Abstract:
A valve assembly for dispensing liquid from a container. A manifold includes a first channel extending downwardly from a first inlet to a first side outlet, and a second channel extending downwardly from a second inlet on the manifold to a second outlet. The first side outlet and the second inlet are located on the same horizontal plane in reference to the longitudinal axis of the manifold. An elastic membrane sheathed around the manifold extends over the first side outlet and the second inlet. External fluid pressure causes the membrane to expand under fluid flow to provide for fluid communication through the manifold. In alternate embodiments fluid pressure flowing through the first and second channels causes the elastic membrane to expand enabling fluid communication between the first side outlet and the second inlet. A sealing sleeve extends around the elastic membrane is movable from a first to a second position.

Description:
[0001]    The present invention relates to a valve assembly for use in discharging a liquid or fluid from a container. In particular the present invention provides for a valve assembly that prevents the flow of contaminants through the valve assembly into the container. 
       BACKGROUND OF THE INVENTION 
       [0002]    Whilst the sterile packaging of liquids can be achieved using many means, those containers that allow the liquids to be dispensed through valves face the problem of the liquid content maintaining sterility and preventing oxygen ingress, especially during dispensing. In dispensing sterile fluids from containers it is important to prevent any back flow of contamination into the container during and after the dispensing operation has been carried out. This is particularly important where the container has an extended period of use. If a container of a sterile fluid has a one-time use and is not intended to be dispensed over an extended period of time, the problem of contaminants flowing into the container usually does not exist. However where a container is used for some time, contamination in the form of materials originating from outside of the valve assembly and container may include microorganisms, atmospheric gases, moisture, dust and the like. If the sterile fluid is contaminated it can affect the quality, potency and even safety of the product. 
         [0003]    The present invention is directed to a valve assembly for use in discharging a liquid from a container and for preventing any flow of contaminants through the valve assembly into the container. The valve assembly includes a valve body with an elastomeric sheath within the valve that when expanded provides for a liquid flow path for dispensing the liquid from the container. 
         [0004]    Maintaining the contents sterile and free of oxygen ingress during dispensing is a challenge for most designers. U.S. Pat. No. 4,846,810 describes a valve assembly that claims to prevent backflow of contaminants including microorganisms and air during and following the dispensing of fluids. 
         [0005]    This patent describes a concept of allowing pressurized liquid to pass through a valve body containing channels that make contact with an elastomeric membrane at the surface before entering another channel. This port as it is referred to in the patent, in the absence of liquid pressure, remains tightly pressed against the valve body (elastomeric force), effectively preventing fluid, contaminants or organisms from moving beyond this point. It is claimed that such a valve has been tested and remains aseptic during use for dispensing of liquid. The invention does however have several limitations. These are:
       1. That pressure higher than gravity is required to dispense from this valve rendering the invention suitable only for pressurized collapsible containers and not so for gravity dispensed liquids stored within a collapsible bag or a rigid container.   2. The invention although suitable for aseptic dispensing, does not describe any suitable method of opening and shutting the valve in order to maintain sterility of the liquid during valve use. Maintaining sterility requires a chain of mechanisms to be useful such as fluid release control.   3. The valve does not mention the use of a breather for it to be adoptable to more rigid containers such as Poly Ethylene Terephthalate (PET) bottles.       
 
       OBJECT OF THE INVENTION 
       [0009]    It is an object of the present invention to overcome at least some of the above mentioned problems or provide the public with a useful alternative. 
         [0010]    It is a further object of the present invention to provide a valve assembly for a container permitting the dispensing of the fluid while preventing any back flow of contaminants through the valve assembly into the container holding the remaining fluid. 
       SUMMARY OF THE INVENTION 
       [0011]    Therefore in one form of the invention there is proposed a valve assembly including;
       a main inlet and a main outlet;   at least two enclosed channels, the first channel having an inlet port in communication with the main inlet and an outlet port, said second channel including an inlet port and an outlet port, said second channel outlet port in fluid communication with the main outlet; and   an elastomeric membrane of a size and shape to seal the outlet port of the first channel and the inlet port of the second channel.       
 
         [0015]    When a fluid is applied under pressure through the valve assembly, it causes the membrane to expand thereby providing a fluid flow path between the main inlet and the main outlet. 
         [0016]    In a further form of the invention there is proposed a valve assembly including;
       a main inlet and a main outlet;   a central core having at least two enclosed channels, the first channel having an inlet port in communication with the main inlet and an outlet port, said second channel including an inlet port and an outlet port, said second channel outlet port in fluid communication with the main outlet;   an elastomeric membrane extending around the central core so as to seal the outlet port of the first channel and the inlet port of the second channel;   a sealed expandable chamber extending around the elastomeric element and including a non-compressible fluid;   a means to expand the size of the chamber to thereby cause a negative pressure within the sealed chamber thereby causing the elastomeric membrane to be drawn into the chamber and so providing a fluid flow path between the exit port of the first channel and the inlet port of the second channel causing fluid entering the valve assembly through the main inlet to exit through the main outlet.       
 
         [0022]    In preference the two enclosed channels are embedded in a cylindrical core and are holes extending through the core. 
         [0023]    In preference there are multiple channels and multiple membranes with each membrane sealing the exit port of a first channel and the entrance port of the immediately adjoining second channel. 
         [0024]    In preference each membrane is housed in a separate chamber, with adjoining chambers having fluid communicating orifices therein between. Thus when the first chamber is expanded a negative pressure extends through the different chambers at a different rate causing progressive drawing of the different membranes and thus progressive fluid flow through the valve. 
         [0025]    In preference the means to expand the chamber includes a cylinder sealingly housing a piston, said piston movable within the cylinder to enlarge the size of the chamber. 
         [0026]    In a further form of the invention there is proposed a valve assembly for dispensing liquid from a container said valve assembly including:
       a manifold having a first channel extending downwardly from a first inlet to a first side outlet on the manifold, a second channel extending downwardly from a second inlet on the manifold to a second outlet, the first side outlet and the second inlet located on the same horizontal plane in reference to the longitudinal axis of the manifold;   an elastic membrane sheathed around at least a part of the manifold to extend over the first side outlet and the second inlet wherein fluid pressure flowing through the first and second channels causes the elastic membrane to expand enabling fluid communication between the first side outlet and the second inlet;   a sealing sleeve extending around the elastic membrane and adapted to be moved from a first to a second position wherein in the first position it engages the elastic membrane adjacent the first side outlet and the second inlet to prevent the elastic membrane form expanding and sealing the valve assembly and wherein in the second position it provides for a cavity for the membrane to expand into.       
 
         [0030]    In preference the sealing sleeve includes sealing rings and the sealing sleeve is moved in the longitudinal axis direction to cause the sealing rings to align with the first side outlet and the second inlet. 
         [0031]    In preference the sealing sleeve includes longitudinal protrusions, the sealing ring being adapted to be rotatable to cause the alignment of the protrusion with the first side outlet and the second inlet in the first position to mechanically prevent the elastic membrane from expanding and in a second position to provide for a cavity for the expansion of the membrane. 
         [0032]    In preference there are more than two channels with the outlet ports and the inlet ports of adjacent channels all located on the same horizontal plane and adapted to be sealed by the membrane. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0033]    The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several implementations of the invention and, together with the description, serve to explain the advantages and principles of the invention. In the drawings: 
           [0034]      FIG. 1  is a cross-sectional view illustrating an embodiment of the present invention when the valve is sealed and at rest; 
           [0035]      FIG. 2  is the value as in  FIG. 1  when the valve is partially operated and the fluid starts to flow through the valve: 
           [0036]      FIG. 3  is the valve as in  FIG. 1  when the valve is fully operated and the fluid starts to flow out of the valve. 
           [0037]      FIG. 4  is the valve of  FIG. 1  when fluid has begun to be dispensed through the valve; 
           [0038]      FIG. 5  is the valve of  FIG. 1  when the valve is operated to start stopping the flow of fluid through the valve; 
           [0039]      FIG. 6  is the valve of  FIG. 1  when the volume of fluid flowing through the valve is reduced; 
           [0040]      FIG. 7  is the valve of  FIG. 1  when it has been fully closed; 
           [0041]      FIG. 8  illustrates a second embodiment of the present invention where the flow of fluid is controlled by a pull/push mechanism and where the valve is in the closed position; 
           [0042]      FIG. 9  is the valve as in  FIG. 8  but when the valve is in an open position with fluid flowing through the valve 
           [0043]      FIG. 10  is a third embodiment of the present invention where the flow of fluid is controlled by a rotatable mechanism and where the valve is in a closed position; 
           [0044]      FIG. 11  is a cross-sectional view of the valve as in  FIG. 10 ; 
           [0045]      FIG. 12  is the valve as in  FIG. 10  but when in an open position before any fluid flows through the valve; 
           [0046]      FIG. 13  is a cross-sectional view of the valve of  FIG. 12 ; and 
           [0047]      FIG. 14  is the valve as in  FIG. 10  but with fluid flowing through the valve 
       
    
    
     LIST OF COMPONENTS 
       [0048]      10  valve 
         [0049]      12  body 
         [0050]      14  inlet 
         [0051]      16  outlet 
         [0052]      18  chamber 
         [0053]      20  chamber 
         [0054]      22  chamber 
         [0055]      24  entrance for chamber  22   
         [0056]      26  exit for chamber  26   
         [0057]      28  elastic membrane (TEM) 
         [0058]      30  chamber 
         [0059]      32  chamber 
         [0060]      34  chamber 
         [0061]      36  entrance port of outlet  16   
         [0062]      38  cylinder 
         [0063]      40  piston 
         [0064]      42  aperture 
         [0065]      44  liquid 
         [0066]      46  flow path 
         [0067]      48  stretched TEM 
         [0068]      50  air 
         [0069]      52  small aperture 
         [0070]      54  aperture 
         [0071]      56  fluid flow path 
         [0072]      58  exit port of chamber  18   
         [0073]      60  entrance port of chamber  20   
         [0074]      62  valve manifold 
         [0075]      64  locking spout 
         [0076]      66  sealing sleeve 
         [0077]      68  retention ring 
         [0078]      70  sealing ring 
         [0079]      72  cavity 
         [0080]      74  flow channels 
         [0081]      76  outlet port 
         [0082]      78  sealing protrusions 
         [0083]      80  inlets 
         [0084]      82  outlets 
       DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0085]    The following detailed description of the invention refers to the accompanying drawings. Although the description includes exemplary embodiments, other embodiments are possible, and changes may be made to the embodiments described without departing from the spirit and scope of the invention. Wherever possible, the same reference numbers will be used throughout the drawings and the following description to refer to the same and like parts. Dimensions of certain of the parts shown in the drawings may have been modified and/or exaggerated for the purposes of clarity or illustration. 
         [0086]    Turning now to the drawings in detail there is illustrated in  FIG. 1  the valve  10  of the present invention. The valve includes a body  12  having an inlet  14  and an outlet  16  used to dispense a liquid. Located between the inlet and the outlet ports are multiple chambers  18 ,  20  and  22  each having an entrance and an exit, such as entrance  24  and exit  26  for chamber  22 . These chambers may take any cross-sectional shape, but typically they are circular holes that extend at a downward angle to the valve body so that fluid can flow down the chambers due to gravity. Covering over each of the entrance and exit ports is a tubular elastomeric membrane (TEM)  28 . The TEM is stretched tightly across all of the ports and seals the outlet of the ports preventing product flowing through the chambers. Of course in the case of the first chamber  18  the TEM does not seal the entrance port. Three chambers are present, each sealed tightly against product passage or bacterial ingress. Each chamber acts as a “trap” against bacteria ingress to the beverage. Of course it is to be understood that the invention is not to be limited to three chambers and there may indeed be a different number of chambers. 
         [0087]    The valve assembly further includes chambers  30 ,  32  and  34  that respectively surround the exit port and adjoining entrance port of sequential chambers. Thus chamber  30  surrounds exit port of chamber  18  and the entrance port of chamber  20 , chamber  32  surrounds exit port of chamber  20  and entrance port of chamber  22  and chamber  34  surrounds exit port of chamber  22  and the entrance port  36  of outlet  16 . When the TEM seals all of the entrance and exit ports no liquid can be dispensed and the valve ensures that no contamination of the liquid can occur. The entrance and exit chambers shall be defined further below. 
         [0088]    Chambers  30 ,  32  and  34  are filled with an incompressible fluid. The valve assembly further includes a cylinder  38  that is sealingly engaged by a piston  40 . The cylinder is in fluid communication with chamber  30 . In the closed state the piston is located at the upper end of the cylinder. Upon depression air (or any other fluid) is caused to be forced out of the cylinder through aperture  42 . This then causes a reduction of pressure in chamber  30  and with a sufficient drop in pressure causes the TEM that seals the exit port of chamber  18  and entrance port of chamber  20  to be forced under pressure into chamber  30 . Assuming that the TEM flexes uniformly this then provides a flow path between the exit port of chamber  18  and the entrance port of chamber  20 . This is best illustrated in  FIG. 2  where liquid  44  flows through the flow path  46  defined by the stretched TEM  48  caused by the de-pressurising of chamber  30  by flow of air  50 . 
         [0089]    Chamber  30  is in fluid communication with chamber  32  through small aperture  52 , with chamber  32  being in fluid communication with chamber  34  through aperture  54 . The size of apertures  52  and  54  is chosen so that it takes time for the three chambers to achieve equal pressure. This results in the TEM covering the ports as discussed above to do so in a progressive manner. Thus as illustrated in  FIG. 3  where the TEM covering the exit port of chamber  20  and entrance port of chamber  22  has just started to expand into chamber  32  causing the fluid flow to progress further. Finally as illustrated in  FIG. 4  after some time the chambers  30 ,  32  and  34  are at an equal pressure causing all of the TEM&#39;s to expand into the respective chambers by the same amount enabling liquid  44  to freely flow out of the valve. 
         [0090]    To close the fluid flow the opposite process is repeated. The piston is moved upwards to pressurise chamber  30  through fluid flow  56 . When the pressure in chamber  30  equals that in chamber  18  the TEM starts to collapse closing of the exit port  58  of chamber  18  and entrance port  60  of chamber  20  stopping any further fluid flow. The remaining fluid flows on to the adjoining chambers until all of the TEM&#39;s have collapsed when the pressure has been equalised along all chambers  30 ,  32  and  34 . The reader can appreciate that operation in  FIGS. 6 and 7 . 
         [0091]    Hence in operating the valve assembly the operator pushes down on piston  40 , drawing non-compressible fluid behind the piston. The elastic membrane in chamber  30  is drawn open to make up for the reduction in volume that has flown into the cylinder behind the piston. The TEM is stretched to a wider diameter and the elastic resistance causes a vacuum in chamber  30 , and resistance to the operator activation of the piston. The diameter of the piston is chosen such that total vacuum could be achieved with low operator activation force. 
         [0092]    When the piston is fully depressed, an action that may take less then one second, the TEM in chamber  30  is strained further than in chambers  32  and  34 . A lower pressure exists in chamber  30  than  32 , and pressure in chamber  32  is less than chamber  34 . This is caused by the pressure drop of the fluid passing through the orifices  52  and  54 . 
         [0093]    The pressure drop of each orifice causes the desired opening lag of TEM in chamber  34 , which lags TEM in chamber  32  opening, which lags the opening of the TEM chamber  32 . This is desired to ensure when the final product outlet to atmosphere is opened, product flows to preventing bacterial ingress. 
         [0094]    As illustrated in  FIG. 5 , when the piston (or button) is held down during dispensing the operator activation force is in equilibrium with the elastic potential energy of the TEM&#39;s. Pressure in each of the three incompressible fluid chambers  30 ,  32  and  34  naturally reaches equilibrium. The TEM in each chamber is open the same amount. The volume of fluid displaced by the piston equals the increase in volume of the TEM from its diameter growing. The TEM is held open purely by the vacuum caused by operator activation force on the piston. Product is free to flow through the aseptic tap body, only needing to overcome friction losses associated with tortured path. The product pressure does not need to force open the TEM. Consequently this can be used as gravity flow valve, not requiring product pressure. 
         [0095]    To stop the dispensing of the liquid the operator releases activation force on the piston. The TEM&#39;s begins to constrict, the constriction changing the volume in the incompressible fluid chamber, consequently drawing up the piston. The fluid is drawn back into each chamber by the constricting TEM. 
         [0096]    The fluid takes longer to be drawn into chamber  34  than chamber  32 , and chamber  32  takes longer to draw the fluid back into the chamber than does chamber  30 . The TEM&#39;s cannot close until the all the fluid is drawn back into the chamber, and the piston reaches top of the stroke again. This causes the desired lag time in closing of the TEM bacteria traps. 
         [0097]    The TEM in chamber  30  will close first, there being no flow resistance in drawing fluid into chamber  30 . Piston  40  is drawn up due to the change in volume of chamber  30  only. Whilst that TEM is constricting, product flow continues through the other TEM&#39;s as these remain open. 
         [0098]    The next TEM will then close, the fluid resistance through orifice  52  causing a lag in closing compared to the TEM in chamber  30 . Whilst constricting, product flow will be continue exiting the last TEM in chamber  34  ad the one in chamber  30  has now shut. 
         [0099]    The TEM in chamber  34  will close last, fluid flow through both orifices  52  and  54  causing the greatest lag. Whilst constricting, product will continue to flow from the outlet  16 . 
         [0100]    During the closing sequence of the TEM&#39;s, or traps, the purposeful lag in TEM trap closings causes a continual flow of product from the outlet. This product outflow prevents bacterial ingress, and is why the sequential trap closing is desired. 
         [0101]    A biasing means, such as a spring (not shown) may be located so to act on the piston to push it up therefore forcing the elastomer to close via force transfer through fluid to the elastomeric membrane. 
         [0102]    The reader will now appreciate the advantages of the present invention including the following:
       1. Opening and closing the valve manually whilst maintaining sterility.   2. Hydraulically operating to open, close and sequentially, in predefined order, operate the valve ports to maintain positive pressure at all times of operation, effectively decreasing the probability even further of contamination into the stored liquid.   3. Manually achieve what the hydraulically operating system achieves. This is a variation of design using similar concept as the hydraulic design.   4. Including in certain applications a breather for the basic valve can be incorporated with the basic valve so that it can filter air through to the dispensing container to replace fluid or liquid loss as a result of dispensing.   5. Gravity and high pressure dispensing from a collapsible container and even dispensing from a semi-rigid containers such as PET bottles with a basic valve having a sterile air filter incorporated.       
 
         [0108]    The basic valve can also vary in shape. Shapes such as cylindrical, cone or horseshoe and others that are not described here. 
         [0109]    In another variation of the invention, the channels can be made totally on the surface, between the valve body and the elastomeric membrane. The number of channels could be at least one or more in number. The elastomeric membrane can either be stuck by heat to the valve, glued or simply remain in place by the force against the valve. The valve body and elastomeric membrane can be made from any suitable material or make use of antimicrobial plastics or other materials or new materials which contain antimicrobial constituents embedded. 
         [0110]    In another variation of the invention, the valve can have more than one liquid entry channel. For example, in one inlet channel, liquid flows and by valve/tap rotation, the liquid flow is stopped and the second inlet fluid or gas, used to disinfect and remove liquid residues can pass through to clean the valve body. 
         [0111]    In a further variation to the invention the piston may be biased by a mechanical means, such as a spring. Without a spring, the total vacuum in pressure to open the tubular membrane may be limited to a small amount. With a spring the hydraulic liquid can be pressurised by greater than atmospheric pressure. 
         [0112]    Whilst not limiting the invention to any particular measurements it is expected that a sealing pressure of some 30 kPa will be applied and that an operator driven piston may provide up to −90 kPa of pressure. As to the dimensions of the valve, the valve body can be typically IOmm diameter and the TEM a 0.18 mm silicon membrane. 
         [0113]    It is also to be understood that it is not intended to limit the invention to the embodiment described above. Thus the following may be variations on the concept that is the intention of the present application. 
         [0114]    The valve body (plastic body with elastomeric membrane on the outside), may be mechanically operable. In a circular shape it will have a rotary concept within the smaller inner circle that will press the elastomeric membrane shut against the valve body when the rotary tap is turned to the left (one way rotation). This works by having half the rotary tap able to press the elastomeric membrane shut against the same sequence described in the hydraulic version. When the tap is again rotated in the one direction, the mechanical impingement of the elastomeric membrane will lift since half of the tap will not impose any pressure on the elastomeric membrane. 
         [0115]    A multiple of spring biasing means may be employed as briefly described above. 
         [0116]    The valve body can be of differing size and shape and have any number of internal channels and surface “traps”, that is TEM&#39;s located within a dedicated chamber. 
         [0117]    There can also be a version of the valve that will not have a peristaltic opening/closing motion. In this variation, a mechanical impingement of flow or an on/off system may be included to operate the flow of the valve. The valve body does not necessarily require channels and all flows can be directed between the valve surface and elastomeric membrane, The channels could be one in number to as many as required. 
         [0118]    In another version of the invention, there may be the option to add a “breather” passage from outside to the inlet should. The breather can filter and sterilise air going back into a PET bottle after squeezing liquid out of the bottle. The breather can help restore or replace the missing volume in such a PET bottle. 
         [0119]    Illustrated in  FIGS. 8 and 9  is a second embodiment of the present invention. Here the aseptic valve is prevented from opening by applying a pressure on the membrane  28  (pouch). The valve manifold  62  supports a locking spout  64  that is slidable along the longitudinal axis of the manifold. The sealing sleeve or membrane  66  sheaths the manifold  62  and is held in place by retaining rings  68 . The locking spout includes sealing rings or protrusions  70  dimensioned so that when the valve is in the closed position they abut the membrane  66  at the inlets and outlets of the various flow channels  74  thus mechanically preventing fluid from flowing through the valve channels. When the locking spout  64  is slid down as shown in  FIG. 9  (although the direction is not important) the sealing rings  70  move to then abut the sleeve  66  against the valve manifold body allowing the sealing sleeve to expand into the cavity  72  defined between the spout and the manifold and thus allowing fluid to flow through the channels in the manifold and out through the outlet port  76   
         [0120]      FIGS. 10 to 14  illustrate a similar embodiment as to  FIGS. 8 and 9  but where the mechanical operation is achieved by a rotatable action rather then a longitudinal motion. 
         [0121]    Thus the locking spout  64  includes longitudinal sealing protrusions  78  that can be rotated into position to mechanically seal the inlets  80  and the outlets  82 . When rotated out of position as illustrated in  FIG. 13 , the sealing sleeve can move into the cavity  72  as shown in  FIG. 14 . 
         [0122]    The embodiments in  FIGS. 8 to 14  illustrate three flow channels. It is however to be understood that there may be less or more flow channels and that the invention is not limited to a particular number. In addition these further embodiments illustrate the mechanical sealing of the various inlets and outlets. It should be understood that in some circumstances one inlet or outlet may indeed be mechanically sealed. Other times there could be a plurality. Thus the present invention is not to be understood as limiting the invention to all inlet and outlets having to be sealed. 
         [0123]    In a further embodiment, not shown, the arrangement of mechanically sealing of the various inlets and outlets may be achieved in a progressive manner. Typically one would first seal the uppermost outlet and then progressively seal the others. This would ensure that any fluid has sufficient time to flow out of the valve manifold so that it does not remain in it and be subject to contamination. This progressive sealing may be achieved by staggering the sealing ring  68  or sealing protrusions  78  so that if the locking spout  64  is slid or rotated the uppermost inlets and outlets would be sealed first. 
         [0124]    Further advantages and improvements may very well be made to the present invention without deviating from its scope. Although the invention has been shown and described in what is conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom within the scope and spirit of the invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent devices and apparatus. 
         [0125]    In any claims that follow and in the summary of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprising” is used in the sense of “including”, i.e. the features specified may be associated with further features in various embodiments of the invention.