Abstract:
A pressure regulator for regulating the pressure of a fluid from an associated pressure reservoir includes a regulator body housing a shuttle assembly and supporting a multiplicity of radially-distributed service lobes. Each service lobe includes features in fluid communication with one or more chambers within the regular body, and performs a particular function relating to the pressure and contents within those chambers. Such lobes may include one or more of a bias lobe for regulating pressure within the shuttle bias chamber, a fill lobe through which the reservoir may be filled, a gauge lobe which displays the pressure within the reservoir, and a relief lobe including one or more burst disks to relieve over pressurization in the reservoir or output chamber of the regulator. Each service lobe may slideably engage a respective interface on the regulator body, and be releasably secured there by way of a threaded retainer.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/472,089, filed on Apr. 5, 2011, the contents of which are incorporated by this reference in its entirety for all purposes as if fully set forth herein. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates generally to pressure regulators. More particularly, the present invention relates 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 
       [0003]    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 directly connected to the mouth of a 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 portions of the paintball marker for use in firing a projectile. 
       SUMMARY 
       [0004]    Certain embodiments of a pressure regulator may comprise a regulator body, a shuttle assembly, a fill lobe, a bias lobe, a relief lobe, and a gauge lobe. The regulator body may have a first end, a second end, and a main bore extending therebetween along a main axis. The second end may be adapted to be placed in fluid communication with a reservoir of pressurized gas, such as a portable compressed air tank for use with paintball marker applications. The shuttle assembly is received within the main bore for axial movement between a fluid release configuration and a fluid retention configuration. The main bore may cooperate with the shuttle assembly to define a bias chamber, and may also cooperate with the shuttle assembly and retainer assembly to define an output chamber. The regulator body may outwardly include a plurality of lobe interfaces generally radially distributed about the main axis. Each lobe interface may include a respective port in fluid communication with the second end. Each of the lobes may be being axially slidably engaged with a respective lobe interface and axially releasably restrained thereat. The bias lobe may include a pilot regulator in fluid communication generally between the second end and the bias chamber for regulating a bias pressure within the bias chamber. A relief lobe may include a high-pressure burst disk in fluid communication between the second end and ambient air. A gauge lobe may include a pressure gauge assembly in pressure-indicating fluid communication with the second end. A fill lobe may include a fill plug in fluid communication with the second end. 
         [0005]    Embodiments of a pressure regulator in accordance with the present invention may further comprise a sleeve element and a retainer assembly. A regulator body may include a first portion at generally the first end. The sleeve element may include an externally threaded portion and a radially-extending sleeve flange, and may be in receiving engagement with the first end. The retainer assembly may include a retainer element threadably received by the main bore generally at the first end and thereby axially releasably restrain one or more of the fill lobe, bias lobe, relief lobe and gauge lobe in engagement with their respective lobe interfaces and axially releasably restraining the sleeve element in its receiving engagement with the first portion. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    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: 
           [0007]      FIG. 1  is a diagrammatic exploded view of a pressure regulator in accordance with the present invention; 
           [0008]      FIG. 2  is a further diagrammatic exploded view of the pressure regulator of  FIG. 1 , but in a more advanced stage of assembly; 
           [0009]      FIG. 3  is a further diagrammatic exploded view of the pressure regulator of  FIG. 1 , but in an even more advanced stage of assembly; 
           [0010]      FIG. 4  is a diagrammatic perspective view of the pressure regulator of  FIG. 1 , but fully assembled; 
           [0011]      FIG. 5  is a diagrammatic side view of the pressure regulator of  FIG. 4 ; 
           [0012]      FIG. 6  is a further diagrammatic side view of the pressure regulator of  FIG. 4 , shown at 90 degrees from the orientation of  FIG. 5 ; 
           [0013]      FIG. 7  is a further diagrammatic side view of the pressure regulator of  FIG. 4 , shown at 90 degrees from the orientation of  FIG. 6 ; 
           [0014]      FIG. 8  is a further diagrammatic side view of the pressure regulator of  FIG. 4 , shown at 90 degrees from the orientation of  FIG. 7 ; 
           [0015]      FIG. 9  is a diagrammatic top view of the pressure regulator of  FIG. 4 ; 
           [0016]      FIG. 10  is a diagrammatic exploded view of the core of a pressure regulator in accordance with the present invention, showing components of a retainer assembly, shuttle assembly and a regulator body; 
           [0017]      FIG. 11  is a diagrammatic perspective view of the regulator body shown in  FIG. 10 , but from the opposite side; 
           [0018]      FIG. 12  is a diagrammatic top view of the regulator body shown in  FIG. 10 , shown with the shuttle assembly inserted within the main bore; 
           [0019]      FIG. 13  is a diagrammatic cross-sectional view taken along line  13 - 13  in  FIG. 9 ; 
           [0020]      FIG. 14  is a diagrammatic cross-sectional view taken along line  14 - 14  in  FIG. 9 ; 
           [0021]      FIG. 15  is a diagrammatic enlarged view of section  15  of  FIG. 14 , in which the pressure within the source chamber is insufficient to overcome the piston spring enough to allow the pilot ball seal to sealingly engage the pilot valve seat; 
           [0022]      FIG. 16  is a diagrammatic enlarged view of section  15  of  FIG. 14 , and in which the pressure within the source chamber has become sufficient to overcome the force of the piston spring enough to allow the pilot ball seal to sealingly engage the pilot valve seat; 
           [0023]      FIG. 17  is a diagrammatic enlarged view of section  17  of  FIG. 14 , and in which the pressure within the bias chamber is insufficient to overcome the bias relief spring enough to allow the bias relief ball seal to break its seal with the bias relief valve seat; 
           [0024]      FIG. 18  is a diagrammatic enlarged view of section  17  of  FIG. 14 , and in which the pressure within the bias chamber is sufficient to overcome the bias relief spring enough to allow the bias relief ball seal to break its seal with the bias relief valve seat; 
           [0025]      FIG. 19  is a diagrammatic cross-sectional view taken along line  19 - 19  in  FIG. 6 ; 
           [0026]      FIG. 20  is a diagrammatic perspective view of a sleeve in accordance with the present invention; 
           [0027]      FIG. 21  is a diagrammatic exploded view of a fill lobe in accordance with the present invention; 
           [0028]      FIG. 22  is a diagrammatic exploded view of a gauge lobe in accordance with the present invention; 
           [0029]      FIG. 23  is a diagrammatic exploded view of a bias lobe in accordance with the present invention; and 
           [0030]      FIG. 24  is a diagrammatic exploded view of a relief lobe in accordance with the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0031]    Referring now to the drawings, like reference numerals designate identical or corresponding features throughout the several views. 
         [0032]    Referring to  FIGS. 1-24 , an embodiment of a gas pressure regulator with slide-mount lobes is shown generally at  100 , and may comprises one or more of the following components and features:
     100  pressure regulator     102  regulator body     104  fill lobe     106  gauge lobe     108  bias lobe     110  relief lobe     112  sleeve     114  retainer     116  shuttle rod     118  high shuttle o-ring     120  low shuttle o-ring     122  shuttle ball seal     124  application o-ring     126  retainer o-ring     128  poppet     130  poppet o-ring     132  poppet spring     134  fill lobe interface     136  gauge lobe interface     138  bias lobe interface     140  relief lobe interface     142  source o-ring     144  main axis     146  sleeve flange     148  retainer flange     150  guide rail     152  axial detent     154  source chamber     156  bias chamber     158  output chamber     160  fill channel     162  fill port     164  gauge channel     166  gauge port     168  bias supply channel     170  bias supply port     172  bias port     174  bias relief channel     176  source-pressure relief channel     178  source-pressure relief port     180  output-pressure relief port     182  source end     184  application end     186  stud     188  threading     190  fill lobe body     192  fill plug     194  flow stopper     196  plug o-ring     198  stopper o-ring     200  guide rail channel     202  gauge lobe body     204  slide-on seal     206  slider ring     208  press-in plug     210  sense pin     212  sense pin top hat     214  gauge spring     216  gauge top plug     218  gauge marker     220  face cover (e.g., translucent or transparent polymer)     222  bias lobe body     224  ball piston     226  piston o-ring     228  piston spring (e.g., Belleville stack)     230  snap ring     232  pilot ball seal     234  pilot o-ring     236  bias relief top plug     238  bias relief spring     240  ball top     242  bias relief ball seal     244  bias relief o-ring     246  bias inlet channel     248  bias relief vent bore     250  pilot valve seat     252  bias relief valve seat     254  relief lobe body     256  high-pressure burst disk     258  low-pressure burst disk     260  burst disk o-ring     262  high-pressure burst vent     264  low-pressure burst vent     266  high-pressure burst chamber     268  low-pressure burst chamber     270  socket (e.g., adapted to receive a stud  186  of sleeve  112 )     272  first end     274  second end     276  main bore     278  retainer assembly     280  shuttle assembly     282  first portion     284  second portion   
 
         [0126]    An embodiment of a pressure regulator  100  A pressure regulator may comprise a regulator body  102 , a shuttle assembly  280  and a multiplicity of service lobes (such as shown, for example, at  104 ,  106 ,  108  and  110 ). A regulator body  102  may have a first end  272 , a second end  274 , and a main bore  276  extending therebetween along a main axis  144 . The second end  274  is generally adapted to be placed and secured in direct fluid communication with a reservoir of pressurized gas (not shown). This securement is typically by way of threadable engagement between a second portion  184  of the regulator body and the neck of the reservoir. The main bore  276  may be adapted to receive the shuttle assembly  280  for axial movement of the shuttle assembly between a fluid release configuration (not shown) and a fluid retention configuration (shown, for example, in  FIG. 14 ). In fluid release configuration, fluid is allowed to pass from the second end  274  into the output chamber  158 . In fluid retention configuration, the shuttle assembly  280  prevents pressurized air from flowing from the send end into the output chamber  158 . 
         [0127]    The main bore  276  is typically further adapted to cooperate with the shuttle assembly  280  to define a bias chamber  156 . The regulator body  102  may outwardly include a plurality of lobe interfaces (such as those shown, for example, at  134 ,  136 ,  138  and  140 ) generally radially distributed about the main axis  144 . Each of said lobe interfaces may include a respective port (such as those shown, for example at  166 ,  170  and  178 ) in fluid communication with the second end  274 . As illustrated, for example, in  FIGS. 1-4 , one or more of the multiplicity of service lobes may be adapted to axially slidably engage a respective lobe interface and be axially releasably restrained thereat. Such slidable engagement may be established between a pair of guide rails  150  on each lobe interface (see, for example,  FIG. 12 ) and a pair of guide rail channels  200  in each respective service lobe (see, for example,  FIG. 21 ). 
         [0128]    Certain embodiments may further comprise a sleeve element  112  and a retainer assembly  278 . The regulator body  102  may include a first portion  282  at generally the first end  272 . The sleeve element  112  may include an externally threaded portion  188  and a radially-extending sleeve flange  146  and may be adapted to receivingly engage the first portion  282 . The retainer assembly  278  may include a retainer element  114  adapted to be threadably received by the main bore  276  generally at the first end  272 . The retainer element by thereby axially releasably restrain the service lobes in the engagement with the respective interfaces, as well as the sleeve element  112  in receiving engagement with the first end  272 . 
         [0129]    In particular embodiments, the retainer assembly  278  may further include a poppet  128  and a poppet spring  132 , both of which may be axially restrained within the retainer element  114  as shown, for example, in  FIG. 13 . 
         [0130]    Referring to  FIGS. 14 and 23  for illustration, one of the service lobes may be a bias lobe  108 . A bias lobe  108  may include a pilot regulator (comprised of, for example, one or more of a pilot ball seal  232 , pilot o-ring  224 , piston o-ring  226 , piston spring  228  and snap ring  230 ). The pilot regulator may be adapted to be in fluid communication generally between the second end  274  and the bias chamber  156  and may thereby regulate bias pressure within the bias chamber  156  when the bias lone  108  is in engagement with its respective lobe interface  138 . 
         [0131]    Referring to  FIGS. 13 and 22  for illustration, one of said service lobes may be a gauge lobe  106 . A gauge lobe  106  may include a pressure gauge assembly (comprising one or more of, for example, a slider ring  206 , a press-in plug,  208 , a sense pin  210 , a sense pin top hat  212 , a gauge spring  214 , a gauge top plug  216 , a gauge marker  218  and a face cover  220 . The pressure gauge assembly may be adapted to be in pressure-indicating fluid communication with the second end  274  when the gauge lobe  106  is in engagement with its respective lobe interface  136 . 
         [0132]    Referring to  FIGS. 13 and 21  for illustration, one of the service lobes may be a fill lobe  104 . A fill lobe  104  may include a fill plug  192  adapted to be in fluid communication with the second end  274  when the fill lobe  104  is in engagement with its respective lobe interface  134 . 
         [0133]    Referring to  FIGS. 14 and 24  for illustration, one of the service lobes may be a relief lobe  110 . A relief lobe  110  may include one or both of a high pressure burst disk  256  and a low pressure burst disk  258 . A high-pressure burst disk  256  may be adapted to be in fluid communication between the second end  272  and ambient air and a low pressure burst disk  258  may be in fluid communication between the output chamber  158  and ambient air when the relief lobe  110  is in engagement with its respective lobe interface  140 . 
         [0134]    In certain embodiments, a relief lobe  110  may include a relief lobe body  254  having one or more of a high-pressure burst vent  262  and a low-pressure burst vent in fluid communication with ambient air. The high-pressure burst disk  256  may have a burst direction generally normal thereto (that is, generally normal to the plane of the burst disk) and being in fluid communication between the second end  272  and the high-pressure burst vent  262 . As illustrated in  FIG. 14 , for example, the high-pressure burst vent  262  and low pressure burst vent  264  may extend in a manner substantially non-parallel to the burst direction so as to more effectively deflect fragments from a respective rupturing burst disk. 
         [0135]    The portion of the regulator body  102  proximate the source end  182  of the pressure regulator  100  is generally adapted to be secured to a tank or similar structure enclosing a fluid reservoir (not shown). This securement may be by way of, for example, threaded engagement, welding, or the like. The tank or similar structure may be adapted to store fluids, such as gases, within the fluid reservoir at pressures of between 3000 psi and 4500 psi or more. The source chamber  154  of the regulator body  102  is typically placed in direct fluid communication with the fluid reservoir. 
         [0136]    The regulator body  102  typically includes radially distributed interfaces, such as one or more of a fill lobe interface  134 , gauge lobe interface  136 , bias lobe interface  138 , and relief lobe interface  140 . The fill lobe  104 , gauge lobe  106 , bias lobe  108  and relief lobe  110  are each adapted to slidably engage a respective interface. This slidable engagement may occur between respective guide rails  150  and guide rail channels  200 . Each lobe may be axially secured with respect to the regulator body  102  by securement between a respective axial detent  152  and sleeve flange  146 . The studs  270  on the sleeve  112  may be adapted to be received by the sockets  270  so as to prevent the rotation of the sleeve  112  about the main axis  144  when the pressure regulator  100  is fully assembled. The sockets  270  may be formed by cooperation of the lobes and regulator body  102  when in their mutually assembled state. The sleeve  112  may be adapted to be axially secured with respect to the regulator body  102  by threaded engagement of the retainer  114  to the regulator body  102 . The retainer  114  may be adapted to securely house all components of the retainer assembly  278 , even when the retainer is removed from threaded engagement with the regulator body  102 . 
         [0137]    The regulator body  102  may be adapted to axially receive and house a shuttle assembly  280  for axial movement between fluid release and fluid retention configurations, thereby regulating the pressure of a fluid within output chamber  158 , the source of that fluid may be the source chamber  154  at the second end  272 . The shuttle assembly  280  is shown in fluid retention configuration in  FIGS. 13 and 14 , wherein shuttle ball seal  122  prevents fluid from passing from the source chamber  154  to the output chamber  158 . The shuttle assembly  280  is considered to be in fluid release configuration when it has moved toward the application end  184  of the pressure regulator  100 , thereby allowing fluid to pass from the source chamber  154  into the output chamber  158 . The engagement between the regulator body  102  and the shuttle assembly  280  may form a bias chamber  156 . Pressurization of the bias chamber  156  (e.g., to a pre-determined “bias pressure”) results in the shuttle assembly  280  being elastically biased toward its fluid release configuration. This elastic bias may be adapted to be overcome once the pressure in the output chamber  158  reaches or exceeds a pre-determined desired output pressure (for example, 800 psi), resulting the shuttle assembly  280  being forced back to its fluid retention configuration. The bias pressure is typically a fraction of the output pressure. 
         [0138]    The bias lobe  108  may include a pilot regulator which regulates the bias pressure of the fluid within the bias chamber  156 , wherein the fluid is supplied from the source chamber  154 . Operation of the pilot regulator is illustrated in part, for example, in  FIGS. 15 and 16 . The pilot regulator may be resiliently biased to allow pressurized fluid to flow from the source chamber to the bias chamber  156  (see, for example,  FIG. 15 ) until the proper bias pressure is achieved within the bias chamber  156 , at which point the pressure on the face of the ball piston  224  results it the ball piston  224  moving against the resilient bias of the piston spring  228  sufficiently to allow the pilot ball seal  232  to sealingly engage the pilot valve seat  250  (see, for example,  FIG. 16 ). The proper bias pressure may be a fraction of the output pressure, for example, approximately 20%-40%, depending on the particular embodiment. The bias lobe  108  also comprises a bias pressure relief system (illustrated in part for example, in  FIGS. 17 and 18 ) which is a safety mechanism adapted to relieve any excess pressure which may accumulate within the bias chamber  156 . Such excess pressure may result from, for example, a change in the temperature of the operating environment. 
         [0139]    The bias pressure within the bias chamber  156  provides a bias force on the shuttle  116 , thereby elastically biasing the shuttle  116  (and the shuttle assembly  280  as a whole) in the direction toward the application end  184  of the regulator  100 . This “regulated gas spring” solution may eliminate the need for a conventional compression spring to be used to achieve proper output pressure, while simultaneously providing a more consistent bias force during the operation and over the life of the regulator. 
         [0140]    In embodiments, the fill lobe may be adapted to be assembled without the need for threaded engagement of the fill plug  192 . The relief lobe  110  may include a high-pressure burst disk  256  and a low pressure burst disk  258 , adapted to relieve excess pressure from the source chamber  154  and output chamber  158 , respectively. The relived fluid and burst disk fragments may be further deflected by way of high and low-pressure burst vents  262  and  264 , respectively. The gauge lobe  106  provides a clear indicator of the pressure within the source chamber  154 , and resultantly, the pressure within the attached fluid reservoir. The gauge marker  218  may move axially along with the sense pin top hat  212  by way of, for example, magnetic interaction. 
         [0141]    Potential advantages of embodiments of the disclosed pressure regulator  100  include the fact that it may be assembled and disassembled using only one tool (e.g., an Allen key used on retainer  114 ), it may have a built-in pressure indicator, it may not rely on a conventional compression spring to provide bias to the shuttle rod  116  (compression springs can perform inconsistently, particularly over time and at different temperatures), the fill plug  192  may be easily secured with respect to the pressure regulator  100  without being required to threadedly engage the regulator body  102  or any other body, and when removing the retainer  114  from the regulator body  102 , the poppet spring  132  and poppet  128  may remain neatly within the retainer  114 . In addition, the gauge lobe body  202  and the relief lobe body  254  can be made of fiber-infused Nylon rather than, for example, Aluminum or other metals. 
         [0142]    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.