Abstract:
A torch assembly having features enabling single handed operation. The torch assembly includes a flame control device that can be operated with a user&#39;s fingers while the user is holding the torch with the same hand. A controller apparatus of the torch assembly includes a trigger for actuating an on/off valve adapted to permit or stop flow through a fuel line, a regulator adapted to at least partially restrict flow in the fuel line and including a regulator valve, and a controller operatively connected to the regulator to adjust the position of the valve to vary the flow of fuel through the fuel line. The controller is interposed between the trigger and the regulator, and can include a rotatably mounted knob.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application Ser. No. 61/386,668 filed Sep. 27, 2010, which is expressly incorporated by reference herein. 
     
    
     FIELD OF THE DISCLOSURE 
       [0002]    The present exemplary embodiment relates generally to a torch design that provides control of a flame, and more particularly to an ergonomic controller of a flame regulator. However, it is to be appreciated that the present exemplary embodiment is also amenable to other like applications. 
       BACKGROUND 
       [0003]    Torches are used in various applications for applying localized intense heat. One such application is pipe soldering. Pipe soldering involves joining together components such as two pipes or fittings through the application of solder to the joint. To flow solder into the joint, a torch is used to heat the joint and/or solder directly until the solder reaches its melting point. Once the solder becomes a liquid, it then flows into the joint and, upon cooling, joins and seals the components together. 
         [0004]    It will be appreciated that controlled application of heat to the joint is often desirable. A user of a conventional torch can control the application of heat by moving the torch into and out of proximity to the joint such that the joint experiences intermittent heating until a desired level of heating is achieved. Another way to manage the application of heat is through adjusting the size of the torch flame. Soldering a pipe, however, typically requires a person to use a first hand to hold the torch and a second hand to hold the solder. To safely adjust the torch flame, a user must set down the solder and use the second hand to manipulate a knob or other device configured to control the flame. This can be inconvenient and can decrease worker efficiency. Moreover, a user may be tempted to adjust the flame without setting down the solder which can present a safety hazard. 
       BRIEF DESCRIPTION 
       [0005]    Embodiments described herein allow the user to hold the torch and adjust the flame with the same (single) hand during operation, such as during a soldering operation, thus eliminating the need for the user to set the solder down to adjust the flame, and/or reducing unsafe conditions that may exist should a user attempt to adjust the flame without setting down the solder. More generally, aspects of the disclosure provide a more user friendly torch designed for single handed operation. 
         [0006]    In accordance with one aspect, a torch assembly adapted to be attached to an associated fuel supply comprises a housing, a fuel line at least partially contained within the housing, a burn tube extending from the housing and adapted to receive fuel from the fuel line, an attachment member operatively connected to the housing for connecting the torch assembly to a fuel supply, the attachment member in fluid communication with the fuel line for delivering fuel from the associated fuel supply to the fuel line, and a control apparatus at least partially supported within the housing and configured to control the flow of fuel through the fuel line. The control apparatus includes a trigger for actuating an on/off valve adapted to permit or stop flow through the fuel line, a regulator adapted to at least partially restrict flow in the fuel line, and a controller operatively connected to the regulator to adjust the position of the regulator to vary the flow of fuel through the fuel line. The controller is interposed between the trigger and the regulator. 
         [0007]    The controller can include a rotatably mounted knob. The housing can include a lower pistol grip portion having a contoured gripping surface and an upper portion including the trigger, and the rotatably mounted knob can be disposed between the trigger and the lower pistol grip portion of the housing. The position of the knob can permit operation of the controller with a person&#39;s hand while the hand is gripping the lower pistol grip portion of the housing. The trigger can be located in spaced relation to a longitudinal axis of the lower pistol grip portion of the housing, and the knob can be located between the longitudinal axis of the lower pistol grip portion of the housing and the trigger. The regulator can include a regulator valve. The knob can be coextensive with at least a portion of the lower pistol grip portion of the housing. The lower pistol grip portion can be adapted to fit in a person&#39;s hand, wherein the trigger is adapted to be activated by the person&#39;s trigger finger, and wherein the knob is positioned to be manipulated by the person&#39;s thumb. 
         [0008]    The knob can be rotatable about an axis generally perpendicular to a longitudinal axis of the lower pistol grip portion of the housing. The knob can be supported within the housing and can protrude from at least two sides of the housing such as, for example, opposite sides of the housing. The regulator can include a piston type regulator. The assembly can further include a trigger lock operative to lock the on/off valve in an on position. An igniter can be operably connected to the trigger. 
         [0009]    In accordance with another aspect, a control apparatus for an associated torch assembly comprises a trigger for actuating an on/off valve adapted to permit or stop flow of fuel through a fuel line of the associated torch assembly, a regulator adapted to at least partially restrict flow in the fuel line of the associated torch assembly and including a regulator valve, and a controller operatively connected to the regulator to adjust the position of the regulator valve to vary the flow of fuel through the fuel line of the associated torch assembly. The controller is interposed between the trigger and the regulator. 
         [0010]    The controller can include a rotatably mounted knob. The regulator can include a piston type regulator. A trigger lock operative to lock the on/off valve in an on position can be provided. The regulator, regulator valve and/or on/off valve can be included in a common valve body. The control apparatus can be installed as a unit in the associated torch assembly. An igniter can be operably connected to the trigger. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  is a side elevation view of an exemplary torch assembly in accordance with the disclosure; 
           [0012]      FIG. 2  is a side elevation view of the torch assembly of  FIG. 1  with portions thereof removed to expose otherwise concealed components; 
           [0013]      FIG. 3  is a cross-sectional view of the torch assembly of  FIG. 1 ; 
           [0014]      FIG. 4  is a perspective view of an exemplary integrated regulator/valve body in accordance with the disclosure; 
           [0015]      FIG. 5  is a cross-sectional view of the integrated regulator/valve body of  FIG. 4 ; 
           [0016]      FIG. 6  is a perspective view of the integrated regulator/valve body including the outer knob; 
           [0017]      FIG. 7  is a cross-sectional view of the integrated regulator/valve body of  FIG. 6 ; 
           [0018]      FIG. 8  is a front elevational view of the integrated regulator/valve body; 
           [0019]      FIG. 9  is a perspective view of an exemplary regulator block in accordance with the disclosure; 
           [0020]      FIG. 10  is an assembly view of the integrated regulator/valve body and intake stem in accordance with the disclosure; 
           [0021]      FIG. 11  is an assembly view of the valve components of the regulator valve; 
           [0022]      FIG. 12  is an exploded view of at least some of the on/off valve components; 
           [0023]      FIG. 13  is another view of the regulator block illustrating installation of a seal screw; 
           [0024]      FIG. 14  is a perspective view of the regulator block and intake stem in accordance with the exemplary embodiment; 
           [0025]      FIG. 15  is a perspective assembly view of the installation of the knob on the regulator block; 
           [0026]      FIG. 16  is a perspective view of the knob installed on the regulator block. 
       
    
    
     DETAILED DESCRIPTION 
       [0027]    An exemplary embodiment of a torch assembly  20  in accordance with the present disclosure is shown in  FIGS. 1-3  and includes a housing  22  made of die cast metal such as steel, or plastic, to form a handle. The housing  22  includes a lower pistol grip portion G configured to be grasped by a user. The grip portion G may have a suitable profile so as to comfortably fit within a palm of a user&#39;s hand. The housing  22  also includes an upper portion U that includes a trigger  26  and a control knob  28  for adjusting the flow of fuel through the torch assembly to control the torch flame. A burn tube  24  extends upwardly from the housing  22 . These components are visible on the exterior of the torch assembly  20  as shown in  FIG. 1 . 
         [0028]      FIGS. 2 and 3  show the internals of the torch assembly  20  in perspective and partial cross-section views, respectively. As will be appreciated, the torch assembly is configured to be attached to a gas cylinder tank or other source of fuel. Gas, such as propane or propylene, is delivered from the tank (not shown) located beneath the housing  22 . An attachment member, in this case a threaded bushing  30 , which may be, for example, a CGA 600 bushing, allows an empty tank to be removed and replaced with a full tank. Alternatively, a quick connect coupler could be used to provide more a rapid tank exchange. 
         [0029]    The housing  22  may be provided in two halves  22   a  that mate to enclose many of the components of the torch assembly including the bushing  30 , an integrated valve and regulator body  32 , an on/off valve  34 , a regulator  36 , a trigger assembly  38 , an intake stem assembly  40 , an orifice adapter  42  for connection to the burn tube  24 , a continuous run lock button  93 , and a trigger lockout button  94 .  FIGS. 3 and 12  show the on/off valve, which includes a valve core  44 , spring  46 , o-ring  48 , actuator  50 , and snap ring  52 . To release fuel into the burn tube  24 , the valve  34  is actuated by pushing the trigger  26 . When the trigger  26  is depressed, the valve  34  is opened to allow the fuel to flow into the burn tube  24  under pressure, subject to any restriction to flow provided by the regulator  36 . The spring  46  returns the valve  34  to the closed position and the trigger  26  to the extended position when the trigger  26  is released. 
         [0030]    The trigger assembly  38  includes an igniter  54 , which may be, for example, a piezoelectric igniter that is also actuated by the trigger  26 . When the trigger  26  is depressed a spark is created in the burn tube  24  simultaneously with, or just after, the flow of gas through the burn tube  24 . Trigger lockout button lock  94  is provided to mechanically lock the trigger  26  in the depressed position to allow “hands free” operation of the torch  20  such that the torch  20  will produce a flame without the user having to continually depress the trigger  26 . 
         [0031]    The intake stem assembly  40  is provided at the lower end of the housing  22 . An extension tube  95  of the intake stem assembly  40  is brazed or otherwise connected to the integrated valve and regulator body  32  at the regulator input  56  and to the bushing  30  as shown in  FIG. 10 . The intake stem  58  is mounted to the bushing  30  with an O-ring  60 , a filter  62 , and a gasket  66 . 
         [0032]    The regulator  36 , which is a piston-type valve in the embodiment shown, controls the flow of gas through a fuel supply line  68 . The regulator includes a valve assembly disposed in the integrated valve and regulator body  32 .  FIG. 11  shows that the regulator  36  includes a valve core  72 , an O-ring  74 , a piston  76 , a spring  78 , a bonnet  80 , and a jam nut  82 . A lubricant, such as a silicon-based lubricant, may be applied to the o-ring  74 , for example, silicone lubricants offered by 3M, Molykote® offered by Dow Corning, Krytox® offered by Loctite, and anti-sieze lubricants offered by Loctite. The regulator  36  and the on/off valve  34  may be the same type of valves as shown, or may be different types and sizes of valve as selected by one of ordinary skill in the art. 
         [0033]    At one end  81  of the bonnet  80 , which has a larger diameter than the body of the bonnet  80 , external threads are provided. At the large opening  83  of the regulator body  32 , internal threads are provided. The bonnet  80  is screwed into the regulator body opening  83 . The bonnet&#39;s threading interfaces with the regulator body&#39;s threading to determine the spring  78  position. The spring position applies force on the piston  76  through compression. This force applied to the piston determines the pressure of the internal gas required to open the valve  72 . The jam nut  82  is passed over the bonnet  80  and the smaller end  85  of the jam nut  82  is screwed into the regulator body opening  83  to prevent withdrawal of the bonnet  80  from the regulator body  32 . 
         [0034]    As shown in  FIGS. 6-8 ,  15 , and  16 , in one embodiment a splined collar  84  is press fitted around the bonnet  80  of the regulator  36 , which has a knurled outer surface. A knob  86  is slid over the splined collar  84  and is exposed through an aperture  88  ( FIG. 1  and  FIG. 3 ) in one or both sides of the housing  22 . The knob  86  may be, for example, plastic or brass. When the knob  86  is rotated, most likely with a person&#39;s thumb and forefinger, the splined collar  84  rotates and the bonnet  80  turns with the splined collar  84 . The knob  86 , splined collar  84 , and bonnet  80  actuate the regulator valve. When the bonnet  80  rotates in one direction, the piston  76  of the regulator  36  is pressed to open the valve, and when the bonnet  80  rotates in the other direction, the piston withdraws, allowing the valve to close. If desired, the valve could be configured to close when pressed. There is a small spring (not visible) in the valve  72  that provides return force to the piston  76 . The position of the knob  86  along its axis of rotation A k  is held constant, while the splined collar  84  travels within the knob  86  along the axis A k  and the bonnet  80  travels with the splined collar  84 . The degree to which the valve is open corresponds to the position of the splined collar and bonnet. 
         [0035]    The orifice adapter  42  may be configured to work with ½-inch thin wall tubing and brass venturis, and may allow burn tube-installed and other orifices. 
         [0036]    Turning back to  FIG. 1 , it will be appreciated that in the illustrated embodiment the knob  28  is rotatable about the axis A k  extending from left to right. This axis is generally perpendicular to a longitudinal axis A g  of the lower pistol grip portion G of the housing  22 . In addition, it will be observed that the trigger  26  is located forward of the longitudinal axis A g  of the lower piston grip portion G, with the knob  28  being between the trigger  26  and such axis. In this embodiment, the knob  28  is coextensive with the lower pistol grip portion G of the housing and set slightly forward of said longitudinal axis A g . In this position, the knob  28  is easily accessible to a finger of a person&#39;s hand while holding the torch. 
         [0037]    One embodiment of a method of manufacturing the on/off valve  34  and regulator  36  is shown in  FIGS. 9-16 . The integrated valve and regulator body  32 , or the regulator block, is shown in  FIG. 9 .  FIGS. 10 and 14  show the installation of the intake stem assembly  40  and parts to seal to the bushing  30  as described above.  FIG. 11  shows the assembly of the regulator  36 , as described above.  FIG. 12  shows the assembly of the on/off valve  34 , also as described above. A seal screw  90  is installed in  FIG. 13 . 
         [0038]    In  FIG. 15  the splined collar  84  is added over the bonnet  80  and the outer knob  86  is added over the splined collar  84 . The assembled integrated valve and regulator is shown in  FIG. 16 , with the orifice assembly  92 , and the burn tube  24  may be installed as shown in  FIG. 1 . 
         [0039]    The integrated valve and regulator body may instead be provided as two separate components, one for the on/off valve and one for the regulator. 
         [0040]    Putting a rotating knob or wheel between the trigger and regulator provides an ergonomic location for an adjustment device for the flame. Locations other than that shown for the adjustment device could be used and remain within the spirit and scope of the ergonomic torch regulator control knob described herein. The described piston regulator for adjusting the pressure of the gas improves control over the flame as compared to the traditional needle valve flow restrictor, though the traditional valve and arrangement could be used. 
         [0041]    The exemplary embodiment has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the exemplary embodiment be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.