Shown in the drawings and described hereinbelow in detail are preferred embodiments of the invention. The present disclosure is an exemplification of the principles of the invention and does not limit the invention to the illustrated embodiments.

Referring now toFIG. 1, paintball regulator10includes a substantially hollow valve body (or main component)12secured to a piston subassembly14. Valve body12has a unitary coupling portion18extending away from an open end20. Opposite coupling portion18, valve body12has an open end20. Coupling portion18is adapted for sealed interconnection with a compressed gas source such as a canister (not shown). The source of compressed gas is typically a canister and the outside surface of coupling portion18is threaded for sealed connection into a canister. In an alternate arrangement, the gas source takes the form of a fitting extending by hose from a more remote tank, in which case the coupling portion has a configuration for sealed connection to the gas supply fitting. An o-ring21is preferably provided on coupling extension18for improved seal to the gas canister.

Valve body12defines open end20, a fill port22, and a discharge opening24and inlet opening26, both towards the distal end27of coupling portion18. An internal plug seat28is positioned between discharge opening24and open end20such that valve body12and plug seat28define a fluid pathway30. A plug32is disposed in pathway30and has a form complementary to valve seat28. Plug32is preferably biased towards plug seat28with a spring34to prevent sticking. An optional o-ring31improves the seal between plug32and seat28.

Pathway30delivers compressed gas from the source into chamber36. A second fluid pathway37is defined between fill port22and inlet opening26to provide a path for compressed gas to enter a gas source. Pathway30is preferably equipped with a contoured mesh filter38. Filter38prevents particles and other gas impurities from entering and fouling the paintball regulator valve mechanisms. A suitable sintered brass filter of 40 microns is commercially available from Capstan Permaflow (Gardena, Calif.). Filter38is secured within body12with hollow retainer40secured to coupling portion18(preferably with complementary threads).

Piston subassembly14includes a piston housing42, a piston44and a main piston spring46. Piston44has a barrier portion48and a stopper portion50. Piston44defines an internal gas flow passageway52extending from radial inlets54in stopper portion50to a central opening56in barrier portion48. Barrier portion48forms a seal with inner side walls58of housing42via an o-ring60. Likewise, stopper portion50of piston44forms a seal with inner side walls62of body12via an o-ring63. Stopper portion50preferably includes an insert64of resilient material.

The gas source canister is filled through paintball regulator10with a supply hose (not shown) temporarily connected into fill port22. Compressed gas enters fill port22and moves through second confined-flow pathway37to inlet opening26and then into supply tank (not shown). In this way, the flow of compressed gas for refill does not enter pathway30or impact other parts (e.g., plug32) of the regulator piston mechanism. Paintball regulator10is illustrated without an adapter in fill port22to better reveal internal details. Fill port22is preferably equipped with an internal seal holder (e.g., a check valve) to seal pressurized gas into the canister.

Although other configurations are contemplated, paintball regulator10is adapted for use as a “screw-in” type paintball regulator. Therefore, piston housing42of subassembly14has a threaded portion66opposite coupling portion18. Portion18is sized and threaded to be received into a corresponding socket on a paintball gun system. An axial outlet port68in housing42delivers regulated gas to the paintball gun. An o-ring seal70is provided in a groove offset from the end of housing42.

In operation, threaded portion66is received in a paintball gun assembly and a charged gas cannister is connected to threaded coupling portion18. Compressed gas flows from the gas canister into discharge opening24and then into pathway30as it passes through filter retainer30and filter38. When body12and piston subassembly14are fully assembled as shown inFIG. 1, plug32is offset from seat28such that gas flows around plug32and into orifice72of seat28.

Paintball regulator10is shown with piston44in the closed condition when the outlet side pressure at port68is at the required pressure. In the closed condition, the controlled-pressure gas indicated generally at36creates a force on the piston44in the direction of seat28that is sufficient to counter the opposing force generated by spring46and compressed gas in pathway30. This in turn urges stopper64against seat28to block flow through paintball regulator10.

When gas pressure on the outlet side drops because, for example, a paintball is fired, the opposing forces balancing on piston44are disrupted as follows. The gas-pressure force on piston44in the direction of seat28momentarily drops allowing the force of spring46and gas pressure at30to open a gap between stopper48and orifice72. With a gap momentarily present between seat28and stopper64, gas flows from the gas canister in discharge opening24into pathway30through filter retainer40and filter38, around plug32, through orifice72of seat28, into chamber36, through radial inlets54and internal passage52and finally out to the paintball gun through outlet68. When gas pressure at68again increases, piston44returns to the closed condition, i.e., the gap between stopper64and seat28is again closed.

As noted above, in normal operation, gas flows through pathway30because plug32is offset from seat28. When body12and piston subassembly14are fully assembled as shown inFIG. 1, spacer member74on plug32coacts with land member76on piston44to keep plug32offset from seat28such that gas flows around plug32and into orifice72of seat28.

A key feature of the present invention is the coaction between first member74and second member76. When body12and piston subassembly14are less than fully assembled together, land76is positioned relatively further from seat28such that plug32can be received by plug seat28. If the main paintball regulator components (12and14) are partially “unscrewed,”—i.e. counter-rotated—when the paintball gun system is charged with compressed gas, paintball regulator10moves to a safety position in which gas through pathway30is blocked by a plug32. This less than fully assembled configuration is shown inFIG. 2.

It is a significant feature of paintball regulators according to the present invention that pathway30becomes blocked during disassembly while the main components (e.g., body12and piston subassembly14) are still mechanically secured together. This feature prevents violent separation of paintball regulator components during disassembly even if an operator inadvertently fails to discharge the gas tank. Regulator10specifically demonstrates this feature via the dimensional relationship that the secured engagement range for main components12and14is greater than the offset plug32and seat28as measured when piston44is in a closed condition and paintball regulator10is fully assembled. As used herein, “secured engagement range” is a reference to the length over which major components (e.g.,12and14) are secured together during assembly and disassembly, a measure of the distance between first engagement and full assembly.

It is also preferred feature of the present invention that the range of axial motion57of piston44is less than the offset between plug32and seat28as measured when piston44is in a closed condition and paintball regulator10is fully assembled. For paintball regulator10, the range of axial motion is identified with reference number57, which reflects the gap between surface78of housing42and an end surface80of piston44. The offset between plug32and seat28when piston44is in a closed condition is indicated by reference number59. It is preferred that range of motion57be a distance less than the length of gap59for more reliable operation of paintball regulators according to the present invention.

Another paintball regulator according to the present invention is shown inFIGS. 3 and 4. Paintball regulator110includes two major components: a hollow body112and a piston subassembly114. Body112includes an open end120, a discharge opening124and an axial bore129extending between discharge opening124and open end120. A retainer128is fixed within body112and positioned between bore129and open end120. Valve body112and retainer128together define in part a gas pathway130.

Opposite open end120, valve body112defines a unitary threaded coupling portion118through which bore129extends. Coupling portion118is adapted for sealed interconnection with a compressed gas canister. An o-ring121provides improved sealing for the connection to a gas canister.

Piston subassembly114is removably secured to open end120of body112with complementary threaded sidewalls: inwardly facing threads133on valve body112and outwardly facing threads135on piston housing114. Subassembly114includes a housing of two parts142A and142B, a piston144and a main piston spring146. Piston144defines an internal gas flow passageway152extending from radial inlets154in a stopper portion150to a central opening156in a barrier portion148. Barrier portion148forms a seal with inner side walls158of housing142via an o-ring160. Stopper portion150preferably includes a disk164of resilient material. Stopper portion150forms a seal with inner side walls162of housing142B via an o-ring163

Piston resilient disk164seals over an orifice172defined by an insert132that is disposed in an insert chamber123of pathway130. Insert chamber123is sized to receive insert132in a sealed arrangement. Insert chamber123includes a relatively narrow zone141surrounded by sidewalls143, a relatively wider zone145surrounded by sidewalls147, and a stop surface151. Insert132has a spool-like configuration with o-rings151and153and respective recesses155and157. Insert132further includes internal passages. These are piston-side internal passages159which communicates with orifice172, and tank-side internal passages161which communicates with bore129. Insert132has an additional o-ring173for sealing with sidewalls162of piston housing142.

When piston subassembly114is fully assembled to body112, insert132serves as confined flow guide directing the flow of gas through pathway130. Paintball regulator110is shown inFIG. 3with piston144in the closed regulator condition when the outlet side pressure at port168is at the required regulated pressure. In the closed condition, the controlled-pressure gas indicated generally at136creates a force on the piston144in the direction of insert132that is sufficient to counter the opposing force generated by spring146and compressed gas in pathway130. This in turn urges stopper164against orifice172to block flow through paintball regulator110.

When gas pressure on the outlet side drops because, for example, a paintball is fired, the opposing forces balancing on piston144are disrupted as follows. The gas-pressure force on piston144in the direction of insert132momentarily drops allowing the force of spring146and gas pressure at130to open a gap between stopper148and orifice172. With a gap momentarily present between orifice128and disk164, gas flows in the following general sequence: from the canister gas source into body112at discharge opening124, through spring retainer140, into opening163and through passages161of insert132, into insert chamber145, returning into insert132at passages159, through orifice128, into chamber136, through radial inlets154and internal passage152and finally out to the paintball gun through outlet168. When gas pressure at168again increases, piston144returns to the closed condition, i.e., the gap between stopper164and orifice128.

The action and function of insert132within chamber123is a key feature of the present invention. A related key feature of the embodiment shown inFIGS. 3 and 4is the coaction between first member174and second member176. When piston subassembly114is fully assembled to body112as shown inFIG. 3, insert132serves as confined flow guide directing the flow of gas through the tank-side of paintball regulator110. In this assembled configuration, one side of insert132seals with walls143(preferably via o-ring151). Compressed gas in pathway130is thereby directed into passages161and159of insert132. As noted above, when body112and piston subassembly114are fully assembled as shown inFIG. 3, spacer member176on piston subassembly114coacts with land member174on spacer132to keep spacer132offset from retainer128such that gas flows through and around insert132and then into orifice172.

When body112and piston subassembly114are less than fully assembled, however, insert132moves past funnel shaped portion181of chamber123and towards retainer164. This less than fully assembled position is shown inFIG. 4. Insert132is adjacent retainer164and the tank-side of insert132seals with sidewalls141with the aid of o-ring153to block gas flow out of body112.

When body112and piston subassembly114are less than fully assembled together, the spacer/extension portion176of piston subassembly114is withdrawn from (or through) retainer128such that insert132moves to a plugged-flow position next to retainer128. If the main paintball regulator components (112and114) are even partially “unscrewed” when the paintball gun system is charged with compressed gas, paintball regulator110will move to a safety position in which gas through pathway130is blocked by insert132, preferably at o-rings153. Pathway130becomes blocked during disassembly while the main components (e.g., body112and piston subassembly114) are still mechanically secured together. This feature prevents violent separation of paintball regulator components during disassembly even if an operator inadvertently fails to discharge the gas tank.

Another safety feature of paintball regulator110is a vent165to pathway130provided in the proximal portion167of coupling118. Coupling118has a proximal, gun-side portion167and a distal portion169. When coupling portion118is fully rotated into the socket of a tank or canister, vent165is closed, i.e., plugged by the tank. When paintball regulator110is disassembled, i.e., unthreaded from a tank, vent165will be unsealed as coupling118moves out from the tank. Because vent165is defined in the proximal portion167of coupling118, vent165will become open to atmosphere before paintball regulator110is fully disassembled. Distal portion169of coupling118remains secured to the tank after vent165is open. This feature is advantageous because, if a gun user inadvertently begins to remove regulator110from a tank without discharging the tank, the compressed gas contents of the tank will escape through vent165and prevent any violent separation which can occur when parts are separated under pressure.

A problem or disadvantage with safety vents in threaded tank couplings is plugging with the glue or other adhesive, which is used to secure threaded tank connections. Vent165of paintball regulator110has a counterbore171to better prevent such glue plugging.

Paintball regulator110also includes a separate gas source filling circuit. Body112defines a fill port122, a second confined-flow pathway137and an inlet opening126in coupling portion118. Inlet opening126communicates with the gas source tank or canister (not shown). Flow of compressed gas for refill does not enter pathway130or impact other parts (e.g., insert132) of the regulator mechanism. Paintball regulators10and110are illustrated without conventional adapters threaded into fill ports22and122to better show internal details. In use, fill ports22and122are equipped with an internal seal holder (e.g., a check valve) to seal pressurized gas into the canister.

FIG. 5shows a gun system aspect of the present invention. Gun system300includes a gun body302, grip frame303, a pressurized gas canister (or tank)304, a first fluid pathway segment312, a second fluid pathway segment314, an adapter307and a hose308. Segments312and314together define in part a fluid pathway385between tank304and gun body302.

In the gun system embodiment shown inFIG. 6, first segment312is a regulator body portion and second segment314is a piston subassembly. Accordingly, first segments312and second segment314when assembled together define a paintball regulator310.

Segment312includes a first safety valve305operably associated with fluid pathway385such that pathway385becomes blocked if segment312is partially disconnected or disassembled from segment314. Safety valve305is maintained in the open state when segments312and314are fully assembled together. Segment314includes a second safety valve306operably associated with fluid pathway385such that pathway385becomes blocked if segment314is partially disconnected or disassembled from adapter307.

A wide variety of conventional materials are suitable for making the components of regulators embodying the present invention. These materials include metals, notably steels, and various high-strength composites without limitation that all or any of the elements be made of the same material. Regulator body (12,112) and actuator housing (42,142A,142B) can be manufactured from a wide variety of materials having the requisite strength, rigidity and corrosion resistance. Aluminum and steel are suitable. Particularly preferred materials of construction are aluminum alloy 6061-T6, 302-304 stainless steel and 316 stainless steel.

The material of construction for stoppers64,164is preferably relatively rigid but softer than the material of construction of seat28and insert132. Stoppers64,164are preferably made from a polymeric material. Presently preferred polymeric materials for stoppers are the fluoropolymer compounds such as polytetrafluoroethylene (PTFE), fluorinated ethylene-propylene (FEP), perfluoroalkoxy fluorocarbon resin (PFA), polychlorotrifluoroethylene (PCTFE), ethylene-chlorotrifluoroethylene copolymer (ECTFE), ethylene-tetrafluoroethylene copolymer (ETFE), polyvinylidene fluoride (PVDF), polyvinyl fluoride (PVF). Most preferred is a polychlorotrifloroethylene (PCTFE) commercially available from 3M Company under the designation “Kel-F.”

An alternate embodiment of the invention and a variation of the paintball gun regulator shown inFIGS. 1 and 2is a paintball gun regulator having a plug32comprising a polymeric material. Presently preferred polymeric materials for plug32are the fluoropolymer compounds such as polytetrafluoroethylene (PTFE), fluorinated ethylene-propylene (FEP), perfluoroalkoxy fluorocarbon resin (PFA), polychlorotrifluoroethylene (PCTFE), ethylene-chlorotrifluoroethylene copolymer (ECTFE), ethylene-tetrafluoroethylene copolymer (ETFE), polyvinylidene fluoride (PVDF), polyvinyl fluoride (PVF). Most preferred is a polychlorotrifloroethylene (PCTFE) commercially available from 3M Company under the designation “Kel-F.”

A variation of the paintball gun regulator shown inFIGS. 1 through 4calls for piston stopper portions50,150to be relatively harder than a relatively softer, polymeric plug seat28or retainer128.

The foregoing specification and drawings are to be taken as illustrative but not limiting of the present invention. Still other configurations and embodiments utilizing the spirit and scope of the present invention are possible.