Abstract:
A valve for forming a foam from a fluid, the valve includes an outer valve wall including a first end and a second end in fluid communication with each other and defining a chamber within the valve; an air intake bore intermediate outer valve wall first end and outer valve wall second end that provides fluid communication between a space outside of valve and the chamber; and at least two barriers within the chamber, wherein each of the at least two barriers defines an aperture.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This applications claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application No. 61/506,672 filed Jul. 12, 2011, the entirety of which is hereby incorporated by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to valves for use in forming fluids into foam material. More particularly, the present invention relates to valves that may be placed in pressurized containers of fluid to form a foam material. 
     SUMMARY OF THE INVENTION 
     According to an aspect, the present invention is directed to a valve for forming a foam from a fluid, the valve including: an outer valve wall comprising a first end and a second end in fluid communication with each other and defining a chamber within the valve; an air intake bore intermediate outer valve wall first end and second end that provides fluid communication between a space outside of valve and the chamber; and at least two barriers within the chamber, wherein each of the at least two barriers includes an aperture. 
     According to another aspect, the present invention is directed to a pressurized container including: an outer surface defining a container space within, wherein the container space comprises a pressurized gas and fluid; an outlet port that provides fluid communication between a position outside of the pressurized container and the container space; a valve within the container space including: an outer valve wall comprising a first end and a second end in fluid communication with each other and defining a chamber within the valve; an air intake bore intermediate outer valve wall first end and second end that provides fluid communication between the container space and the chamber; and at least two barriers within the chamber, wherein each of the at least two barriers includes an aperture; a fluid tube within the container space that is in fluid communication with the fluid of the pressurized container; and wherein the fluid tube is in further communication with the valve wall first end and the outlet port is in further fluid communication with the valve wall second end. 
     The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the invention and, together with the description, serve to explain the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A full and enabling disclosure of the present invention is set forth in the specification, which refers to the appended figures, in which: 
         FIG. 1  is a side cross-sectional view of a valve in accordance with a first embodiment of the present invention; 
         FIG. 2  is a perspective cross-sectional view of the valve of  FIG. 1 ; 
         FIG. 3  is a side cross-sectional view of the valve of  FIG. 1  placed in a pressurized container; 
         FIG. 4  is a side cross-sectional view of a valve in accordance with a second embodiment of the present invention; 
         FIG. 5  is a top view of a first barrier from the valve of  FIG. 4 ; and 
         FIG. 6  is a side cross-sectional view of the valve of  FIG. 4  placed in a pressurized container. 
     
    
    
     Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention. 
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     Reference will now be made in detail to presently preferred embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope or spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents. 
     The present invention relates to improved valves for use in creating foam from a fluid that may be used in connection with fire extinguishers, pressurized water containers, compressed air tanks, and other containers. As more fully explained below, valves of the present invention are constructed such that foam may be created as fluid moves through them.  FIGS. 1 and 2  illustrate a first embodiment of the valve  100  of the present invention. As shown in the referenced figures, valve  100  includes an outer valve wall  102  with a first end  104  and a second end  106  and an air intake  108  intermediate first and second ends  104 , 106 . Although valve wall  102  of the first embodiment is shown as being cylindrical in shape, in other embodiments, valve wall  102  may be constructed of any shape based on the user&#39;s specifications. For example, in some embodiments, valve wall  102  may be oblong, oval, square, triangular, rectangular, trapezoidal, an irregular shape, or others known in the art. The user&#39;s specifications may dictate the particular shape utilized. 
     As further shown in  FIG. 1 , air intake  104  is a hole or bore in outer valve wall  102  that establishes fluid communication between an external portion  110  of valve  100  and an internal portion  112  of valve  100 . In some embodiments, air intake  108  may be positioned such that when a gas enters valve  100  through air intake  108 , the gas is forced into a swirling motion within valve wall  102 . Such action may be accomplished by boring air intake  108  at a particular angle, as this may increase the mixing and turbulence within valve  100 , thus contributing to improved foaming. In such embodiments, air intake  108  may be a hole or bore in valve wall  102  which is positioned at an angle between about 0° and about 90° based on a position on valve wall  102 . 
     As more clearly shown in  FIG. 2 , internal portion  112  of valve  100  includes a series of spaced barriers  114  each with at least one aperture  116 . As shown in  FIG. 2 , barriers  114  may be shaped in order to conform to the shape of internal portion  112  of valve  100 . In such embodiments, apertures  116  of the present invention may be of any shape to meet the specifications of the user. For example, round, square, rectangular, triangular, or other shaped apertures  116  may be utilized. However, in additional embodiments, barriers  114  may be constructed in a shape that is different from internal portion  112  of valve  100 . For example, barriers  114  may be constructed in a triangular shape, while internal portion  112  may be cylindrical in shape. In such embodiments, the variation in shape between barriers  114  and internal wall  112  may naturally create apertures  116  of barriers  114 . 
     Valve  100  may include any number of spaced barriers  114  based on the specifications of the user. For example, and as shown in  FIGS. 1 and 2 , valve  100  may include four spaced barriers  114 . In additional embodiments, the number of spaced barriers  114  within valve  100  may range between about two and about thirty. In other embodiments, the number of barriers  114  within valve may range between about three and about twenty. The number of barriers  114  may vary based upon the particular application and size of valve utilized. 
     In some embodiments of the invention, to aid in the foaming process, apertures  116  of adjacent spaced barriers  114  may be off-set from one another. For example and as clearly shown in  FIG. 2 , apertures  116  may be off-set by about 180° from one another. In additional embodiments, apertures  116  of adjacent spaced barriers  114  may be off-set between about 45° and about 180°. As indicated above, the off-set nature of apertures  116  between adjacent spaced barriers  114  may force the fluid mixture that moves through the valve to be forced in varying directions, thereby aiding in the foaming process. 
     In some embodiments of the present invention, spaced barriers  114  may be fixedly attached to valve wall  102  such that they are stationary within valve  100 . In additional embodiments, however, spaced barriers  114  may be rotatable or mobile within valve wall  102 , such that additional movement may be employed to create additional foaming of the fluid. 
     Valves of the present invention may be manufactured or produced using any method known in the art. For example, the valves may be manufactured via a manual lathe or milling machine, a CNC lathe or milling machine, plastic injection, blow molding, casting in a foundry, cut out by an EDM machine, water jet machine, plasma machine, or laser machine, punch pressed, stamped out through a set of dies, printed in a 3D modeling printer, vacuum formed, or swaged or crimped in forming dies. 
     In addition, any materials known in the art may be utilized to form the valves of the present invention. The skilled artisan will understand that the materials utilized may vary based upon the particular application. The materials may include ferrous and non-ferrous metals (for example: steel, aluminum, brass, bronze, lead, nickel, stainless steel, silver, gold, pewter, titanium, platinum, iron, copper, tin, zinc and others), plastics generally (for example: ABS, PVC, CPVC, acrylic, polypropylene, polycarbonate and others), fiberglass-reinforced plastics, Micarta, phenolic materials, carbon fiber, glass, resins, epoxies, plexiglass, graphite and/or others. 
     Valve  100  may be included in any type of pressurized container  118  that includes both a fluid  120  and pressurized gas  122 , as mentioned above and as shown in  FIG. 3 . Within such a container  118 , valve wall first end  104  may be in fluid communication with a fluid tube  124  that is in further fluid communication with fluid  120  located within pressurized container  118 . In addition, valve wall second end  106  may be in fluid communication with an outlet port  126  of pressurized container  118  that provides an outlet from pressurized container  118  to the atmosphere. Although  FIG. 3  illustrates a connector  127  connecting the pressurized container  118  to an external source of pressurized gas  129 , in other embodiments, pressurized container  118  may include a localized source of pressurized gas. In accordance with certain embodiments illustrated by, for example,  FIG. 3 , the external source of pressurized gas  129  that may be fed through an air compressor or other known device. 
     In some embodiments of the invention, the fluid  120  of pressurized container  118  may further include a foaming agent to aid in the foaming process. For example, in some embodiments, surfactants such as sodium laureth sulfate or sodium lauryl ether sulfate may be utilized in the fluid  120  of pressurized container  118  to aid in the foaming process. 
     In addition, the pressurized gas  122  may be any known gas that may be utilized in such pressurized situations. For example, air, helium, or other known gasses may be utilized. In addition, the pressurized gas utilized in connection with the present invention may be at a pressure between about 10 psi and about 4500 psi. The particular pressure of the pressurized gas may vary based on the dimensions of the valve and the pressurized container. 
     In operation, pressurized gas  122  of pressurized container  118  is activated such that fluid  120  is forced though fluid tube  124  and into valve wall first end  104 . In addition, pressurized gas  122  is further forced through air intake  108  and makes contact with fluid  120  that has entered valve wall first end  104 . As fluid  120  and pressurized gas  122  are combined and move from valve wall first end  104  to valve wall second end  106  through apertures  116  of spaced barriers  114 , a resulting foam is created that exits outlet port  126  and enters the atmosphere. 
       FIGS. 4 and 5  illustrate a second embodiment of the valve  200  of the present invention. Valve  200  includes a valve wall  202  with a first end  204  and a second end  206  and an air intake  208  proximate first and second ends  204 ,  206 . As shown in  FIG. 4 , valve wall  202  may be, in some embodiments, tapered at first and second ends  204 ,  206 . Such tapering may allow ends  204 ,  206  to properly adapt to the specification of a fluid tube and exit port within a pressurized container, as further explained below, and/or may also add additional force to the movement of a fluid to aid in the foaming process. 
     Valve  200  further includes first and second mixing areas  210 ,  212  proximate first and second ends  204 ,  206  that are confined by first and second barriers  214 ,  216  as shown in  FIG. 4 . First and second barriers  214 ,  216  further include at least one aperture  218  that establishes fluid communication between valve wall first and second ends  204 ,  206 . The number and size of apertures  218  may vary based on the particular use of the present invention and the embodiment illustrated in  FIGS. 4 and 5  only serves as an example of an available embodiment. 
     As shown in the figures, first and second barriers  214 ,  216  may be configured to conform to the shape of valve wall  202  or may be constructed of a different shape than valve wall  202  such that apertures  218  are provided naturally, as discussed above with respect to the first embodiment. In addition and as shown in the figures, first and second barriers  214 ,  216  may be constructed in a U-Shape and may be fixedly attached to valve wall  202  or, in other embodiments, may consist of a singularly-flat piece that may be adhered to valve walls  202  by any known method in the art. 
     Air intake  208  of valve  200  is a hole or bore in valve wall  202  that establishes fluid communication between an external portion  220  of valve  200  and an internal portion  222  of valve  200 . In some embodiments, as discussed above with respect to the first embodiment, air intake  208  may be a bore or hole at a particular angle that allows for gas to enter valve  200  in a swirling motion. In such embodiments, air intake  208  may be a hole or bore in valve wall  202  which is positioned at an angle that may be between about 0° and about 90° based on the position of valve wall  202 . 
     Valve  200  may be included in any number of pressurized containers  118  that include both a fluid  120  and a pressurized gas  122 , as mentioned above with respect to the first embodiment and as shown in  FIG. 6 . Within such a container  118 , valve wall first end  204  may be in fluid communication with a fluid tube  124  that is in further fluid communication with fluid  120  located within pressurized container  118 . In addition, valve wall second end  206  may be in fluid communication with an outlet port  126  of pressurized container  118  that provides an outlet from pressurized container  118  to the atmosphere. 
     In operation, pressurized gas  122  of pressurized container  118  is activated such that fluid  120  is forced though fluid tube  124  into valve wall first end  204  and first mixing area  210  and then through apertures  218  of first barrier  214 . Pressurized gas  122  is further forced through air intake  208  and contacts fluid that has exited apertures  218  of first barrier  214 . As fluid  120  and pressurized gas  122  combine, the mixture moves through apertures  218  of second barrier  216  and into second mixing area  212  creating a foam material that exits pressurized container  118  through valve wall second end  206  and outlet port  126 . 
     Although the valves of the present invention have been shown in connection with a pressurized container, in other embodiments, valve may be utilized without such a container. In such embodiments, the valves of the present invention may have feeds of fluid from an external source through their respective first ends and may also include a feed of pressurized gas from an external source into their respective air intakes. Further, in such embodiments, the aforementioned first ends and air intakes may include appropriate fittings known in the art that could allow fluid connection to such external sources. 
     The valves and pressurized containers of the present invention have many applications and may be used in the aerosol industry, the fire fighting industry, the automotive industry, the aerospace industry, or any other industry known in the art to have a need for liquid foaming. For example, in an embodiment, the valves and pressurized containers of the present invention may be used to foam and expand a solution to exhaust, prevent, or control fire. 
     The devices of the present invention further simplify current methods used to foam liquid. As such, the inventive device requires fewer or no hoses, ball valves, check valves, and plumbing, in general, and provides suitable foam expansion of a fluid as compared to other methods. In addition, other benefits of the internal valve of the invention include that the valve may not be tampered with, modified by unauthorized individuals, or damaged as easily as an external valve, and the valve and the plumbing will not be exposed to environmental elements. 
     These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention so further described in such appended claims. Therefore, the spirit and scope of the appended claims should not be limited to the description of the versions contained therein.