Patent Publication Number: US-2007102662-A1

Title: Valve for single-use and multi-use applications

Description:
FIELD OF THE INVENTION  
      This invention relates to valves for use in delivering liquid, semi-liquid, solid, and semi-solid products in various applications and, in particular, for single-use and multi-use applications.  
     PROBLEM  
      It is a problem in the field of liquid, semi-liquid, solid, and semi-solid products to provide an economical applicator system for containing and dispensing a product in a safe, convenient, uniform, and simple manner on to a surface. The applicator system must be economical and simple to manufacture, especially when the applicator system is directed to the field of a single-use or a limited number of uses product application.  
      Many liquid, semi-liquid, solid, and semi-solid products can be applied to the desired surface by the user simply by placing the product on their hand from a container and then manually spreading the product on the desired surface. Examples of such products are personal care products such as sunscreen lotions, insect repellant, skin lotion, makeup, and the like; medical care products, such as topical lotions, medicated creams, and the like; sports products such as muscle heat ointments, eye black, anti-fogging coatings for lenses, and the like; and other products that can be abusive and irritating to the skin. The manual method of product application is the most inexpensive applicator system, but is also inefficient, messy, and may result in non-uniform application of the product to the desired surface. Contamination and microbiological concerns are significant when consumers handle topical products by hand. The product containers are also typically designed for multiple uses and, therefore, contain a fairly large quantity of the product, making the containers inconvenient to carry with the user. This quantity of product also may result in waste of the unused portion of the product. A further problem with this system is that the product is typically contained in a jar, tube, or bottle and is subject to spillage. For many of the products dispensed in this manner, it is undesirable to have a residue remain on the user&#39;s hands; the user, therefore, must have a mechanism available to clean their hands once the product has been applied to the desired surface.  
      To avoid the problems noted above, the liquid, semi-liquid, solid, and semi-solid products can be applied to the desired surface by the use of a separate applicator element, which the user must place in contact with the product. The applicator soaks up a quantity of the product from a product container, and the user then holds the product-containing applicator in their hand to spread the product on the desired surface. As noted above, the product containers are typically designed for multiple uses and, therefore, contain a fairly large quantity of the product, making the containers inconvenient to carry with the user. This quantity of product also may result in waste of the unused portion of the product.  
      One solution to the problems noted above is the use of single-use applicators, where the product is stored in a packet or reservoir and constitutes a sufficient amount for a single use. The cost of these disposable single-use applicators must be low to make them economical, so they typically rely on a burstable packet to release the stored product. A difficulty with burstable packet designs is that the mechanism used to rupture the packet is susceptible to operation at times other than desired by the inadvertent application of excessive force. In addition, the flow of the product through the rupture in the packet cannot be reliably controlled. The smaller heat seal used to direct product flow can rupture during elevated temperatures during transit, handling, or in a purse, pocket, car, or bag. Therefore, there is a need for a simple and inexpensive valve mechanism that can be used in single-use and multi-use applications, yet does not suffer from the disadvantages of existing burstable packet designs.  
     SOLUTION  
      The above-described problems are solved and a technical advance achieved by the present valve for single-use and multi-use applications which functions with a minimal number of parts to provide a simple and reliable mechanism that presents a fluid conduit to control the flow of a product. The product in one implementation is stored in a packet or container and the valve is connected to the packet and functions to enable a user to reliably open a fluid conduit in the valve to connect the packet to an outlet in the housing that enables the user to apply the product to a surface. The valve is not susceptible to accidental operation and provides a fluid conduit of predetermined dimensions to control the flow of the product through the valve.  
      The valve consists of a minimal number of functional features implemented in a variable number of parts, which functional features include: a housing, a piston, and a piston control mechanism configured to enable a user to operate the valve to enable flow of a product through the valve. The housing is shown as having a substantially streamlined shape, with the thickness of the housing being smaller than the length and width dimensions, thereby providing a major surface that enables a user to grasp the housing between the thumb and one or more fingers of the hand. For example, the user would hold the product container (like the handle of a screwdriver) and use only the thumb to move the button and/or lever element to open and close the valve. The valve would be attached to the container via any of a number of methods: screw threads, adhesive, or any bonding method.  
      The housing contains at least one channel formed therein extending from a first end of the housing and from a second end of the housing to thereby form a flow controllable fluid conduit to enable passage of the product through the fluid conduit. The flow of product is regulated by a piston located in the channel and movable from a first position in the channel where the piston blocks the fluid conduit to a second position in the channel where the piston fails to block the fluid conduit. The piston is controlled by a control element, comprising either a slidable button or lever, which is connected to the piston and extends outside of the housing through an aperture to enable a user to operate the control element and thereby move the piston from the fluid conduit blocking position to a fluid conduit open position. In one embodiment, the valve is operable only in one direction, such that, once the valve is opened to allow the product to flow through the fluid conduit, the valve locks in place and cannot be closed by the reverse operation of the valve operation mechanism.  
      This valve thereby provides a low-cost element for product dispensing applications and can be manufactured with a minimal number of parts.  
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  illustrates a perspective view of one embodiment of the present valve for single-use applications;  
       FIGS. 2A-2C  illustrate additional details of the housing in top cross-section, end cross-section, and side cross-section views, respectively;  
       FIGS. 3A and 3B  illustrate a cross-section view of one embodiment of the valve which uses a button to operate the piston;  
       FIGS. 4A and 4B  illustrate a cross-section view of one embodiment of the valve which uses a lever to operate the piston;  
       FIGS. 5A-5C  illustrate first end, side, and second end cross-section views of the piston of  FIGS. 3A, 3B ,  4 A, and  4 B;  
       FIGS. 6A-6D  illustrate additional details of the button in top cross-section, end cross-section, and side cross-section views, respectively; and  
       FIG. 7  illustrates a cross-section view of a second embodiment of the valve. 
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS  
       FIG. 1  illustrates a perspective view of one embodiment of the present valve  100  for single-use and multi-use applications, where the housing  101  is shown as having a substantially streamlined shape, with the thickness of the housing  101  being smaller than the length and width dimensions, thereby providing a major surface that enables a user to grasp the housing  101  between the thumb and the index finger of the hand. The valve  100  controls the flow of a product, and the housing  101  shown in  FIG. 1  is affixed to a reservoir of product, such as a packet or container, that encloses a predetermined quantity of the product. The valve  100  illustrated in  FIG. 1  is shown with a slidable button  103  as the control element, which is described in additional detail below. The slidable button  103  can be operated by the user to open a fluid conduit within the valve  100  that allows product to flow from the product reservoir through the valve  100 , to be dispensed at an outlet of the valve.  
       FIGS. 2A-2C  illustrate additional details of the housing  101  in top cross-section, end cross-section, and side cross-section views, respectively. The housing  101  in this embodiment contains a fluid conduit (illustrated by dotted line FC) that extends from a first end  101 F of the housing  101  to a second end  101 S of the housing  101 . The fluid conduit FC in this embodiment is implemented by using three coplanar channels formed in the body of the housing  101 . A first  101 A and a second  101 B of these channels extend from a first end  101 F of the housing  101 , where they are open to the interior of the product reservoir and thence the product stored therein, to a location near the second end  101 S of the housing  101 . At this latter location, the first  101 A and second  101 B channels connect to a third, centrally located, channel  101 C that provides the final extent of the fluid conduit FC to the outlet of the valve  100 . Thus, as clearly seen in  FIG. 2B , the three channels are coplanar, with the first  101 A and second  101 B channels being located one on either side of the third channel  101 C. The third channel  101 C is connected to the first  101 A and second  101 B channels via respective apertures  101 D,  101 E formed in the walls of the third channel  101 C. The third channel  101 C itself is formed in the body of the housing  101  and extends from the outlet on the second end  101 S of the housing  101  to the first end  101 F of the housing  101 , with the extent of the third channel  101 C being capable of optionally being terminated (such as by a plug  101 K) without exiting the first end  101 F of the body of the housing  101 . The third channel  101 C as shown in these Figures extends all the way through the body of the housing  101 , although this is not a requirement. The section  101 G of the third channel  101 C that extends past the apertures  101 D,  101 E that interconnect the first  101 A and second  101 B channels to the third channel  101 C is used to accommodate the sliding of the piston  102  that is installed in the third channel  101 C to regulate the flow of product through the fluid conduit FC, as is described below. Therefore, the fluid conduit FC consists of the first  101 A and second  101 B channels, extending from the first end  101 F of the body of the housing  101  to the apertures  101 D,  101 E where these two channels join the third channel  101 C. The fluid conduit FC thence further extends through these apertures  101 D,  101 E and down the length of the third channel  101 C to the valve outlet.  
      While this embodiment illustrates the use of two channels in parallel as the first segment of the fluid conduit, it is evident that a single channel can be used in place of the two channels shown herein. The exact configuration of the channels, apertures, piston, and control mechanisms shown herein are for illustration purposes, and it is expected that variations can be devised that perform the same function as the configuration disclosed herein.  
       FIGS. 3A and 3B  illustrate a cross-section view of one embodiment of the valve  100  of  FIG. 1  which uses a button  103  to operate the piston  102 . This valve  100  consists of a housing  101  that includes a third channel  101 C formed therein through which the product flows. As described with respect to  FIGS. 2A-2C , two apertures (first and second apertures)  101 D,  101 E are formed in the walls of the third channel  101 C to enable a flow of product to exit the third channel  101 C. A piston  102  is located in the third channel  101 C and is slidable along the length of the third channel  101 C to either block the first and second apertures  101 D,  101 E or to open a path from the third channel  101 C to the apertures  101 D,  101 E. A third aperture  101 H is formed in one wall of the third channel  101 C to enable a control element, such as slidable button  103 , to engage piston  102 . The slidable button  103  can be transposed by a user from a first end of the third aperture  101 H to a second end of the third aperture  101 H to thereby relocate piston  102  from a first position shown in  FIG. 3A , where piston  102  blocks first and second apertures  101 D,  101 E to a second position shown in  FIG. 3B , where piston  102  is in a position to enable fluid communication from third channel  101 C to first and second apertures  101 D,  101 E.  
      The shape and position of the longitudinal piston  102  is configured so that no crevice exists to accumulate fluid residue after partial use. This concept is critical in medical fluid applications and some adhesive products.  
       FIGS. 4A and 4B  illustrate a cross-section view of one embodiment of the valve  100  of  FIG. 1  which uses a lever  104  to operate the piston  102 . This valve  100  consists of a housing  101  that includes a third channel  101 C formed therein through which the product flows. As described with respect to  FIGS. 2A-2C , two apertures (first and second apertures)  101 D,  101 E are formed in the walls of the third channel  101 C to enable a flow of product to exit the third channel  101 C. A piston  102  is located in the third channel  101 C and is slidable along the length of the third channel  101 C to either block the first and second apertures  101 D,  101 E or to open a path from the third channel  101 C to the apertures  101 D,  101 E. A third aperture  101 H is formed in one wall of the third channel  101 C to enable a control element, such as hinged lever  104 , to engage piston  102 . The hinged lever  104  can be rotated by the user, causing the distal end of the hinged lever to transpose from a first end of the third aperture  101 H to a second end of the third aperture  101 H to thereby relocate piston  102  from a first position shown in  FIG. 4A  where piston  102  blocks first and second apertures  101 D,  101 E to a second position shown in  FIG. 4B  where piston  102  is in a position to enable fluid communication from third channel  101 C to first and second apertures  101 D,  101 E. The hinged lever  104  consists of a hinge point  104 A which attaches the hinged lever  104  to the housing  101  and around which the hinged lever  104  rotates. The engaging end  104 B of the hinged lever  104  is shaped to fit into and engage the necked-down portion  102 A of the piston  102 . The curved face of the engaging end  104 B enables the hinged lever  104  to slide the piston  102  laterally along the third channel  101 C. The face of the hinged lever  104  opposite the curved face is flat, thereby preventing the engaging end  104 B of the hinged lever  104  from slidably engaging the necked-down portion  102 A of the piston  102 . This prevents the hinged lever  104  from being used to return the piston  102  back to its original position, since the flat face of the engaging end  104 B of the hinged lever  104  functions to lock the hinged lever  104  into an operating position.  
      The shape and position of the longitudinal piston  102  is configured so that no crevice exists to accumulate fluid residue after partial use. This concept is critical in medical fluid applications and some adhesive products.  
       FIGS. 5A-5C  illustrate first end, side, and second end cross-section views of the piston  102  of  FIGS. 3A, 3B ,  4 A, and  4 B. The piston  102  consists of a substantially cylindrical element that is shaped along its length with features to provide a valve closing/opening function as described below. In particular, a necked down portion  102 A of the piston  102  is provided near a second end  102 S of the piston  102  to accommodate connection to the control element  103 / 104  as shown in  FIGS. 3A, 3B ,  4 A, and  4 B. This enables the control element  103 / 104  to engage the piston  102  and apply a lateral force thereto to slide the piston  102  along the third channel  101 C from the closed position of  FIGS. 3A, 4A  to the open position of  FIGS. 3B, 4B . In addition, a shoulder  102 B is formed in the piston  102  to thereby provide a sealing element to deter flow of the product from the fluid conduit FC down the third channel  101 C along the length of the piston  102 . The first end  102 F of the piston  102  is shaped with two shoulder features  102 C,  102 D separated by a depression  102 E, which serves to seal the fluid conduit FC at the second end  101 S by engaging with the mating feature  101 L and allow for smooth movement of the piston  102  along the third channel  101 C as it is operated.  
       FIGS. 6A-6D  illustrate additional details of the button  103  in top cross-section, end cross-section, and side cross-section views, respectively. The button  103  consists of a planar surface  103 A to which is attached an operating element  103 B that connects to the necked-down  102 A portion of the piston  102 . The button  103  clips onto the shaft (necked-down portion  102 A) of the piston  102  via shaped opening  103 C in the operating element  103 B. The planar surface  103 A is a low profile shape to minimize the size of the valve  100 , yet provide an adequate point of contact for the user to enable simple operation of the valve  100  via a sliding movement.  
       FIG. 7  illustrates a cross-section view of a second embodiment of the valve  100 . This embodiment uses a housing  701  with a single channel  701 A formed therein, extending from a first end  701 F of the body of the housing  701  to a second end  701 S of the body of the housing  701 . An aperture  702 B is formed in the wall of the channel  701 A to accept a piston (sealing element)  702 . The piston  702  is located in the channel  701 A at the second end thereof to block the flow of the product through the fluid conduit FC that is formed by the channel  701 A. The piston operating mechanism consists of a lever  704 , which is connected to the body of the housing  701  by a living hinge mechanism  704 A and attached to the piston  702 . When the lever  704  is pulled upward away from the body of the housing  701 , it pulls the piston  702  into the aperture  702 B, thereby unblocking the channel  701 A and allowing the product to flow through the fluid conduit FC to the outlet of the valve  100 . The piston part  702  (or sealing element) of the one-part valve can be positioned anywhere along the length of the lever  704 , from the living hinge mechanism  704 A to the end of the lever  704 B. If the piston part  702  is positioned at the hinge end  704 A, the user has great leverage and the lever movement is much greater. If the piston part  702  is located at the opposite end of the lever  704 , the user has less leverage and the movement is much less.  
     SUMMARY  
      The valve consists of a housing, a piston, and a piston control mechanism configured to enable a user to operate the valve to enable flow of a product through the valve. The housing is shown as having a substantially streamlined shape, with the thickness of the housing being smaller than the length and width dimensions, thereby providing a major surface that enables a user to grasp the housing between the thumb and the index finger of the hand. The housing contains a channel formed therein extending from a first end of the housing to a second end of the housing forming a fluid conduit that enables passage of the product through the fluid conduit. The flow of product is regulated by a piston located in the channel and movable from a first position in the channel where the piston blocks the fluid conduit to a second position in the channel where the piston fails to block the fluid conduit. The piston is controlled by a control element, comprising either a slidable button or lever, which is connected to the piston and extends outside of the housing through an aperture to enable a user to operate the control element and thereby move the piston from the fluid conduit blocking position to a fluid conduit open position.