Two-Stage Gas Regulator Plug Assembly for Compact Pressure Reduction
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Solution Overview
Problem
Existing pressure regulators face challenges in efficiently reducing high-pressure gas from sources like compressed gas cylinders to lower, usable pressures while maintaining compactness and simplifying assembly, often exposing multiple components to high pressures and requiring complex configurations.
Innovation Solution
A multi-stage pressure regulator design featuring a valve chamber body with a plug that includes both a piercing element and a first valve seat, allowing high-pressure gas to be routed directly to the valve seat, reducing the number of components exposed to high pressure and simplifying assembly by using first and second stage valve elements that can be received through a common opening, with springs and gaskets for sealing and pressure regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate components are used for piercing element and first valve seat, then reliability of high-pressure connection is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent combines the piercing element and first valve seat into a single integrated plug component. The plug includes a piercing tip for penetrating gas cylinder valves and a first valve seat formed as an integral part of the plug body, eliminating the need for separate components and reducing assembly complexity while maintaining reliable high-pressure connections.
2Reliability
If multiple separate components are used for valve elements, then reliability of pressure regulation is improved, but ease of manufacture and assembly deteriorates
Solution Approach 1:
The patent enables both first and second stage valve elements to be received through a common opening in the valve body, allowing them to be assembled together as a unit. This reduces the number of separate assembly operations required while maintaining the functional separation and reliability of multi-stage pressure regulation.
3Reliability
If more components are exposed to high pressure, then pressure regulation performance is improved, but compactness and high-pressure exposure minimization deteriorates
Solution Approach 1:
The patent segments the pressure regulation function into two distinct stages: a first stage valve that handles high-pressure gas from the cylinder and a second stage valve that reduces pressure to the final output level. This segmentation allows each component to be optimized for its specific pressure range, with only essential components exposed to high pressure.
4Ease of manufacture
If common opening is used for both valve elements, then assembly is simplified, but manufacturing precision requirements increase
Solution Approach 1:
The patent incorporates guide features and positioning structures within the common opening that pre-align the first and second stage valve elements during assembly. These preliminary positioning actions ensure proper alignment before the valve elements are fully installed, reducing the overall manufacturing precision requirements for the opening itself.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables efficient pressure reduction from 1000 to 3000 psi to 10-50 psi, maintains a compact design by minimizing high-pressure exposure, and simplifies assembly by using a common opening for both stage valve elements, ensuring reliable gas-tight seals and effective pressure regulation across varying conditions.
Implementation Method 1
gas pressure in the cavity can urge the first stage valve element to move against the bias of the first stage spring and toward the first end of the valve chamber body to close the first stage valve
Implementation Method 2
a first stage spring can be configured to bias the first stage valve element toward the second end of the valve chamber body and to open the first stage valve
Implementation Method 3
A second stage spring can be provided in the second bore and be configured to bias the second stage valve element toward the second valve seat and to close the second stage valve
Implementation Method 4
the first stage valve element can be sealingly engaged with the first bore to form and maintain a gas-tight seal throughout a range of motion of the first stage valve element relative to the first bore
Data Source
AI summary
A gas regulator includes a valve chamber body that houses two valves of the regulator. Valve elements that move to open and close the two valves are received via a same opening into the valve chamber body, which is closed by a plug. The plug can define a first valve seat as well as a piercing element used to pierce a compressed gas cylinder. A retainer can hold a gasket at a valve seat as well as provide a bore or other support for a valve element and valve element spring.