Abstract:
Exemplary embodiments of a gas biased pressure regulator comprise a capsule subassembly and a regulator body. The regulator body is adapted to connect to a source of pressurized gas. The capsule subassembly is removably received within the regulator body and includes a capsule body and a piston. The piston is axially slidable between fluid release and fluid seal configurations. When the piston is in its fluid release configuration, an output chamber is placed in fluid communication with the source. When the piston is in its fluid seal configuration, the output chamber is sealed from fluid communication with the source. A pressurizable bias chamber within the capsule body contains a bias pressure urging the piston toward its fluid release configuration. Pressure from the source urges the piston toward its fluid seal configuration. The piston may also have a fluid charge configuration for facilitating the pressurization of the bias chamber.

Description:
RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 61/506,404, filed on Jul. 11, 2011, the contents of which are incorporated by this reference in its entirety for all purposes as if fully set forth herein. 
    
    
     TECHNICAL FIELD 
     The present invention relates generally to regulators for regulating gas from a tank that contains compressed gas to a paintball gun, marker, or other application designed to utilize or be activated by gas at a controlled pressure. 
     BACKGROUND 
     Pressure regulators are commonly relied on to reduce the pressure of a gas as it is delivered from a pressurized gas reservoir, such as a portable compressed air tank, to an application device, such as a paintball marker. Paintball markers may feature a gas pressure regulator which is typically directly connected to the mouth of a portable tank designed to store gasses at very high pressures, typically between 3000-4500 psi. Commonly referred to as “tank regulators,” these gas pressure regulators may reduce the pressure of the gas delivered from the tank down to, for example, 600-800 psi before the gas enters the paintball marker for use in firing a projectile. 
     Conventional gas pressure regulators, such as those used in the sport of paintball, are commonly designed so that the unregulated high pressure from the reservoir applies a force which works toward disengaging the seal between the source chamber and the output chamber. As a result, such regulators can easily fail in the open position when dirt and debris become trapped between the respective valve seat and seal. Such failures may enable the unrestricted flow of unregulated pressurized gas from the pressurized gas reservoir into the application device, causing safety concerns as well as damage to the application device. 
     SUMMARY 
     Certain deficiencies of the prior art may be overcome by the provision of a pressure regulator comprising a regulator body and a capsule subassembly. The regulator body may have a source end, an application end and a main bore extending therebetween, a first portion at the source end and a second portion at the application end. The source end may be adapted to being placed in fluid communication with a source of pressurized gas. 
     Examples of a capsule subassembly may include a capsule body, a piston, a seat element and a pin seal. The capsule body may have a generally open distal end and a closed proximal end. The capsule body may be least partially defined by a capsule wall housing a cavity therein. The cavity may extend, for example, generally from the distal end toward the proximal end. The capsule wall may have an inner surface, an outer surface and at least one capsule port extending therethrough. The capsule subassembly may be in removable received engagement with the main bore and disposed thereat in fluid communication between a source chamber and an output chamber. 
     The piston may be received by the cavity for defining, at least in part, a pressurizible bias chamber within the cavity and for slidable axial movement of the piston within the cavity between a fluid release configuration, a fluid seal configuration, and in some embodiments, a charge configurations. The seat element may have a pin bore and a pin seal seat. The seat element may be, for example, press-fit or threaded into the capsule body. In certain embodiments, the seat element is threadedly moveable between a charge position and an operational position. The pin seal may have a pin shaft and a pin seal face. The pin shaft may extend through the pin bore and be in fixed connection with the piston. Embodiments may include a retainer element for, at least in part, axially retaining or securing the capsule body within the main bore. 
     When the piston is in its fluid release configuration, the capsule ports are in fluid communication with the distal end of the capsule body. When the piston is in its fluid seal configuration the capsule ports are sealed from fluid communication with the bias chamber and the distal end. In particular embodiments in which the piston has a charged configuration, when the piston is in its charge configuration, the capsule ports are in fluid communication with the bias chamber. 
     In certain embodiments having a seat element, threaded movement of the seat element into its charge position may results in movement of the piston to its charged configuration. Contrastingly, threaded movement of the seat element into its operational position may force the piston toward its fluid release configuration. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further advantages of the present invention may become apparent to those skilled in the art with the benefit of the following detailed description of the preferred embodiments and upon reference to the accompanying drawings in which: 
         FIG. 1  is a diagrammatic exploded view of a pressure regulator in accordance with the present invention; 
         FIG. 2  is a diagrammatic side view of a pin seal element; 
         FIG. 3  is a diagrammatic perspective view of a seat element; 
         FIG. 4  is a further diagrammatic perspective view of the seat element of  FIG. 3 ; 
         FIG. 5  is a diagrammatic end view of the seat element of  FIG. 3 ; 
         FIG. 6  is a diagrammatic side view of the seat element of  FIG. 3 ; 
         FIG. 7  is a further diagrammatic end view of the seat element of  FIG. 3 , showing the opposite end from that of  FIG. 5 ; 
         FIG. 8  is a diagrammatic cross-sectional view taken along line  8 - 8  in  FIG. 7 ; 
         FIG. 9  is a diagrammatic perspective view of a piston; 
         FIG. 10  is a diagrammatic side view of the piston shown in  FIG. 9 ; 
         FIG. 11  is a diagrammatic cross-sectional view taken along line  11 - 11  in  FIG. 10 ; 
         FIG. 12  is a diagrammatic perspective view of a capsule body; 
         FIG. 13  is a diagrammatic end view of the capsule body shown in  FIG. 12 ; 
         FIG. 14  is a diagrammatic side view of the capsule body shown in  FIG. 12 ; 
         FIG. 15  is a further diagrammatic end view of the capsule body shown in  FIG. 12 ; 
         FIG. 16  is a diagrammatic cross-sectional view taken along line  16 - 16  in  FIG. 15 ; 
         FIG. 17  is a diagrammatic cross-sectional view taken along line  17 - 17  in  FIG. 13 ; 
         FIG. 18  is a diagrammatic view of detail  18  in  FIG. 17 ; 
         FIG. 19  is a diagrammatic view of detail  19  in  FIG. 17 ; 
         FIG. 20  is a diagrammatic side view of a regulator body; 
         FIG. 21  is a diagrammatic cross-sectional view taken along line  21 - 21  in  FIG. 20 ; 
         FIG. 22  is a diagrammatic perspective view of a retainer element; 
         FIG. 23  is a diagrammatic end view of the retainer element shown in  FIG. 22 ; 
         FIG. 24  is a further diagrammatic end view of the retainer element shown in  FIG. 22 , showing the opposite end from that of  FIG. 23 . 
         FIG. 25  is a diagrammatic side view of the retainer member shown in  FIG. 22 ; 
         FIG. 26  is a diagrammatic cross-sectional view taken along line  26 - 26  in  FIG. 25 ; 
         FIG. 27  is a diagrammatic cross-sectional view of an embodiment of a pressure regulator, showing the seat element outwardly threaded to allow the bias chamber to be in fluid communication with the capsule ports, thereby allowing the bias chamber to be pressurized by way of the capsule ports; 
         FIG. 28  is a further diagrammatic cross-sectional view of an embodiment of a pressure regulator, showing the seat element in an intermediate threaded position whereby the pressurized bias chamber has been sealed from fluid communication with the capsule ports; 
         FIG. 29  is a further diagrammatic cross-sectional view of an embodiment of a pressure regulator, in which the seat element is fully inwardly threaded and the pressure within the output chamber is sufficient to aid in overcoming the force on the piston imposed by the pressure within the bias chamber, thereby resulting in the sealing engagement between the pin seal and the pin seal seat; 
         FIG. 30  is a further diagrammatic cross-sectional view of an embodiment of a pressure regulator, showing the pin seal in an open configuration thereby allowing gas to flow from the source chamber to the output chamber; 
         FIG. 31  is a further diagrammatic cross-sectional view of an embodiment of a pressure regulator which incorporates alternative examples of a regulator body, and capsule subassembly; 
         FIG. 32  is a diagrammatic end view of an alternative poppet element; 
         FIG. 33  is a diagrammatic side view of the alternative poppet element of  FIG. 32 ; and 
         FIG. 34  is a diagrammatic cross-sectional view taken along line  34 - 34  in  FIG. 33 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to the drawings, like reference numerals designate identical or corresponding features throughout the several views. Shown generally at  100  are one or more embodiments of a pressure regulator in accordance with the description herein. Referring to  FIG. 1  for illustration, a pressure regulator  100  may comprise, for example, a regulator body  102  and a capsule subassembly  184 . 
     Certain embodiment of a regulator body  102  may have a source end  144 , an application end  146 , a main bore  150  extending therebetween, a first portion  152  at the source end  144  and a second portion  154  at the application end  146 . The source end  144  may be adapted to being placed in fluid communication with a source of pressurized gas, such as the tank shown at  192  in  FIG. 31 . 
     Particular embodiments of a capsule subassembly  184  may include a capsule body  110  and a piston  108 . The capsule body  110  may have a distal end  178  and a proximal end  176 , and may be at least partially defined by a capsule wall  210  housing a cavity  204  therein. The cavity  204  may extend generally from the distal end  178  toward the proximal end  176 . The capsule wall may have an inner surface  200 , an outer surface  202  and at least one capsule port  122  extending therethrough. The capsule subassembly  184  may be adapted to being in removable received engagement with the main bore  150  and disposed thereat in fluid communication between a source chamber  118  and an output chamber  120  such that, for example, the distal end  178  is in fluid communication with the source chamber  118 . 
     In particular preferred embodiments, the piston  108  may be adapted to being received by the cavity  204  for defining, at least in part, a pressurizible bias chamber  116  within the cavity  204  and for slidable axial movement of the piston  108  within the cavity  204  between a fluid release configuration, a fluid seal configuration, and in certain embodiment, a charge configuration. When the piston is in its fluid release configuration (as illustrated, for example,  FIG. 30 ), the at least one capsule port  122  may be in fluid communication with the distal end  178 , and thereby the source chamber  118 . When the piston  108  is in its fluid seal configuration (as illustrated, for example,  FIG. 29 ), the at least one capsule port  122  is sealed from fluid communication with the bias chamber  116  and the distal end  178 . In embodiments in which the piston  108  has a charge configuration, when the piston  108  is in its charge configuration (as illustrated, for example,  FIG. 27 ), the at least one capsule port  122  may be in fluid communication with the bias chamber  116 . 
     In embodiments in which the piston  108  does not have a charge configuration, the bias chamber  116  may be pressurized or “charged” by way of, for example, a charge aperture at or near the proximal end. In such embodiments, the aperture may be sealed prior to the capsule subassembly  184  being used in operation of the pressure regulator. 
     In certain embodiments, the capsule subassembly  184  may include a seat element  106  and a pin seal  104 . The seat element  106  may have a pin bore  186  and a pin seal seat  172 . Referring initially to  FIG. 28  for illustration, the seat element  106  may be adapted to be secured in connection with the capsule body  110  by way of, for example, threaded engagement, press fit or other axial securing means. Alternatively or in addition, the seat element  106  may be adapted for threaded movement between a charge position (as illustrated, for example, at  FIG. 27 ) and an operational position (as illustrated, for example, at  FIG. 29 . The pin seal  104  may have a pin shaft  208  and a pin seal face  174 . The pin shaft  208  may be adapted to extend through the pin bore  186  and be in fixed connection with the piston  108 . The pin seal face  174  may be adapted to move into and out of sealing engagement with the pin seal seat  172  thereby respectively preventing and allowing fluid flow through the pin bore (as illustrated, for example, between  FIGS. 29 and 30 ). 
     As illustrated in  FIG. 27 , for example, in particular embodiments so adapted, threaded movement of the seat element  106  into a charge position may result in movement of the piston  108  to its charged configuration. Contrastingly, threaded movement of the seat element  106  into its operational position (as illustrated, for example, in  FIGS. 29-31 ) may force the piston  108  toward its fluid release configuration, that is, in a direction toward the proximal end  176 . 
     Particular embodiments may further comprise a retainer element  114  adapted to threadedly engage the main bore  150  generally within the second portion  154 , thereby axially retaining the capsule body  110  within the main bore  150 . Embodiments may also comprise a poppet element  112 , certain embodiments of which may be adapted to retain a poppet seal  148 . In such embodiments, for example, the output chamber  120  may be defined, at least in part, by a combination or interface of the regulator body  102 , the capsule body  110 , the retainer element  114  and the poppet element  112 . 
     In certain embodiments, the capsule body  110  includes a capsule seal groove  182  generally circumferentially disposed thereabout. The capsule seal groove  182  may be adapted to receive an outer capsule seal  130  for establishing a seal between the outer surface  202  and the main bore  150 . 
     Referring to  FIG. 31  for example, in particular embodiments, the regulator body  102  may further include an intermediate portion  156  disposed between the first portion  152  and the second portion  154 . The intermediate portion  154  may have a plurality of generally radially extending ports, such as the illustrated high-side port  188  and the illustrated low-side port  190 . In such embodiments, at least one of the generally radially extending ports (as shown at  188 , for example) may be adapted to be in fluid communication with the source chamber  118  by way of a high-side flow channel  127  formed between the outer surface  202  and the main bore  150  when the capsule subassembly  184  is in removable received engagement with the main bore  150 . In contrast, at least one of the generally radially extending ports (as shown at  190 , for example) may be adapted to be in fluid communication with the output chamber  120  by way of a low-side flow channel  126  formed between the outer surface  202  and the main bore  150  when the capsule subassembly  184  is in removable received engagement with the main bore  150 . 
     In certain embodiments, such as the one illustrated in  FIG. 31  the first portion  152  may include external threads for threaded engagement with a reservoir  192  for storing pressurized gas, and the second portion may adapted to threadedly engage an application fitting (such as an ASA adaptor associated with a paintball marker). 
     In certain embodiments, the capsule subassembly  184  may include a light compression spring  194  adapted to be axially disposed within the bias chamber  116  to contribute, at least in part, to the overcoming of static friction between the piston  108  and the inner surface  200 . 
     Embodiments in accordance with the description herein provide a pressure regulator  100  which may use a pre-loaded compression chamber or bias chamber  116 , as a biasing means for the pressure regulating system. As a result, in typical embodiments, no significant spring bias may be required in the regulating mechanism, and the pressure within the bias chamber  116  can be set based on the desired output pressure of the regulator  100 . 
     Referring to  FIGS. 20 and 21  for illustration, a mounting tube or regulator body  102  may be made of, for example a metal such as aluminum 6061, and may include a source seal groove  138 . The first portion  152  may include external threads (not shown) and may be adapted to be threadedly inserted into a source of pressurized gas. A source seal groove  138  may be adapted to retain an O-ring, as illustrated in  FIG. 31 , to aid in maintaining a seal between a source of pressurized gas  192  and the regulator body  102 . A second portion  154  may include external threading adapted to threadedly engage, for example, an adaptor fitting associated with an application device such as a paintball marker. The generally radially extending ports may include one or more of a pressure gauge port, a fill port, high-pressure burst disk port and a low-pressure burst disk port. 
     Referring to  FIGS. 12 through 19  for illustration, a capsule body  110  may be made of for example, aluminum  6061  or a strong Nylon, and may include one or more low-pressure channel reliefs  158 , one or more high-pressure channel reliefs  206 , one or more capsule ports  122 , an annular groove  180  and a capsule seal groove  182 . In certain embodiments, the capsule body  110  may have a capsule length defined by the distance between the capsule proximal end  176  and the capsule distal end  178 . In particular embodiments, the capsule length may be, for example, approximately one inch. 
     Referring to  FIGS. 9 through 11  for illustration, a piston  108  may be made of a metal, such as for example, brass, and may include a first piston surface  162 , a second piston surface  164 , one or more piston seal grooves  166  and a pin detent  160 . 
     Referring to  FIGS. 3 through 8  for illustration, a seat element  106  may include a seat seal groove  168 , a manifold or piston seat  170 , a pin seal seat  172  and a pin bore  186 . The seat seal groove  168  may retain a seat seal  142 . Particular preferred embodiments, the seat element  106  may be comprised substantially of a polymer such as DuPont&#39;s Delrin, another Polyoxymethyline, or similar material. Such materials may provide a significant operational advantage for the disclosed regulator, in that dirt or debris trapped between the pin seal face  174  and pin seal seat  172  may be substantially absorbed (e.g., compressively) by the seat element  106 , thereby allowing an effective seal to continue to be established between the pin seal face  174  and the pin seal seat  172 . In certain embodiments, the diameter of the pin bore  186  may be, for example, between 0.040 and 0.060 inches. 
     Referring to  FIG. 2  for illustration, a pin seal  104  may be made of a metal such as, for example, stainless steel, or a durable polymer. The pin seal  104  may include a pin seal face  174  adapted to sealingly engage a pin seal seat  172  of a seat element  106 . 
     Referring to  FIGS. 22 through 26  for illustration, a retainer element  114  may be made of, for example, aluminum  6061 , and may include one or more retainer ports  124 , one or more bleed grooves  128  and an application seal groove  140 . A retainer element  114  is typically adapted to threadedly engage inner threading (not shown) of the second portion  154  of the regulator body  102 . As illustrated, for example, in  FIG. 27 , while in this threaded engagement, the retainer element  114  may be relied upon to axially secure the capsule body  110  within the mounting tube or regulator body  102 , and to limit the axial movement of a poppet element  112 . In this configuration, the poppet element  112  may be elastically axially depressible by way of a poppet spring  196  generally disposed, for example, between the poppet element  112  and the proximal end  176  of the capsule body  110 . In particular embodiments, the poppet may be made of a molded polymer or urethane (such as the poppet element depicted in  FIGS. 32 through 34 , for example). Further, in certain embodiments, the poppet element may be adapted so that the pressure within the output chamber  120  is sufficient to depressibly force the poppet into its sealing position. 
     As illustrated, for example, in  FIG. 27 , the bias chamber  116  can be filled to a selected preload pressure when the seat element  106  is threadedly moved toward the capsule distal end  178 , otherwise referred to as a fill configuration. In certain embodiments, the selected preload pressure may be, for example, approximately 20% over the desired output pressure of the regulator. In the fill configuration the seat element  106  may hold the piston  108  in a fill position by way of the pin seal  104 . In its fill position, the piston  108  may allow the capsule ports  122  to remain in fluid communication with the bias chamber  116  in bypass of the manifold chamber  198 , thus allowing pressurized gas to enter the bias chamber  116  by way of, for example, a depressed poppet element  112 . Such a pathway is at least partially illustrated by bias chamber fill flow path  136 , which may extend through the output chamber  120 , retainer ports  124 , flow channels  126  and finally through capsule ports  122 . In certain embodiments, the capsule ports  122  may be accessed for bias chamber  116  pressurization by way of, for example, a radially-disposed capsule fill port (not shown) in the intermediate portion  156  of a regulator body  102 . 
     Referring now to  FIG. 28 , once the bias chamber  116  is pressurized to the selected preload pressure, the seat element  106  may be threaded toward the capsule proximal end  176 , thereby moving the piston  108  axially such that the capsule ports become sealed from fluid communication with the bias chamber  116 , and enter fluid communication with the manifold chamber  198 . This seal may be provided by way of, for example, the first piston seal  132  and second piston seal  134 . A seat element  106  is shown in its fully inwardly threaded position in  FIG. 29 . 
     As illustrated in  FIGS. 29 and 30 , during operation of a pressure regulator  100 , the source chamber  118  is typically in fluid communication with a source of pressurized gas, such as a compressed Nitrogen or CO2 tank  192 , and the output chamber  120  is provided with pressure-regulated gas which originates from the source chamber  118  and is regulated by the capsule subassembly  184 . 
     As illustrated in particular in  FIG. 29 , when the desired output pressure is reached or exceeded within the output chamber  120 , the output pressure acts against the first piston surface  162  to help move the piston  108  against the force of the bias pressure within the bias chamber  116 . As a result, the pin seal face  174  may be forced to seat against the pin seal seat  172  and cut off flow from the source chamber  118  to the output chamber  120 . Notably, preferred embodiments of the pressure regulator described herein are configured so that high pressure from the source chamber  118  works toward urging the sealing of the bore  186  rather than toward its unsealing. This provides a safety mechanism which may significantly reduce the chance that the regulator will fail in the open position, particularly when such configuration is combined with the debris-absorbing qualities of the material of which preferred seat elements  106  may be comprised. 
     As illustrated in particular in  FIG. 30 , when the output pressure falls below the desired level, the force exerted on the first piston surface  162  is insufficient to cause movement of the piston  108  against the bias pressure within the bias chamber  116 . As a result, the piston  108  is forced toward the piston seat  170  and the pin seal face  174  becomes unseated from the pin seal seat  172 , allowing gas to flow from the source chamber  118  to the output chamber  120  through, for example, the pin bore  186 . 
     In certain embodiments and related methods, a bias chamber  116  may be pressurized or “charged” to the selected preload or bias pressure, as described, while the capsule subassembly  184  is temporarily disposed within a mounting or “charge” tube separate from the regulator body  102  shown, for example, in  FIG. 31 . The capsule subassembly  184  with pressurized bias chamber  116  may then be removed from the separate mounting tube and placed into a regulator body as illustrated, for example, in  FIG. 31 , for use, for example, in cooperation with a portable compressed air tank associated with a paintball marker. 
     While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.