Patent Publication Number: US-2016223095-A1

Title: Valve for inflatable devices

Description:
FIELD OF THE INVENTION 
     The invention relates to an improved valve for inflatable devices. The invention is particularly suited to use in inflatable devices such as air mattresses and other inflatable outdoor equipment. 
     BACKGROUND TO THE INVENTION 
     The following discussion of the background to the invention is intended to facilitate an understanding of the present invention. However, it should be appreciated that the discussion is not an acknowledgment or admission that any of the material referred to was published, known or part of the common general knowledge in any jurisdiction as at the priority date of the application. 
     Inflatable devices take many forms. In some cases, such as where the device is inflatable so as to assist its transport, the use of inflating aids (such as pumps) may be limited if available at all. However, regardless of their use, inflation and deflation of the device is typically through the use of a self-sealing valve. 
     The typical self-sealing inflate valve facilitates movement of fluid in a single direction through an aperture. A flexible diaphragm occludes the aperture in its original position. As fluid is forced into the valve, the diaphragm flexes in the single direction (and thus no longer occlude the aperture so as to allow fluid to enter into the inflatable device). However, the diaphragm is biased or otherwise operates to return to its original position and thus again occlude the aperture and prevent the flow of fluid in a second, opposing direction. 
     This configuration presents a number of problems:
         As the diaphragm is designed to return to its original position, manipulation of the diaphragm in a manner for which it was not readily designed is required to facilitate deflation of the inflatable device; AND   Even when the diaphragm can be manipulated as required, deflation is very slow until there is a significant reduction in air pressure within the inflatable device.       

     To address these problems some inflatable devices incorporate a separate deflate valve. This creates yet further problems in the form of:
         adding to the complexity of operation and manufacturing costs, as well as potentially increasing the height profile of the inflatable device (an undesirable characteristic for transportable inflatable devices).   creating an additional site of potential failure in case of user error; AND   adding a further component increases confusion in finding the correct valve for inflation or deflation specially in active field use situations, such as low light or distress situations.       

     Attempting to solve the last two problems has seen two-way valves introduced in place of the self-sealing inflate valve. However, such valves typically exacerbate the first problems mentioned above. In particular, two-way valves require mechanical contrivances, such as switches, to facilitate their intended operation. This significantly increases the operation and manufacturing costs as well as creating a higher probability of total failure of the valve. At the same time, a two-way valve is not able to maintain a low profile that is a desired characteristic for mobile inflatable devices such as outdoor inflatable mattresses. 
     It is therefore an object of the present invention to provide an improved valve that eliminates, or ameliorates at least in part, one or more of the aforementioned problems. 
     SUMMARY OF THE INVENTION 
     Throughout this document, unless otherwise indicated to the contrary, the terms “comprising”, “consisting of”, and the like, are to be construed as non-exhaustive, or in other words, as meaning “including, but not limited to”. 
     In a first aspect of the present invention there is an improved valve for an inflatable device comprising:
         a valve port received within an aperture of the inflatable device;   a valve seat having fluid apertures provided therein; and   a diaphragm connected to the valve seat in a manner that occludes the fluid apertures when fluid is not forced therethrough,
 
whereby, the improved valve may, at any time, be manipulated so as to physically remove the valve seat from the valve port to facilitate deflation of the inflatable device and physically insert the valve seat into the valve port to facilitate inflation of the inflatable device.
       

     The valve seat may have first ribs provided on an external surface thereof, such that when the valve seat is inserted into the valve port, the first ribs create an interference fit between the valve seat and the valve port. 
     The improved valve may include a cap, the cap operable to act as a further seal for the valve. As with the valve seat, the cap may include second ribs provided on an external surface thereof, such that when the cap is inserted into the interior surface of the valve seat, the second ribs create an interference fit between the cap and the valve seat. 
     The valve seat and/or cap may have a tab extending therefrom. The purpose of the component from which the tab(s) extends may be identified by way of one or more of the following: colour; labels; visual texture; tactile texture. 
     The valve port is preferably connected to the valve seat by first connecting means in a manner that facilitates the valve seat to be inserted into the valve port. Similarly, the valve seat is preferably connected to the cap by second connecting means in a manner that facilitates the cap to be inserted into the valve seat. In either case, the connecting means may be one of the following: a flexible connector; a hinge, a cord; a two part construction where the parts are connected by mechanical means; a two part constructions where the parts are connected by magnetic means. 
     The valve seat may be further modified to facilitate the retention of an inflating aid. 
     Ideally the improved valve has a low profile. In its preferred form, the improved valve is somewhere between two and three centimeters in height when fully sealed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will now be described, by way of example only, with reference to the accompanying drawings, in which: 
         FIG. 1  is a cross-sectional view of an inflatable device incorporating an improved valve according to a first embodiment of the present invention. 
         FIG. 2  is an exploded view of the improved valve as shown in  FIG. 1  in perspective view. 
         FIG. 3  is an exploded view of the improved valve as shown in  FIG. 1  in plan view. 
         FIG. 4 a    is an exploded perspective view of the improved valve as show in  FIG. 1  as configured for inflation. 
         FIG. 4 b    is a plan view of the same configuration in  FIG. 4   a.    
         FIG. 4 c    is an exploded perspective view of the improved valve as shown in  FIG. 1  as configured for deflation. 
         FIG. 4 d    is a plan view of the same configuration of  FIG. 4   c.    
         FIG. 4 e    is an exploded perspective view of the improved valve as shown in  FIG. 1  as configured for sealing. 
         FIG. 4 f    is a plan view of the same configuration of  FIG. 4   e.    
         FIGS. 5 a  through 5 c    are various views of an improved valve according to a second embodiment of the present invention. 
         FIGS. 6 a  through 6 c    are various views of an improved valve according to a third embodiment of the present invention. 
     
    
    
     PREFERRED EMBODIMENTS OF THE INVENTION 
     In accordance with a first embodiment of the invention there is an improved valve  10  for inflatable devices  12  comprising: 
     a valve port  14 ; 
     a diaphragm  16 ; 
     a valve seat  18 ; and 
     a cap  20 . 
     The inflatable device  12  has an inflatable compartment. An opening  22  is provided in the inflatable compartment. The opening  22  operates to receive the valve port  14 . 
     The valve port  14  comprises a flange  24  and a body  26 . The body  26  takes the form of a squat hollow cylinder. The flange  24  extends from the circumference of one end of the body  26 . 
     Following receipt of the valve port  14  within the opening  24  at the time of manufacture, the material from which the inflatable compartment  22  is made is welded to the flange  24 . Once welded, the flange  24  operates to conceal and protect the weld. 
     The valve seat  18  is cylindrical in shape and has an interior profile  28  and an exterior profile  30 . The exterior profile  30  has a plurality of ribs  32  provided thereon. The ribs  32  operate to generate an interference fit between the valve seat  18  and the valve port  14  when received therein. 
     One end  34  of the valve seat  18  is open. Extending from the open end  34  is a removal flange  36 . A first tab  38  protrudes radially from the removal flange  36 . 
     The other end  40  of the valve seat  18  has four apertures  42  of equal size and shape provided therein. A fifth circular aperture  44  is also provided in the valve seat  18  at a central position relative to the four apertures  42 . 
     The diaphragm  16  is disc shaped and made from a flexible material. Extending centrally from the diaphragm  16  is a locating projection  46 . The locating projection  46  is dimensioned so as to fit within circular aperture  44  and when so fitted, securely retain the diaphragm  16  to the valve seat  18 . 
     The size of the diaphragm  16  is such that, when retained to the valve seat  18 , the diaphragm  16  closes off the four apertures  42  in their entirety. 
     The cap  20  also is cylindrical in shape with an interior profile  48  and an exterior profile  50 . The exterior profile  50  has a plurality of ribs  52  provided thereon. The ribs  52  operate to generate an interference fit between the cap  20  and valve seat  18  when received therein. 
     One end  54  of the cap  20  is open. Extending from the open end  54  is a cap flange  56 . Extending from the cap flange  56  is a second tab  58 . 
     The other end  60  of the cap  20  is closed. End  60 , as projects towards the interior profile  48 , is spherical. 
     This embodiment will now be described in the context of its intended use. 
     As indicated above, during manufacture of the improved valve  10  the valve port  14  is welded to the inflatable compartment. Also as part of the manufacturing process, the diaphragm  16  is installed into the valve seat  18 . 
     Installation of the diaphragm  16  into the valve seat  18  is achieved by inserting the locating projection  46  through the circular aperture  44 . Due to the presence of notch  62  in the diaphragm  16 , as the locating projection  46  is inserted it deforms. This deformation continues until the locating projection  46  has been inserted to the position of notch  62 . Once the locating projection  46  has been inserted to the position of notch  62 , the portion of the locating projection  46  already inserted through the circular aperture  44  resumes its original form. This creates a configuration whereby the end  40  of the valve seat  18  about the position of the circular aperture  44  is sandwiched between the locating projection  46  and the remainder of the diaphragm  16 . 
     As manufactured, and also as required to facilitate sustained inflation of the inflatable compartment, the valve seat  18  is inserted into the valve port  14  such that the diaphragm  16  is encircled by the valve port  14  (see  FIG. 4 f   ). The interference fit formed between the valve port  14  and the exterior profile  30  of the valve seat  18  forms a seal between the two. This seal is able to withstand the pressure of the fluid in the inflatable compartment to a required pre-determined functional magnitude. 
     The cap  20  is also inserted into the valve seat  18 . Again the interference fit formed between the exterior profile  50  of the cap  20  and the interior profile  28  of the valve seat  18  secures this connection. 
     To inflate the inflatable compartment, the cap  20  is removed. This is achieved by either hooking a finger into the interior profile  48  of the cap  20  and pulling or by leveraging the second tab  58 . In either case, the force applied to the cap  20  breaks the interference fit formed between the cap  20  and the valve seat  18  and allows the cap  20  to be removed. 
     With the cap  20  removed a user can then force air through the improved valve  10  using any manner as would be readily known to the person skilled in the art. Forcing air through the improved valve  10  causes base portion  64  of the diaphragm  16  to deform as shown in  FIG. 4 b   . In this deformed state, the diaphragm  16 , no longer closes off the four apertures  42  in their entirety—thus allowing the forced air to pass through and inflate the inflatable compartment. 
     At the same time, as soon as there is a cessation in air being forced through the improved valve  10  the diaphragm  16  returns to its original position again closing off all four apertures  42  in their entirety. This thereby prevents the air already entered into the inflatable compartment from exiting the improved valve  10 . 
     To deflate the inflatable compartment, the valve seat  18  is removed from the valve port  14  (either with or without the cap  20  connected). Removal is generally achieved by leveraging first tab  38 . As before, the force applied to the valve seat  18  by way of the leverage of first tab  38  breaks the interference fit formed between the valve seat  18  and the valve port  14  and allows the valve seat  18  to be removed. 
     With the valve seat  18  removed, air contained within the inflatable compartment is then free to exit by way of the open valve port  14 . 
     In accordance with a second embodiment of the invention, where like numerals reference like parts, there is an improved valve  100 . The improved valve  100  is identical to improved valve  10  save for the following modifications. 
     Valve port  14  and valve seat  18  are connected by way of a first flexible connector  102 . Flexible connector  102  is connected to side of valve seat  18  opposite first tab  38 . 
     Valve seat  18  and cap  20  are connected by way of a second flexible connector  104 . Flexible connector  104  is connected to the valve seat  18  at a position between the point of connection of the flexible connector  102  and the first tab  38 . Flexible connector  104  is connected to the cap  20  at a position opposite second tab  58 . 
     Manufacture of the improved valve  100  is done on the same principles as described above, but as would be modified by the person skilled in the art to incorporate the flexible connectors  102 ,  104 . 
     In use, the improved valve  100  operates substantially as described above. However, to inflate the inflatable compartment, the cap  20  is removed by leveraging second tab  58 . The leveraged force applied to the cap  20  by way of second tab  58  breaks the interference fit formed between the cap  20  and the valve seat  18  and allows the cap  20  to be removed. 
     While the interference fit between the cap  20  and the valve seat  18  is broken, the cap  20  remains connected to the valve seat  18  by way of flexible connector  104 . 
     With the interference fit connection between cap  20  and valve seat  18  broken and the cap  20  removed from the valve seat  18 , a user can then force air through the improved valve  10  using any manner as would be readily known to the person skilled in the art. Forcing air through the improved valve  100  causes base portion  64  of the diaphragm  16  to deform as shown in  FIG. 4 b   . In this deformed state, the diaphragm  16 , no longer closes off the four apertures  42  in their entirety—thus allowing the forced air to pass through and inflate the inflatable compartment. 
     At the same time, as soon as there is a cessation in air being forced through the improved valve  100  the diaphragm  16  returns to its original position again closing off all four apertures  42  in their entirety. This thereby prevents the air already entered into the inflatable compartment from exiting the improved valve  100 . 
     Once the desired level of inflation has been achieved, cap  20  is re-inserted into the valve seat  18  by appropriate manipulation of the flexible connector  104 . This re-establishes the interference fit between the cap  20  and the valve seat  18  thereby secures the improved valve  100 . 
     To deflate the inflatable compartment  22 , the valve seat  18  is removed from the valve port  14  (either with or without the cap  20  connected). Removal is achieved by leveraging first tab  38 . As before, the force applied to the valve seat  18  by way of the leverage of first tab  38  breaks the interference fit formed between the valve seat  18  and the valve port  14  and allows the valve seat  18  to be removed. 
     As before, while the interference fit between the valve seat  18  and the valve port  14  is broken, the valve seat  18  remains connected to the valve port  14  by way of flexible connector  102 . 
     With the interference fit between the valve seat  18  and the valve port  14  broken and the valve seat  18  removed from the valve port  14 , air contained within the inflatable compartment is then free to exit by way of the open valve port  14 . 
     As would be readily apparent to the person skilled in the art each of the above embodiments produces an improved valve of low profile. Hence allowing the inflatable device as a whole to be far more compressed than such devices incorporating existing valve structures. 
     It should also be appreciated by the person skilled in the art that the above invention is not limited to the embodiment described. In particular, the following modifications and improvements may be made without departing from the scope of the present invention:
         In a variation of the second embodiment, first tab  38  may be omitted. Ideally, flexible connector  102  is reconfigured to be attached to the valve seat  18  at the position otherwise to be occupied by first tab  38 . A representation of this variant is shown here as  FIGS. 5 a    through  5   c.  Use of this variant allows the user to apply leverage solely to the second tab  58  to break the interference fit between the cap  20  and the valve seat  18  and the interference fit between the valve seat  18  and the valve port  16 .   The first tab  38  and/or the second tab  58  can be modified to facilitate easy identification of the inflate/deflate functions. Modifications in this vein may take the form of tabs  38 ,  58  of differing colours, appropriate labels on the tabs  38 ,  58  or tabs  38 ,  58  of differing textures for visual and/or tactile identification.   While the cap  20  plays an important role in further sealing the improved valve  10 ,  100  beyond the sealing function provided for by the diaphragm  16 , it is not essential to the invention and may be omitted.   Other forms of securing the various components of the improved valve  10 ,  100  may be adopted in place of the ribs  32 ,  52  and interference fit arrangements they produce as described. For instance, one element may be provided with a male threaded portion and the other element provided with a mating female threaded portion.   Tab  38  may be omitted requiring the user to facilitate removal of the valve seat  18  by way of the removal flange  36 . However, this is not preferable due to the difficulty this is likely to present to the user.   Similarly, tab  58  may be omitted requiring the user to facilitate removal of the cap  20  by way of the cap flange  56 . Again, this is not preferable due to the difficulty this is likely to present to the user.   More or less apertures may be provided in the valve seat  18  than described.   The diaphragm  16  need not be positioned by way of notch  62 , but may be positioned so as to occlude the apertures  42  through other means.   The valve seat  18  may be further modified to facilitate retention of an inflating aid. For instance, the interior profile  28  of valve seat  18  may have a lower portion adapted for the securing of the inflating aid and an upper portion having ribs  32  provided thereon for creating the described interference fit with the cap  20 .   One or both of flexible connectors  102 ,  104  may be replaced with other arrangements. However, any such replacement must physically connect the two components that the replaced flexible connector  102 ,  104  otherwise joins and allows manipulation of those two components such that one may be inserted into the other. Accordingly, an arrangement such as a hinge may be used as a replacement for one or both flexible connector  102 ,  104 .   The profile of the improved valve is preferably no greater than three centimeters in height when fully sealed, and, in its most preferred form, is no greater than two centimeters in height when fully sealed. In this context fully sealed means:
           where the embodiment incorporate cap  20 , the insertion of the valve seat  18  (with cap  20 ) into the valve port  14 ; OR   where the embodiments does not incorporate cap  20 , the insertion of the valve seat  18  into the valve port  14 .   
               

     It should be further appreciated by the person skilled in the art that the above variations and modifications, not being mutually exclusive, can be combined to form yet further embodiments that fall within the scope of the present invention.