Abstract:
A free floating disc check valve is provided by the present application. The check valve includes a seal disc having an integral truncated torroidal shaped portion. The torroidal shaped portion provides structural rigidity to the seal disc to minimize deflection of the disc under higher differential fluid pressures. The torroidal shaped portion of the disc cooperates with finger-shaped projections inside the valve body to limit lateral displacement of the disc relative to the axial flow of the fluid. The torroidal shaped portion and the flat portion of the disc form a cup shape that creates a hydrodynamic force that assists in moving the disc to an opened or closed position. The seal disc is made of an elastomeric material that is coated with a dry film lubricant.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application claims the benefit of provisional application No. 60/366,590, filed Mar. 22, 2002, the disclosure of which is incorporated by reference herein. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates to check valves. More particularly, this invention relates to check valves for fluids employing a free-floating disc that allows fluid flow in an unchecked direction with a minimal increase in fluid pressure and turbulence while maximizing the rate of fluid flow through the valve. 
   2. Description of the Background Art 
   Presently, there exist many types of disc valves that employ a free-floating disc that seats in a checked direction of fluid flow and unseats in an unchecked direction. Optimal designs of disc valves seek to minimize the increase in fluid pressure in the unchecked fluid flow direction, minimize turbulence within the valve and maximize the rate of fluid flow through the valve. It is an object of this invention to provide an improvement that is a significant contribution to the advancement of the disc valve art. 
   Another object of this invention is to provide a disc valve having a maximum fluid flow rate. 
   Another object of this invention is to provide a disc valve having a minimal dimensional package size. 
   Another object of this invention is to provide a disc valve having a minimal tendency of the seal disc to stick in the open or closed position. 
   Another object of this invention is to provide a disc valve having a minimal seal disc deformation under differential pressure loads. 
   Another object of this invention is to provide a disc valve having minimal fluid turbulence through the valve. 
   Another object of this invention is to provide a disc valve having high differential seal pressures. 
   Another object of this invention is to provide a disc valve having a high ultimate burst pressure. 
   Another object of this invention is to provide a disc valve having an improved kinematic action of the seal disc. 
   Another object of this invention is to provide a disc valve composed of modular components to enable various assemblies of end connections. 
   Another object of this invention is to provide a disc valve having an improved ergonomic design of the valve body/housing. 
   Another object of this invention is to provide a disc valve having a simplicity of components. 
   Another object of this invention is to provide a disc valve capable of being consistently and durably manufactured/molded and assembled at a low manufactured cost. 
   Another object of this invention is to provide a disc valve that is particularly suited for liquid applications, but that may be employed in limited gas media applications. 
   Another object of this invention is to provide a disc valve that is particularly suited for human blood and blood products applications. 
   The foregoing has outlined some of the pertinent objects of the invention. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the intended invention. Many of the beneficial results can be attained by applying the disclosed invention in a different manner or modifying the invention within the scope of the disclosure. Accordingly, other objects and a fuller understanding of the invention may be had by referring to the summary of the invention and the detailed description of the preferred embodiment in addition to the scope of the invention defined by the claims taken in conjunction with the accompanying drawings. 
   SUMMARY OF THE INVENTION 
   For the purposes of summarizing this invention, the invention comprises a free-floating disc type check valve that out-performs similar, competitive valve designs and offers a wide variety of customer desired end connections not readily offered by competitive disc valve manufacturers. The valve was designed specifically for liquid applications, however limited gas media applications are possible with the design. Utilization of the valve for human blood and blood products applications is also intended with this design. 
   One embodiment of the present invention is directed toward a valve for controlling the flow of a fluid through a fluid passage such that a fluid flow in the fluid passage is permitted in a first direction and restricted in a second direction. The valve includes a valve body having an internal fluid chamber with internal side walls. A valve member is contained in the internal fluid chamber. The valve member is a free floating disc-shaped check valve having a first side with an attached truncated torroidal shaped portion and a relatively flat second side. An array of finger-shaped projections are positioned on the valve body that receive the valve member when fluid is flowing through the valve in the first direction. The finger-shaped projections are positioned a distance away from the internal side walls of the valve body such that the disc-shaped check valve is held in the center portion of the valve body by the finger-shaped projections thereby facilitating fluid flow around the outside edges of the disc-shaped check valve. In addition, the finger-shaped projections are dimensioned to receive the truncated torroidal shaped portion of the disc-shaped check valve such that fluid is allowed to flow between the finger-shaped projections. The valve body consists of an inlet portion and an outlet portion that are designed to sealing couple together to form the valve body. The inlet portion of the valve body has an annular sealing protrusion such that when a fluid attempts to flow in the second direction the annular sealing protrusion and the flat portion of the disc-shaped check valve couple to create a seal against the fluid flow in the second direction. In a preferred embodiment, the valve member is constructed of a single piece of elastomeric material, the inlet portion of the valve body is constructed from a single piece of plastic and the outlet portion of the valve body that includes the finger-shaped projections is constructed from a single piece of plastic. Furthermore, the valve body is preferably constructed from a clear plastic that allows the operation of the valve to be visually monitored. 
   The above described valve offers a number of improvements over the prior art. First, the finger like projections restrict the movement of the valve member in the valve body and significantly reduce the likelihood that the valve member will become jammed in the open or closed position. In addition, the truncated torroidal structure adds rigidity to the valve member that keeps it from bending or becoming stuck when sealing the valve in response to a fluid flow in the restricted direction through the valve. Finally, the simplistic construction and operation of the valve decreases the costs associated with use of the valve. Thus, the above described embodiment offers a number of improvements in the prior art. 
   Another embodiment of the present invention is directed toward a valve for preventing fluid from flowing in one direction through a fluid channel. The valve includes a valve member having a sealing side portion and a flow side portion wherein the sealing side portion is substantially flat and the flow side portion is substantially cup-shaped. A valve body contains the valve member. The valve member is constructed from a single piece of elastomeric material coated with a non-stick material that minimizes friction between the valve member and valve body. The valve body has a valve member receiving section that is configured to receive the flow side portion of the valve member when fluid is flowing through the valve such that fluid flows through openings in the valve member receiving section. The valve member receiving section includes a plurality of projections positioned such that an opening exists between each projection and such that the valve member is centered within the valve body when received by the valve member receiving section. Preferably, the plurality of projections are finger-shaped and arranged in an substantially circular configuration. In such an embodiment, the flow side portion of the valve member is then received inside of the substantially circular projection configuration when fluid is flowing through the valve such that the fluid flows around the outside edges of the valve member and between the plurality of projections. 
   Yet another embodiment of the present invention is directed toward a method of preventing fluid from flowing through a pipe in one direction. The method commences by positioning a valve body in the pipe. Preferably, the valve body is constructed out of a transparent material such that proper operation of the valve can be visually confirmed. A free floating valve member is then enclosed inside of the valve body. The valve member is configured to create a hydrodynamic sealing force on the valve member when fluid attempts to flow through the pipe in the flow-inhibited direction. The valve member is engaged with a flow-through seal member having finger-like projections such that it is centered in the valve body when fluid is flowing through the pipe in the flow allowed direction. The free floating valve member is engaged with a flow-inhibiting seal member when fluid is attempting to flow through the pipe in the flow-inhibited direction. 
   The above described embodiments improve upon the prior art by using the finger-like projections to center the valve member in the valve body such that the flow rate is maximized and the failure rate due to the valve member becoming stuck is minimized. In addition, configuring the valve member to create a hydrodynamic sealing force helps move the valve member from the open position to the closed position while insuring that it does not become stuck. The use of a transparent construction allows a user to visually inspect the valve to determine if it is properly operating. Thus, the above described method offers a number of advantages over the prior art. 
   The foregoing has outlined rather broadly the more pertinent and important features of the present invention in order that the detailed description of the invention that follows may be better understood so that the present contribution to the art can be more fully appreciated. Additional features of the invention will be described hereinafter which form the subject of the claims of the invention. It should be greatly appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other methods for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent methods do not depart from the spirit and scope of the invention as set forth in the appended claims. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a more succinct understanding of the nature and objects of the invention, reference should be directed to the following description taken in conjunction with the accompanying drawings in which: 
       FIG. 1  is a cross-sectional view of the assembled disc valve of the invention; 
       FIG. 2  is a cross-sectional view of the downward flow portion of the disc valve of the invention; 
       FIG. 3  is an end view of  FIG. 2 ; 
       FIG. 4  is a cross-sectional view of the disc of the disc valve of the invention; 
       FIG. 5  is an end view of  FIG. 4 ; 
       FIG. 6  is a cross-sectional view of the assembled disc valve of the invention with male and female luer lock fittings; 
       FIG. 7  is a cross-sectional view of the assembled disc valve of the invention with luer fittings; 
       FIG. 8  is a cross-sectional view of the assembled disc valve of the invention with male luer lock fittings; 
       FIG. 9  is a cross-sectional view of the assembled disc valve of the invention with a female luer lock fittings; 
       FIG. 10  is a cross-sectional view of the assembled disc valve of the invention with tube and male luer lock fittings; 
       FIGS. 11 and 12  is a cross-sectional view of the assembled disc valve of the invention with tube and male luer lock fittings; and 
       FIG. 13  is a diagram showing the flow rates of the disc valve of the invention as compared to several prior art disc valves. 
   

   Similar reference numerals refer to similar parts throughout the several figures. 
   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   A. Seal Disc Configuration and Function: 
   As shown in  FIGS. 1–5 , the new disc check valve utilizes a unique seal disc  12 , employing a specific geometry to accomplish multiple specific functions in operation. The configuration of the seal disc  12  may be described as a flat circular disc  14  integrally mated to a modified, truncated torroidal shape  16  projecting from the downward-flow surface of the disc  12 . The torroidal shape  16  is the key element of the design of the seal disc  12 . This geometry provides the following functional features: 
   1. The cylindrical mass of the torus  16  on one side of the disc  12  imparts structural rigidity to the seal, helping to keep the seal surface  18  of the disc  12  flat with respect to the annular seal  20  of the valve body  22 . The torus  16  shape is positioned so as to have its mass over the annular seal  20 . Deflection of the valve seal disc  12 , and ultimate leakage or failure, is minimized under higher differential pressures. “Compression set”, or permanent deformation of the valve seal disc  12  is mitigated by the structural stiffness added by the torroidal shape  16 , and flexural deformation in transition between open and closed positions of the valve seal  12  are minimized. This helps to prevent “sticking” or locking of the valve seal  12  in the open or closed position evidenced in traditional check valves utilizing a common flat disc seal. 
   2. The torroidal shape  16  is designed to work in conjunction with “fingers” or projections  24  inside the valve body  22 . These projections  24  loosely surround the periphery of the torus  16  limiting the lateral displacement of the seal disc  12  in relation to the annular seal  20  of the valve body  22 . The projections  24  are designed to permit predetermined axial travel of the valve seal disc  12  to the open position permitting fluid flow through the valve body  22 . The specific profile of the periphery of the torus  16  is also designed to allow angular displacement of the seal disc  12  with respect to the centerline axis of the valve assembly  10 , while preventing the seal disc  12  from becoming wedged or entrapped in the open position with the “fingers” or projections  24 . In this arrangement, the axial displacement of the seal disc  12  and annular clearance between the circumference of the valve seal disc  12  and the annular seal  20  of the valve body  22  is maximized, along with the annular area between the seal disc  12  and the valve body internal wall  26 . The outer profile of the torroidal shape  16  also functions cooperatively with the internal valve body shape to direct fluid flow transitionally into the convergent orifice of the valve body outlet  28  when the disc  12  is in the open position, as discussed further in section “Valve Performance, Flow and Pressure”. 
   3. The “cup” shape formed by the modified torus  16 , and bounded on one axial end by the flat disc shape, forms a piston  30  that takes advantage of liquid flow moving from the distal toward the proximal end of the valve interior and uses the hydrodynamic force of the liquid to assist in moving the seal disc  12  from the open to the closed position. The velocity of the fluid is higher in proximity to the center axis of the valve assembly  10  as is the fluid pressure, due to the projections  24 , or “fingers”, surrounding the annular seal  20  directing the larger mass of fluid flow into the “cupped” section  30  of the seal disc  12 . This acts to make the valve assembly  10  more quickly responsive to differential pressure to close the valve. 
   Seal disc  12  may be integrally formed of silicone or polyisoprene or other appropriate elastomeric material. All candidate materials are USP class VI and have notable chemical and biocompatibility properties, as well as structural properties. Elastomeric material hardness offers the optimal balance between structural stiffness and material compression is required to effect a suitable seal in contact with the annular seal  20  of the valve body  22 . Fabrication of the polyisoprene material is usually limited to compression molding and, owing to the cost of the material and the manufacturing process, realizes a significantly higher production cost versus the silicone material. The silicone material may be either compression molded or liquid injection molded, (LIM). Production costs and quantities are inversely proportional between compression and liquid injection molding processes, with LIM, offering the higher production quantity with the lower cost per part. Tooling costs for the LIM process are much higher than the compression method however. 
   Both materials for the valve seal  12  may be coated with Parylene N, which functions as a dry film lubricant. This acts to reduce the breakaway friction, or “stiction” of the valve seal  12  from the valve body annular sealing  20 , thereby greatly reducing the valve opening activation force, (pressure), required. The Parylene coating also functions a lubricant to act in conjunction with the outside profile of the torroidal shape  16  of the disc seal  12  in contact with the projections or “fingers”  24  inside the valve body  22 . The shape of the disc valve  12 , coupled with the Parylene coating insures that the valve seal will be prevented from sticking or mechanically “locking” in the open position. Evaluation of uncoated silicone seal discs, demonstrated that the seal disc adheres to the valve body seat when dry and left static for 24 hours or less. Pressure required to dislodge the seal disc varied from 0.5 PSI to 2.0 PSI. Test valves with uncoated silicone seal discs that were left for 24 hours in the open position also demonstrated that the seal disc adheres to the “fingers” inside the valve body. Although more easily dislodged than seals that were left closed, this effect clearly demonstrates the benefit of the Parylene coating in helping to prevent valve failures and enhancing valve performance. 
   B. Valve Body Configuration and Function: 
   The valve body  22  is designed as a two-piece assembly comprising an inlet body half  22 I and an outlet body half  220 . Both body halves are joined at a midline, perpendicular to the centerline flow axis of the valve. The joint interface is an overlapping “L” shape  32  that provides for either solvent bonding, or sonic welding of the two valve body components. 
   Operation of the valve is integral with the interior cavity formed by the two body halves  22  and the seal disc  12 . This internal cavity is specifically shaped to allow smooth fluid flow transitions from the inlet to the outlet, and minimize turbulence. Residual volume and collection of residual fluid in the valve interior is reduced via generous radii at flow vector transitions. Development testing of fluid flow through assembled valve bodies both with, and without, the seal disc  12  installed demonstrated a significant improvement of fluid mass flow rate with the seal disc  12  installed. Tested assemblies measured an average of 20-ml/min. higher flow rate with seal discs installed. 
   This observation assists in supporting the efficacy of the fluid dynamic properties of the valve design. It is theorized that differential fluid flow velocities within the valve cavity, sans seal disc, create an appreciable turbulent zone in proximity to the internal “fingers” or projections on the valve outlet body component. Higher velocity fluid flowing near the longitudinal axis of the valve assembly devoid of the obstruction of the seal disc, meets lower velocity laminar fluid flow conforming to the valve body internal surfaces and flowing between the “finger” projections resulting in turbulence near the convergent section of the valve body outlet. 
   As shown in  FIGS. 6–12 , both inlet and outlet valve body components are designed to incorporate five varieties of standard medical type end connections: male slip luer, female slip luer, male luer lock, female luer lock, and/or straight tube connection. 
   Each of the end connection configurations is interchangeable between inlet and outlet body components, offering 25 different modular combinations of end connections according to customer needs. All iterations of valve bodies retain the same basic center section geometry and volume, differing only in the end connections, and all variations utilize a common valve seal disc. 
   Series production for various valve body configurations may be accomplished with interchangeable mold tool inserts where practical, thus offering more cost effective flexibility in manufacturing and faster response to various customer requirements. Male luer lock configurations present specific challenges with respect to the internal threads of the design and consequently may not be a candidate for interchangeable tooling, however the balance of the end connection configurations all present themselves as acceptable candidates for the modular tooling concept. Survey of other check valves of this type currently in the market, appears to indicate that the male luer lock end connection is not prevalent at this time. The most prevalent end connection combination currently on the market is a combination of a male slip luer fitting and straight tube fitting. 
   The valve design is parametrically scalable and the proportion of valve seal and valve body size can be easily scaled to achieve parity with increased end connection sizes. This allows a broad range of customer required sizes, including unique and non-standard end connection configurations. For example, ISO standard medical type end connections currently in popular clinical use may be employed. The assembled size of the valve design is roughly 50% smaller than competitive valves with similar flow rates. 
   Polycarbonate and PVC, (USP class VI), materials are preferably selected for the valve body components. Tests with polypropylene resulted in excessive material shrinkage sufficient to render the male slip luer dimensional tolerances well below limits, and nonfunctional with standard mating components. While the polypropylene parts were produced on tooling not designed for that material shrinkage, polypropylene material may be a poor candidate material for this design, whereas with polycarbonate and PVC materials yield excellent results in test articles for dimensional stability, material strength, and weld ability. 
   All materials, (polycarbonate, PVC and polypropylene), exhibit excellent weld characteristics. Further refinement of weld parameters, including through analysis and design of optimal weld tooling are anticipated for series production. Dukane Corporation offers weld tool design analysis and may be consulted as capital assembly equipment is produced. Test weld tooling should be relative to the verified natural vibration frequencies of the product assembly and the weld tool, since a durable and consistent manufacturing process will rely heavily on the critical weld interface integrity of the valve assembly. 
   Leak and pressure testing of welded valve assemblies demonstrated consistent weld integrity above 60 psig air. No discernable leaks or bubbles were detected in over 200 consecutively welded valves. As gravity feed applications average approximately 3 psi and intravenous pump applications specify 20 psi maximum operating pressure capability, this precluded ultimate burst pressure testing subsequent to determining that the welded assemblies routinely survived over 60 psi in weld integrity tests. 
   Optimal weld parameters with the test tooling and sample prototype parts on the Dukane welder were determined to be:
         Amplifier: 2:1   Weld distance: 0.002 in.   Weld dwell time: 1.0 second   Ram pressure: 30 psig       

   These weld settings yielded acceptable welds with little or no flash or distortion and exhibited consistent weld integrity via pressure testing. Destructive examination of welded assemblies further demonstrated acceptable strength of the weld join. 
   Series production weld parameters may be based on the above values as a nominal datum. 
   C. Parylene Coating: 
   Parylene “N” is selected as a coating for the silicone and polyisoprene substrate seal discs. 
   The coating serves as dry film lubricant to ensure smooth consistent valve operation, prevent sticking of the seal disc in the open or closed position and maintain opening, (crack), pressure of the valve as low as possible. 
   Parylene is recognized as a USP Class VI polymer and is gaining wide use and acceptance in medical components and devices. Generically known as parylene, the material called “Parylene N” is polyparaxylylene, a linear crystalline material. The coating is applied to the substrate by means of vapor deposition process in a vacuum chamber. Depending on processed load quantities, the Parylene coating adds an average estimated cost of $0.003 per coated component to the manufactured cost. The benefit of improved competitive performance makes