Patent Description:
Current airsoft projectile launching systems (as well as non-airsoft systems) include pneumatic and spring power sources. Existing designs suffer from deficiencies that affect accuracy, usability and/or durability.

For example, current spring-powered launching systems use a compressed spring to drive a piston longitudinally within a cylinder, compressing air in front of the piston. As the air is compressed it is directed behind the projectile to launch the projectile from a barrel. The spring may be compressed by human power or by an electric motor. Due to the stresses applied by the compressed spring, these types of systems are prone to mechanical failure. Pneumatic launching systems exist but still suffer from shortcomings in performance and usability as well as limitations in compatibility with equipment that is common in the sport of airsoft.

There is therefore a need for improved projectile launching systems.

An example of a pneumatic assembly for a paintball gun is described in <CIT>, which preferably includes a bolt slidably arranged on a valve stem. <CIT> relates to a shooting structure of a paint bullet gun. The paint bullet gun includes a main body and a handle. <CIT> relates to a structure of a paintball gun.

In at least one aspect of the invention a pneumatically operated projectile launching system according to claim <NUM>, including a pneumatic assembly and a means of actuating the fluid control valve contained within the pneumatic assembly is provided. The fluid control valve is preferably a solenoid valve, actuated electrically by signals received from an electronic control unit, however, electronic control is not necessary for operation of the system and the fluid control valve may also be actuated mechanically or pneumatically.

In operation, a constant supply of compressed gas is supplied to the input port of the pneumatic assembly. When the system is idle, this compressed gas fills a firing chamber surrounding the nozzle section and biases the nozzle in the rearward position. The fluid control valve is a "<NUM> -way" normally closed (NC) poppet or spool valve which prevents the flow of gas from the input port of the valve until it is actuated. When the valve is actuated the input port is in fluid communication with the first output port, allowing gas to flow between them. When the valve is idle the first output port is in fluid communication with the second output port, which in turn is in fluid communication with the atmosphere. The input port of the solenoid is in constant fluid communication with the input port of the pneumatic assembly through a flow control port in the rear cylinder. The size of the flow control port allows the velocity of the nozzle to be limited without reducing the force applied to the nozzle. While the nozzle is in the rearward position, gas flow through the nozzle is prevented by a seal between the nozzle and the secondary valve body. The nozzle is configured for fluid actuation to a forward position by gas flow through the fluid control valve acting upon the rear face of the nozzle. When the system is firing, a fluid control valve directs compressed gas from the firing chamber to the rear surface of the nozzle. As the rear surface area of the nozzle is greater than the front surface area, the nozzle is actuated to the forward position to chamber a projectile. When the nozzle reaches the full forward position it travels beyond the sealing surface of the secondary valve body, allowing compressed gas to flow through a series of radial ports in the nozzle, then through the bore of the nozzle and launch the projectile. Compressed gas will continue to flow through the nozzle until the fluid control valve is deactivated, allowing the nozzle to return to the rearward position.

Various aspects of the invention are designed for use in conventional airsoft guns bodies. Breech, barrel and magazine are provided by the gun body in which one aspect of the invention is installed. The trigger may be part of the launching system or part of the gun body. Some aspects make use of the existing AEG (Automatic Electric Gun) gearbox housing as a host to adapt the launching system to existing airsoft gun bodies; other aspects can be manufactured as standalone systems which may be installed in place of the original AEG gearbox. Additionally, other aspects can be manufactured as an integral component of an airsoft gun.

In other aspects of the invention a pneumatic assembly for a projectile launching system includes a body defining a continuous bore from a substantially open forward end of the body to a substantially closed rearward end of the body; a nozzle positioned within the bore adjacent the forward end of the body, the nozzle moveable between a rearward position wherein the nozzle facilitates passage of a projectile through a projectile port and a forward position wherein a projectile is fired and nozzle blocks the projectile port to prevent passage of an additional projectile therethrough; and a fluid control valve, actuatable between a first position that facilitates passage of fluid from an input port to a rear of the nozzle and a second position that prevents passage of fluid from an input port to the rear of the nozzle while also allowing passage of fluid from the rear of the nozzle to atmosphere.

In other aspects the pneumatic assembly further includes a nozzle stem, upon which the nozzle seals and through which fluid can flow between the nozzle fluid chamber and the fluid control valve.

In other aspects of the invention, the nozzle includes a forward radial seal and a rear radial seal, the radial seals extending from a sail at the rear of the nozzle and separated by one or more radial ports, the forward radial seal biasing the nozzle in the rearward position while also preventing the flow of fluid from a firing chamber through the one or more radial ports until the nozzle has traveled a specific distance in the forward direction, the rear radial seal and seal on the nozzle stem creating a nozzle fluid chamber to receive fluid from a fluid control valve.

In other aspects the pneumatic assembly further comprises a secondary valve body including a bore into which the nozzle stem extends and within which the nozzle linearly moves, said bore for providing an internal passage for fluid between the firing chamber and an input port.

In other aspects the pneumatic assembly further comprises a means for actuating the fluid control valve. In other aspect the means for actuating the fluid control valve comprises a solenoid valve actuatable by signals received from an electronic control unit.

In other aspects the fluid control valve of the pneumatic assembly is a poppet or spool valve in a normally closed position.

In other aspects the rear surface area of the nozzle of the pneumatic assembly is greater than a front surface area of the nozzle.

For a better understanding of the invention, and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which:.

In the drawings, like numerals indicate like elements throughout. Although the invention is illustrated and described herein with reference to specific aspects, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope of the claims and without departing from the invention. The invention is described below with reference to a compressed gas, however, it is understood that the compressed gas may be any fluid as known to those skilled in the art or which may become discovered by those skilled in the art.

Referring to the figures, the pneumatic assembly <NUM> may be utilized with a breech <NUM>, a hop-up chamber or the like as known in the art. The breech <NUM> may be positioned adjacent an open end <NUM> of the pneumatic assembly <NUM> such that a bore therethrough is coaxial with a nozzle <NUM> of the pneumatic assembly <NUM>. The breech <NUM> includes a projectile port <NUM> which supplies projectiles <NUM>, for example, from a hopper, magazine or the like as is known in the art.

Referring to <FIG> and <FIG>, the exemplary pneumatic assembly <NUM> includes a front cylinder <NUM> and a rear cylinder <NUM> joined longitudinally to house the components of the assembly. An o-ring <NUM> forms a seal at the joint between the front cylinder <NUM> and the rear cylinder <NUM>. The front cylinder <NUM> defines a series of bores <NUM>, <NUM> of varying sizes. The bores <NUM>, <NUM> are concentric in the figures, however, they may also be eccentric. The shoulder <NUM> formed by the forward bores <NUM>,<NUM> of the front cylinder <NUM> acts as a stop to limit the forward travel of the nozzle <NUM>. Referring to <FIG>, the rear cylinder <NUM> defines a series of concentric bores <NUM>,<NUM>,<NUM> of varying sizes. A middle bore <NUM> in the rear cylinder <NUM> intersects with the bore of the input port <NUM> allowing compressed gas to flow into the rear cylinder <NUM>.

Referring to <FIG>, <FIG> and <FIG>, a tubular secondary valve body <NUM> may be retained in the bore <NUM> of the rear cylinder <NUM>. The secondary valve body <NUM> defines a series of concentric bores <NUM>, <NUM>. The shoulder <NUM> formed by the bores <NUM>, <NUM> acts as a stop to limit the rearward travel of the nozzle <NUM>. An o-ring <NUM> in the bore <NUM> acts as a crush washer and seal between the secondary valve body <NUM> and the front cylinder <NUM>. A forward tubular protrusion <NUM> of the valve body <NUM> extends into the rearmost bore <NUM> of the front cylinder <NUM>. The outside diameter of the forward protrusion <NUM> may be less than the inside diameter of the bore <NUM> of the front cylinder <NUM> and the length of the protrusion <NUM> may be less than the depth of the bore <NUM> of the front cylinder <NUM> such that a compressed gas passage <NUM> is formed between the secondary valve body <NUM> and the front cylinder <NUM>. A series of ports <NUM> located radially around the secondary valve body <NUM> place the bores <NUM>,<NUM>,<NUM> of the rear cylinder <NUM> in constant fluid communication with the gas passage <NUM> between the secondary valve body <NUM> and the front cylinder <NUM>.

Referring to <FIG>, a cylindrical nozzle stem <NUM> extends into the bores <NUM>,<NUM> of the valve body <NUM> and may be retained against the rear face <NUM> of the secondary valve body <NUM>. The nozzle stem <NUM> may be defined by two or more diameters <NUM>,<NUM>, the forward diameter being smaller than the rear diameter. The shoulder <NUM> formed by the two diameters <NUM>,<NUM> acts as a stop to locate the nozzle stem <NUM> within the secondary valve body <NUM>. A bore <NUM> in the nozzle stem <NUM> places the rear face <NUM> of the nozzle stem <NUM> in fluid communication with one or more radial ports <NUM> in the forward diameter <NUM> of the nozzle stem <NUM>. The ports <NUM> are located longitudinally along the nozzle stem <NUM> such that when the nozzle stem <NUM> may be retained against the rear face <NUM> of the secondary valve body <NUM>, the ports <NUM> are within the internal bores <NUM>,<NUM> of the valve body. An o-ring <NUM> may be located at the base of the forward diameter <NUM> of the nozzle stem <NUM> and seals on the inside of a bore <NUM> in the rear face <NUM> of the secondary valve body <NUM>. An external groove in the rear diameter <NUM> of the nozzle stem <NUM> receives an o-ring <NUM> and seals on the inside of a rear bore <NUM> of the rear cylinder <NUM>. In other aspects of the invention, the nozzle stem <NUM> may be removed entirely. In this aspect the back of nozzle <NUM> would be closed off. This would result in slightly more compressed air being used.

Referring to <FIG>, the tubular nozzle <NUM> slides in the bores <NUM>,<NUM> of the front cylinder <NUM> and the secondary valve body <NUM>. The tubular nozzle <NUM> also slides on the nozzle stem <NUM>. An internal groove in the nozzle <NUM> receives an o-ring <NUM> and seals on the outside of the forward diameter <NUM> of the nozzle stem <NUM>. A rear sail <NUM> extends radially from the rear of the nozzle <NUM> and two external grooves in the nozzle rear sail <NUM> receive o-rings <NUM>, <NUM> and seal on the inside of the forward bore <NUM> of the secondary valve body <NUM>. A series of radial ports <NUM> are located between the external o-rings <NUM>,<NUM> in the nozzle rear sail <NUM> and extend into the nozzle bore <NUM>. The rear external o-ring <NUM> in the rear sail <NUM> may be located so that it remains sealed within the forward bore <NUM> of the secondary valve body <NUM> at all times. The forward o-ring <NUM> in the nozzle rear sail <NUM> may be located so that it has left the forward bore <NUM> of the secondary valve body <NUM> and is no longer sealing when the nozzle <NUM> has reached the full forward position. Forward of the rear sail <NUM>, a second external groove receives an o-ring <NUM> and seals on the inside of the forward bore <NUM> of the front cylinder <NUM>. This forms a firing chamber <NUM> that can receive and release a volume of compressed gas through the gas passage <NUM> formed by the secondary valve body <NUM> and the front cylinder <NUM>. The firing chamber <NUM> also releases compressed gas through the radial ports <NUM> in the nozzle <NUM> when the nozzle <NUM> is in the full forward position. The seals formed by the rear o-ring <NUM> in the nozzle rear sail <NUM> and the internal o-ring <NUM> of the nozzle <NUM> form a nozzle fluid chamber <NUM> that can receive and release a volume of compressed gas from the valve output port fluid control valve <NUM> through the nozzle stem <NUM> from a gas passage <NUM> in the rear cylinder <NUM>. Those of skill in the art will appreciate that rather than routing air internally from the source of supply to the nozzle sail <NUM>, an external airline may be used that routes compressed gas to the front of the nozzle sail.

Referring to <FIG>, <FIG> and <FIG>, the fluid control valve <NUM> may be secured into a bore <NUM> of the rear cylinder <NUM>. The fluid control valve <NUM> may be a "<NUM>-way" valve. In this particular aspect of the invention, the fluid control valve <NUM> may be a MAC <NUM>-Way Bullet Valve solenoid valve. A solenoid coil <NUM> integral to the Bullet Valve provides the actuating force on the fluid control valve stem <NUM> when power is applied by the electronic control unit <NUM>.

Four external grooves in the fluid control valve <NUM> receive o-rings <NUM>, <NUM>, <NUM>, <NUM> which seal on the inside of the bore <NUM> of the rear cylinder <NUM> and divide the bore <NUM> longitudinally into four isolated sections <NUM>, <NUM>, <NUM>, <NUM>. The forward section <NUM> may be in fluid communication with atmosphere through a vent port <NUM> in the rear cylinder <NUM>, allowing gas in front of the fluid control valve <NUM> to be drawn in from and vented to atmosphere as the fluid control valve stem <NUM> moves. The second section <NUM> places the valve input port <NUM> in constant fluid communication with the input port <NUM> through a flow control port <NUM>. The third section <NUM> places the nozzle fluid chamber <NUM> in constant fluid communication with the valve output port <NUM> through the nozzle stem <NUM> and gas passage <NUM> in the rear cylinder <NUM>. The fourth section <NUM> places the valve exhaust port <NUM> in constant fluid communication with atmosphere.

The fluid control valve <NUM> may be configured to prevent the flow of gas from the valve input port <NUM>, but allow flow between the valve output port <NUM> and the valve exhaust port <NUM>, until the fluid control valve <NUM> is actuated. When the fluid control valve <NUM> is actuated, compressed gas is allowed to flow between valve input port <NUM> and the valve output port <NUM>, which is in constant fluid communication with the nozzle fluid chamber <NUM>. While the fluid control valve <NUM> is actuated, the valve exhaust port <NUM> remains in fluid communication with atmosphere, but isolated from the compressed gas within the pneumatic assembly <NUM>.

The fluid control valve <NUM> and compressed gas passages to and from the fluid control valve <NUM> are located within the rear cylinder <NUM>, however, the fluid control valve may be located separate from the pneumatic assembly <NUM> as well.

A firing sequence will be explained with reference to <FIG>. In <FIG>, the fluid control valve <NUM> is in a default, closed position such that flow between the valve input port <NUM> and the valve output port <NUM> is prevented. Referring to <FIG>, upon actuation of the solenoid coil <NUM>, for example via a trigger (not shown), the valve stem <NUM> may be moved reward as indicated by arrow A and gas is allowed to flow between the valve input port <NUM> and the valve output port <NUM> then into the nozzle fluid chamber <NUM>. The gas contacts the rear of the nozzle <NUM> and pushes the nozzle forward as indicated by arrow B in <FIG>. As the nozzle <NUM> moves sufficiently forward, the forward o-ring <NUM> in the nozzle rear sail <NUM> leaves the forward bore <NUM> of the secondary valve body <NUM> and gas flows through the radial ports <NUM> and out of the nozzle <NUM>, as indicated by arrow C, to fire the projectile <NUM>. Referring to <FIG>, the solenoid coil <NUM> may be deactivated such that the fluid control valve <NUM> returns to its default closed position, as indicated by arrow D. Gas flow between the valve input port <NUM> and valve output port <NUM> is stopped and compressed gas in the nozzle fluid chamber <NUM> is allowed to vent to atmosphere through the fluid control valve <NUM>. As gas pressure has been removed from the rear of the nozzle <NUM>, gas flow through the ports <NUM> will return the nozzle <NUM> to the original position shown in <FIG>. The process may thereafter be repeated.

Referring now to <FIG> another aspect of a pneumatic assembly in accordance with the invention is depicted. Like numerals indicate like elements as in the pneumatic assembly of <FIG>. Bore <NUM> in the nozzle stem <NUM> does not seal on the nozzle stem <NUM>. Rather, the rear face <NUM> of the nozzle stem <NUM> has been plugged <NUM>. As a result fluid communication is directed to the entire rear face <NUM> of the nozzle.

Claim 1:
A pneumatic assembly (<NUM>) for a projectile launching system comprising:
a body (<NUM>, <NUM>) defining a continuous bore (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) from a substantially open forward end of the body to a substantially closed rearward end of the body (<NUM>, <NUM>);
a nozzle (<NUM>) positioned within the bore (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) adjacent the forward end of the body (<NUM>, <NUM>), the nozzle (<NUM>) moveable between a rearward position wherein the nozzle (<NUM>) facilitates passage of a projectile (<NUM>) through a projectile port (<NUM>) and a forward position wherein a projectile (<NUM>) is fired and nozzle (<NUM>) blocks the projectile port (<NUM>) to prevent passage of an additional projectile (<NUM>) therethrough, wherein in the forward position fluid flows through one or more radial ports (<NUM>) in the nozzle (<NUM>) and in the rearward position fluid is prevented from flowing through the one or more radial ports in the nozzle (<NUM>); and
a fluid control valve (<NUM>), actuatable between a first position that facilitates passage of fluid from an input port (<NUM>) to a rear of the nozzle (<NUM>) and a second position that prevents passage of fluid from the input port (<NUM>) to the rear of the nozzle (<NUM>) while also allowing passage of fluid from the rear of the nozzle (<NUM>) to atmosphere; and
a nozzle stem (<NUM>), upon which the nozzle (<NUM>) seals and through which fluid can flow between a nozzle fluid chamber (<NUM>) and the fluid control valve (<NUM>); and
a secondary valve body (<NUM>) including a bore (<NUM>) into which the nozzle stem (<NUM>) extends and within which the nozzle (<NUM>) linearly moves, said secondary valve body (<NUM>) and said body (<NUM>, <NUM>) for providing an internal passage (<NUM>) for fluid between a firing chamber (<NUM>) and the input port (<NUM>);
wherein, when the system is idle, compressed gas fills the firing chamber (<NUM>) surrounding the nozzle section and biases the nozzle (<NUM>) in the rearward position; and
wherein the system is configured such that, during a firing sequence, gas flows between the input port (<NUM>) and the nozzle fluid chamber (<NUM>) and the gas contacts the rear of the nozzle (<NUM>) and pushes the nozzle (<NUM>) to the forward position; and
wherein the firing chamber (<NUM>) is configured to release compressed fluid through the one or more radial ports (<NUM>) in the nozzle (<NUM>) when the nozzle (<NUM>) is in the forward position.