Patent Publication Number: US-2023143865-A1

Title: Hydraulic power pack system

Description:
BACKGROUND 
     High pressure, high load, compact, interchangeable hydraulic tools are commonly used in many industries, these tools produce high forces from small diameter cylinders supplied with high pressure hydraulic fluid that&#39;s typically in the 10,000 pounds per square inch (psi) range. Hydraulic fluid flow and pressure is usually delivered to the cylinders by hydraulic power units incorporating low flow high pressure pumps coupled to a motor that is powered by electricity or fuel. An alternative method of generating a low fluid flow with pressures high enough for use with these types of cylinders is with hand pumps, which are similar in function to a hydraulic bottle jack. Delivering 10,000 psi hydraulic fluid to these tools is relatively easy from large stationary pumping systems with virtually unlimited power sources, but the weight, size, and power requirement of these systems prohibit their ability to be carried by a user and used as portable power sources. 
     Portable backpack hydraulic power units are usually powered by a low power small electric motor driven hydraulic pump and usually use rechargeable batteries to power the motor, these systems have several limitations. Nominal battery charge must be maintained to run the pump at full pressure and flowrate, and recharge rates can be slow typically around 30-60 minutes per battery pack. When the batteries do need to be recharged if electricity isn&#39;t currently available, the unit can become useless in emergency situations. Batteries have a limited energy capacity with a high density to power ratio, carrying multiple spare batteries in a backpack (whether they are charged or discharged) can get heavy for the user. 
     Maximum hydraulic pressure and flow from hydraulic pumps is limited by the mechanical power available from the electric motor that drives the pump, and the electric motor is limited by the power available from the electric source. As batteries loose charge the power delivered to the pump will diminish which will reduce pump flow rates and pressure to the system. Electric motor driven hydraulic systems are not suitable for wet or underwater environments or flammable and explosive areas. Electric motor driven pumps can also be noisy and in some covert situations a low noise alternative could be more desirable. 
     Emergency services normally use fueled engine driven hydraulic power units to actuate lifesaving hydraulic tools (e.g., “The Jaws of Life” used by Firemen). These engine powered systems can be large and heavy which limits their use mostly to ground applications like vehicle crash sites, and the hand held tools can be bulky, heavy and strenuous for long term use. A light weight hydraulic power pump in a backpack could be worn and used with hand held hydraulic tools to open doors, lift heavy debris, or cut metal (e.g., Locks, bolts, rebar, or cable) not only on the ground but also easily carried in multistory buildings or other remote structures. 
     Breaching is a term that is used by police swat teams and military special forces that are trained to enter fortified buildings or structures, this is normally done by forcing a locked door open by some means of force. Breaching doors can be accomplished several ways with explosives, shotgun rounds, gas or thermite cutting torches and many different hand tools like crow bars, battering rams, and cutting tools. The drawbacks to some of these methods is they make very high sounds and pressure waves that require highly trained and blast protected personnel to use them. Breaching explosives can be dangerous to the users and bystanders and take a lot of time to setup on a door by a team and then move to a safe distance detonate and then run back to the breached entry. Shotgun rounds also make high amount of noise and can take multiple rounds to breach a door. Cutting torches are quieter than explosives and shotguns but they make a lot of smoke and heat, which can fill a building hallway with blinding smoke. Portable hydraulic power units with spreading wedges, cutting or prying tools are also used to breach doors. The hydraulic tool is usually wedged into the door jam and when the pump supplies pressure to the tool it expands and either breaks the lock or the door frame and the door can be pushed open. Battery powered hydraulic tools are limited in available power, and batteries have a maximum amperage discharge rate which limits fluid pumping horsepower and fluid flowrates at high pressures making tool operation speed slow. 
     Demolition, construction and industrial workers use high pressure hydraulic tools on a daily basis. Industrial hydraulic pumping systems are usually large, heavy, stationary, and normally used in a factory, but there are uses for onsite portable high pressure hydraulics; lifting and leveling structures, cable cutting, bar cutting, bolt cutting, clamping and pressing are a few of the industrial applications. 
     SUMMARY 
     The hydraulic power pack of the disclosed invention offers a portable high pressure hydraulic system that can be powered by interchangeable portable compressed gas supply vessels. With its portability and being powered by compressed gas it can be carried by a single user, and be used with many hydraulic tool attachments in almost any environment including hazardous and underwater. 
     These advantages and others are achieved, for example, by a hydraulic power pack system that includes a gas supply vessel containing high pressure compressed gas, a pneumatic manifold comprising a first control valve and a second control valve, a first stage intensifier, a second stage intensifier, a hydraulic manifold, and a pilot line. The first and second control valves are configured to receive the compressed gas from the gas supply vessel. The first stage intensifier includes a first pneumatic cylinder connected to the first and second control valves, a first hydraulic cylinder axially connected to the first pneumatic cylinder, a first pneumatic piston disposed in the first pneumatic cylinder, and a first hydraulic piston disposed in the first hydraulic cylinder and axially connected to the first pneumatic piston. The first control valve when actuated is configured to direct the compressed gas to the first pneumatic cylinder. The second stage intensifier includes a second pneumatic cylinder connected to the first and second control valves, a second hydraulic cylinder axially connected to the second pneumatic cylinder, a second pneumatic piston disposed in the second pneumatic cylinder, and a second hydraulic piston disposed in the second hydraulic cylinder and axially connected to the second pneumatic piston. The second control valve when actuated is configured to direct the compressed gas to the second pneumatic cylinder. The hydraulic manifold is configured to transfer hydraulic pressure in the first hydraulic cylinder or the second hydraulic cylinder to a tool cylinder that operates at least one tool coupled to the tool cylinder. The pilot line connects the first hydraulic cylinder to the second control valve. The second control valve is configured to be actuated by pressure in the first hydraulic cylinder. 
     The first stage intensifier may further include a first spring disposed in the first pneumatic cylinder under the first pneumatic piston. The first spring is configured to be compressed by the first pneumatic piston when the first pneumatic piston moves downward. The second stage intensifier may further include a second spring disposed in the second pneumatic cylinder under the second pneumatic piston. The second spring is configured to be compressed by the second pneumatic piston when the second pneumatic piston moves downward. The hydraulic manifold may include a shuttle valve connected to the tool cylinder, the first hydraulic cylinder and the second hydraulic cylinder. The shuttle valve is configured to allow fluid flow from a higher pressure of the first and second hydraulic cylinders to the tool cylinder. 
     The hydraulic power pack system may further include a backpack that contains the gas supply vessel, the pneumatic manifold, the hydraulic manifold, the first and second stage intensifiers, and the pilot line. The backpack is configured to be portably carried by a user. The hydraulic power pack system may further include an accumulator configured to store fluid and to supply the fluid for the first and second hydraulic cylinders to replace lost fluid. 
     These advantages and others are also achieved, for example, by a hydraulic power pack system that includes a gas supply vessel containing high pressure compressed gas, a pneumatic manifold comprising a control valve that is configured to receive the compressed gas from the gas supply vessel, an intensifier, a hydraulic manifold, and a backpack. The intensifier includes a pneumatic cylinder connected to the control valve, a hydraulic cylinder axially connected to the pneumatic cylinder, a pneumatic piston disposed in the pneumatic cylinder, a hydraulic piston disposed in the hydraulic cylinder and axially connected to the pneumatic piston, and a spring disposed in the pneumatic cylinder under the pneumatic piston. The spring is configured to be compressed by the pneumatic piston when the pneumatic piston moves downward. The control valve when actuated is configured to direct the compressed gas to the pneumatic cylinder. The hydraulic manifold is configured to transfer hydraulic pressure in the hydraulic cylinder to a tool cylinder that operates at least one tool coupled to the tool cylinder. The backpack contains the gas supply vessel, the pneumatic manifold, the hydraulic manifold, and the intensifiers. The backpack is configured to be portably carried by a user. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The preferred embodiments described herein and illustrated by the drawings hereinafter be to illustrate and not to limit the invention, where like designations denote like elements. 
         FIG.  1    is a perspective front view of the hydraulic power pack system in an open backpack of the disclosed invention. 
         FIG.  2    is a front view of the hydraulic power pack system in a closed backpack of the disclosed invention. 
         FIG.  3    is an elevated view of the user hand grip and a hydraulic wedge tool of the disclosed invention. 
         FIG.  4    is a perspective rear view of the hydraulic power pack system in a closed backpack of the disclosed invention. 
         FIG.  5    is a front view of the intensifier pump of the disclosed invention. 
         FIG.  6    is a top view of the intensifier pump of the disclosed invention. 
         FIG.  7    is a cross-sectional view of the intensifier pump of the disclosed invention. 
         FIG.  8    is a circuit schematic of a two-stage intensifier pump of the disclosed invention. 
         FIG.  9    is a circuit schematic of a single stage intensifier pump of the disclosed invention. 
     
    
    
     DETAILED DESCRIPTION 
     The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. 
     This novel system or device of the disclosed invention is a portable pneumatic/hydraulic intensifier pump that pressurizes hydraulic oil to a high pressure using a lower pressure supply of compressed gas via a pneumatic and hydraulic circuit with control valves and differential area pistons. This high pressure hydraulic oil then flows from a valve manifold through a hose that is attached to a hydraulic tool that is operated by a user. The differential area of the coupled gas and hydraulic pistons create a pressure intensification ratio which means it delivers a higher hydraulic output pressure than the input gas supply pressure. For example if the input piston to output piston area ratio was 2:1 then the output hydraulic fluid pressure would be two times the input gas pressure. The pistons differential area ratio can be changed to obtain the desired output hydraulic fluid pressure from the pneumatic gas supply pressure. Increasing the intensification ratio can be accomplished by increasing the diameter of the input piston and decreasing the diameter of the output piston. Higher intensification ratios increase the output to input pressure ratio of the coupled pistons, but higher ratios will decrease the output to input fluid volume of the pistons. To obtain the maximum required output pressure while also delivering enough fluid volume to the hydraulic tool the intensifier pistons sizing and ratios need to be correctly chosen. 
     The device in its current configuration is a portable gas powered or driven fixed volume positive displacement pump that produces high fluid pressures in a single fluid pumping direction and is small enough and light enough to be carried by the user in backpack. The device could be made to reciprocate and pump in two directions with higher flow rates but this would make the device larger and heavier which is not ideal for a light weight portable backpack unit. The device could include a single or multiple compressed gas or liquid CO 2  pressure vessels, a pneumatic input control circuit, one or more intensification piston stages, a hydraulic output control circuit, hydraulic fluid reservoir or accumulator, hydraulic hoses, fittings and couplers to connect the hoses to the user tool, and user controls. The pneumatic and hydraulic control circuits include but not be limited to check valves, pneumatic and hydraulic directional flow control valves, pressure control valves, safety relief valves, and pressure gauges. 
     With reference to  FIG.  1   , shown is a perspective front view illustrating an embodiment of device  100  of the disclosed invention with a two-stage intensifier device (or pump)  101  contained in an open backpack. Backpack  150  is designed to contain the intensifier device  101  and make it easy to carry either on a person&#39;s shoulders by shoulder straps (not shown in this view) or by handle  151 . The intensifier device  101  is made of several pneumatic and hydraulic components that complete a fluid circuit that produces hydraulic fluid pressure and flow used to produce high forces by various hydraulic tool attachments. The components contained in backpack  150  are the two-stage intensifier device  101  that includes a pneumatic manifold  102 , low pressure intensifier pneumatic cylinder  104 , high pressure intensifier pneumatic cylinder  108 , hydraulic manifold  112 , control valve  130 , valve actuator  131 , pilot valve  132 , gas supply vessel  155 , pressure regulator  103 , safety burst disc  136 , accumulator  135 , user control cable  145 , hydraulic hose  149 , and various pneumatic and hydraulic valves and fittings that complete the fluid circuit. 
     Hydraulic hose  149  is a flexible hose that connects hydraulic manifold  112  at output fitting  118  to handgrip  140  and tool cylinder  143 . Hose  149  is a conduit that supplies fluid flow and pressure to and from tool cylinder  143 , which extends or retracts its rod to apply force to the spreading wedge tool  144 . Hose  149  connects to the aft end of a pipe that passes through user handgrip  140  and coupling  142  is mounted to the forward end of this pipe. Various tool configurations with many different functions can be used with the device  100 , and a quick disconnect coupling  142  is mounted to the tool cylinder to be able to change tool attachments when desired. The quick disconnect coupling  142  includes a male and female fitting that allows hydraulic plumbing to be easily disconnected from hydraulic attachments without much fluid loss; these fittings are common to the industry and typically the male half of the fitting would be mounted to the end of hose and the female half of the fitting would be mounted to the attachment cylinder. The device illustrated in  FIG.  1    has the male portion of coupling  142  mounted to user handgrip  140  and the female portion mounted to tool cylinder  143 . 
     Control cable  145  connects to the aft end of user handgrip  140  and is coupled with a button or trigger  141  that is housed inside handgrip  140 ; when trigger  141  is depressed, cable  145  operates valve actuator  131  that shifts pneumatic valve  130 , supplying gas to the pneumatic cylinders  104  and  108  which apply force to the hydraulic cylinders  107 ,  111  (see  FIG.  7   ) and send high pressure hydraulic fluid to tool cylinder  143 . After tool cylinder  143  has finished its operation and the user releases trigger  141  tool, cylinder  143  retracts and hydraulic fluid returns to the intensifier hydraulic cylinders  107 ,  111  for the next high pressure cycle. Tool cylinder  143  is classified as a single acting spring return hydraulic cylinder, which means hydraulic pressure and flow are delivered to the piston end of the cylinder to extend it and an internal spring is located on the rod end of the cylinder and applies the required force to retract the cylinder. Control cable  145  and valve actuator  131  are illustrated as mechanical devices but could easily be exchanged for wires and a battery operated electric solenoid actuator without changing the intended operation of the device  100 . 
     The control valves connected to manifold  102  are a combination of pneumatic control valves that would most likely include but not limited to a manually or electrically operated directional valve  130 , a piloted directional valve  132 , inlet pressure regulator  103  and a safety pressure relief valve or burst disc  136 . When the user actuates valve  130  and high pressure gas flows through the control valves and manifold  102 , it is directed to the multistage intensifier cylinders. Each cylinder contains a set of axially coupled pistons (see  FIG.  7   ), one being connected to the pneumatic circuit and another connected to the hydraulic circuit. The pneumatic piston  105 ,  109  diameters are larger than the coupled corresponding hydraulic piston  106 ,  110  diameters that they are coupled with which creates a differential area between the coupled pistons. The larger the differential area is between the coupled pistons results in a larger input to output pressure intensification ratio, which produces a higher output hydraulic pressure than the input pneumatic pressure. 
     The differential area ratio of the first stage intensifier driven by pneumatic cylinder  104  is less than the differential area ratio of the second stage intensifier driven by pneumatic cylinder  108 ; having two intensifier cylinders with different ratios will provide a larger volume of high pressure hydraulic fluid than what a single stage intensifier could provide to cylinder  143 . The area ratio difference between the two intensification stages delivers a first stage high volume low pressure (2,000-5,000 psi range) fluid to tool cylinder  143  that pre-loads tool  144 , as the tool load increases and the sequence pressure is reached the device transitions to the lower fluid volume higher pressure (5,000-10,000 psi range) second intensifier stage cylinder. The timing or sequence of the transition from the first to second stage intensifier cylinder is made by a pilot operated valve  132  that is part of the pneumatic circuit, which is actuated by a feedback pressure (pilot pressure) from the first stage of the hydraulic circuit. The pilot pressure setting can be adjusted to a higher or lower pressure to obtain the maximum number of pressure cycles per vessel  155  gas volume, which is a function of the applied tool load and fluid volume required to extend tool cylinder  143 . The pilot pressure is delivered to valve  132  from the hydraulic circuit via pilot fluid line  172 . The use of multiple intensification stages in device  100  increases the fluid volume delivered at lower pressures (up to 5000 psi) to quickly extend the operators tool  144  until it reaches a set resistance or force, this pre-loads tool  144  before the switch from the low pressure to the high pressure stage. Having two intensification stages increases the amount of fluid that can be delivered to tool cylinder  143  while also reducing the amount of supply gas expended per pressure cycle. 
     The hydraulic pressure supplied to tool cylinder  143  by the intensifier cylinders is maintained as long as the user depresses trigger  141  and control valve  130  is actuated or shifted to its second position. When valve  130  is released and shifts back to its first position the high pressure gas that is acting on the pneumatic pistons is allowed to vent to atmosphere and the pistons start retracting. This allows hydraulic fluid to reverse its flow from cylinder  143  which retracts or returns to its original un-pressurized state and will be ready for the next operation or pressure cycle. 
     Accumulator  135  is a fluid storage device that could be either an open (vented to atmosphere) or closed (not vented to atmosphere) design, its primary function is to store and replace fluid lost from the system possibly from a tool cylinder seal leak or from a leak at a hose connection or fitting. Accumulators typically use gas pressure or springs to apply a force to their internal partition which forces stored fluid from the accumulator  135  when system pressures are low. Accumulator  135  would also provide a place for the user to fill or add fluid to the system when low or empty and blead trapped air from the hydraulic circuit. If accumulator  135  is an open design, it would have an internal partition with fluid on one side of the partition and a spring on the side of the partition that was vented to atmosphere. If accumulator  135  is a closed design, it would not have a spring but would instead be charged with a low pressure gas and not be vented to atmosphere. The non-vented accumulator version would allow the system to be fully closed and used under water. 
     There are many hydraulic attachments and tools currently available in the market that could be used with the device  100  (e.g., cable or bolt cutters, spreading jaws, pressing and clamping cylinders, and lifting cylinders). Future novel specialty attachments and tools could be designed and tailored for use with the device  100 . These high pressure low fluid volume hydraulic tools are generally designed with working pressures in the 10,000 psi range. The device  100  should be designed with fluid intensification ratios to deliver the required working pressure and volume required by the tool cylinder and its application. 
     With reference to  FIG.  2   , shown is a front view illustrating the device  100  with the front panel of backpack  150  closed with the intensifier device  101  contained inside. The backpack  150  has a handle  151  mounted at the top to carry the device  100  when not being worn on the user&#39;s shoulders. Hydraulic hose  149  and control cable  145  exit the backpack  150  at the lower left side of the backpack and both circle behind the backpack to the user handgrip  140  (see  FIG.  1   ). The quick connect coupler  142 , tool cylinder  143 , and wedge tool  144  can be seen on the right hand side of the backpack  150 . The position of the hose  149  and tool cylinder  143  could be switched to either side of backpack  150  to accommodate a left handed or right handed user. 
     With reference to  FIG.  3   , shown is a side view that illustrates user handgrip  140  with tool cylinder  143  attached by a quick connect coupler  142  fitting. Handgrip  140  is equipped with a full grip hand hole  146  and a forward single finger hole  145  that contains the trigger  141 . Housing the trigger in a separate finger hole should reduce a user from accidentally operating the tool. If required a secondary palm depression leaver could be added to further reduce the possibility of accidental operation. The aft end of handgrip  140  has a connection fitting  148  for the user control cable to attach and a connection fitting  147  for the hydraulic hose  149  to attach. Handgrip  140  is shown with the user cable connection fitting  148  above hose connection  147 ; this could be reversed if needed for better fitment of internal trigger parts or for a more ergonomic design of the handgrip. 
     Tool cylinder  143  and wedge tool  144  are provided as an assembly and when a different tool configuration is required both would be changed out by removing the tool cylinder assembly from handgrip  140  by separating the quick connect coupling  142 . When a tool assembly is detached from handgrip  140  at the quick connect  142  fitting very little oil is lost, both the male and female halves of the fitting have a sealing feature much like a check valve; when the two halves are connected fluid flows though the fitting and when disconnected fluid is “checked” off and doesn&#39;t flow through. All extra tool cylinder attachments would be supplied with the female half of coupling  142  allowing fast tool interchangeability with low fluid losses. Wedge tool  144  shown here is typically used to spread and bend structures or breach or open locked doors. 
     Many different hydraulic cylinders and tool configurations are currently available in the market that could be used with this system, but specialized novel tools could be designed and optimized for use with the device  100  (e.g., cable or bolt cutters, bending and shearing tools, spreading jaws, clamping cylinders, and heavy structure lifting cylinders). This system  100  could also be designed for underwater use and novel specialty tools could be designed and tailored for this type of use. These high pressure low fluid volume hydraulic tools are generally designed for working pressures in the 10,000 psi range. The device  100  will be designed with a fluid intensification ratio to obtain the required working pressure of the tool cylinders and their applications. 
     With reference to  FIG.  4   , shown is a perspective view of backpack  150  that further illustrates its design with shoulder straps  152  attached to the backside of the backpack  150 , and handle  151  being attached to the top of the backpack  150 . Shoulder straps  152  would be made to adjust in length to fit various users&#39; shoulder size. Hydraulic hose  149  and control line  145  are shown on the right side of the backpack  150 , connecting handgrip  140  to the intensifier device contained inside the backpack. Handgrip  140  in this view would be held by the left hand of the user but could easily be changed for right handed use by routing hose  149  and control line  145  to the left hand side of backpack  150 . 
     With reference to  FIG.  5   , shown is a front view of a two-stage intensifier device  101  that illustrates the external locations for many of the components of the embodied device&#39;s pneumatic and hydraulic circuits. Manifold  102  and  112  are coupled to the top and bottom ends of pneumatic cylinders  104  and  108  and the assembly of these four components is held together by a plurality of threaded tie rods  116  and the tie rod nuts  117 . 
     Pneumatic manifold  102  provides a mounting surface and closure for the top of pneumatic cylinders  104  and  108 ; manifold  102  also contains internal fluid passages that provide fluid communication between all the pneumatic circuit components and the cylinders. Manifold  102  has a directional valve  132  mounted on the top and directly above cylinder  108  and directional valve  130  mounted on the right side of the manifold. Valve  130  has a gas pressure regulator  103  mounted to its right side and a gas storage vessel  155  is mounted to the bottom of regulator  103 . Pressure regulator  103  has a pressure gauge  114  mounted on its front side and a safety burst disc  136  mounted on its right side. Valve  130  has an exhaust muffler  139  plumbed to an exhaust port that suppresses the sound of venting gas from the pneumatic circuit. Control valves  130  and  132  direct gas flow to and from the pneumatic cylinders to act on the pneumatic pistons to power the intensifier device. Cylinders  104  and  108  respectively contain pneumatic pistons  105 ,  109  that are axially coupled with the hydraulic pistons  106 ,  110  which are contained in hydraulic manifold  112  (see  FIG.  7   ). 
     Gas supply vessel  155  is a high pressure storage vessel that contains and supplies high pressure compressed gas to the pneumatic circuit. The gas contained in storage vessel  155  could be of any suitable gas or air under high pressure (typically in the 800 psi to 4000 psi range) and could be in a gaseous or liquid state (e.g., liquid CO 2 ). When the gas pressure in vessel  155  falls below a usable pressure, it can easily be refilled or replaced with a spare vessel at full pressure. 
     Hydraulic manifold  112  provides a mounting surface and closure for the bottom of pneumatic cylinders  104  and  108 ; manifold  112  also contains the first and second stage hydraulic pistons and fluid passages that provide fluid communication between all the hydraulic circuit components and the cylinders. The fluid control valves and components that make up the hydraulic circuit that are illustrated here include shuttle valve  138 , check valve  133 , elbow fitting  118 , pressure relief valve  134 , and accumulator  135 . Elbow fitting  118  can be installed with its outlet facing the left or right hand side of manifold  112  to allow the hydraulic hose  149  to exit the backpack on either side for left hand or right hand tool use. Hydraulic pilot line  172  connects the output of the first stage hydraulic cylinder to the pilot of pneumatic valve  132 , when pilot pressure is high enough valve  132  will shift and send pressurized gas to the second stage pneumatic cylinder. 
     Accumulator  135  is a hydraulic fluid storage vessel with an internal partition that seals and separates hydraulic fluid from the gas side of the partition. Accumulator  135  can be configured as a vented to atmosphere device or a closed device depending on the setting of fitting  137 . Fitting  137  is mounted on top of accumulator  135  and is in fluid communication with the gas side of the internal partition and can function two different ways depending on the embodied device&#39;s application performance and intended usage; one function of valve  137  would be to vent gas from the gas side of the partition to atmosphere, and the second would be to hold a low pressure gas charge on the gas side of the partition. The bottom end of accumulator  135  is the fluid side of the internal partition and contains hydraulic fluid which can be added or removed from the system depending on system pressure and the gas pressure acting on the gas side of the accumulator partition. Fitting  153  is on the hydraulic fluid side of the accumulator  135  partition and can be used to fill or drain the system of hydraulic fluid. 
     The illustrated locations of the pneumatic and hydraulic components and fittings on manifold  102  and  112  are for representation only; they could be moved to any location or to any external side of the device if needed to better facilitate the internal fluid passage connections with the valves and other components of the circuits. The functions and sequence of operation of the pneumatic and hydraulic valves and components will be fully described in following schematics of the embodied device circuit. 
     With reference to  FIG.  6   , shown is a top view of intensifier device  101  that further illustrates the external locations of the embodied device&#39;s valves and other components. From this view, valve  132  is shown mounted to the top of manifold  102  directly above cylinder  108  and valve  130  is mounted on the right side of manifold  102 . The locations of the pneumatic valves on manifold  102  can be changed if needed to better facilitate the placement of the internal plumbing passages between the pneumatic valves and the pneumatic cylinders. 
     With reference to  FIG.  7   , shown is a section view taken about line  7 - 7  in  FIG.  6    that illustrates the internal components of the two-stage intensifier device  101 . Typically hydraulic and pneumatic cylinder construction includes a coupled piston and rod housed in a cylinder tube that is sealed or capped on both ends; on the forward rod end the cap is typically called a “head” and on the aft piston end it is called an “end cap.” Cylinders typically have external plumbing with a pipe or tube attached to the cylinder head and end cap that supplies fluid to extend and retract the coupled piston and rod. Cylinder end caps are typically a solid construction that provides a mounting and sealing surface for the aft end of the cylinder tube; end caps are usually connected to an external load and provide an aft piston stop surface when fully retracted. The cylinder head provides a mounting and sealing surface for the forward end of the cylinder tube, and provides a forward piston stop surface when extended. Cylinder heads also have a central through hole with rod seals that is concentric with the cylinder tube that the piston rod passes through, allowing the rod to be connected to an external load. Both the end cap and head typically provide some plumbing ports to supply fluid flow to the rod end and piston end of the cylinder, and provide a place for threaded tension rods or “tie rods” and nuts or alternate way to hold the assembly together. 
     The two intensifier cylinders contained in device  101  are similar in construction to a typical cylinder with the exceptions of sharing a common end cap (pneumatic manifold  102 ), and share a common head (hydraulic manifold  112 ), and the pistons rods are used as hydraulic pistons (piston  106  and  110 ). The two pneumatic cylinders  104  and  108  are mounted between an aft pneumatic manifold  102  and forward hydraulic manifold  112 , and the assembly is held together by a plurality of threaded tie rods  116  and nuts  117 . Cylinders  104  and  108  are sealed on both ends by elastic O&#39;ring type seals on the inside diameter of the bore that prevents gas leakage between the cylinders and the manifolds; cylinder  104  has tube seals  165  and cylinder  108  has tube seals  171 . The benefit of having both intensifier cylinders sharing a common head and end cap is the internal manifold circuit plumbing or fluid passages for communication between the cylinders and valves; this reduces plumbing components, weight, and many potential leak points from fluid lines and fittings. 
     Both intensifier cylinders are a single action design with an internal return spring to retract the pistons after being extended and the pressure cycle is finished. The use of single action cylinders reduces supply gas usage which increases the number of pressure cycles that can be performed from a single full gas supply vessel  155 ; this reduces the amount of gas needed which also reduces the size and weight of the device making it more portable. One drawback of using single acting cylinders verses double acting is the reduction of hydraulic fluid volume delivered to the tool cylinder; if a higher volume system is required the intensifier cylinders could be modified to become double acting (although this would reduce the number of pressure cycles per gas vessel and would add some circuit complexity and weight to the system). Pistons  106  and  110  have a similar appearance as typical cylinder rods connected to pistons  105  and  109 , but they are contained in cylinder bores and function as displacement pistons that pressurize and move fluid in and out of the hydraulic bores  107  and  111 . Piston  106  has a seal  160  that stops leakage of hydraulic fluid into cylinder  104  and piston  110  has seal  170  that stops leakage of hydraulic fluid into cylinder  108 . 
     The first stage cylinder  104  is noticeably smaller in diameter than the second stage cylinder  108  and in this figure it is located on the right hand side of the second stage cylinder. Both cylinders and their pistons are positioned parallel with each other, and each has similar construction and components. Hydraulic cylinders  107  and  111  are bored into hydraulic manifold  112  and fluid passages are drilled into the manifold to connect the cylinders with the hydraulic circuit and valves. Boring the hydraulic cylinder cavities in manifold  112  could be the preferred method of construction but if weight or manufacture cost could be reduced the construction could be changed to a cylinder tube and manifold design with threaded tie rods similar to the construction and assembly of the pneumatic cylinders  104  and  108  with manifold  102 . 
     The first stage intensifier includes a pneumatic cylinder  104  that is concentric with and axially coupled with hydraulic cylinder  107 . Pneumatic cylinder  104  contains pneumatic piston  105  that is axially coupled to the aft end of hydraulic piston  106  and is fastened to piston  106  by piston nut  163 . The diameters of piston  105  and  106  can be changed to obtain the required output fluid pressure and volume from each stroke; the chosen diameters will be dependent on volume of vessel  155  and gas pressure available to drive piston  105 . The stroke  164  of piston  105  and  106  can be made longer or shorter to deliver the required system fluid volume while also keeping the device as compact as possible. Piston  105  is equipped with elastic piston seal  161  that maintains a positive seal with the internal bore of cylinder  104  and prevents gas leakage from the aft end to the forward end of piston  105 . Piston  105  is equipped with a return compression spring  113  that is coupled to the forward end of piston  105  and to spring seat  162  at the aft end of the hydraulic cylinder  107 . Spring seat  162  insures that spring  113  maintains its concentricity with hydraulic piston  106  and doesn&#39;t contact the piston during piston stroke. 
     Cylinder  107  is equipped with an elastic medium pressure piston seal  160  at the aft end of the bore that maintains a positive seal with piston  106  and the bore, preventing hydraulic fluid leakage into the forward end of pneumatic cylinder  104 . The first stage cylinder would typically produce between 2,000 psi and 5,000 psi hydraulic fluid pressure, and seal  160  and all other cylinder component materials will be selected to withstand the maximum pressure and stress produced by cylinder  107 . Cylinder  104  and  107  and all the internal components of the cylinders should maintain good concentricity with one another providing low fiction operation without binding and prolong seal life. 
     The second stage intensifier includes a pneumatic cylinder  108  that is concentric with and axially coupled with hydraulic cylinder  111 . Pneumatic cylinder  108  contains pneumatic piston  109  that is axially coupled to the aft end of hydraulic piston  110  and is fastened to piston  109  by piston nut  168 . The diameters of piston  109  and  110  can be changed to obtain the required output fluid pressure and volume from each stroke; the chosen diameters will be dependent on vessel  155  volume and gas pressure available to drive piston  109 . The stroke  169  of piston  109  and  110  can be made longer or shorter to deliver the required system fluid volume while also keeping the device as compact as possible. Piston  109  is equipped with an elastic piston seal  167  that maintains a positive seal with the internal bore of cylinder  108  and prevents gas leakage from the aft end to the forward end of piston  109 . Piston  109  is equipped with a return compression spring  115  that is coupled to the forward end of piston  109  and to the aft end of seal gland  166 . The spring seat on the aft end of seal gland  166  insures that spring  115  maintains its concentricity with hydraulic piston  110  and doesn&#39;t contact the piston during piston stroke. 
     Cylinder  111  is equipped with a high pressure piston seal  170  at the aft end of the bore that maintains a positive seal with the piston  110  and the bore, preventing hydraulic fluid leakage into the forward end of pneumatic cylinder  108 . High pressure seal  170  is made from a low elasticity material and requires a removable seal gland  166  to ease installation of the seal and support the seal while exposed to high pressures. Installation of seals  170  into cylinder bore  111  would be done first followed by seal gland  166  being threaded into the cylinder bore to support and retain the aft end of seals  170 . The second stage cylinder would typically produce between 5,000 psi and 10,000 psi of hydraulic fluid pressure, and seal  170  and all other cylinder component materials will be selected to withstand the maximum pressure and stress produced by cylinder  111 . Cylinders  108  and  111  and all the internal components of the cylinders should be held concentric with one another to providing low fiction operation without binding and prolong seal life. 
     With reference to  FIG.  8   , shown is a diagram or schematic representation of an embodiment of pneumatic and hydraulic circuit  100   a  for the two-stage hydraulic pressure intensifier device  101  that is illustrated in  FIGS.  1 ,  5 ,  6 , and  7   ; that contains but not limited to a gas supply vessel  155 , several hydraulic and pneumatic valves and regulators, pneumatic cylinders  104  coupled to hydraulic cylinder  107 , and pneumatic cylinder  108  coupled to hydraulic cylinder  111 , and fluid flow paths to connect all components. Industry standard pneumatic and hydraulic symbols are used to depict the circuit components and one skilled in the art should be able to understand its layout and operation. 
     The device  100  may include two circuits with isolated fluids that transmit pressure to each other through two stages of axially coupled pistons contained in cylinders of different diameters; each having a pneumatic piston that is in contact with a gas (pneumatic circuit) and being of a larger diameter than the hydraulic piston that is in contact with a fluid (hydraulic circuit) creating a pressure intensifying circuit. The fluids of the circuits do not mix but do transmit pressure and flow to each circuit via the coupled pistons contained in the pressure intensifying cylinders. Each intensifier cylinder has a pneumatic piston of a given diameter that is axially coupled to a smaller diameter hydraulic piston. Stage one intensifier includes pneumatic piston  105  contained in cylinder  104  and hydraulic piston  106  contained in cylinder  107 ; stage two intensifier includes pneumatic piston  109  contained in cylinder  108  and hydraulic piston  110  contained in cylinder  111 . When high pressure gas is applied to the pneumatic piston of each intensifier cylinder, an axial force is created and transmitted to the smaller diameter hydraulic pistons; the force on the hydraulic piston is transmitted into the hydraulic fluid thereby increasing the pressure of the hydraulic fluid in the hydraulic circuit to a higher pressure than the supplied gas pressure of the pneumatic circuit. 
     The diameter of piston  105  being larger than the diameter of piston  106  creates a differential area between the two coupled pistons. The larger the differential area between the two coupled pistons results in a larger pressure intensification ratio of the input to output pressures. A two-to-one (2:1) intensification ratio or area ratio would result in the output hydraulic pressure produced by piston  106  being two times higher than the input gas pressure acting on piston  105 . The device intensification ratios can be changed to obtain almost any fluid pressure ratio within system material design strength limitations, allowing it to be tailored to various applications and requirements. 
     The differential area ratio between the stage one pistons  104  and  106  should be less than the differential area ratio of the stage two pistons  109  and  110 . The area ratio difference between the two intensification stages provides a first stage high volume low pressure fluid flow to the cylinder  143  that transitions to a second stage low volume higher pressure fluid flow to cylinder  143  during high tool force requirements. The reason for multiple stages is to provide a larger fluid volume at a lower pressure to quickly extend cylinder  143  at lower tool loads until it reaches a set resistance or force, this pre-loads cylinder  143  during the pressure cycle and conserves supply gas. 
     The circuit is a bidirectional flow type, meaning that during the pressure cycle pressurized hydraulic fluid flows through the circuit paths in one direction from cylinders  107  and  111  to tool cylinder  143  and extends it, when the system is depressurized fluid flows in the opposite or reverse direction using the same paths to empty and retract cylinder  143  while refilling cylinder  107  and  111 . Cylinders  104 ,  108 , and tool cylinder  143  have internal springs that apply a force to help return or retract the pistons and rods to their original positions after extending during the pressure cycle. Detailed circuit design, device operation, pneumatic and hydraulic flow directions and sequences will be provided in the following sections. 
     Pneumatic Circuit 
     The main components of the pneumatic portion of the circuit include a gas supply vessel  155 , pressure regulator  103 , pressure gauge  114 , overpressure safety burst disc  136 , directional control valves  130  and  132 , pneumatic cylinder  104  containing piston  105  and spring  113 , pneumatic cylinder  108  containing piston  109  and spring  115 , and a manifold (not shown) with internal fluid communication passages. The manifold provides a mounting surface or cavity for all the pneumatic circuit components and provides fluid communication between all the components and the two pneumatic cylinders. 
     Gas supply vessel  155  is a high pressure storage vessel that contains and supplies high pressure compressed gas to the pneumatic circuit. The gas contained in storage vessel  155  could be of any suitable gas or air under high pressure and could be in a gaseous or liquid state (e.g., liquid CO 2 ). When the gas pressure in vessel  155  falls below a usable pressure, it can easily be refilled or replaced with a spare vessel at full pressure. A pressure gauge  114  is mounted between gas vessel  155  and pressure regulator  103  that allows the user to see the current gas pressure in vessel  155 . Pressure regulator  103  allows adjustment of the system pressure by reducing the high pressure supply gas contained in vessel  155  to the lower system operating pressure. Vessel  155  and regulator  103  could be of novel design or similar in design as ones currently used with recreational paintball guns. Pressure regulator  103  is equipped with a safety burst disc  136  that protects vessel  155  from being over pressurized; over pressurization could happen if the vessel was full and left in a high heat environment for extended periods. 
     Two directional control valves are plumbed downstream of regulator  103 . Valve  130  is a two position spring returned manual or electrically actuated valve and valve  132  is a two position spring returned pilot actuated valve. Control valves  130  and  132  work in concert to supply and vent pressurized gas to cylinders  104  and  108 . Control valve  130  has a two position internal port connection configuration with a first position having pressure port  130 P blocked and the cylinder ports  130 A and  130 B connected to a vent port  130 R; and a second position with port  130 P connected to port  130 B, and the port  130 R connected to port  130 A. In  FIG.  8   , the left box of the control valve  130  represents the first position and the right box of the control valve  130  (with crossed arrows) represents the second position. Control valve  130  is shifted to its second position when the user presses a leaver or button  141  on the control handgrip  140 , connected to valve actuator  131 . Control valve  132  has a two position internal port configuration with a first position having pressure port  132 P and vent port  132 R blocked, and port  132 A connected to port  132 B; and a second position with port  132 P connected to port  132 B, and port  132 A connected to port  132 R. In  FIG.  8   , the left box of the control valve  132  represents the first position and the right box of the control valve  132  (with crossed arrows) represents the second position. Valve port  132 R is externally blocked as it is not needed, which prevents gas from being vented to atmosphere while valve  132  is shifted to its second position. Control valve  132  is shifted to its second position when the set “sequence” or pilot pressure is supplied to the valves pilot actuator via line  172  that is plumbed to the hydraulic output line of cylinder  107 . Valve  132  acts as a sequence valve to shift the system pressure and flow from the first stage cylinder  104  to the second stage cylinder  108 , when the desired hydraulic sequence pressure is reached. 
     Valves  130  and  132  would most likely be of a two position “spool” design with internal port connections that depend on spool design and the spools current position within the valve body. The internal port connections of valve  130  and  132  are shown in their “normal” or first positions in  FIG.  8   . When both valves  132  and  130  are in their first positions gas pressure to the system is not allowed or blocked and both cylinders  104  and  108  are vented to atmosphere. Depending on positions, these two valves work in concert to deliver the needed pneumatic gas flow and pressure to or from cylinders  104  and  108 . Valve  132  is equipped with a muffler  139  connected to port  130 A which is used to reduce or suppress the sound of venting high pressure gas exiting from cylinders  104  and  108 , when valves  130  and  132  are shifted back to their normal positions and pistons  105  and  109  are retracting. Control valve  130  and  132  may have alternate internal port connections and flow paths than illustrated in  FIG.  8    and could be two, three or four position valves if additional circuit flow paths are needed to operate device  100  as intended. 
     Hydraulic Circuit 
     The main components of the hydraulic portion of the circuit are the hydraulic cylinder  107  containing piston  106 , hydraulic cylinder  111  containing piston  110 , shuttle valve  138 , safety relief valve  134 , accumulator check valve  133 , accumulator  135 , and tool cylinder  143 . Hydraulic cylinders  107  and  111  are plumbed in parallel with each other in the hydraulic circuit and each contains a hydraulic piston  106  and  110  that is axially coupled with the pneumatic pistons. Piston  106  in cylinder  107  is larger in diameter than piston  110  in cylinder  111 ; making the output volume produced by cylinder  107  greater than cylinder  111 , but at a lower output pressure than cylinder  111 . Increasing the pressure intensification ratio of a cylinder reduces its output fluid volume delivered to the hydraulic circuit per piston stroke. Piston  106  and  110  diameters and their cylinder strokes need to be sized correctly to deliver a high enough pressure with sufficient fluid volume to fully extend tool cylinder  143 . The required second stage piston  110  diameter and stroke is mostly determined by the maximum operating pressure of tool cylinder  143 ; while the required first stage piston  106  diameter and stroke is mostly determined by the maximum fluid volume needed by tool cylinder  143  when fully extended. The exact sizing of the two intensifier cylinders will be tailored to the needs of the specific pressure and fluid volume required by the tool cylinder for the given application. 
     When pressurized gas is supplied to cylinders  104  and  108 , an axial force is transmitted from the pneumatic pistons to the hydraulic pistons; this force is converted into fluid pressure in the hydraulic circuit which is equal to the force applied times the area of the hydraulic pistons. As an example, if an application needed 10,000 psi delivered to the tool cylinder and 800 psi gas pressure was available, one possible combination of intensification ratios would be 2.5:1 for the first stage and 12.5:1 for the second stage. This would deliver up to 2,000 psi fluid to the tool cylinder during the operation of the first stage and would sequence to the second stage between 1,800 and 1,900 psi to the second stage that would deliver up to 10,000 psi. Having two intensifier stages increases the volume of hydraulic fluid delivered to cylinder  143  during low tool loads before the high pressure low volume second stage is required. 
     Downstream of the hydraulic cylinders  107  and  111  outlet is a shuttle check valve  138  plumbed in the circuit that isolates the output flow of cylinders  107  and  111  from the rest of the circuit and tool cylinder  143 . Shuttle check valve  138  only allows flow from the higher pressure of the two cylinders  107 ,  111  to be connected to the tool cylinder  143  at any given time during a pressure cycle. Shuttle valve  138  prevents any backflow to the lower pressure intensifier cylinder by blocking or “checking” (e.g., similar to a check valve) it off from the current higher pressure intensifier cylinder. Backflow from one intensifier cylinder to the other during the pressure cycle would result in a waste of supply gas if vented before the pressure cycle was finished and could also inadvertently increase the gas pressure of the pneumatic circuit above the system working pressure (possibly resulting in the safety burst disc venting supply gas). Neither outcome is desirable. When gas is vented form cylinder  104  and  108  and hydraulic pressure equalizes between cylinder  107  and  111 , shuttle valve  138  would return to center allowing fluid to reverse flow, empting tool cylinder  143  and filling cylinder  107  and  111  for the next pressure cycle. 
     In another embodiment, check valves (not shown) may be used instead of the shuttle valve  138  to provide utilities similar to those of the shuttle valve  138 . For example, a combination of check valves individually coupled to the hydraulic cylinders  107 ,  111  may be used to direct flow from the higher pressure of the two intensifier cylinders  107 ,  111  to the tool cylinder  143  at any given time during a pressure cycle and to prevent backflow to the lower pressure intensifier cylinder. 
     Downstream of shuttle valve  138 , the hydraulic circuit has a relief valve  134  and a check valve  133  plumbed in parallel between accumulator  135  and tool cylinder  143 . Relief valve  134  is a safety device that relieves hydraulic fluid to accumulator  135  in case of an overpressure event in the hydraulic circuit. Check valve  133  is plumbed in parallel with relief valve  134  blocking high pressure hydraulic fluid from entering accumulator  135  during the pressure cycle. After the pressure cycle is over and system pressure drops, check valve  133  opens and allows any relieved fluid to escape from accumulator  135  back to the hydraulic circuit, and return to cylinders  107  and  111  for the next pressure cycle. 
     Accumulator  135  is a multifunctional storage vessel, holding an extra volume of fluid in case of small leakages from fittings and the rod seals of the tool cylinder  143  and storing any fluid that has to be relieved by valve  134 . If the system runs low on fluid from external leakage accumulator  135  will replace the lost fluid with some of its stored reserve fluid. In the event that all the extra fluid is exhausted from accumulator  135 , it can be partially refilled to a specified volume, while conserving some empty space or volume for the relief valve  134  to function properly. Accumulator  135  could be designed as an open (e.g. vented to atmosphere) or closed gas charged (e.g. not vented to atmosphere) fluid storage device, and could have a internal elastic bladder or a ridged piston partition that separates the gas from the stored fluid. If not vented, one side of the internal partition would be charged with a low pressure gas and the side of the partition connected to the hydraulic circuit would be filled with hydraulic fluid. This would allow the system to be closed and used under water. If the accumulator is a vented design, it would most likely have a piston partition with a spring on the vented side of the partition and hydraulic fluid on the side connected with the hydraulic circuit. Accumulator  135  would also serve as a place to hold and blead trapped air from the hydraulic circuit during system fluid charging. If it is found that the functions of a partitioned accumulator are not needed by the hydraulic circuit, accumulator  135  could be replaced with a single chamber light weight vented reservoir. 
     Tool cylinder  143  is a single acting spring return design having an internal spring on the rod end of the cylinder that applies a force to retract the piston and rod when not under pressure. When the user releases the trigger and the gas control valves vent pressure from cylinders  104  and  108 , hydraulic pressure reduces and the spring force retracts cylinder  143 ; this forces the fluid that extended cylinder  143  to reverse its flow back to the hydraulic circuit, returning fluid to intensifier cylinders  107  and  111  for the next cycle. 
     Additional Control valves could be added or removed from the hydraulic and pneumatic circuits if needed to improve performance. Modifying the pneumatic and hydraulic components and circuits to improve the device performance will not change the system&#39;s intended use or purpose, or the novelty and design intent of the embodied device. 
     Tool Cylinder Extend/Pressure Cycle Sequence Of Operations 
     When the user shifts valve  130  to its second position connecting port  130 P to port  130 B while valve  132  is in its first position, pressurized gas is allowed to flow from pressure vessel  155  through pressure regulator  103  to the first stage intensifier cylinder  104 , while simultaneously venting gas from the second stage intensifier cylinder  108  through ports  130 A,  130 R,  132 B, and  132 A. Venting cylinder  108  at this time prevents it from applying pressure to the hydraulic circuit (which would override the lower pressure of cylinder  107  by shifting shuttle valve  138 ) before cylinder  107  is able deliver most, if not all, of its volume at pressures up to, for example, 5000 psi to extend tool cylinder  143  at low tool loads. 
     After the first intensifier stage supplies enough hydraulic fluid for cylinder  143  to extend and reach the required tool pre-load force, first stage hydraulic fluid typically in the 1,500 to 5,000 psi range is delivered by line  172  shifting valve  132  to its second position; this connects ports  132 P to  132 B supplying pressurized gas to valve ports  130 R and  130 A and the second stage cylinder  108 . In other words, the control valve  132  is configured to be actuated when the pressure in the hydraulic cylinder  107  is higher than a predetermined pressure. The second stage intensifier increases the fluid pressure downstream of cylinder  111 , which shifts shuttle valve  138  blocking flow to or from cylinder  107  and delivering 5,000 to 10,000 psi hydraulic fluid to tool cylinder  143  for the tool&#39;s high force application. The sequence or shifting pressure of valve  132  would most likely be between 1,500 to 3,000 psi, shifting pressures can be adjusted to optimize the system performance for a given applications force requirements. 
     The hydraulic pressure supplied to tool cylinder  143  is maintained as long as the user has the trigger  141  depressed and control valve  130  is shifted to its second position. When valve  130  is allowed to return to its first position, the high pressure gas that was acting on pistons  105  and  109  is allowed to vent to atmosphere though muffler  139  by connecting ports  130 A and  130 B to port  130 R and hydraulic fluid pressure starts dropping in the circuit. As system pressure drops below the pressure produced by the cylinder spring forces of the intensifier pistons and cylinder  143  they begin retracting, allowing hydraulic fluid to reverse its flow from cylinder  143  back to cylinder  107  and  111 , returning the pistons to their original un-pressurized state and ready for the next pressure cycle. 
     With reference to  FIG.  9   , shown is a diagram or schematic representation of another embodiment of the pneumatic and hydraulic circuit  100   b  for another embodiment of device  100 ′. Device  100 ′ has a similar structure with device  100  that is illustrated in  FIGS.  1 ,  5 ,  6 , and  7   . The device  100 ′ however has a single stage intensifier device that includes pneumatic cylinder  108 ′ and hydraulic cylinder  111 ′, which are shown in the pneumatic and hydraulic circuit  100   b.  The schematic is of a single stage device that contains but not limited to a gas supply vessel  155 , several hydraulic and pneumatic valves and regulators, pneumatic cylinder  108 ′ coupled to hydraulic cylinder  111 ′, and fluid flow paths to connect all components. Industry standard pneumatic and hydraulic symbols are used to depict the circuit components and one skilled in the art should be able to understand its layout and operation. 
     The device  100 ′ may include two circuits with isolated fluids that transmit pressure to each other through axially coupled pistons contained in cylinders of different diameters; having a pneumatic piston that is in contact with a gas (pneumatic circuit) and being of a larger diameter than the hydraulic piston that is in contact with a fluid (hydraulic circuit) creating a pressure intensifying circuit. The fluids of the circuits do not mix but do transmit pressure and flow to each circuit via the coupled pistons contained in the pressure intensifying cylinders. The intensifier device of the device  100 ′ includes pneumatic piston  109 ′ contained in cylinder  108 ′ that is axially coupled to hydraulic piston  110 ′ contained in cylinder  111 ′. When high pressure gas is applied to the pneumatic piston  109 ′ of the intensifier cylinder an axial force is created and transmitted to the smaller diameter hydraulic piston  110 ′; the force on the hydraulic piston  110 ′ is transmitted into the hydraulic fluid thereby increasing the pressure of the hydraulic fluid in the hydraulic circuit to a higher pressure than the supplied gas pressure of the pneumatic circuit. 
     The diameter of piston  109 ′ being larger than the diameter of piston  110 ′ creates a differential area between the two coupled pistons. The larger the differential area between the two coupled pistons results in a larger pressure intensification ratio of the input to output pressures. A two-to-one (2:1) intensification ratio or area ratio would result in the output hydraulic pressure produced by piston  110 ′ being two times higher than the input gas pressure acting on piston  109 ′. The device intensification ratios can be changed to obtain almost any fluid pressure ratio within system material design strength limitations, allowing it to be tailored to various applications and requirements. 
     The circuit is a bidirectional flow type, meaning that during the pressure cycle pressurized hydraulic fluid flows through the circuit paths in one direction from cylinder  111 ′ to tool cylinder  143  and extends it, when the system is depressurized fluid flows in the opposite or reverse direction using the same paths to empty and retract cylinder  143  while refilling cylinder  111 ′. Cylinder  108 ′ and tool cylinder  143  have internal springs  115 ′,  143   a  that apply a force to help return or retract the pistons and rods to their original positions after extending during the pressure cycle. Detailed circuit design, device operation, pneumatic and hydraulic flow directions and sequences will be provided in the following sections. 
     Pneumatic Circuit 
     The main components of the pneumatic portion of the circuit include a gas supply vessel  155 , pressure regulator  103 , pressure gauge  114 , overpressure safety burst disc  136 , directional control valve  230 , pneumatic cylinder  108 ′ containing piston  109 ′ and spring  115 ′, and a manifold (not shown) with internal fluid communication passages. The manifold provides a mounting surface or cavity for all the pneumatic circuit components and provides fluid communication between all the components and the pneumatic cylinder. 
     Gas supply vessel  155  is a high pressure storage vessel that contains and supplies high pressure compressed gas to the pneumatic circuit. The gas contained in storage vessel  155  could be of any suitable gas or air under high pressure and could be in a gaseous or liquid state (e.g., liquid CO 2 ). When the gas pressure in vessel  155  falls below a usable pressure it can easily be refilled or replaced with a spare vessel at full pressure. A pressure gauge  114  is mounted between gas vessel  155  and pressure regulator  103  that allows the user to see the current gas pressure in vessel  155 . Pressure regulator  103  allows adjustment of the system pressure by reducing the high pressure supply gas contained in vessel  155  to the lower system operating pressure. Vessel  155  and regulator  103  could be of novel design or similar in design as ones currently used with recreational paintball guns. Pressure regulator  103  is equipped with a safety burst disc  136  that protects vessel  155  from being over pressurized; over pressurization could happen if the vessel was full and left in a high heat environment for extended periods. 
     A directional control valve  230  is plumbed downstream of regulator  103 . Directional control valve  230  is a two position spring returned manual or electrically actuated valve, which supplies and vents pressurized gas to cylinder  108 ′. Control valve  230  has a two position internal port connection configuration with a first position having pressure port  230 P and port  230 R blocked and the cylinder ports  230 A and  230 B connected; and a second position with port  230 P connected to port  230 A, and the port  230 R connected to port  230 B. In  FIG.  9   , the left box of the control valve  230  represents the first position and the right box of the control valve  230  (with parallel arrows) represents the second position. Valve port  230 R is externally blocked as it is not needed and port  230 B has muffler  139  externally mounted to it. Control valve  230  is shifted to its second position when the user presses a trigger (leaver or button)  141  on the control handgrip  140  connected to actuator  131 . 
     Control valve  230  would most likely be of a two position “spool” design with internal port connections that depend on spool design and the spools current position within the valve body. The internal port connections of valve  230  are shown in their “normal” or first positions in  FIG.  9   . When valve  230  is in its first position, gas pressure to the system is blocked or not allowed, and cylinder  108 ′ is vented to atmosphere. When valve  230  is in the second position, gas is allowed to flow to cylinder  108 ′. Muffler  139  connected to port  230 A reduces or suppress the sound of venting high pressure gas exiting from cylinder  108 ′ when valve  230  is shifted back to its normal position and piston  109 ′ is retracting. Control valve  230  may have alternate internal port connections and flow paths than illustrated in  FIG.  9    and could be a two, three or four position valve if additional circuit flow paths are needed to operate device  100 ′ as intended. 
     Hydraulic Circuit 
     The main components of the hydraulic portion of the circuit are the hydraulic cylinder  111 ′ containing piston  110 , safety relief valve  134 , accumulator check valve  133 , accumulator  135 , and tool cylinder  143 . Hydraulic cylinder  111 ′ contains hydraulic piston  110  that is axially coupled with the pneumatic piston  109 ′. Increasing the pressure intensification ratio of a cylinder reduces its output fluid volume delivered to the hydraulic circuit per piston stroke. Piston  110 ′ diameter and cylinder stroke need to be sized correctly to deliver a high enough pressure with sufficient fluid volume to fully extend tool cylinder  143 . The exact sizing of the intensifier cylinder will be tailored to the needs of the specific pressure and fluid volume required by the tool cylinder for the given application. 
     When pressurized gas is supplied to cylinder  108 ′, an axial force is transmitted from pneumatic piston  109 ′ to hydraulic piston  110 ′; this force is converted into fluid pressure in the hydraulic circuit which is equal to the force applied times the area of the hydraulic piston. As an example if an application needed 10,000 psi delivered to the tool cylinder and 800 psi gas pressure was available a pressure intensification ratio of 12.5:1 would be needed. 
     Downstream of cylinder  111 ′, the hydraulic circuit has a relief valve  134  and a check valve  133  plumbed in parallel between accumulator  135  and tool cylinder  143 . Relief valve  134  is a safety device that relieves hydraulic fluid to accumulator  135  in case of an overpressure event in the hydraulic circuit. Check valve  133  is plumbed in parallel with relief valve  135  blocking high pressure hydraulic fluid from entering accumulator  135  during the pressure cycle. After the pressure cycle is over and system pressure drops check valve  133  opens and allows any relieved fluid to escape from accumulator  135  back to the hydraulic circuit returning to cylinder  111 ′ for the next pressure cycle. 
     Accumulator  135  is a multifunctional storage vessel, holding an extra volume of fluid in case of small leakages from fittings and the rod seals of the tool cylinder  143  and storing any fluid that has to be relieved by valve  134 . If the system runs low on fluid from external leakage, accumulator  135  will replace the lost fluid with some of its stored reserve fluid. In the event that all the extra fluid is exhausted from accumulator  135 , it can be partially refilled to a specified volume, while conserving some empty space or volume for the relief valve  134  to function properly. Accumulator  135  could be designed as an open (e.g. vented to atmosphere) or closed gas charged (e.g., not vented to atmosphere) fluid storage device, and could have an internal elastic bladder or a ridged piston partition that separates the gas from the stored fluid. If not vented, one side of the internal partition would be charged with a low pressure gas and the side of the partition connected to the hydraulic circuit would be filled with hydraulic fluid. This would allow the system to be closed and used under water. If the accumulator is a vented design it would most likely have a piston partition with a spring on the vented side of the partition and hydraulic fluid on the side connected with the hydraulic circuit. Accumulator  135  would also serve as a place to hold and blead trapped air from the hydraulic circuit during system fluid charging. If it is found that the functions of a partitioned accumulator are not needed by the hydraulic circuit, accumulator  135  could be replaced with a single chamber light weight vented reservoir. 
     Tool cylinder  143  is a single acting spring return design having an internal spring  143   a  on the rod end of the cylinder that applies a force to retract the piston and rod when not under pressure. When the user releases the trigger  141  and the gas control valve  230  vents pressure from cylinder  108 ′, hydraulic pressure reduces and the spring force retracts cylinder  143 ; this forces the fluid that extended cylinder  143  to reverse its flow back to the hydraulic circuit, returning fluid to intensifier cylinder  111 ′ for the next cycle. 
     Additional Control valves could be added or removed from the hydraulic and pneumatic circuits if needed to improve performance. Modifying the pneumatic and hydraulic components and circuits to improve the device performance will not change the system&#39;s intended use or purpose, or the novelty and design intent of the embodied device. 
     Tool Cylinder Extend/Pressure Cycle Sequence Of Operations 
     When the user shifts valve  230  to its second position connecting port  230 P to port  230 A, pressurized gas is allowed to flow from pressure vessel  155  through pressure regulator  103  to intensifier cylinder  108 ′ which applies a force to piston  111 ′ that delivers up to 10,000 psi hydraulic fluid to cylinder  143 . The hydraulic pressure supplied to cylinder  143  is maintained as long as the user has the trigger  141  depressed and control valve  230  is shifted to its second position. When valve  230  is allowed to return to its first position, the high pressure gas that was acting on piston  109 ′ is allowed to vent to atmosphere though muffler  139  by connecting ports  230 A to  230 B, and hydraulic fluid pressure starts dropping in the circuit. As system pressure drops below the pressure produced by the cylinder spring forces of the intensifier piston and tool cylinder  143 , they begin retracting, allowing hydraulic fluid to reverse its flow from tool cylinder  143  back to cylinder  111 ′, returning the pistons to their original un-pressurized state and ready for the next pressure cycle. 
     Since many modifications, variations, and changes in detail can be made to the described preferred embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Consequently, the scope of the invention should be determined by the appended claims and their legal equivalents.