Abstract:
A valve mechanism adapted for a mouth portion of a tube-type fluid container includes: a valve seat portion having an opening through which a fluid passes; a disc-shaped valve portion; and an annular fixing portion for affixing the valve portion to the valve seat portion. The valve portion includes: an annular supporting portion, a closing portion for closing the opening, and multiple connecting portions connecting the closing portion to the annular supporting portion to urge the closing portion toward the opening. The annular supporting portion, the closing portion, and the multiple connecting portions are integrally formed.

Description:
BACKGROUND OF THE INVENTION 
   The present invention relates to a valve mechanism, particularly to a valve mechanism which can be used for a tube-type fluid container. 
   As this type of valve mechanism, for example, as described in Japanese Patent Laid-open No. 2001-179139, a valve mechanism having a spherical valve body and a spring for giving momentum to the valve body toward a valve seat has been used. Manufacturing costs of the valve mechanism using the spherical valve body and the spring, however, tend to be high. 
   Consequently, a valve mechanism having a resinous valve seat, and a resinous valve body which moves between a closed position in which the valve body contacts the valve seat and an open position in which the valve body separates from the valve seat is commonly used. 
   In the resinous valve mechanism, it is preferred that the valve mechanism has a simple configuration which can close a fluid flow reliably. Additionally, it is preferred that the configuration can alter a flow rate of the fluid passing through the valve mechanism discretionally according to a pressure applied to the fluid. As matters stand, however, a valve mechanism satisfying these requirements is not reported. 
   SUMMARY OF THE INVENTION 
   The present invention has been achieved to solve the above-mentioned problems. It aims to provide a valve mechanism which can close a fluid reliably while its configuration is simple and which can alter a flow rate of the fluid passing through the valve mechanism discretionally according to a pressure applied to the fluid. 
   The present invention includes, but is not limited to, the embodiments explained below. Solely for the sake of understanding some embodiments of the present invention easily, reference numerals used in the figures explained later are referred to. However, the present invention is not limited to the structures defined by these reference numerals, and any suitable combination of elements indicated by these reference numerals can be accomplished. 
   In an embodiment, a valve mechanism adapted for a mouth portion (a head portion, e.g.,  42 ) of a tube-type fluid container (a container main unit, e.g.,  40 ), comprising: (a) a valve seat portion (e.g.,  30 ,  130 ) having an opening (e.g.,  43 ,  133 ) through which a fluid passes; (b) a disc-shaped valve portion (e.g.,  20 ) comprising: (i) an annular supporting portion (e.g.,  21 ), (ii) a closing portion (e.g.,  22 ) for closing the opening, said closing portion having an outer diameter (e.g., A) smaller than an inner diameter (e.g., B) of the annular supporting portion and larger than an inner diameter (e.g., C) of the opening, and having a convex shape (e.g.,  22 ′) toward the opening; and (iii) multiple connecting portions (coupling portions, e.g.,  23 ) connecting the closing portion to the annular supporting portion to urge the closing portion toward the opening, wherein the annular supporting portion, the closing portion, and the multiple connecting portions are integrally formed; and (c) an annular fixing portion (e.g.,  101 ,  16 ) for affixing the valve portion to the valve seat portion by interposing the supporting portion between the fixing portion and the valve seat portion. 
   The present invention includes, but is not limited to, the following configurations in other embodiments: The valve seat portion may have a convex annular portion (e.g.,  44 ,  134 ) around the opening toward the closing portion. The annular fixing portion may be an integrated part of a nozzle cap (e.g.,  10 ,  110 ,  19 ) for discharging a fluid. The valve seat portion (e.g.,  30 ) may be integrally formed in the mouth portion (e.g.,  42 ) of the container. The valve seat portion (e.g.,  130 ) may be fitted in the mouth portion (e.g.,  142 ) of the container. The valve seat portion (e.g.,  30 ,  130 ) may have an annular step (e.g.,  35 ,  135 ) at its periphery which is in contact with the annular supporting portion (e.g.,  21 ). The connecting portions may have at least three (e.g., three to six) connectors (e.g.,  23 ). The connecting portions (e.g.,  23 ) may connect the closing portion to the annular supporting portion (e.g.,  21 ) in radial directions (or outward spiral directions). Further, the valve seat portion may be replaceable and selected based on the consistence of the fluid. 
   In another aspect of the present invention, a tube-type fluid container (e.g.,  40 ) comprises a container body (e.g.,  41 ) for storing a fluid having a mouth portion (e.g.,  42 ,  142 ), and the valve mechanism described above attached to the mouth portion. 
   According to an embodiment or embodiments of the present invention, a fluid can be closed reliably although a configuration is simple; it becomes possible to change a flow rate of the fluid passing through the opening discretionally according to a pressure applied thereto. Particularly, when using a fixing portion integrated with a nozzle cap and/or when using a valve seat portion integrated with a mouth portion, it becomes possible to reduce the number of parts. 
   In the above, the fluid can be discharged from an outlet of the mouth portion of the container through the valve mechanism by pressing the container, wherein the connectors and the container are deformed. When releasing the pressure, both the deformed connectors and the deformed container begin restoring the shapes. The restoring force of the container causes the inner pressure to lower, thereby generating reverse flow which facilitates restoration of the connectors to close the opening of the valve seat portion, thereby effectively preventing air from coming into the container through the outlet of the mouth portion. Thus, even if the restoring force of the connectors themselves is not sufficient to close the opening of the valve seat portion, the outlet of the mouth portion can effectively be closed in combination with the restoring force of the container. Thus, even if the fluid is very viscous, the valve mechanism in combination with the container can discharge the fluid and then seal the container. 
   Further, in an embodiment of the present invention, the valve portion has a closing portion having a convex shape toward the opening, and due to the convex shape, the connectors can slightly be deformed even when the opening is closed, and restoring force is exerted on the closing portion toward the opening, thereby improving sealability. This feature may be improved when providing a convex portion in the valve seat portion (e.g., around the opening and/or around the periphery). 
   For purposes of summarizing the invention and the advantages achieved over the related art, certain objects and advantages of the invention have been described above. Of course, it is to be understood that not necessarily all such objects or advantages may be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein. 
   Further aspects, features and advantages of this invention will become apparent from the detailed description of the preferred embodiments which follow. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     These and other features of this invention will now be described with reference to the drawings of preferred embodiments which are intended to illustrate and not to limit the invention. 
       FIG. 1  is an exploded explanatory diagram showing an embodiment of a tube-type container to which the valve mechanism according to Embodiment 1 of the present invention applies. 
       FIG. 2  is an exploded sectional view showing the relevant part of the tube-type container to which the valve mechanism according to Embodiment 1 of the present invention applies. 
       FIG. 3A  and  FIG. 3B  are a cross sectional view and a top view of the valve material  20 , respectively. 
       FIG. 4  and  FIG. 5  are explanatory diagrams showing fluid discharging motions by the tube-type container to which the valve mechanism according to Embodiment 1 of the present invention applies. 
       FIG. 6  is an exploded explanatory diagram showing a tube-type container to which the valve mechanism according to Embodiment 2 of the present invention applies. 
       FIG. 7  is an exploded cross sectional view showing the relevant part of the tube-type container to which the valve mechanism according to Embodiment 2 of the present invention applies. 
       FIG. 8  and  FIG. 9  are explanatory diagrams showing fluid discharging motions by the tube-type container to which the valve mechanism according to Embodiment 2 of the present invention applies. 
       FIG. 10  is an explanatory diagram showing a modified version of the valve mechanism according to Embodiment 2 of the present invention. 
     Explanation of symbols used is as follows:  10 : Fixing material;  11 : Opening portion;  12 : Female screw portion;  19 : Fixing material;  20 : Valve material;  21 : Supporting portion;  22 : Closing portion;  23 : Connecting portion;  30 ,  130 : Valve seat material;  131 : Flange portion;  132 : Concave portion;  133 : Opening portion;  134 : Convex portion;  40 : Container main unit;  41 : Fluid storing portion;  42 ,  142 : Head portion;  43 : Opening portion;  44 : Convex portion;  45 : Male screw portion 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   Preferred embodiments of the present invention will be described with referent to the drawings. The present invention is not limited to the embodiments. 
   An embodiment of the present invention may be characterized in that comprising a valve seat material in which an opening portion for passing a fluid therethrough is formed; a valve material comprising a resin having elasticity, which comprises a ring-shaped supporting portion, a closing portion having an outer diameter smaller than an inner diameter of the supporting portion and larger than an inner diameter of the opening portion, is disposed nearly at the center of the supporting portion and is able to close the opening portion in the valve seat portion, and multiple connecting portions which couple the supporting portion and the closing portion; a fixing material which fixes the valve material by holding the valve material tightly between the valve seat material. 
   Another embodiment of the present invention may be characterized in that the closing portion in the valve material has a convex shape facing toward the opening portion in the valve seat material. 
   Still another embodiment of the present invention may be characterized in that on the outer circumferential portion of the opening portion in the valve seat material, a convex portion facing toward the closing portion in the valve material is formed. 
   Yet another embodiment of the present invention may be characterized in that the fixing material has a nozzle shape for discharging a fluid. 
   Preferred embodiments of the present invention are described with referent to the drawings. However, the present invention is not limited to these drawings.  FIG. 1  is an exploded explanatory diagram showing a tube-type container to which the valve mechanism according to Embodiment 1 of the present invention applies.  FIG. 2  is an exploded sectional view showing the relevant part of the valve mechanism.  FIG. 3A  and  FIG. 3B  are enlarged explanatory diagrams showing the valve material  20 .  FIG. 3A  shows a longitudinal section of the valve material  20 ;  FIG. 3B  shows a plan view of the valve material  20 .  FIG. 4  and  FIG. 5  are explanatory diagrams showing fluid discharging motions by the tube-type container to which the valve mechanism according to Embodiment 1 of the present invention applies. 
   This tube-type container is used as a container for beauty products for storing gels such as hair gels and cleansing gels or creams such as nourishing creams and cold creams used in the cosmetic field. Additionally, this tube-type container also can be used as a container for medicines, solvents or foods, etc. 
   In this specification, regular liquids, high-viscosity liquids, semifluids, gels that sol solidifies to a jelly, and creams are all referred to as fluids. Application of the present invention, however, is not limited to a valve mechanism used for the above-mentioned fluids; the present invention can apply to a valve mechanism used for the entire fluids including gases. 
   This tube-type container comprises a container main unit  40 , a valve material  20  and a fixing material  10 . 
   The container main unit  40  comprises a fluid storing portion  41  for storing a fluid inside it and a head portion  42  on whose outer circumferential portion, a male screw portion  45  is formed and on whose upper end portion, an opening portion  43  for letting the fluid pass through is formed. On the outer circumferential portion of the opening portion  43  in the head portion  42 , a ring-shaped convex portion  44  facing toward the valve material  20  is formed. Additionally, this container main unit  40  comprises a synthetic resin alone or a lamination of a synthetic resin and aluminum, and has an elasticity recovering force which tries to recover its original shape when a pressure applied to it is removed. The head portion  42  in the container main unit  40  functions as the valve seat material according to the present invention. 
   The above-mentioned valve material  20 , as shown in  FIG. 3A  and  FIG. 3B , comprises a ring-shaped supporting portion  21 , a closing portion  22  which is arranged at nearly the center of the supporting portion  21 , and four connecting portions  23  which couple the supporting portion  21  and the closing portion  22 . An outer diameter of the closing portion  22  in the valve material  20  is smaller than an inner diameter of the supporting portion  21  and larger than an inner diameter of the opening portion  43  formed in a head portion  42  of the container main unit  40 . Additionally, this closing portion  22  has a convex shape facing toward the opening portion  43  in the head portion  42 . Consequently, the closing portion  22  is able to close the opening portion  43  by contacting the convex portion  44  formed on the outer circumferential portion of the opening portion  43 . 
   As shown in  FIG. 3A  and  FIG. 3B , the closing portion  22  in the valve material  20  has a convex shape in both directions: In the direction of the opening portion  43  in the head portion  42 ; in the direction opposite to the opening portion  43  in the head portion  42 . In other words, the closing portion  22  has a plane-symmetrical shape, which facilitates assembling work when a valve mechanism using this valve material  20  is assembled. 
   The valve material  20  comprises a resin having elasticity. As a resin having this elasticity, a resin such as polypropylene, synthetic rubber such as silicon rubber or a mixture of these materials can be used. 
   The above-mentioned fixing material  10  is used for fixing the valve material  20  by holding the valve material  20  tightly between its lower end portion  13  and the head portion  42  of the container main unit  40 . On the inner circumferential portion of the fixing portion  10 , as shown in  FIG. 2 , a female screw portion  12  which screws together with the male screw portion  45  formed on the outer circumferential portion of the above-mentioned head portion is formed. Additionally, the fixing portion  10  has a nozzle shape having an opening portion  11  for discharging a fluid. 
   In a tube-type container having the above-mentioned configuration, in a normal position, the convex closing portion  22  in the valve material  20  and the ring-shaped convex portion  44  formed in the head portion  42  in the container main unit  40  are in contact with each other as shown in  FIG. 4 , and the opening portion  43  is closed. 
   In this position, when a pressure is applied to the fluid inside the fluid storing portion  41  by pressing the fluid storing portion  41  in the container main unit  40 , the opening portion  43  is opened as the convex closing portion  22  in the valve material  20  and the ring-shaped convex portion  44  formed in the head portion  42  in the container main unit  40  separate from each other by the elasticity of the valve material  20  as shown in  FIG. 5 ; the fluid inside the fluid storing portion  41  is discharged outward via the opening portion  11  in the fixing material  10 . 
   In this position, a distance between the convex closing portion  22  in the valve material  20  and a ring-shaped convex portion  44  formed in the head portion  42  in the container main unit  40  is proportional to a pressure applied to the fluid inside the fluid storing portion  41 . Consequently, by changing a pressure applied to the fluid inside the fluid storing portion  41 , changing a flow rate of the fluid passing through the opening portion  43  discretionally becomes possible. When a regular liquid is used as a fluid, therefore, discharging the liquid drop by drop by applying a small pressure to the liquid inside the fluid storing portion  41  becomes possible as well. 
   When the pressure applied to the fluid storing portion  41  is removed after a necessary amount of the fluid is discharged, the fluid inside the fluid storing portion  41  is depressurized by the elasticity recovering force of the container main unit  40 ; the air tries to flow back toward the fluid storing portion  41  from the opening portion  11 . In this tube-type container, however, as shown in  FIG. 4 , the opening portion  43  in the container main unit  40  is closed by the elasticity of the valve material  20 , a fluid flow path is closed. Consequently, the reverse flow of the air can be prevented effectively. 
   In the tube-type container to which the valve mechanism according to the above-mentioned Embodiment 1 applies, because the fixing portion  10  having a nozzle-shape, which can be used as both fixing portion and a nozzle, is adopted, the number of parts can be reduced. 
   An alternative embodiment of the present invention is described below.  FIG. 6  is an exploded explanatory diagram showing the tube-type container to which the valve mechanism according to Embodiment 2 of the present invention applies.  FIG. 7  is an exploded sectional view showing its relevant part.  FIG. 8  and  FIG. 9  are explanatory diagrams showing the fluid discharging motions by the tube-type container to which the valve mechanism according to Embodiment 2 of the present invention applies. 
   In the same manner as the tube-type container according to Embodiment 1, this tube-type container is used as a container for beauty products for storing gels such as hair gels and cleansing gels or creams such as nourishing creams and cold creams used in the cosmetic field. Additionally, this tube-type container also can be used as a container for medicines, solvents or foods, etc. 
   This tube-type container comprises a container main unit  40 , a valve seat material  130 , a valve material  20  and a fixing material  110 . 
   In the same manner as in Embodiment 1, the above-mentioned container main unit  40  comprises a fluid storing portion  41  for storing a fluid inside it, and a head portion  142  on the outer circumferential portion of which a male screw portion  45  is formed and in the upper end of which an opening portion  143  for letting a fluid flow is formed. In the container main unit  40 , however, an inner diameter of the opening portion  143  in the head portion  142  is larger than that of the opening portion of Embodiment 1; a convex portion  44  as formed in Embodiment 1 is not formed on the outer circumferential portion of the opening portion  143 . Additionally, this container main unit  40  comprises a synthetic resin alone or a lamination of a synthetic resin and aluminum and has an elasticity recovering force which tries to recover its original shape when a pressure applied to it is removed. 
   The above-mentioned valve seat material  130  has a shape which can be fixed inside the opening portion  143  formed in the head portion  142  by contacting the flange portion  131  with the head portion  142  of the container main unit  40 . At the bottom of this valve seat material, an opening portion  133  for letting the fluid through is formed; on the outer circumferential portion of this opening portion  133 , a ring-shaped convex portion  134  facing toward the valve material  20  is formed. Additionally, on the inner circumferential surface of this valve seat material  130 , a ring-shaped concave portion  132  is formed. 
   In the same manner as in Embodiment 1, the above-mentioned valve material  20  has a configuration shown in  FIG. 3A  and  FIG. 3B . An outer diameter of the closing portion  22  in the valve material  20  is smaller than an inner diameter of a supporting portion  21  and larger than an inner diameter of the opening portion  133  formed in valve seat material  130 . Additionally, this closing portion  22  has a concave shape facing toward the opening portion  133  in the valve seat material  130 . Consequently, the closing portion  22  is able to close the opening portion  133  by contacting the convex portion  134  formed on the outer circumferential portion of the opening portion  133 . 
   The above-mentioned fixing material  110  is used for fixing the valve material  20  by holding the valve material  20  tightly between its lower end portion  16  and the above-mentioned valve seat material  130 . On the outer circumferential portion of this fixing material  110 , a convex portion  15  which can engage with a concave portion  132  formed on the inner circumferential portion of the above-mentioned valve seat material  130  is formed. Consequently, this fixing material  110  is fixed inside the valve seat material  130  in a position in which the valve material  20  is held between the lower end portion  16  of the fixing material and the valve seat material  130 . 
   In the tube-type container having the above-mentioned configuration, in a normal position, as shown in  FIG. 8 , the convex closing portion  22  in the valve material  20  and a ring-shaped convex portion formed in valve seat material  130  are in contact and the opening portion  133  is closed. 
   In this position, when a pressure is applied to the fluid inside the fluid storing portion  41  by pressing the fluid storing portion  41  in the container main unit  40 , the opening portion  133  is opened as the convex closing portion  22  in the valve material  20  and the ring-shaped convex portion  134  formed in the valve seat material  130  separate from each other by the elasticity of the valve material  20  as shown in  FIG. 9 ; the fluid inside the fluid storing portion  41  is discharged outward via the opening portion  14  in the fixing material  110 . 
   In this position, a distance between the convex closing portion  22  in the valve material  20  and a ring-shaped convex portion  134  formed in the valve seat material  130  is proportional to a pressure applied to the fluid inside the fluid storing portion  41 . Consequently, by changing a pressure applied to the fluid inside the fluid storing portion  41 , changing a flow rate of the fluid passing through the opening portion  133  discretionally becomes possible. When a regular liquid is used as a fluid, therefore, discharging the liquid drop by drop by applying a small pressure to the liquid inside the fluid storing portion  41  becomes possible as well. 
   When the pressure applied to the fluid storing portion  41  is removed after a necessary amount of the fluid is discharged, the fluid inside the fluid storing portion  41  is depressurized by the elasticity recovering force of the container main unit  40 ; the air tries to flow back toward the fluid storing portion  41  from the opening portion  14 . In this tube-type container, however, as shown in  FIG. 8 , the opening portion  133  in the valve seat material  130  is closed by the elasticity of the valve material  20 , a fluid flow path is closed. Consequently, the reverse flow of the air can be prevented effectively. 
   Additionally, in the tube-type container to which the valve mechanism according to the above-mentioned Embodiment 2 applies, because the valve mechanism can be installed inside the head portion  142  in a commercially-available container main unit  40 , installing an opening/closing valve feature in the opening portion of the commercially-available container main unit  40  becomes possible. 
   Additionally, in the above-mentioned Embodiment 2, the fixing material  110  which is nearly planate is used. A fixing material  19  having a nozzle shape similar to the one used in Embodiment 1, however, can be used as well to reduce the number of parts by using it as both a fixing material and a nozzle. 
   In the above-mentioned Embodiments 1 and 2, the closing portion  22  in the valve material  20  has a convex shape as well as a ring-shaped convex portion  44  facing toward the valve body  20  is formed on the outer circumferential portion of the opening portion  143  in the head portion  142  of the container main unit  40 , or a ring-shaped convex portion  134  facing toward the valve material  20  is formed on the outer circumferential portion of the opening portion  133  in the valve material  130 . If a convex shape is adopted for the closing portion  22  of the valve material  20 , however, the above-mentioned ring-shaped convex portions  134  and  44  can be omitted. Additionally, when the ring-shaped convex portions  134  and  44  are adopted, it is possible to construct the closing portion  22  in the valve material  20  to be planate similarly to the supporting portion  21 . 
   In the above-mentioned Embodiments 1 and 2, only the modes in which the valve mechanism according to the present invention is applied to the tube-type fluid storing container are described. The valve mechanism according to the present invention, however, also can be applied to fluid discharge pumps used for fluid storing containers, etc. 
   Furthermore, in respective embodiments mentioned above, although the present invention is applied to the valve mechanisms used for fluids, the present invention can be applied to valve mechanisms used for gases. In these cases, by using a material having high rigidity for the connecting portion  23 , stronger momentum should be given to the closing portion  22  in the direction of convex portion  134  or  44 . 
   In the present invention, any suitable plastic material can be used including rubbers such as silicon rubbers or soft resins such as soft polyethylene. For support portions (such as the valve seat portion) to which other portions (such as the valve portion) are fitted by press- fitting, hard resins such as hard polyethylene can preferably be used. The structures can be formed by any suitable methods including injection molding. The resin material can be selected based on the type of fluid stored in the container. If a high viscose fluid such as a gel is stored in the container, a hard resin may be used for the valve mechanism. If a low viscose fluid such as a thin liquid or a formed liquid is stored in the container, a more resilient resin may be used for the valve mechanism. 
   It will be understood by those of skill in the art that numerous and various modifications can be made without departing from the spirit of the present invention. Therefore, it should be clearly understood that the forms of the present invention are illustrative only and are not intended to limit the scope of the present invention.