Self-sealing valve, a self-sealing, non-latex balloon and a method for producing such a balloon

Abstract: The present invention relates to a self-sealing flexible plastic valve (10) for a non-latex balloon (12). The valve includes a positioning tab and a bonding barrier (76) at the inlet (64) end to facilitate automated insertion of the valve into the balloon.

Description: BACKGROUND OF THE INVENTION The present invention relates generally a self-sealing, non-latex balloon and a method for manufacturing such balloons, and more specifically to a self-sealing valve mechanism for a non-latex balloon. As used herein, the term "balloon" refers to any inflatable toy having a body and an inflation stem. The popularity of non-latex balloons has grown tremendously over the past five years. This type of balloon includes two flexible plastic sheets which are heat-sealed together in many different configurations ( e.g. , a circle or heart shape). One or both of the sheets may be decorated or metallized to provide an aesthetically-pleasing balloon. Since non-latex balloons are highly impermeable, sealing of the balloon stem is critical to extended inflated life. A well-sealed non-latex balloon may remain virtually fully inflated for several weeks even when the inflation fluid is helium. Until recently, non-latex balloons were filled with air or helium to the desired pressure using a pump mechanism and then sealed by (i) a tightly-tied string, (ii) a clip or cup assembly adapted to crimp the balloon stem, or (iii) heat sealing. The disadvantages of these three systems are self-evident. The string provides only a marginal seal and can be difficult to apply in the field. Refilling of the balloon is also cumbersome. The clip and cup assemblies add a significant incremental cost and cannot be effectively utilized with helium-filled balloons. Furthermore the balloon stem is often damaged during an attempt to refill the balloon. Heat sealing provides a virtually permanent seal, but completely eliminates the ability to refill the balloon. It also requires a heat-sealing mechanism and an appropriate power supply. In addition, proper use of the presently available heat sealing mechanisms requires training and practice. Recently the non-latex balloon industry has sought to develop a self-sealing balloon and valve mechanism. The objectives have always been clear: reliability, minimal cost, ease of valve fabrication, and simplicity of incorporation into the balloon production system. To-date, several valves formed from two flexible plastic sheets have been made, but despite the efforts of many, each suffers from one or more serious disadvantages. These disadvantages include unacceptably high failure rates, costly fabrication procedures, and difficulty incorporating the valve insertion step into the balloon-manufacturing process. In addition, most presently available self-sealing valves extend beyond the balloon stem with the two plastic valve sheets being coterminous. Several problems therefore exist. First, the valve itself is exposed and subject to damage, e.g. , by puncture through engagement with the inflation mechanism. Second, the size of the valve is less than that of the conventional balloon stem so as to require an adaptor for conventional pump mechanisms. Third, the valve sheets are difficult to fully separate such that interference with the inflation process is often experienced. The most relevant prior art valve is that described in US Patent No. 4,674,532 (Koyanagi). It is shown in Figures 6 and 7 of the accompanying drawings. As set out in the preamble to claims 1 and 2 respectively, this valve has: a first flexible plastic valve sheet having a first inlet end and a first outlet end and a second flexible plastic valve sheet having a second inlet end and a second outlet end, the flexible plastic valve sheets being bonded together and providing a valve inlet and a valve outlet. At column 2, line 58 to 62, the Koyanagi specification reads: "The check valve V also has a guide tongue 7 for fluid charge/discharge means disposed at the fluid inlet/outlet port edge of the fluid pipe 1. This guide tongue 7 is disposed for facilitating the charge/discharge of a fluid." At column 3, line 12 to 36, the Koyanagi specification reads: "... a flat balloon toy body a is made of two plastic films c of a substantially circular shape each having a lip-like projecting portion b at a portion of the periphery thereof. These films c are bonded to each other at their peripheries, except the tip peripheries of the projecting portions b. The body a has an opening d at a portion of the periphery thereof. The check valve V can be inserted in the balloon toy body a through the opening d with the valve body mounting side of the check valve V turned to the inside of the balloon toy body a. The tip end of the fluid pipe 1 slightly projects from the projecting portion b of the main body a. As shown in [Figure 7], the outer peripheral surface of the check valve V is heatingly bonded, at one linear portion e thereof, to the inner surface of the opening d of the body a. The remaining inner surfaces of the opening d are heatingly bonded to one another at linear portions f thereof. There is thus formed a balloon toy of which the inside and the outside communicate with each other only through the check valve V. When blowing gas into the balloon toy constructed as above-mentioned, the guide tongue 7 of the fluid pipe 1 of the check valve V can be used. That is, the tip of a supply port of a gas supply means (not shown) can easily be inserted into the fluid pipe 1. When gas is then supplied, the gas is smoothly charged into the body a ..." SUMMARY OF THE INVENTION The present invention relates to a self-sealing valve for use in conjunction with a non-latex balloon and extends to a balloon incorporating such a self-sealing valve and a method of manufacture. The valve itself includes two flexible plastic valve sheets secured together to define a valve inlet, valve outlet and valve passageway. One of the valve sheets extends beyond the other at the valve inlet to provide a positioning tab, which substantially facilitates automation of the valve insertion process. The self-sealing valve fits entirely within the balloon, partially within the stem and partially within the body thereof. During assembly of the balloon, the positioning tab and the valve inlet, i.e ., the valve portion within the stem, are bonded or fused to the interior surfaces of the balloon sheets. This substantially avoids potential valve damage and potential interference during inflation since there are no free ends or edges of the self-sealing valve exposed to the inflation mechanism. The two flexible plastic valve sheets also define, in the region of the valve inlet, a bonding barrier. This avoids the complete or partial closing of the valve inlet during assembly of the balloon or, more particularly, as the balloon sheets are bonded together and to the self-sealing valve. It is thus an object of the present invention to provide a self-sealing, non-latex balloon. Another object is to provide a non-latex balloon with a reliable self-sealing valve mechanism. It is also an object to provide a self-sealing valve for a non-latex balloon which may be readily incorporated into the balloon assembly process. Still another object of the present invention is an inexpensive, mass-producible, self-sealing balloon valve. An additional object is a self-sealing, non-latex balloon which may be filled by conventional mechanisms without use of a special adaptor. It is yet another object of the present invention to provide a method for fabricating a self-sealing, non-latex balloon. A further object is to provide a method for fabricating a non-latex balloon having a self-sealing valve wherein the stem portion of the valve is bonded or fused such that there are no free ends or edges. It is also an object to provide a non-latex, self-sealing balloon wherein the stem portion of the valve is not exposed and does not interfere with the balloon-filling process. According to one aspect of the invention there is provided a self-sealing valve comprising: a first flexible plastic valve sheet having a first inlet end and a first outlet end and a second flexible plastic valve sheet having a second inlet end and a second outlet end, the flexible plastic valve sheets being bonded together and providing a valve inlet and a valve outlet; characterised in that: the flexible plastic valve sheets are arranged so as to provide a positioning tab, the self-sealing valve includes barrier means to provide a bonding barrier between the flexible plastic valve sheets at the valve inlet, and the barrier means extends on the first or second flexible plastic valve sheet at least inwardly from the valve inlet. According to a second aspect of the invention there is provided a self-sealing valve for a non-latex balloon, the non-latex balloon having a balloon body and a balloon stem formed by sealing a first balloon sheet to a second balloon sheet, the self-sealing valve comprising: a first flexible plastic valve sheet having a first inlet end and a first outlet end and a second flexible plastic valve sheet having a second inlet end and a second outlet end; the flexible plastic valve sheets being bonded together and providing a valve inlet and a valve outlet; characterised in that: the flexible plastic valve sheets are arranged so as to provide a positioning tab receivable entirely within the balloon stem, the self-sealing valve includes barrier means to provide a bonding barrier between the flexible plastic valve sheets at the valve inlet, the barrier means extends on the first or second flexible plastic valve sheet at least inwardly from the valve inlet, and the self-sealing valve is adapted to be preliminarily heat bonded to the first or second balloon sheet at the balloon stem prior to sealing formation of the non-latex balloon, balloon body and balloon stem and to thereafter include a first floating portion defining the valve outlet within the balloon body and a second portion defining the valve inlet within the the stem. According to a third aspect of the invention there is provided a self-sealing valve of the first or second aspect in combination with a non-latex balloon, the combination comprising: a first balloon sheet having an interior surface and a second balloon sheet bonded to the first balloon sheet along a boundary so as to define a balloon body and in addition thereto a balloon stem of the non-latex balloon, the self-sealing valve having a first floating portion within the balloon body and a second portion, the valve inlet being within the second portion and the valve outlet being within the first floating portion; wherein the second portion of the self-sealing valve is bonded to the balloon sheets within the balloon stem, and wherein the positioning tab is initially bonded within the length of the second portion to the interior surface of the first or second balloon sheet at a predetermined position and orientation within the balloon stem. According to a fourth aspect of the invention there is provided a method of producing a self-sealing, non-latex balloon, having a balloon body and a balloon stem defined by a first balloon sheet bonded to a second balloon sheet, comprising the steps of: bonding a first flexible plastic valve sheet to a second flexible plastic valve sheet so as to provide a self-sealing valve having a valve inlet, a valve outlet and a positioning tab; treating the first or second flexible plastic valve sheet to provide barrier means for providing a bonding barrier between the first and second flexible plastic valve sheets at the valve inlet; bonding the positioning tab to the first balloon sheet to a predetermined position such that the self-sealing valve has a predetermined orientation with respect to the first balloon sheet; registering the second balloon sheet with respect to the first balloon sheet; and bonding the first and second balloon sheets together and to the self-sealing valve such that the self-sealing valve includes a first floating portion within the balloon body and a second portion bonded to the balloon stem, the second portion including the positioning tab and the valve inlet. These and other features, objects and advantages of the present invention are described or implicit in the following detailed description. BRIEF DESCRIPTION OF THE DRAWING A preferred embodiment of the present invention is described herein with reference to the drawing wherein: FIGURE 1 is a perspective view of a metallic-coated, non-latex balloon including a preferred embodiment of the self-sealing valve, illustrating the extent of bonding with one balloon sheet peeled away solely for illustrative purposes; FIGURE 2 is an enlarged top view of the valve of FIGURE 1; FIGURE 3 is an enlarged perspective view of the bonded sheets of the valve shown in FIGURES 1 and 2; FIGURE 4 is a schematic view of an apparatus for fabricating the non-latex balloon of FIGURE 1; FIGURE 5 is a greatly enlarged cross-sectional view of one balloon sheet shown in FIGURE 1; and Figures 6 and 7 reproduce figures 6 and 5 respectively of the US-A-4 674 532. DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT A preferred embodiment of the present invention is shown as a self-sealing valve 10 for a metallic-coated, non-latex balloon 12. As is well known in the art, the balloon 12 includes a body 14 and a stem 16, defined by two flexible plastic balloon sheets 18, 20 of a metallic-coated, heat-sealable material 22. As best shown in FIGURE 5, each balloon sheet 18, 20 includes a thin metallic coating 24 applied to a plastic sheet 26, which includes a layer of nylon 28 and a layer of polyethylene 30. The polyethylene layers 30 are sealed or fused together by application of heat along a substantially peripheral heat-seal line 32. The body 14 of the balloon 12 is inflatable with an inflation fluid, such as air or helium, through the stem 16. For purposes hereof, the stem 16 extends from a boundary 34, shown as a dashed line in FIGURE 1 and defined by a relatively smooth, continuous extension of the heat-seal line 32 in the region of the stem 16. With particular reference to FIGURE 4, the heat-sealable material 22 is provided in roll form with a width three feet (1 foot ≈ 305 mm). Two rolls 36, 38 are utilized to produce the balloon 12 or more particularly the two balloon sheets 18, 20. After printing, the two rolls 36, 38 are aligned, registered and ultimately brought together by a series of rollers, generally designated 40. The balloon 12 is formed by a heat-sealing dye 42 and a cutting dye 44, as is well known in the art. As best shown in FIGURES 2 and 3, the valve 10 includes first and second flexible plastic valve sheets 46, 48, sealed or fused along two longitudinal edge lines 50, 52. Preferably the first and second sheets 46, 48 are low density polyethylene. The first and second sheets 46, 48 have a thickness in the range of one to three mils (1 mil ≈ 0,001" ≈ 0,25 mm). In this preferred embodiment, the first sheet 46 is one and one-half mils., and the second sheet 48 is two mils. The first sheet 46 is substantially rectangular and has a first inlet end 54 and a first outlet end 56. The second sheet 48 is also substantially rectangular, having a second inlet end 58 and a second outlet end 60. As shown, the second sheet 48 is preferably longer than the first sheet 46. More importantly, the second inlet end 58 extends beyond the first inlet end 54 in the assembled valve state, as best shown in FIGURE 2, so as to define a positioning tab 62. In the assembled valve state, the first and second valve sheets 46, 48 cooperate to define a valve inlet 64, valve outlet 66 and valve passageway 68 extending therebetween. The valve passageway 68 preferably includes an inlet section 70 extending from the valve inlet 64, an outlet section 72 extending from the valve outlet 66, and an interconnecting offset section 74. As shown, the outlet section 72 has a width corresponding to the width of the valve outlet 66, and the inlet section 70 has greater width corresponding to that of the valve inlet 64. The offset section 74 provides a relatively smooth transition between the inlet and outlet sections 70, 72 and defines an offset angle, designated "A" on FIGURE 2, in the range of fifteen to forty degrees. The offset angle "A" is preferably twenty degrees. The first and second sheets 46, 48 also cooperate to define barrier means, generally designated 76. The barrier means 76 provides a bonding barrier at the valve inlet 64, such that the inlet 64 is not sealed or closed during the balloon assembly process. In this preferred embodiment, the barrier means 76 is a coating 78 of heat-resistant nitrocellulose ink, applied to the second sheet 48. The ink coating 78 extends across the width of the second sheet 48 between the two longitudinal edge lines 50, 52. The longitudinal extent of the ink coating 78 must be sufficient, based upon valve and balloon assembly tolerances, to ensure that the first inlet end 54 of the first valve sheet 46 overlaps the ink coating 78. As shown in FIGURE 1, the valve 10 lies entirely within the balloon 12. That is, a first portion 80 of the valve 10 extends into the body 14 and is substantially free or floating. This floating portion 80 facilitates sealing under pressure in that the floating portion 80 often partially folds over to crease the valve passageway 68. A second portion 82 of the valve 10 extends beyond the boundary 34 and partially into the stem 16. This second portion 82 includes the positioning tab 62 and valve inlet 64 and is preferably completely bonded to the balloon stem 16 in the final assembled balloon state. In this preferred embodiment, heat sealing integrally fuses the second portion 82 of the valve 10 to the balloon sheets 18, 20. Fusion thereof substantially facilitates inflation of the balloon 12 by conventional mechanisms. First, fusion of the positioning tab 62 and valve inlet 64 eliminates any free end or edge of the valve 10 within the balloon stem 16. This substantially avoids valve interference with the inflation process. Second, the flexible plastic sheets 46, 48 of the valve 10 are not directly exposed to the inflation equipment and puncture thereof is substantially avoided. The fused positioning tab 62 and valve inlet 64 also thicken and reinforce the flexible balloon sheets 18, 20 in the region of the boundary 34, offering further protection against puncture. Third, the fused positioning tab 62 and valve inlet 64, in conjunction with the floating portion 80, cooperate to "snap open" the valve 10 under initial inflation pressure. The valve inlet 64 opens as the inflation mechanism is inserted into the balloon stem 16, and the inflation fluid readily passes through the valve passageway 68 emerging from the valve outlet 66 into the balloon body 14. Finally, the valve 10 does not reduce in any way the size of the balloon stem 16. As such, no adaptor is needed for the conventional inflation equipment. During assembly of the balloon 12, the valve 10 is secured to an interior surface 84 of the polyethylene layer 30 of the balloon sheet 20. More particularly, the valve 10 is properly placed upon the interior surface 84, and the positioning tab 62 is preferably completely fused thereto by a second heat sealing dye 86. The first and second balloon sheets 18, 20 are then heat-sealed together and to the valve 10. This heat seal extends about the entire periphery of the body 14 and along the edges of the stem 16. It also extends along the boundary 34 such that the balloon sheets 18, 20 are sealingly bonded to the first and second valve sheets 46, 48, respectively, integrally fusing the valve inlet 64 to the balloon stem 16 without closure thereof. For a conventional eighteen inch (1 inch ≈ 25,4 mm) non-latex balloon 12 to be filled with helium to a pressure of approximately three quarters of a pound per square inch (1 psi ≈ 0,069 bar), the valve 10 is preferably seven inches in total length and one inch in total width, with a one-half inch positioning tab 62. The widths of the inlet and outlet sections 70, 72 are three-quarters and seven-sixteenths inch, respectively. Preferably the ink coating 80 extends one inch.

Claims: A self-sealing valve (10) comprising: a first flexible plastic valve sheet (46) having a first inlet end (54) and a first outlet end (56) and a second flexible plastic valve sheet (48) having a second inlet end (58) and a second outlet end (60), the flexible plastic valve sheets (46, 48) being bonded together and providing a valve inlet (64) and a valve outlet (66); characterized in that: the flexible plastic valve sheets (46, 48) are arranged so as to provide a positioning tab (62), the self-sealing valve includes barrier means (76) to provide a bonding barrier between the flexible plastic valve sheets (46, 48) at the valve inlet (64), and the barrier means (76) extends on the first or second flexible plastic valve sheet (46 or 48) at least inwardly from the valve inlet (64). A self-sealing valve (10) for a non-latex balloon (12), the non-latex balloon (12) having a balloon body (14) and a balloon stem (16) formed by sealing a first balloon sheet (18) to a second balloon sheet (20), the self-sealing valve (10) comprising a first flexible plastic valve sheet (46) having a first inlet end (54) and a first outlet end (56) and a second flexible plastic valve sheet (48) having a second inlet end (58) and a second outlet end (60), the flexible plastic valve sheets (46, 48) being bonded together and providing a valve inlet (64) and a valve outlet (66); characterized in that: the flexible plastic valve sheets (46, 48) are arranged so as to provide a positioning tab (62) receivable entirely within the balloon stem (16), the self-sealing valve (10) includes barrier means (76) to provide a bonding barrier between the flexible plastic valve sheets (46, 48) at the valve inlet (64), the barrier means (76) extends on the first or second flexible plastic valve sheet (46 or 48) at least inwardly from the valve inlet (64); and the self-sealing valve (10) is adapted to be preliminary heat bonded to the first or second balloon sheet (18 or 20) at the balloon stem (16) prior to sealing formation of the non-latex balloon (12), balloon body (14) and balloon stem (16) and to thereafter include a first floating portion (80) defining the valve outlet (66) within the balloon body (14) and a second portion (82) defining the valve inlet (64) within the balloon stem (16). A self-sealing valve as claimed in claim 1 or 2, wherein the first and second flexible valve sheets (46, 48) further define a valve passageway (68) between the valve inlet (64) and the valve outlet (66), the valve passageway (68) including an offset section (74). A self-sealing valve as claimed in any one of claims 1 to 3, wherein the barrier means (76) is a coating of heat resistant ink. A self-sealing valve as claimed in any one of claims 1 to 4, wherein the valve inlet (64) is at the first inlet end (54) of the first flexible plastic valve sheet (46). A self-sealing valve as claimed in any one of claims 1 to 5, wherein the barrier means (76) extends on the second flexible valve sheet (48) also outwardly with respect to the first inlet end (54) of the first flexible valve sheet (46). A self-sealing valve as claimed in any one of claims 1 to 5, wherein the second inlet end (58) of the second flexible valve sheet (48) extends beyond the first inlet end (54) of the first flexible plastic valve sheet (46) to provide the positioning tab (62). A self-sealing valve as claimed in any preceding claim in combination with a non-latex balloon (12) comprising: a first balloon sheet (18) having an interior surface and a second balloon sheet (20) bonded to said first balloon sheet along a boundary (34) so as to define a balloon body (14) and in addition thereto a balloon stem (16) of the non-latex balloon (12), the self-sealing valve (10) having a first floating portion (80) within the balloon body (14) and a second portion (82), the valve inlet (64) being within the second portion (82) and the valve outlet (66) being within the floating portion, wherein the second portion (82) of the self-sealing valve is bonded to the balloon sheets (18, 20) within the balloon stem (16), and wherein the positioning tab (62) is initially bonded within the length of the second portion (82) to the interior surface of the first or second balloon sheet (18 or 20) at a predetermined position and orientation within the balloon stem (16). A self-sealing valve as claimed in claim 8, wherein the second portion (82) of the self-sealing valve (10) is completely bonded to the balloon stem (16) in the final assembled state of the non-latex balloon (12). A self-sealing valve as claimed in claim 8 or 9, wherein the second portion (82) of the self-sealing valve (10) is fused to the balloon stem (16) by heat sealing. A method of producing a self-sealing, non-latex balloon (12), having a balloon body (14) and a balloon stem (16) defined by a first balloon sheet (18) bonded to a second balloon sheet (20), comprising the steps of: bonding a first flexible plastic valve sheet (46) to a second flexible plastic valve sheet (48) so as to provide a self-sealing valve (10) having a valve inlet (64), a valve outlet (66) and a positioning tab (62); treating the first or second flexible plastic valve sheet (46,48) to provide barrier means (76) for providing a bonding barrier between the first and second flexible plastic valve sheets (46,48) at the valve inlet (64); bonding the positioning tab (62) to the first balloon sheet (18) to a predetermined position such that the self-sealing valve (10) has a predetermined orientation with respect to the first balloon sheet (18); registering the second balloon sheet (20) with respect to the first balloon sheet (18); and bonding the first and second balloon sheets (18,20) together and to the self-sealing valve (10) such that the self-sealing valve (10) includes a first floating portion (80) within the balloon body (14) and a second portion (82) bonded to the balloon stem (16), the second portion (82) including the positioning tab (62) and the valve inlet (64). A method of producing a self-sealing, non-latex balloon as claimed in claim 11, further including the step of forming a valve passageway (68) between the valve inlet (64) and the valve outlet (66), the valve passageway (68) including an offset section (72). A method of producing a self-sealing, non-latex balloon as claimed in claims 11 or 12, wherein the step of treating includes coating with a heat resistant ink. A method of producing a self-sealing, non-latex balloon as claimed in any one of claims 11 to 13, wherein the bonding steps include applying heat to form a fused heat seal.

Inventors: KIEVES GARRY, KIEVES, GARRY
Applicants: ANAGRAM INT INC, ANAGRAM INTERNATIONAL, INC.
Application year: 1989
Main classification: F16K15
IPC codes: A63H27