Valve assembly for a gas lighter

A gas lighter valve assembly that can be fitted easily and tightly into a gas lighter body or a well as a free-floating entity not fixed to the gas lighter body or well. The valve assemblies integration as a free floating entity within the lighter body or well avoids the necessity of an interference fit. To avoid the necessity of an interference fit, valve assembly positioning and stability is achieved by the use of an o-ring which is compressed by downward force exerted by a pressing cover upon a bushing or directly upon the o-ring. By eliminating the stress and friction typically caused by an interference fit, the lighter body and reservoir can be made from a variety of materials including non-crystalline resins.

This application is a national stage application of International Application No. PCT/IB2012/002306, filed on Oct. 12, 2012, the entire contents of which are incorporated herein by reference.

FIELD OF INVENTION

The embodiments of the present invention relate to a valve assembly for gas lighters and methods for assembly and integration of the valve assembly with and into a gas lighter body or well formed therein.

BACKGROUND OF THE INVENTION

Generally, the embodiments of the present invention relate to a method by which a valve assembly is tightly and easily integrated into a gas lighter body made from a non-crystalline resin such as styrene acrylonitrile (AS/SAN) resin, ABS, polycarbonate (PC) and the like. Specifically, the embodiments of the present invention relate to a method of integrating a valve assembly into a lighter body or well therein as a free floating entity not fixed to the lighter body, a well therein, or another component which is itself fixed to the lighter body or a well therein.

Inexpensive gas lighters are typically made of amorphous polymers which have the advantage of transparency such that users are able to see the level of fuel remaining within the lighter's reservoir. Despite this advantage, typically used polymers such as AS/SAN, ABS, and polycarbonate may be brittle as a result of their non-crystalline structure. Additionally, to prevent gas leaks, valve assemblies must be integrated into lighter bodies tightly and with precision. This is often accomplished by press or interference fitting the valve assembly within the lighter body. The stress of this interference fit is often too much for the non-crystalline resin and results in cracking of the lighter body and the necessary disposal of the lighter body.

To avoid this costly issue, several methods have emerged to facilitate integration of valve assemblies without compromising the integrity of the lighter body. One such method, as disclosed in WO 01/18452 A1 and U.S. Pat. No. 4,101,262, employs the use of screw threads and an o-ring such that the valve assembly is screwed upon its thread into the lighter body or a well therein. However, the use of screw threads elongates the manufacturing process as complex moulds are necessary to form the component's threads. Similarly, the introduction of threads complicates the assembly process as it is often difficult to automate the act of screwing the component into the lighter body or well therein. While possibly minimizing the chance of cracking upon the valve assembly's insertion, the use of screw threads is costly in terms of manufacture and assembly.

Additional alternatives include the introduction of a snap-fitting mechanism in which the bottom most part of a valve assembly is formed with a “bulging pawl” that is larger than the well in which the assembly is fit such as disclosed in Japanese patent application JP 7-055140. Upon insertion, the wider “bulging pawl” is compressed such that it snaps into place under the lip of the well at the top of the lighter reservoir. This snapping, in turn, holds the valve assembly in place but does not eliminate the possibility of cracking as the assembly must be inserted with sufficient force to snap the wider section of the assembly (the “bulging pawl”) into place.

Finally, attempts have been made to avoid cracking of a lighter body's resin by the use of an o-ring, press fitting, and annular projections that are ultrasonically welded to the lighter body or a well therein as disclosed in patent WO 2007/140048 A2. That is, the valve assembly itself is formed with projections on its periphery that are melted into the lighter body or a well therein ultrasonically. The disadvantage of this method, however, is the risk of damaging the lighter's permeable membrane by the vibrations produced during ultrasonic welding. Such damage to the permeable membrane may affect the quantity of fuel supplied by the valve assembly and, subsequently, may result in dangerous flame height and fuel leakage during use.

SUMMARY OF THE EMBODIMENTS OF THE PRESENT INVENTION

The embodiments of the present invention aim to eliminate the above mentioned complications and disadvantages by a simplified integration of a lighter's valve assembly within the lighter body or a well therein while also providing for a gas tight seal. In this respect, the valve assembly and method of integration of the embodiments of the present invention will permit the continued use of non-crystalline resins without compromising the integrity of the lighter or increasing the cost of production or assembly.

To this end, a gas lighter and valve assembly is proposed with the valve assembly being inserted into a well in the lighter body as a free-floating entity without interference fit with the lighter or well therein. The valve assembly is characterized by an o-ring positioned on its lower periphery that is compressed by a pressing cover fixed to the top of the lighter body or well therein by means of gluing or ultrasonic weld. Downward force exerted by the pressing cover compresses the o-ring against the lighter body or floor of a well therein such that the valve assembly is held in place. In this respect, the valve assembly is held in between the compressed o-ring and pressing cover and is not directly fixed to the lighter body, a well therein, or any component fixed to the lighter body or well therein.

The valve assembly's peripheral o-ring may be positioned at the assembly's lower end such that it is compressed indirectly by the pressing cover between the valve assembly's bushing and the floor of the lighter well, as in embodiment 1. Alternatively, the valve assembly's peripheral o-ring may be positioned at the assembly's upper portion such that the o-ring remains external to the lighter's well in a peripheral recess created in the lighter's body. The o-ring is compressed directly by the pressing cover against the valve assembly on one side and the floor of the peripheral recess on the other. In both positions, however, compression of the assembly's peripheral o-ring is accomplished by means of the pressing cover exerting downward force. Further, regardless of the o-ring's location relative to the pressing cover, the valve assembly is integrated into the lighter body's well without interference with the lighter body, the lighter body's well, or any component directly fixed to the lighter body or well therein.

DETAILED DESCRIPTION OF THE EMBODIMENTS OF THE PRESENT INVENTION

FIG. 1is a vertical cross sectional view of embodiment 1 showing a unitary valve regulating assembly18with a diameter of approximately 3.5 millimeters and a length of approximately 15 millimeters and facilitating, at its bottom portion, gas pressure reduction and evaporation for the liquid fuel contained in the lighter's reservoir. To perform these functions, the bottom portion of the valve regulating assembly18contains a permeable membrane6, maintained by a disk crimped inside the valve body1. The upper portion of the valve regulating assembly18facilitates opening and closing functions for gas flow through the valve regulating assembly's18jet2and is equipped with an outlet12having a shoulder21, a globe seal4maintained under pressure exerted by a jet spring3and guided by a washer5inside the valve regulating assembly's18body1.

A cylindrical bushing9made preferably from crystallized resin such as polyoxymethylene is integrated on the peripheral of the valve regulating assembly18by interference fit. An o-ring10is mounted below the cylindrical bushing9around the periphery of the valve regulating assembly18.

Comprised of the components above, the valve regulating assembly18includes an independent and complete unit that can be freely mounted in a cylindrical well8of a lighter body7. The o-ring10positioned below the valve regulating assembly's18bushing9and above the well's8floor, ensures the stability and fit of the unitary valve regulating assembly18. The position of the valve regulating assembly18, and the seal to prevent fuel leaks, is ensured by a recess16positioned at the bottom most portion of the valve regulating assembly18at the bottom of the well8and just above the lighter's reservoir11. Further, compression of the o-ring10is maintained by means of a pressing cover17fixed to the lighter body7atop the well8by ultrasonic welding14or other means. Additionally, the gas tight seal could be secured by the introduction of liquid glue into the peripheral recess15into which the pressing cover11is disposed atop the lighter's well8.

In the second embodiment, shown inFIG. 2, a valve regulating assembly18with a diameter of approximately 3.5 millimeters and a length of approximately 15 millimeters is shown facilitating, at its bottom portion, gas pressure reduction and evaporation for the liquid fuel contained in the lighter reservoir11. As with the embodiment shown inFIG. 1, the bottom portion of the valve regulating assembly18contains a permeable membrane6, maintained by a disk crimped inside the valve body1. The upper portion of the valve regulating assembly18facilitates opening and closing functions for gas flow through the valve regulating assembly's18jet2and is equipped with an outlet12, a globe seal4maintained under pressure exerted by a jet spring3and guided by a washer5inside the valve regulating assembly's18body1.

The o-ring10depicted inFIG. 2is positioned around the periphery of the unitary valve regulating assembly18, but is positioned such that it is not contained within the cylindrical well8of the lighter body7. Rather, the o-ring10is positioned such that it is compressed between the pressing cover17on its top side and the floor of the peripheral recess15on its bottom side. Downward compression of the o-ring10results in the lateral stabilization of the valve assembly18by the o-ring10. In this respect, the pressing cover17acts directly on the o-ring10to maintain the stability of the valve regulating assembly18within the well8of the lighter body7. As was the case with embodiment 1, the pressing cover17is disposed within the peripheral recess15and fixed to the lighter body7by ultrasonic weld14. Similarly, the position of the valve regulating assembly18, and the seal to prevent fuel leaks, is ensured by a recess16positioned at the bottom most portion of the valve regulating assembly18at the bottom of the well8and just above the lighter's reservoir11.

In both embodiments disclosed above, the O-ring10is pressed downward onto a bearing13formed either on the bottom of the well (FIG. 1) or at the top of the well (FIG. 2). The vertical compression along the valve axis X squeezes the annular O-ring which consequently expands radially. As a result, the radially interior portion22of the O-ring presses on the cylindrical external surface24of the valve assembly18thereby providing a first gastight contact surface. Similarly, the inferior portion23of the O-ring presses on the bearing13so as to provide another annular gastight contact surface. Both gastight contact annular surfaces ensure a gastight seal between the valve regulating assembly18and the lighter body7to prevent gas leakage.

Further, due to the frusto-conical shape of the gluing/welding area14, the pressing cover is centered relative to the well axis. As a result of this arrangement, the above mentioned radial forces have an effect of centering the valve assembly18in the well axis, so that the valve axis X coincides with the well axis; also the above mentioned radial forces have an effect of laterally stabilizing the valve assembly18into the well.

It shall be appreciated that the disclosed valve assembly on lighter does not require a force fit insertion into the well since a clearance is arranged in both embodiments, i.e. between the outer surface of bushing9and inner wall of well8in the first embodiment, and between the outer surface24of valve assembly18and inner wall of well8in the second embodiment. Further, the assembly arrangement of valve assembly18on lighter is deprived of any thread. It should also be noted that, in the depicted examples, the bearing13extends substantially perpendicular to the valve axis X, although it could also be otherwise or inclined.

The advantages of the unitary valve regulating assembly18are many and include the ability to fully inspect all components of the valve regulating assembly18as an independent unit and prior to installation for compliance with functional requirements such as evaporation, flow regulation, flow stability, opening/closing, and sufficient sealing. Further, the use of an o-ring10and a pressing cover17ensures that the valve regulating assembly18is integrated into the well8of the lighter body7without being directly fixed to the well8or the lighter body7or any component that is fixed to the lighter body7or well8therein. This free-floating assembly and integration of the valve regulating assembly18prevents even the possibility of interference with and, consequently, the introduction of stress into, the lighter body7or well therein8and the introduction of cracks or fractures.

The embodiments of the present invention have been described according to the preferred embodiments depicted inFIG. 1andFIG. 2, respectively. These embodiments, however, provide an example of the invention and, as such, the invention is not restricted thereto. Rather, it will be understood by those familiar with and skilled in the art that modification and variation may be made within the scope of the present invention as defined and limited only by the following claims.