Patent Publication Number: US-2009229591-A1

Title: Pressure Regulator for Non-Lethal Projectile Launcher

Description:
RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Application Ser. Nos. 61/029,146 for a “Paintball Gun Adapter With Sliding On/Off Valve and Venting,” 61/029,116 for a “Direct Mount Pressure Regulator With Sliding On/Off Valve,” and 61/029,104 for a “Direct Mount Adjustable Pressure Regulator” all filed Feb. 15, 2008, the entire disclosures of which are hereby incorporated by reference. 
    
    
     TECHNICAL FIELD 
     The present invention generally relates to an apparatus for launching projectiles. In particular, the invention relates to a pressure regulator for use with a projectile launcher. 
     BACKGROUND 
     Marking guns (commonly known as paintball guns or paintball markers) typically use compressed gas to propel frangible projectiles that break upon impact. These types of devices have a wide variety of applications. For example, a popular recreational use is in paintball games, in which opposing sides attempt to seek out and “shoot” one another with paintballs. Frangible projectiles have also been used to segregate cattle within a herd. Likewise, law enforcement personnel employ frangible projectiles with immobilizing materials for crowd control. 
     The compress gas used to propel the projectiles is typically stored in tanks or canisters. Although a high pressure gas is needed power these type of devices and propel projectiles, the pressure in the tank is usually much greater than the pressure needed to propel projectiles. As such, it is necessary to regulate the pressure of the compressed gas while allowing the projectile to be fired at a constant velocity. 
     Pressure regulators that reduce or cut off inlet flow of gas when the outlet pressure starts to exceed a predetermined level and then opens or increases flow when the outlet pressure has been reduced are known in the art. Such regulators generally include a pressure sensing actuator responsive to excess inlet pressure which closes the valve member. In this arrangement increasing gas pressure compresses the spring to force the valve member towards a valve seat. As the valve member approaches the valve seat, gas flow through the regulator becomes more restricted. When the defined pressure level is reached, the valve member contacts the valve seat to cut off flow. When the output pressure drops below the defined pressure, the valve member moves away from the valve seat and flow increases. This cycle is repeated to maintain desired outlet pressure. 
     The most popular regulator used with paintball guns is a direct mount type, where the outlet port is configured to be attached through a threaded ASA connection with the paintball gun adapter. This type of design causes challenges in providing outlet pressure adjustment since the spring adjustment end is placed inside the regulator body without any external access. These types of pressure regulators are being used in the paintball industry with a preset only for a specific outlet pressure valve. Since different paintball guns have a wide variety of different working pressures, there exists a need for a variable pressure regulator that allows for continuous adjustment of outlet pressure without taking apart the regulator components. 
     A disadvantage of this type of connection is that an opening for gas flow is provided before the regulator is fully secured and received into the adapter. As soon as a slight channel for gas flow is provided, gas exerts pressure and therefore resistance between the components. More specifically, opposing forces are exerted on the face of the regulator and on the internal surface of the adapter. In the case of gas pressure of 850 psi, the force on a given component can be as much as 320 lbs. After the gas flow this small channel is first created, additional turns are needed for the check valve to be fully open and, therefore, provide a proper full-flow channel to power the paintball gun. Those few additional turns under pressure have adverse effect on the microfinish of the thread surface. Frequent mounting and unmounting cycles lead to a distortion of the threads to the point of a friction welding phenomenon, especially when both connecting parts are made of aluminum, Utilization of aluminum as a choice of material is due to a light weight which is an important factor for paintball players. 
     The above described disadvantages can lead to catastrophic consequences ending in a violent disassembly of the main parts of the regulator. Since the regulator piston housing becomes friction welded to the adapter at the threaded connection, the two main parts of the regulator (i.e., piston housing and main body) can he inadvertently disassembled when the untrained user continues forcing the process of unscrewing. 
     SUMMARY 
     According to one aspect, the invention provides a gas pressure regulator that employs a user-friendly On/Off valve which permits or stops gas flow to the outlet port of the regulator and vents the remaining gas from the outlet port in the OFF position. In some embodiments, an existing piston housing is utilized as a spool valve and an extra sleeve is used to turn the valve on and off. When the sleeve is in the off position, the regulator gas flow from the piston chamber is blocked and the gas outlet is vented to atmosphere. When the sleeve is in the on position, gas communication between piston chamber and outlet is open and at the same time the venting passageway is closed. 
     According to another aspect, the invention provides a direct mount pressure regulator. Embodiments are contemplated in which the regulator includes a main body with high pressure inlet, a piston housing, a regulator valve and a check valve pin which permits removal of the regulator from the ASA adapter without loss of gas. A piston may be disposed within the regulator housing and movable between an open regulator condition and closed regulator condition. Typically, a spring urges the regulator piston to the open regulator condition and is located on the outside portion of the piston. In some embodiments, the regulator&#39;s outlet pressure may be adjusted with a threaded ring placed between the wall of the regulator body and the regulator spring. Several cavities may be provided on the outside cylindrical surface of the ring for the rod insertion to rotate the ring which will change position along a symmetrical line of the regulator through threaded connection. An opening in the regulator body is disposed to provide access for the rod to communicate with the ring cavities for the pressure adjustment. 
     According to a further aspect, invention provides an adapter assembly disposed between the regulator and the a projectile launcher, such as a paintball marker, and is equipped with a user friendly on/off valve which permits or stops gas flow to the paintball gun and vents the remaining gas from the gun in the OFF position. In some embodiments, the adapter assembly includes an adapter housing having a female socket for receiving a threaded portion of the pressure regulator and a male head for engaging with the paintball marker. The male head can include means for threadedly engaging with the paintball marker or any other means for sealed connection. A sliding ring or a spool type of actuator is provided to turn the gas on and off, and vent the remaining gas from the paintball marker in off position. 
     Additional features and advantages of the invention will become apparent to those skilled in the art upon consideration of the following detailed description of the illustrated embodiment exemplifying the best mode of carrying out the invention as presently perceived. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
       The present disclosure will be described hereinafter with reference to the attached drawings which are given as non-limiting examples only, in which: 
         FIG. 1  is a side elevation view of the prior art regulator with pressure tank and the paintball gun grip illustrating a damaged (friction welded) thread on the regulator-adapter connection in partial cross section which resulted in disassembly of the main parts of the regulator. 
         FIG. 2  is a partial cross-sectional view of the regulator-gun connection used in prior art in the position when the check valve pin is about to be activated by the extending element of the adapter. 
         FIG. 3  is a partial cross-sectional view of the regulator-gun connection used in prior art in the position when the check valve pin is pushed open in the initial stage creating a slight opening. 
         FIG. 4  is a partial cross-sectional view of the regulator-gun connection used in prior art in the position when the check valve pin is fully opened. 
         FIG. 5  is a cross-sectional view of the adapter according to present invention with sliding on/off valve shown in off position. 
         FIG. 6  is a partial cross-sectional view of the adapter with sliding on/off valve in on position. 
         FIG. 7  is a cross-sectional view of the alternative embodiment of the adapter with spool-socket type on/off valve shown in on position. 
         FIG. 8  is a cross-sectional view of the alternative embodiment of the adapter with spool-socket type on/off valve shown in off position. 
         FIG. 9  is a side elevation view of a paintball gun system partly in section to reveal internal details and showing regulator-gun adapter combination in which the adapter includes on/off mechanism according to an embodiment of the present invention. 
         FIG. 10  is a cross-sectional view of the direct mount adjustable pressure regulator according to an embodiment of the present invention shown in closed condition. 
         FIG. 11  is a partial cross-sectional view of the regulator valve shown in  FIG. 10  in open condition. 
         FIG. 12  is a partial cross-sectional view of the regulator adjustment mechanism and it shows the amount of adjustment in relation to  FIG. 10 . 
         FIG. 13  is a horizontal cross-sectional view taken generally along the plane  5 - 5  in  FIG. 12 . 
         FIG. 14  is a partial side elevation view of the regulator shown in  FIG. 10 , illustrating the adjusting ring with cavities seen through the regulator body opening. 
         FIG. 15  is a partial cross-sectional view of the regulator-adapter connection used in prior art in the position when the check valve pin is about to be activated by the extending element of the adapter. 
         FIG. 16  is a partial cross-sectional view of the regulator-adapter connection used in prior art in the position when the check valve pin is pushed open in the initial stage creating a slight opening. 
         FIG. 17  is a cross-sectional view of the regulator according to an embodiment of the present invention with on/off valve shown in off position and check valve pin fully opened. The ASA adapter with the extending pin is not shown. 
         FIG. 18  is a partial cross-sectional view of the regulator with on/off valve in on position. 
         FIG. 19  is a partial cross-sectional view of the regulator with additional gas filling the passageway and a filter. 
         FIG. 20  is a partial cross-sectional view of the regulator plug chamber and shows regulator valve in open position. 
         FIG. 21  is a partial cross section of the alternative embodiment of the on/off valve activating mechanism and shows thread engagement of the valve sleeve with piston housing. 
         FIG. 22  is a side elevation view of the prior art regulator with pressure tank and the paintball gun adapter illustrating a damaged (welded) thread on the regulator-adapter connection in partial cross section which resulted in disassembly of the main parts of the regulator. 
         FIG. 23  is a side elevation view of a paintball gun system partly in section to reveal internal details and showing a regulator-gun adapter combination in which the regulator includes an on/off mechanism according to the present invention. 
     
    
    
     Corresponding reference characters indicate corresponding parts throughout the several views. Components in the Figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. The exemplification set out herein illustrates embodiments of the invention, and such exemplification is not meant to be construed as limiting the scope of the invention in any manner. 
     DETAILED DESCRIPTION OF THE DRAWINGS 
     The configuration presented in  FIG. 1  relates to prior art arrangements where the threaded ASA connection between the regulator  10  and gun  11  is damaged which ultimately leads to violent disassembly of the piston housing  12  from the regulator body  13  which is coupled with the tank  14 . 
     Referring to the  FIG. 1 , a prior art regulator-gun connection is shown with piston housing  12  and gun body  11 . Check valve  15  blocks the gas opening between the regulator  10  and the gun  11 . As shown in  FIG. 3 , additional continuation of screwing the regulator  10  into the gun  11  will result in engagement of the extending pin  16  with the check valve pin  15 , resulting in slight opening L 1  which is not sufficient to power the paintball gun at this time. 
     With reference now to  FIG. 4 , the length of opening L 2  provides sufficient flow rate to power the gun. The distance L 2  was achieved by screwing the regulator into the gun under pressure causing the thread connection to be prone to damage. In a preferred embodiment, adapter  20  is equipped with ON/OFF valve. A sliding ring  22  is placed around the adapter housing  21  and has two working positions.  FIG. 5  represents ON/OFF valve in OFF position where gas passageway  25  is blocked by O-ring  23  and  24 . Any gas residue in outlet port is vented as indicated by directional line  26 . A fragmentary cross-sectional view of the ON/OFF valve in ON position is provided in  FIG. 6 . Directional line  25  shows the gas pathway from inlet port to outlet port.  FIG. 7  shows alternative embodiment of the adapter in OFF position. A spool  30  is placed in cylindrical surface of the adapter housing  31 . Gas passageway from inlet port is blocked by O-rings  32  and  33 . Remaining gas from outlet port is vented to atmosphere through passageway  35 . Adapter  20  includes inlet side cavities  42  for communication with a plurality of radial passageways  44  distributed circumferentially around housing  21 . A retaining ring  46  is preferably secured around housing  21  between sliding ring  22  and the distal mounting threaded portion  48 . Retaining ring  46  is received in a circumferential groove  52  on housing  21 . Housing  21  farther includes a second set of radial passageways  54  distributed circumferentially around housing  21 . 
     As seen in  FIG. 8 , the ON/OFF valve is in the ON position and gas passageway  36  represents gas pathway from inlet port to outlet port. O-rings  33  and  34  prevent gas from escaping to the atmosphere. 
       FIG. 9  shows a gun system aspect of the present invention which includes a gun  50 , pressurized gas tank  60 , pressure regulator  65 , and adapter  20  according to present invention. Fill nipple  70  includes a check valve (not shown) and is used to fill the tank with compressed gas. 
       FIGS. 10-14  illustrate a regulator according to an alternative embodiment. Referring now to  FIG. 10 , a regulator  110  is shown which generally includes a main body  112 , a piston housing  114 , piston  116 , and a regulator valve comprised mainly of valve seat  132  and valve plug  130 . The body  112  and piston housing  114  threadedly engage one another to seal the regulator  110  as a unit. A spring  118  is disposed around the piston  116  and between the body  112  and a wall of the piston to bias regulator piston to an open condition. A check valve pin  140  located in the outlet port  150  provides a sealable flow path from regulator  110  to the paintball gun (not shown). Spring  142  is utilized to bias the check valve pin  140  to closed position. Pin  140  permits removing the regulator  110  from the paintball gun without loss of compressed gas. Gas flows into the regulator  110  and tank  170  through inlet port  160  and passageways  162  and  164 . Unitary with the valve body  116  is a coupling portion  166  extending away from the base  115 . As illustrated, the source of compressed gas is typically a tank  170  coupled with regulator  110  through threaded connection  168  and sealing member  169 . The inlet port  165  opens into plug chamber  134 . A seat  132  defines the entry into the plug chamber  134 . The plug chamber  134  is configured to accommodate a plug valve  130  of the piston  116 . The plug valve  130  is placed on the end of piston  116  and serves as a seal when seated on the valve seat  132 . When plug valve  130  is positioned away from seat  132 , gas enters piston chamber  138  through passageways  139  and  136 . In this type of arrangement increasing gas pressure compresses the spring  116  to force valve plug  130  towards a valve seat  132 . When the defined pressure level is reached, further flow restriction is stopped when valve plug  130  contacts the valve seat  132  as shown in  FIG. 10 . When the output pressure drops below the defined level, the valve plug  130  along with the piston  116  moves away from the seat  132  to permit gas flow to the piston chamber  138  and subsequently to the outlet port  150  as shown in  FIG. 11 . This cycle is repeated as to maintain desired outlet pressure required by the user. Plug chamber  134  is sealed with an O-ring  144  and piston chamber  138  with an O-ring  146 . 
     According to the one embodiment, adjusting ring  152  is provided with several cavities  141 , placed on the outside cylindrical wall of the ring  152 . Outside surface of the ring  152  is threadedly coupled with the regulator body  112 . In order to make a gas pressure adjustment, a rod  180  is placed into the cavity  141  through the regulator body opening  148 , as illustrated in  FIG. 11 , and then rotated in desired direction until it touches the edge  143  of the opening  148 , as shown in  FIG. 13 . Rod  180  is then pulled from the adjustment ring cavity  141  and placed into another cavity located on the opposite edge  147  of the regulator body opening  148 . The cycle is repeated over and over until desired pressure level is reached. The sector L in  FIG. 12  represents the distance the adjusting ring  152  traveled along the symmetrical line of the regulator due to a screw-nut coupling phenomenon known in prior art. The angle adjustment A between regulator body opening shown as surface  143  and  147  in  FIG. 13  should be equal or greater than angle B, the angular space between adjusting ring cavities  141 . O-ring  154  placed on outside diameter of the adjustment ring  152  prevents dirt particles from entering the regulator&#39;s internals and also serves as a locking device preventing adjusting ring from self-rotating during the regulator operations.  FIG. 14  is a side elevation view of the regulator  110 , illustrating adjusting ring  152  with cavities  141  placed in the regulator body  112  and seen through the regulator body opening  148 . 
       FIGS. 15-23  illustrate a regulator according to an alternative embodiment. Referring to the  FIG. 15 , a prior art regulator-adapter connection is shown with piston housing  212  and adapter body  270 . Check valve pin  230  blocks the opening between piston chamber  250  to the outlet port  256 , since the mounting process is not completed as the extending pin  272  is not engaged with the check valve pin  230 . O-ring  236  with land  274  seals gas from escaping to the atmosphere. Spring  232  is used to bias check valve pin  230  to a closed position. 
     As shown in  FIG. 16 , additional continuation of screwing the regulator  215  into the adapter  220  will result in engagement of the extending pin  272  with the check valve pin  230  resulting in slight opening L 1  permitting gas flow to the paintball gun. The gas flow rate at opening L 1  is not sufficient to power the paintball gun at this time. With reference now to  FIG. 17 , the check valve pin  230  is fully opened by the extending pin  272  (not shown). The length of the opening L 2  provides sufficient flow rate to power the gun. The distance L 2  was achieved by screwing the regulator into the adapter under pressure causing thread connection to be prone to damage. 
     The regulator  210  includes generally a main body  211 , piston housing  214 , piston  216 , and piston spring  218 . Regulator body  211  and piston housing  214  threadedly engage with one another with thread connection  217  as a two main structural components of the regulator. Coupling portion  228  extends away from valve body  211  and is adapted for sealed connection to a gas source. Fill port  232  includes a check valve (not shown) to seal pressurized gas from escaping from the tank and communicates through the passageway  233  and  234  with the tank. Inlet opening  234  communicates with the tank (not shown) and the plug chamber  222 . A piston chamber  250  is defined within the sealed piston housing  214  and the piston  216  with an O-ring  248 . The spring  218  is disposed between the piston  216  and the main body  211 . The plug chamber  222  is configured to accommodate a valve plug  224  mounted on the piston  216  and serves as a sealing disc with valve seat  220 . The plug  224  can be formed from a resilient material, such as KLF or urethane, to provide a tight seal when the plug  224  is seated on the seat  220 , as shown in  FIG. 17 . O-ring  226  is positioned on the piston  216  and defines plug chamber  222  along with piston  216  and cylindrical wall  236 . 
     In a preferred embodiment, regulator  210  is equipped with ON/OFF valve for selectively blocking the flow of the regulated gas from piston chamber  250  to the outlet chamber  260  and at the same time venting gas from the output port  256  to the atmosphere when the valve is in OFF position. As shown in  FIG. 17  and  FIG. 18 , sliding valve ring  240  with knurled gripping surface  241  is placed around piston housing  214  and has two working positions.  FIG. 17  shows sliding valve ring in OFF position, where gas from piston chamber  250  enters valve chamber  252  through passageway  258 . Valve chamber  252  is sealed by O-rings  242  and  244 . Gas from outlet port  256  is being vented through the passageway  259 . 
     A fragmentary cross-sectional view of the ON/OFF valve in ON position is provided in  FIG. 18 . According to  FIG. 18 , regulated gas from piston chamber  250  enters valve chamber  252  through the gas passageway  258  and then through passageway  259  to the outlet chamber  260  and ultimately to outlet port  256  through passageway  257 , as shown in  FIG. 17 . Snap ring  264  prevents the valve ring  240  from sliding off the piston housing  214 . 
     With reference now to  FIG. 19 , a second passageway  239  is provided for compressed gas to enter the tank  271  (see  FIG. 23 ). Extending between fill port  232  and inlet opening  241  first, flow passageway  234  connects discharge opening  235  and plug chamber  222  and is preferably equipped with contoured mesh filter  243 . Filter  243  prevents particles and other gas impurities from entering and fouling the regulator valve mechanism. Hollow socket set screw  237  secures filter  243  inside passageway  234 . 
       FIG. 20  shows the regulator valve in open position with the gap present between the valve plug  224  and valve seat  220  creating a gas path  225  from inlet opening  234  to the central bore  235  of the regulator piston  226  which connects with piston chamber  250 . The piston chamber  250  comprises an impingement surface  255  against which the (pressure) regulated gas exerts a force for moving the piston  226  against the force of the spring  218 . When the force generated by the compressed gas offsets the force of the spring  218 , regulator valve is closed. Different spring compressions will result in different outlet pressures. When the outlet pressure drops below the desired level, the resilient force of the spring moves the piston  226  with the valve plug  224  away from the seat  220  and gas flow into the piston chamber  250  increases. 
     An alternative method of turning the valve ON and OFF is present in  FIG. 21  where the valve sleeve  340  is threadedly engaged with piston housing  314 . Turning valve ON or OFF is done by rotating the valve sleeve  340  clockwise (CW) or counter clockwise (CCW). 
     The configuration presented in  FIG. 22  relates to prior art arrangement where the thread connection between the ASA adapter  220  and regulator  215  is damaged which ultimately leads to violent disassembly of the piston housing  214  from the regulator body  211  which is coupled with the tank  300 . 
     Although the present disclosure has been described with reference to particular means, materials, and embodiments, from the foregoing description, one skilled in the art can easily ascertain the essential characteristics of the present disclosure and various changes and modifications may be made to adapt the various uses and characteristics without departing from the scope and spirit of the present invention as set forth in the following claims.