Abstract:
A valve for selectively sealing and unsealing an opening in a bladder is disclosed. The valve includes a flange for mounting the valve around the opening in the bladder, a valve seat supported on the flange, and an air passageway. A spring plate is supported on the flange and spaced from the valve seat. A floating valve disk is provided between the valve seat and the spring plate for movement towards and away from the valve seat to seal and unseal the opening in the bladder. A spring is provided to bias the floating valve disk towards the valve seat. Deflation lugs are provided to hold the floating valve disk away from the valve seat against the force of the spring. The floating valve disk is free to pivot but is prevented from pivoting to such an extent that movement of the floating valve disk is impeded as by binding.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     None. 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT 
     Not applicable. 
     REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISC 
     Not applicable. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention concerns the field of valves and, more specifically, valves that are useful in rapidly filling and deflating dunnage air bags. 
     2. Background of the Invention 
     In a prior art search directed to the subject invention, the following US Patents were noted: U.S. Pat. Nos. 8,181,664; 7,410,145; 7,401,619; 7,051,753; 6,929,021; 6,550,086; 6,089,251; 5,941,272; 5,111,838; 4,927,397; 3,308,981; 3,785,395; and D536,565. Published US Patent application no. 2010/0043914 was also noted. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention is a valve especially suited for rapidly inflating and deflating a bag such as a bag that might be used to cushion freight in transit, also known as a dunnage bag. The valve has a flange for mounting it on a dunnage bag, and an air inlet accessible from outside of the bag. The flange supports a valve seat which faces the inside of the bag and a floating valve disk that is biased by a spring, for example, towards the valve seat for sealing engagement therewith. When the valve disk engages the valve seat, the valve is in a closed condition. Air delivered under pressure to the air inlet acts on the valve disk to overcome the bias and unseat the valve disk thereby opening the valve. When the valve is opened this way, pressurized air moves through the inlet and through the open valve to the inside of the bag to fill it to a desired pressure. When the desired pressure is reached, the source of pressurized air is removed from the air inlet and the biased valve disk engages the valve seat closing the valve to impede the flow of air out of the bag through the air inlet. A cap may be applied to the air inlet to further impede the flow of air out of the bag. 
     The valve includes a spring plate which is releasably connected to and axially spaced from the flange. A spring or other resilient member positioned between the spring plate and the valve biases the valve disk away from the spring plate and towards the valve seat. In a preferred embodiment, the spring plate comprises axially extending members which frictionally engage axially extending members supported on the flange. These members may comprise posts and cooperating cylindrical members for receiving the posts and, in this case, it is preferred that the posts frictionally engage the inside wall of the cylindrical posts to releasably support the spring plate on the flange spaced axially a given distance therefrom. 
     In a preferred embodiment, the flange supports pegs which extend axially from the flange towards the spring plate. The pegs have support surfaces at their distal ends which are spaced axially from the spring plate. The valve disk may be provided with radially extending tabs which can engage the support surfaces on the pegs to hold the valve disk in an open position against the force of the spring to facilitate deflation of the bag. In order for the valve disk to be held in the open position, the valve disk is pushed towards the spring plate, against the force of the spring, until the axial position of the valve disk tabs is between the spring plate and the peg support surfaces. The valve disk is then rotated to position the valve disk tabs over the peg support surfaces so that, when the pushing force is released, the spring pushes the valve disk so that the tabs engage the peg support surfaces and the pegs prevent the valve disk from seating against the valve seat. Finger knobs are provided on the valve disk and they extend axially into the air inlet so that they may be engaged from outside of the bag. The finger knobs are configured and positioned to facilitate movement of the valve disk towards the spring plate and rotation of the valve disk so that the valve disk tabs engage the peg support surfaces. Using only his or her fingers, a person can open the valve from outside of the bag and rotate the valve disk so that the valve disk is held in the open position to facilitate deflation of the bag. 
     Accordingly, it is an object of the invention to provide a valve for inflating and deflating a bag. 
     It is another object of the invention to provide a valve with a minimum number of parts which can be assembled by hand to produce the valve. 
     It is another object of the invention to provide a valve with a valve disk which is biased towards a valve seat. 
     It is another object of the invention to provide a valve with a valve disk which is moved into an open position by air pressure when a filling nozzle delivers air under pressure into the valve air inlet. 
     It is another object of the invention to provide a valve with a valve disk that closes when air under pressure is not being delivered through the valve air inlet. 
     It is another object of the invention to provide a valve with a valve disk that can be manipulated by hand from outside of the air inlet to open the valve. 
     It is another object of the invention to provide a valve with a valve disk that can be manipulated by hand from outside of the air inlet to lock the valve in the open position. 
     These and many other objects and advantages of the invention will be understood by persons skilled in the art who study the following description and the accompanying drawings which, although thorough, are merely illustrative. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
         FIG. 1  is a perspective view of a first example of a valve according to the invention with the valve in a closed condition. 
         FIG. 2  is a side view of a valve according to the first example of the invention with a valve disk held in an open position against the force of a biasing spring. 
         FIG. 3  is a perspective exploded view of a valve according to the first example of the invention from a first angle. 
         FIG. 4  is a perspective exploded view of a valve according to the first example of the invention from a second angle. 
         FIG. 5  is a perspective view of a valve according to a second example of the invention with the valve in a closed condition. 
         FIG. 6  is a side view of a valve according to the second example of the invention with a valve disk held in an open position against the force of a biasing spring. 
         FIG. 7  is a perspective exploded view a valve according to the second example of the invention from a first angle. 
         FIG. 8  is a perspective exploded view of a valve according to the second example of the invention from a second angle. 
         FIG. 9  is a side view of a valve according to the first example of the invention with the valve in a closed condition. 
         FIG. 10  is a side view of a valve according to the second example of the invention with the valve in a closed condition. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     A valve according to a first embodiment of the invention is indicated generally at  10  in  FIGS. 1 through 4  and  9 . The valve  10  comprises a flange  12  for mounting it on a bag (not shown) or any other air bladder. Bag, as used herein, refers to a dunnage bag and to air bladders generally. An air inlet indicated at  14  is positioned generally outside of a bag when the flange  12  is secured to a side wall of the bag as by sonic welding, heat welding, chemical welding or other suitable means. The inlet  14  defines a passageway through which air can flow into, as well as out of, a bag through an opening in a wall of the bag. The air inlet  14  is defined by a generally cylindrically shaped inlet tube  16  which is supported on and extends outwardly from the flange  12 . The inlet tube  16  has external threads which engage corresponding threads provided on the inside of a cap  18 . 
     It is preferred that the inside wall of the inlet tube  16  taper, slightly, so that the inside diameter of the inlet tube  16  at its distal end  20  is slightly larger than the inside diameter of the inlet tube  16  at its proximal end  22  adjacent to the flange  12 . With this configuration, a cylindrical filling tube (not shown) with a constant outside diameter is easily received in the inlet tube  16  if the outside diameter of the filling tube is slightly less than the inside diameter of the inlet tube  16  at the distal end  20 . In this case, it is preferred that the inside diameter of the inlet tube  16  at the proximal end  22  be slightly smaller than the outside diameter of the filling tube so that the filling tube seats against the inside surface of the inlet tube  16  somewhere between the distal end  20  and the proximal end thereof. 
     The valve  10  includes a valve disk  24  which is supported in the valve  10  for movement between open positions and a closed position. When the valve disk  24  is in an open position, such as shown in  FIG. 2 , air can flow freely through the valve  10  and through the air inlet  14 . In this position, the valve disk  24  is positioned away from the flange  12  and away from a valve seat  26  ( FIG. 4 ). When the valve disk  24  is in the closed position, as shown in  FIG. 9 , the valve disk  24  is seated on the valve seat  26  and air flow through the valve  10  and through the air inlet  14  is restricted or prevented. 
     A spring  28  biases the valve disk  24  towards the closed position, i.e., towards the valve seat  26  and towards the flange  12 . A first end  30  of the spring  28  acts on the valve disk  24  and a second end  32  of the spring  28  acts on a spring plate  34 , which is supported relative to the flange  12  at a fixed distance from the flange  12 . As the valve disk  24  moves from the closed position to an open position, the spring  28  is compressed. Radial movement of the first end  30  of the spring  28 , relative to the valve disk  24 , is restricted by a recess, indicated at  36 , in the valve disk  24 . The recess  36  has a diameter that is larger than the diameter of the first end  30  of the spring  28 . Radial movement of the second end  32  of the spring  28 , relative to the spring plate  34  is restricted by a raised circular boss  38  which has a diameter that is larger than the diameter of the second end  32  of the spring  28 . 
     The spring plate  34  has projections  40  which extend axially from the spring plate  34  towards the flange  12 . Projections  42  extend axially from the flange  12  towards the spring plate  34 . When the flange  12  and the spring plate  34  are aligned axially, the projections  42  and  40  can be aligned with each other. In the embodiment shown in the drawing Figures, the projections  40  are configured as posts and the projections  42  are configured as cylinders although these configurations can be reversed. It is preferred that the outside diameter of the posts and the inside diameter of the cylinders are controlled so that there is enough frictional engagement between the posts and the cylinders when they are engaged to connect the plate  34  to the flange  12  and to keep them connected. This type of connection eliminates the need for any additional connection between these parts while keeping the flange  12  and the spring plate  34  connected and separated by a given distance, as needed. This type of connection allows one to connect the spring plate  34  to the flange  12  by hand, without the need for tools or adhesives of any kind. However, it will be appreciated that other means for connecting the flange  12  and the spring plate  34  must be considered to be within the scope of the invention, even though they are not preferred. 
     The valve disk  24  includes tabs  44  which extend radially outwardly from a central, substantially round portion  46  of the valve disk  24 . When the spring plate  34  is connected to the flange  12  and the valve disk  24  is axially aligned therewith, the central portion  46  of the valve disk  24  fits within the area defined by the projections  42 . The central portion  46  is sized and the projections  42  are positioned so that the valve disk  24  is supported for rotational movement relative to the spring plate  34  and the valve seat  26 . When the flange  12  is connected to the spring plate  34 , and the valve disk  24  is between them, the valve disk  24  is held captive although it can move axially, to a limited degree and it can rotate. The tabs  44  extend radially outwardly to the extent that they limit rotational movement of the valve disk  24 . Specifically, the valve disk  24  can rotate until the tabs  44  contact the projections  42  and, due to this contact, further rotation of the valve disk  24  is prevented. With four projections  42  on the flange  12 , relative rotation between the valve disk  24  and the spring plate  34  will be limited to less than ninety degrees. There may be less than four projections  42  in which case the relative rotation will be limited to less than 120 degrees. There may be more than four projections  42  in which case the relative rotation will be limited to less than 72 degrees. Excellent results have been obtained in the case where there are four projections  42 . A minimum of three axially extending projections are preferred. 
     The valve  10  may be assembled in the following manner. The valve disk  24  is positioned against the flange  12  with the tabs  44  positioned between adjacent projections  42 . The first end  30  of the spring  28  is inserted into the spring recess  36 . The spring plate  34  is moved towards the flange  12 . The projections  40  are aligned with corresponding projections  42 , the second end  32  of the spring  28  is aligned with the spring retention boss  38 , and the plate  34  and the flange  12  are manipulated to bring the projections  40  and  42  into frictional engagement with each other. The parts are configured and sized so that, when the valve  10  is assembled, the spring  28  holds the valve disk  24  against the valve seat  26 . Before these assembly steps are carried out, the flange  12  may be secured to a bag around an edge defining an opening in a bag. Alternatively, the valve can be assembled before the flange  12  is secured to a bag. 
     In order to fill a bag equipped with a valve corresponding with the valve  10 , air under pressure is delivered to the air inlet  14 . As pressure builds up in the air inlet  14 , it acts on the valve disk  24  against the force of the spring  28 . When the pressure reaches a threshold, the spring force of the spring  28  is exceeded by the force of the air under pressure acting on the valve disk  24  and it moves towards the spring plate  34 . It is preferred that the threshold be comparatively low so that the valve  10  opens when the valve disk  24  sees air at a pressure of less than 90 p.s.i. It is more preferred that the threshold be low enough so that the valve  10  opens when the valve disk  24  sees air at a pressure of less than 70 p.s.i. and, even more preferably, the threshold pressure will be less than 60 p.s.i. With the valve  10  open, air will flow through the air inlet  14  into the bag until the source of pressure is removed from the air inlet  14 . At that point, the spring  28  will move the valve disk  24  towards the flange  12  until the valve disk  24  seats on the valve seat  26 . This will prevent or restrict the flow of air out of the bag although some air may escape through the valve slowly due to the relatively low spring force of the spring  28 . The cap  18  may be secured to the inlet tube  16  to essentially prevent the flow of air out of the bag. 
     The valve  10  is especially suited for deflating an inflated bag. The valve disk  24  includes a manually operable deflation actuator  48  comprising a plurality of finger engagement tips  50  supported on a raised portion  52  of the valve disk  24 . When the valve  10  is assembled, the finger engagement tips  50  extend a substantial distance into the inlet tube  16  towards its distal end  20 . By pressing against the tips  50 , the force of the spring  28  is easily overcome, even if pressure is applied only by a finger or fingers, and the valve disk  24  will unseat from the valve seat  26  so that air may flow out of the bag through the inlet tube  16 . No tool is required to unseat the valve disk so that a bag may be inflated and no tool is required to unseat the valve disk so that a bag may be deflated. This gives the valve of the present invention numerous advantages over known valves adapted for use in inflating and deflating dunnage bags. 
     When the valve  10  is opened to deflate a bag, it is desirable to have a mechanism for maintaining the valve  10  in the open position during deflation so that attention can be turned to deflating other bags in a load while air escapes from a bag with an open valve. For this purpose, deflation lugs  54  are provided on the flange  12 . The lugs  54  extend axially from the flange  12  towards the spring plate  34 . Tab surfaces  56  are provided on the deflation lugs  54  and these are spaced from the spring plate  34  when the valve  10  is assembled, as can be seen in  FIG. 9 . The deflation lugs  54  are positioned so that they are outside of the central portion  46  of the valve disk  24  when the valve is assembled and so that the valve disk tabs  44  will come into contact with the tab surfaces  56  when the valve disk  24  is moved toward the spring plate, rotated and released. Coaction between the valve disk tabs  44  and the tab surfaces  56  in this case will maintain the valve disk  24  in an open position against the force of the spring  28  and this condition is illustrated in  FIG. 2 . It is preferred that, when the valve disk  24  is moved towards the spring plate  34  and rotated until the tabs  44  come into contact with the projections  42 , the tabs  44  will be aligned with tab surfaces so that, when the valve disk  24  is released, the spring  28  will move the disk towards the flange  12  and the tabs  44  will seat on the tab surfaces  56 . 
     When it is desired to close the valve  10 , the valve disk  24  is rotated from the position shown in  FIG. 2  to a point where the tabs  44  are no longer in contact with the tab surfaces  56 . When the tabs  44  are clear of the tab surfaces  56  and the valve disk  24  is released, the spring force of the spring  28  will move the valve disk  24  towards the flange  12  and into contact with the valve seat  26 , thereby closing the valve  10 . Rotation of the valve disk  24  from the position shown in  FIG. 2  can be carried out by manipulating the finger engagement tips  50  on the valve disk  24 . Rotation is facilitated if the valve disk  24  is moved towards the spring plate  34  before the valve disk  24  is rotated. In case the valve disk  24  is moved towards and into contact with the spring plate  34  before the valve disk is rotated, low friction bumps  57  can be provided in the valve disk  24  to minimize friction between the valve disk  24  and the plate  34 , further facilitating rotation of the valve disk  24 . 
     Referring now to  FIGS. 5 through 8  and  10 , a second embodiment of a valve according to the invention is indicated at  100 . There are substantial similarities between the valve  10  and the valve  100 , and there are some significant differences. Like reference numbers are used in these Figures to refer to like parts or substantially like parts shown in  FIGS. 1 through 4  and  9  and reference is made to the foregoing description of those parts. 
     A sealing disk  58  is illustrated in  FIGS. 7 and 8 . It comprises a central region  60  and loops  62 . The central region  60  is substantially co-extensive with the central region  46  of the valve disk  24 . The sealing disk  58  is secured to the valve seat side of the valve disk  24  by engagement between the loops  62  and the tabs  44 . The loops  62  are pulled over the tabs  44  so that portions of the loops are on the spring plate side of the valve disk  34  and the tabs  44  extend through the loop openings, indicated at  64 . It is preferred that the sealing disk  58  be made from a strong, resilient, somewhat soft material such as silicone. This promotes a good seal between the sealing disk  58  and the valve seat and it facilitates the step of connecting the sealing disk  58  to the valve disk  24 . The sealing disk  58  can improve the overall sealing properties of the valve  100 . In assembling the valve  100 , the sealing disk  58  would be connected to the valve disk  24  before the valve disk  24  is assembled in the valve  100 . 
     The spring plate  34  has a raised central portion  66  which serves as a spring locator. The second end  32  of the spring  28  is positioned over the raised portion  66  and this restricts radial movement of the spring  28 . The central portion  66  is a more aggressive spring locator than the circular boss  36  on the spring plate  34  in the valve  10 . 
     The flange  12  includes deflation lugs  68  with tab surfaces  70 . Each lug  68  has two tab surfaces  70 . The profile of the deflation lugs  68  is somewhat smaller than the profiles of the deflation lugs  54  of the valve  10 . The smaller profile helps because a portion of each of the tabs  44  is covered by a portion of the corresponding loop  62  leaving a smaller portion of each tab  44  available to engage the corresponding deflation lug  68 . This lug configuration helps to prevent contact between portions of the sealing disk  58  and the deflation lugs  68  which might hamper the free movement of the valve disk  24 . 
     The valve disk  24  is supported in the valve  10  and the valve  100  for axial movement between the flange  12  and the spring plate  34  and for rotational movement. However, in this valve, the valve disk  24  floats meaning that it may become skewed so that its axis is not coincident with the axes of the valve seat and the spring. In order to prevent the orientation of the valve disk  24  from becoming too skewed, and interfering with the operation of the valves  10  and  100  and the free movement of the valve disk  24 , it is preferred to have the diameter of the central portion  46  of the valve disk  24  be greater than the distance between the valve seat  26  and the spring plate  34 . This positively prevents the valve disk  24  from turning sideways, for example, and binding and getting stuck. It is preferred to have the diameter of the central portion  46  of the valve disk  24  be at least twice the distance between the valve seat  26  and the spring plate  34 . 
     It will be appreciated that a valve according to the present invention can be adapted for use in a wide variety of applications. The invention resides in the valves made up of the components described above and in sub combinations of these components which are new: and unobvious. The foregoing description of the preferred embodiments of the invention are presented merely to convey to a person having ordinary skill in the field of valves the various features of the invention, and not to limit the invention to the embodiments described above.