Patent Publication Number: US-2023136671-A1

Title: Pressure Relief Valve with Installation Indicator

Description:
CROSS-REFERENCE 
     The present application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Ser. No. 63/272,830, which was filed on Oct. 28, 2021 and is entitled “PRV Barcode Installation Indicator.” The contents of which are hereby incorporated by reference. 
    
    
     BACKGROUND 
     The disclosure relates to a return air blocking device for ventilation of the interior of a vehicle, such as a motor vehicle. Such return air blocking devices are fitted in apertures in the body of a vehicle. In operation, if a positive pressure predominates in the interior of the vehicle relative to the environment of the vehicle, the valve flaps of the return air blocking device open to allow air to flow out of the vehicle interior and reduce the positive pressure. In the opposite flow direction, the valve flaps block the openings. Example return air blocking devices to ventilate the interior of vehicles are described in commonly owned U.S. Pat. No. 8,328,609 to Daniel Schneider and U.S. Pat. No. 10,391,838 to Nikolaus Schwarzkopf and Marco Spanier. 
     When a return air blocking device is installed incorrectly such that the return air blocking device is not fully inserted into the aperture within the vehicle, the seal between the return air blocking device and the vehicle will not compress sufficiently to perform the function of sealing. As a result, the interior of the vehicle could be damaged by inward dust and water leakage from the exterior environment. Therefore, it would be desirable to provide an installation indicator to enhance proper installation of the return air blocking device during assembly with a vehicle. 
     SUMMARY 
     The present disclosure relates generally to a return air blocking device with an installation indicator to enhance proper installation of the return air blocking device, substantially as illustrated by and described in connection with at least one of the figures, as set forth more completely in the claims. 
    
    
     
       DRAWINGS 
       The foregoing and other objects, features, and advantages of the devices, systems, and methods described herein will be apparent from the following description of particular examples thereof, as illustrated in the accompanying figures; where like or similar reference numbers refer to like or similar structures. The figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the devices, systems, and methods described herein. 
         FIGS.  1   a  and  1   b    illustrate, respectively, isometric views of an example return valve installation system before and after assembly in accordance with an aspect of this disclosure. 
         FIGS.  2   a  and  2   b    illustrate, respectively, front perspective and rear perspective, views of the pressure vent valve. 
         FIGS.  2   c  through  2   f    illustrate, respectively, first, second, third, and fourth side elevational views of the pressure vent valve. 
         FIGS.  2   g  and  2   h    illustrate, respectively, top plan and bottom plan, views of the pressure vent valve. 
     
    
    
     DESCRIPTION 
     References to items in the singular should be understood to include items in the plural, and vice versa, unless explicitly stated otherwise or clear from the text. Grammatical conjunctions are intended to express any and all disjunctive and conjunctive combinations of conjoined clauses, sentences, words, and the like, unless otherwise stated or clear from the context. Recitation of ranges of values herein are not intended to be limiting, referring instead individually to any and all values falling within and/or including the range, unless otherwise indicated herein, and each separate value within such a range is incorporated into the specification as if it were individually recited herein. In the following description, it is understood that terms such as “first,” “second,” “top,” “bottom,” “side,” “front,” “back,” “upper,” “lower,” and the like are words of convenience and are not to be construed as limiting terms. For example, while in some examples a first side is located adjacent or near a second side, the terms “first side” and “second side” do not imply any specific order in which the sides are ordered. 
     The terms “about,” “approximately,” “substantially,” or the like, when accompanying a numerical value, are to be construed as indicating a deviation as would be appreciated by one of ordinary skill in the art to operate satisfactorily for an intended purpose. Ranges of values and/or numeric values are provided herein as examples only, and do not constitute a limitation on the scope of the disclosure. The use of any and all examples, or exemplary language (“e.g.,” “such as,” or the like) provided herein, is intended merely to better illuminate the disclosed examples and does not pose a limitation on the scope of the disclosure. The terms “e.g.,” and “for example” set off lists of one or more non-limiting examples, instances, or illustrations. No language in the specification should be construed as indicating any unclaimed element as essential to the practice of the disclosed examples. 
     The term “and/or” means any one or more of the items in the list joined by “and/or.” As an example, “x and/or y” means any element of the three-element set {(x), (y), (x, y)}. In other words, “x and/or y” means “one or both of x and y”. As another example, “x, y, and/or z” means any element of the seven-element set {(x), (y), (z), (x, y), (x, z), (y, z), (x, y, z)}. In other words, “x, y, and/or z” means “one or more of x, y, and z.” 
     The term “processor” means processing devices, apparatuses, programs, circuits, components, systems, and subsystems, whether implemented in hardware, tangibly embodied software, or both, and whether or not it is programmable. The term “processor” as used herein includes, but is not limited to, one or more computing devices, hardwired circuits, signal-modifying devices and systems, devices and machines for controlling systems, central processing units, programmable devices and systems, field-programmable gate arrays, application-specific integrated circuits, systems on a chip, systems comprising discrete elements and/or circuits, state machines, virtual machines, data processors, processing facilities, and combinations of any of the foregoing. The processor may be, for example, any type of general purpose microprocessor or microcontroller, a digital signal processing (DSP) processor, an application-specific integrated circuit (ASIC). The processor may be coupled to, or integrated with a memory device. The memory device can be any suitable type of computer memory or any other type of electronic storage medium, such as, for example, read-only memory (ROM), random access memory (RAM), cache memory, compact disc read-only memory (CDROM), electro-optical memory, magneto-optical memory, programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically-erasable programmable read-only memory (EEPROM), a computer-readable medium, or the like. 
     Disclosed is a return air blocking device with an installation indicator to enhance proper installation of the return air blocking device in a vehicle. In one example, a pressure vent valve for ventilation of an interior of a vehicle comprises: a frame defining a vent opening; a valve flap mounted on the frame and configured to transition between an idle position where airflow through the vent opening is blocked and an open position where airflow through the vent opening is not blocked; and an installation indicator formed in or on the frame. 
     In another example, a return valve installation system for a vehicle component, the return valve installation system comprises: a pressure vent valve having a frame and a valve flap configured to block a vent opening formed in the frame; an installation indicator coupled to the pressure vent valve; and a reader separate from the pressure vent valve and operatively coupled to a computer, the reader configured, via a processor, to track the installation indicator during installation of the pressure vent valve into an aperture of the vehicle component. 
     In some examples, the installation indicator comprises a lever extending from the frame. In some examples, the lever is coupled to the frame via a hinge. In some examples, the lever includes a 2-dimensional fiduciary marker or a 3-dimensional fiduciary marker. In some examples, the 2-dimensional fiduciary marker is a quick response (QR) code or an AprilTag. In some examples, the 3-dimensional fiduciary marker is integral with the lever. In some examples, the installation indicator further comprises a projection coupled to the lever. In some examples, the projection is configured to engage a surface of a vehicle component to rotate the lever about the hinge. In some examples, the frame further comprises at least one sealing surface and a plurality of fastening projections, wherein the at least one sealing surface and the plurality of fastening projections are positioned adjacent the vent opening. In some examples, the valve flap abuts the at least one sealing surface in the idle position to block the airflow and, when a pressure increases in the interior of a vehicle, the valve flap assumes the open position where the valve flap is lifted from the sealing surface to allow airflow through the vent opening. In some examples, the valve flap has a thickness between about 0.75 mm and 1.25 mm. In some examples, the frame is fabricated from a rigid material and the valve flap is fabricated from a flexible material. In some examples, the frame and the valve flap are a unitary structure. 
       FIGS.  1   a  and  1   b    illustrate, respectively, isometric views of an example return valve installation system  100  before and after assembly in accordance with an aspect of this disclosure. The illustrated return valve installation system  100  generally comprises a pressure vent valve  104  for installation in a vehicle component  102 , a reader  106 , and a computer  108 . As will be discussed in connection with  FIGS.  2   a  through  2   g   , the vehicle component  102  defines an aperture  110  configured to receive and retain the pressure vent valve  104  relative to a vehicle. During assembly, the pressure vent valve  104  is inserted into the aperture  110  in the vehicle component  102  body in the direction shown by an arrow  112 . 
     The return valve installation system  100  is positioned between an interior of a vehicle and the exterior environment of the vehicle and used for ventilation of the interior. The vehicle component  102  maybe attached to, or integral with, the vehicle. The vehicle may be, for example, a motor vehicle. In operation, the pressure vent valve  104  is inserted in an aperture  110  provided therefor in the body of the vehicle. The pressure vent valve  104  is inserted such that the back of the pressure vent valve  104  faces the interior of the vehicle, and the front of the pressure vent valve  104  is allocated to a region outside the vehicle interior. 
     If a pressure vent valve  104  is installed incorrectly (e.g., the pressure vent valve  104  is not fully inserted into the aperture  110  within the vehicle component  102 ), the valve seal  114  will not compress sufficiently to perform the function of sealing. The valve seal  114  may be, for example, a thermoplastic vulcanisate (TPV) 2K seal that surrounds the periphery of the pressure vent valve  104 . Should this occur, there is the potential to allow inward dust and water leakage from the exterior environment that could cause damage to the interior of the vehicle component  102 . 
     To that end, the reader  106  can be positioned adjacent the pressure vent valve  104  and/or vehicle component  102  to monitor assembly of the pressure vent valve  104  with the vehicle component  102 . The reader  106  is communicative coupled to the computer  108  via a wired or wireless link. The reader  106  is arranged to image or otherwise track an installation indicator  116  associated with the pressure vent valve  104 . As will be discussed, the installation indicator  116  may be integral with the pressure vent valve  104 . If the computer  108 , via one or more processors  108   a  coupled to a memory device  108   b , determines based at least in part on the installation indicator  116  that the pressure vent valve  104  is not properly mounted to the vehicle component  102 , an alert may be communicated to the operator (e.g., via a portable communication device) and/or, if robotic assembly is employed, the robot may automatically repeat the assembly process to correct the error. 
     While a single installation indicator  116  is illustrated, multiple installation indicators  116  can be employed and associated with the pressure vent valve  104  during installation thereof. For example, a plurality of installation indicators  116  can be formed in or on the pressure vent valve  104  (e.g., along the perimeter) to provide redundancy and/or increase accuracy by having multiple positional data points. 
       FIGS.  2   a  and  2   b    illustrate, respectively, front perspective and rear perspective, views of the pressure vent valve  104 .  FIGS.  2   c  through  2   f    illustrate, respectively, first, second, third, and fourth side elevational views of the pressure vent valve  104 . Finally,  FIGS.  2   g  and  2   h    illustrate, respectively, top plan and bottom plan, views of the pressure vent valve  104 . 
     The pressure vent valve  104  includes a frame  202  (or similar housing) that defines a generally rectangular form (though other shapes are contemplated). The frame  202  generally comprises a wall  204 , a flange  206 , and one or more attachments clips  208 . In the illustrated example, the frame  202  defines, inter alia, at least one vent opening  210 , at least one sealing surface  212 , and a plurality of fastening projections  214 . The one or more attachments clips  208  are configured to engage the aperture  110  and/or the vehicle component  102 . 
     As noted above, the pressure vent valve  104  further comprises an installation indicator  116 . In the illustrated example, the pressure vent valve  104  includes an installation indicator  116  in the form of a lever  216  extending from an edge of a flange  206  of the frame  202 . The lever  216  is illustrated as a generally flat structure defining a first planar surface  216   a  and a second planar surface  216   b . The lever  216  includes a hinge  218  that allows all or a portion of the lever  216  to be pivoted, bent, and/or otherwise moved relative to the frame  202 . 
     The installation indicator  116  includes a fiduciary marker  222  (e.g., a barcode, quick response (QR) code, AprilTag, etc.) positioned on the first planar surface  216   a  of the lever  216  and a projection  220  extending outwardly from the second planar surface  216   b  at a generally orthogonal angle. The example projection  220  is illustrated as a slightly tapered protrusion (i.e., a conical frustum), however, as will be discussed, other shapes and sizes are contemplated. While the lever  216  is illustrated as a generally flat structure, it is conceivable that other shapes can be used to orient a fiduciary marker  222  (illustrated as position on the first planar surface  216   a ) at the proper angle relative to the reader  106  when the vehicle component  102  is properly inserted and seated into the aperture  110  of the vehicle component  102 . 
     The lever  216 , the hinge  218 , projection  220 , and/or fiduciary marker  222  may be integrally formed with the frame  202  during the molding process. For example, the hinge  218  may be formed as a thin region in the lever  216  to permit bending. In another example, the hinge  218  may be formed post-molding by scoring channels into one or both sides of the lever  216  to permit bending at such point. 
     An example fiduciary marker  222 , in the form of a QR code, is best illustrated in Detail A of  FIG.  2   a   . While a 2-dimensional fiduciary marker  222  is illustrated throughout the figures, 3-dimensional fiduciary markers can be employed. The fiduciary marker  222  may be attached to, printed on, or positioned in any other suitable manner on the lever  216 . In a 2-dimensional application, the fiduciary marker  222  may be printed directly on the lever  216  using ink or applied as a sticker using adhesive. In other examples, the fiduciary marker  222  may be formed in or on the lever  216  during fabrication of the frame  202  and/or the lever  216 . In addition to positioning, the fiduciary marker  222  may include information regarding, for example, the pressure vent valve  104 . Such information could include, for example, a model number, serial number, manufacturing date, lot number, material type, etc. 
     In the case of a 3-dimensional fiduciary marker  222 , the 3-dimensional fiduciary marker  222  can be fabricated with the lever  216  or separately and later adhered to the lever  216 . The 3-dimensional fiduciary marker  222  may be, for example, a known arrangement of 3-dimensional elements or shapes, the orientation of which can be tracked by the combination of the reader  106  and the computer  108 . 
     With reference to  FIG.  2   e   , the pressure vent valve  104  is inserted into the aperture  110 , the projection  220  on the lever  216  configured to engage a surface of the vehicle component  102  during installation to causes the lever  216  to rotate about the hinge  218  as indicated by arrow  224 . In the illustrated example, the projection  220  is positioned about 90 degrees (i.e., an orthogonal angle) relative to second planar surface  216   b  of the lever  216 . As noted previously, while the projection  220  is generally illustrated as having a conical frustum shape, the projection  220  may be otherwise sized and shaped depending on the desire application. For example, if the pressure vent valve  104  is installed in a vehicle component  102  adjacent a vertical surface (e.g., a wall), the projection  220  may be shortened or otherwise shaped to engaged the vertical surface such that the lever  216  is still bent to the desired angle upon installation. 
     A reader  106 , such as a barcode reader or other reader, could be positioned at about 90 degrees to a plane  226  of the pressure vent valve  104  running through the flange  206  and/or parallel to the lever  216 . Once the pressure vent valve  104  is fully and properly inserted, the fiduciary marker  222  will be at an angle of about 90 degrees (i.e., an orthogonal angle) with respect to the plane of the pressure vent valve  104  running through the flange  206  and at about 90 degrees with respect to the original position of the lever  216 . For example, where the reader  106  is an optical reader with a lens, the lens would then be generally parallel to the plane defined by the first planar surface  216   a  upon which the fiduciary marker  222  is mounted (i.e., the lever  216 ). From this vantage point, the reader  106  would be able to read the fiduciary marker  222 . In which case, the valve seal  114  around the pressure vent valve  104  would be sufficiently compressed to provide protection from dust and water. If the lever  216  with fiduciary marker  222  is at another angle, the fiduciary marker  222  would not be read and the computer  108  would issue an error notification. 
     Depending on the application, the frame  202  may be fabricated from a rigid material, such as, for example, synthetic or semi-synthetic polymers (e.g., plastics, such as acrylonitrile butadiene styrene (ABS) and polyvinyl chloride (PVC), etc.), composite materials (e.g., fiber glass), metal (or a metal alloy), or a combination thereof. In the illustrated example, the frame  202  can be fabricated using a relatively hard plastic via a plastic injection molding process. Therefore, in some examples, the frame  202  and its various features can be formed as a unitary structure. For example, the lever  216  and projection  220  may be formed integrally with the frame  202 , for example, as part of an injection molding process. Optionally, the lever  216  and projection  220  may be formed separately and attached to the pressure vent valve  104 . While the lever  216  is shown as being attached to the flange  206  of the pressure vent valve  104 , the lever  216  may optionally be attached to any other suitable part of the pressure vent valve  104 . 
     As best illustrated in  FIG.  2   h   , the frame  202  can be divided by one or more webs  232  to define the one or more vent openings  210 . In the illustrated example, the five vent openings  210  are arrange in a column or series arrangement. Other quantities and arrangements, however, are contemplated (e.g., in a quad, triangular, etc.). In particular, the illustrated frame  202  provides four webs  232  to define forms five vent openings  210 . The vent openings  210  are illustrated as generally rectangular openings, though other shapes are contemplated (e.g., square, trapezoidal, etc.). 
     The frame  202  includes at least one sealing surface  212  and at least one flexible valve flap  228  mounted on the frame  202 . Each of the plurality of valve flaps  228  is coupled to the frame  202  at or adjacent each of the plurality of vent openings  210 . As illustrated, a valve flap  228  is arranged adjacent each of the five vent openings  210  and configured to cover each respective one of the five vent openings  210  when in the idle position. Each of the valve flaps  228  is configured to alternate between the idle position and an open position. 
     The frame  202  is formed with sealing surfaces  212  such that the valve flaps  228 , when in the idle position, substantially and/or completely prevent airflow through the vent openings  210  of the frame  202 . Therefore, the sealing surfaces  212  are generally located at the contact regions between the valve flap  228  and frame  202 . The sealing surfaces  212  for the valve flaps  228  can be fabricated using a softer plastic material. For example, the sealing surfaces  212  can be molded onto the frame  202  in a multi-component injection molding process. In one example, the one or more sealing surfaces  212  are provided at the perimeter of each of the vent openings  210 . The sealing surface  212  around each vent opening  210  may be continuous or segmented. Therefore, in some examples, the sealing surface  212  generally surrounds the vent openings  210  (or at least a bottom edge) and contacts the valve flap  228 . 
     The valve flaps  228  are fabricated using a material that is flexible and/or softer relative to the material of the frame  202 . In some examples, the flexible valve flap  228  is made of a flexible material, such as closed pore, foamed material. It is also conceivable that the valve flaps  228  could comprise other plastic and/or rubber flexible materials. In any case, the valve flaps  228  are generally thin and hence very flexible to allow them to alternate or otherwise transition between the idle position and the open position. 
     The valve flaps  228  are mounted at one end (e.g., along one edge) on the frame  202  via, inter alia, one or more fastening projections  214  formed on the frame  202 . In the illustrated example, a plurality of fastening projections  214  are arranged and aligned in a row along an upper edge of each of the vent openings  210 . 
     To prohibit the valve flap  228  from detaching, the plurality of fastening projections  214  can pass through the valve flap  228 . To that end, the valve flaps  228  each have a plurality of flap openings  230  formed along an edge through which the fastening projections  214  of the frame  202  are passed to secure the valve flap  228  to the frame  202 . The valve flaps  228  are mounted by passing the fastening projections  214  through the flap openings  230 . The fastening projections  214  may be tapered and sized such that a tip of the fastening projection  214  is smaller than the flap opening  230 , while a base end of the fastening projection  214  is larger than the flap openings  230 . As a result, when installed, the flap opening  230  can stretch and/or deform to better contact and secure to the fastening projections  214  at the base end. 
     The various figures illustrate the valve flap  228  in the idle position (e.g., closed). In the idle position, the valve flap  228  abuts the sealing surface  212  and is configured to block airflow through the vent opening  210 . When a pressure increases in the interior of a vehicle, the valve flap  228  assumes the open position such that the valve flap  228  is lifted from the sealing surface  212  to allow airflow through the vent opening  210 . 
     When the air pressure increases within the cabin, for example, the valve flaps  228  assume a vent position whereby the flaps valve flaps  228  flex upward and away from the frame  202  to allow air flow through the vent opening  210  of the frame  202 . In other words, when a sufficient pressure occurs, assumes an open position lifted from the sealing surface  212  in which it allows airflow through the pressure vent valve  104 . Once the pressure between the vehicle interior and the environment has balanced, the valve flaps  228  close automatically under their own weight (i.e., they return to the idle position). 
     In some examples, the valve flap  228  has a thickness between about 0.75 mm and 1.25 mm, or about 1.0 mm. Thicker or thinner thicknesses for the valve flap  228  may be used; however, attention must be paid to the overall thickness and/or rigidity of the valve flap  228  to ensure that the valve flap  228  remains sufficiency flexible to deflect into the open position during operation. 
     While the present method and/or system has been described with reference to certain implementations, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the present method and/or system. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. For example, block and/or components of disclosed examples may be combined, divided, re-arranged, and/or otherwise modified. Therefore, the present method and/or system are not limited to the particular implementations disclosed. Instead, the present method and/or system will include all implementations falling within the scope of the appended claims, both literally and under the doctrine of equivalents.