Two-Stage Gas Regulator 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 high-pressure gas handling, then reliability of pressure regulation is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The plug merges multiple functions into a single component: it contains the piercing element for high-pressure gas intake, defines the first valve seat for the first stage valve, and provides structural support for the valve element. This consolidation reduces the number of separate high-pressure components while maintaining reliable pressure regulation through integrated design
2Manufacturing precision
If multiple valve elements are received through separate openings, then assembly precision is improved, but manufacturing and assembly complexity increase
Solution Approach 1:
The valve chamber body consolidates multiple valve element reception openings into a single common opening, allowing both the first stage valve element and second stage valve element to be installed through the same access point. This simplifies assembly operations while maintaining precise positioning through dedicated seating surfaces and retention mechanisms within the chamber
Solution Approach 2:
The common opening serves multiple functions: it accommodates insertion of different valve elements (first stage and second stage), provides access for assembly and disassembly, and maintains structural integrity of the valve chamber body. This multi-functional design reduces manufacturing steps without compromising positioning precision
3Reliability
If more components are exposed to high pressure, then pressure regulation effectiveness is improved, but compactness and high-pressure exposure minimization worsen
Solution Approach 1:
The regulator segments high-pressure and low-pressure zones through distinct structural divisions. The plug and its integrated components handle high-pressure gas directly from the cylinder, while the valve chamber body and outlet mechanisms operate at reduced pressures. This segmentation allows compact arrangement by confining high-pressure components to a minimal volume near the piercing element
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 first and second stage valve elements, ensuring reliable gas-tight seals and effective pressure regulation.
Implementation Method 1
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 2
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 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
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.