Patent Publication Number: US-2015075001-A1

Title: Elastomeric valve

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Patent Application No. 60/978,377 filed Oct. 8, 2007 titled “Elastomeric Valve and Apparatus and Method for Making Same” 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to valves and more particularly to methods of making a petal valve such that the opening of the valve is formed during the molding of the valve and the opening of the valve is formed in an open position. 
     BACKGROUND OF THE INVENTION 
     Soft plastic, such as silicone or a thermoplastic elastomer can be used to make a petal valve. Traditionally, to make such a valve, the soft valve body is molded and then ejected from a molding tool. Then, the molded material is punched or sliced to form an X-opening. Forming the X-opening after the molding process adds an extra step to the process of making a petal valve and accordingly adds to the cost of making such a valve. 
     Previously, it has not been practical to form the X-opening in the valve body during the molding process of the valve body because openings formed by a tool during the molding process would likely be too large to permit effective sealing of the valve. When petal valves or component parts with a petal valve function are made, it is important that the sealing petals or lips can close tightly together after opening without the need for significant compression in the sealing area. 
     There is thus a continuing, ongoing need for a method of making a petal valve such that the opening of the valve can be made during the molding process and can be made in a open position. Additionally, there is a need for a petal valve with an opening that separates when under fluid pressure and closes to seal the opening against flow when the fluid pressure is relieved. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Various examples of objects, features and attendant advantages of the present invention will become fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, wherein: 
         FIG. 1  is a cross-section of a valve in accordance with the present invention; 
         FIG. 2  is a cross-section of a valve sealing lip configuration with a large sealing surface area in accordance with the present invention; 
         FIG. 3  is a cross-section of a valve sealing lip configuration incorporating a trap/zipper function in accordance with the present invention; 
         FIG. 4  is a cross-section of a valve sealing lip configuration incorporating a directional valve function/flow in accordance with the present invention; 
         FIG. 5  is a cross-section of a valve sealing lip configuration incorporating a substantially rigid material in accordance with the present invention; 
         FIG. 6  is a cross-section of a valve molded in an open valve position in accordance with the present invention; 
         FIG. 7  is a cross section of a valve reversed or bent into a closed valve position in accordance with the present invention; 
         FIG. 8  is a side view of a valve molded in an open valve position in accordance with the present invention; 
         FIG. 9  is a perspective view of a valve reversed or bent into a closed valve position in accordance with the present invention; 
         FIG. 10  is a substantially rigid skeleton material in accordance with the present invention; 
         FIG. 11  is a preloaded substantially rigid skeleton material in accordance with the present invention; 
         FIG. 12  is a top view of a molded valve in a closed position in accordance with the present invention; 
         FIG. 13  is a side view of a molded valve in a closed position in accordance with the present invention; 
         FIG. 14  is a top view of a directional flow valve in accordance with the present invention; 
         FIG. 15  is a side view of a directional flow valve in accordance with the present invention; 
         FIG. 16  is a side view of a of an open valve made from non-compatible material in accordance with the present invention; 
         FIG. 17  is a side view of a core for molding a valve in accordance with the present invention; 
         FIG. 18  is a side view of a core for molding a valve with a molded valve body thereon in accordance with the present invention; 
         FIG. 19  is a side view of a molded valve body in accordance with the present invention; 
         FIG. 20  is a side view of a molded valve body and a second core in accordance with the present invention; 
         FIG. 21  is a side view of a second core entering a molded valve body in accordance with the present invention; 
         FIG. 22  is a side view of a second core in a molded valve body in accordance with the present invention; 
         FIG. 23  is a side view of a second core bending or preloading part of a molded valve body in accordance with the present invention; 
         FIG. 24  is a side view of a second core in a preloaded molded valve body and molding a sealing portion in accordance with the present invention; 
         FIG. 25  is a side view of the preloaded molded valve body and a sealing portion in accordance with the present invention; 
         FIG. 26  is a side view of a released molded valve body and a sealing portion in a closed position in accordance with the present invention; 
         FIG. 27  is a side view of a molded valve body and sealing portion in a closed position under pressure; 
         FIG. 28  is a side view of a molded valve body and sealing portion in a partially open position under pressure in accordance with the present invention; 
         FIG. 29  is a side view of a molded valve body and sealing portion in a fully open position under pressure in accordance with the present invention; 
         FIG. 30  is a side view of a molded valve body and sealing portion in a closed position in accordance with the present invention; 
         FIG. 31  is a side view of a molded valve body and sealing portion in a closed position in accordance with the present invention; 
         FIG. 32  is a side view of a molded valve body and a sealing portion with a center valve in a closed position under pressure in accordance with the present invention; 
         FIG. 33  is a side view of a molded valve body and sealing portion with a center valve in a partially open position under pressure in accordance with the present invention; 
         FIG. 34  is a side view of a molded valve body and a sealing portion with a center valve in a fully open position under pressure in accordance with the present invention; 
         FIG. 35  is a side view of a molded valve body and a sealing portion with a center valve in a closed position in accordance with the present invention; 
         FIG. 36  is a side view of a core for valve configuration in accordance with the present invention; 
         FIG. 37  is a side view of a core for valve configuration with a molded substantially rigid valve skeleton thereon in accordance with the present invention; 
         FIG. 38  is a side view of a core for valve configuration with a molded substantially rigid valve skeleton partially released therefrom in accordance with the present invention; 
         FIG. 39  is aside view of a core for valve configuration with a molded substantially rigid valve skeleton fully released therefrom in accordance with the present invention; 
         FIG. 40  is a side view of molded substantially rigid valve skeleton in accordance with the present invention; 
         FIG. 41  is a side view of a second core entering a molded substantially rigid valve skeleton in accordance with the present invention; 
         FIG. 42  is a side view of a second core in a molded substantially rigid valve skeleton in accordance with the present invention; 
         FIG. 43  is a side view of a second core bending or preloading part of a molded substantially rigid valve skeleton in accordance with the present invention; 
         FIG. 44  is a side view of a second core with a preloaded molded substantially rigid valve skeleton thereon and a sealing portion being molded thereon in accordance with the present invention; 
         FIG. 45  is a side view of a preloaded molded substantially rigid valve skeleton and a sealing portion in accordance with the present invention; 
         FIG. 46  is a side view of partially preloaded molded substantially rigid valve skeleton and a sealing portion in accordance with the present invention; 
         FIG. 47  is a side view of a released molded substantially rigid valve skeleton and a sealing portion in a closed position in accordance with the present invention; 
         FIG. 48  is a cross-section of a valve in an open position in accordance with the present invention; 
         FIG. 49  is a cross-section of a valve in an open position and a substantially rigid skeleton in accordance with the present invention; 
         FIG. 50  is a cross-section of substantially rigid skeleton approaching a valve in an open position in accordance with the present invention; 
         FIG. 51  is a cross-section of a substantially rigid skeleton closing a valve in accordance with the present invention; 
         FIG. 52  is a cross-section of a substantially rigid skeleton closing a valve in accordance with the present invention; 
         FIG. 53  is a cross-section of a substantially rigid skeleton closing a valve in accordance with the present invention; 
         FIG. 54  is a cross-section of a substantially rigid skeleton closing a valve in accordance with the present invention; 
         FIG. 55  is a cross-section of a substantially rigid skeleton holding a valve in a closed position in accordance with the present invention; 
         FIG. 56  is a side view of a valve where the sealing portion has been closed; and 
         FIG. 57  is a side view of a valve where the sealing portion has been over molded with a substantially rigid material in its closed position. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     While the present invention is susceptible to embodiments in various forms, there is shown in the drawings and will be described herein in detail specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention. It is not intended to limit the invention to the specific illustrated embodiments. 
     Embodiments of the present invention include a petal valve with an opening that can separate when under fluid pressure and can close to seal the opening against flow when the fluid pressure is relieved. Further embodiments include a method of making a petal valve such that the opening of the valve can be made during the molding process while in an open position. 
     A valve in accordance with the present invention can be a resilient one-way valve that can be used, for example, for dispensing household, cosmetic and personal care liquids, lotions or gels or can be used, for example, in medical and industrial fluid transfer applications. Valves in accordance with the present invention can be made of a soft plastic, for example, a silicone or a thermoplastic elastomer. 
     A valve in accordance with the present invention, can be molded inside out and then reversed so as to be functional after molding is complete. To achieve such molding, a molding assembly that reverses the valve can be used to support and keep the new geometry of the valve and to ensure that the valve stays in its working position geometry once reversed. In preferred embodiments, after a valve is reversed into its working position, the valve can be overmolded with a substantially rigid material to lock the valve in its working position. The valve can be overmolded while it is still in a first mold. 
     In accordance with this embodiment of the present invention, a valve can be molded with the petals of the valve opening in an open position.  FIG. 6  is a cross-section of a valve  10  in an open valve position, and  FIG. 8  is a side view of the valve in an open position. By molding the valve in an open position, the petals of the valve opening can be configured during the molding process to seal against fluid flow when they are in a closed position. Further, when the valve is molded in an open position, the sealing configurations as seen and described with respect to  FIGS. 2-4  can be molded. 
     The sealing boundaries of the petals can be configured to be flat. In alternate embodiments, the sealing boundaries of the petals can have complimentary shapes to further enhance the seal between the petals when they are in a closed position.  FIG. 1  is a cross-section of a valve  10  in accordance with the present invention with sealing lips  11  in a closed position. As can be seen in  FIGS. 2-4 , the valve sealing lip configuration can be formed to increase the surface of the sealing area ( FIG. 2 ), to enable a trap/zipper function ( FIG. 3 ), or to enable a directional valve function flow ( FIG. 4 ). When a trap/zipper function is enabled as seen in  FIG. 3 , the sealing effect of the valve is further enhanced. 
     In embodiments of the present invention as shown in  FIG. 2 , the petals can be molded so that the surface area of the sealing region has a greater thickness than the thickness of the body of the valve. The added thickness of the petals can reinforce the sealing function of the valve to achieve a unique valve that, for example, has a larger sealing contact area or has a special design for the intended flow pattern or special trap features. The added thickness can also allow adjustments to be made to the fluid force needed to open a valve by adding material in the sealing area on either the upstream or downstream side of the valve. 
     In embodiments of the present invention as shown in  FIG. 3 , sealing petals of the valve can have grooves or protrusions that interlock in the sealing area. Such interlocking creates sealing traps to enhance the sealing feature of the valve. 
     After the valve is molded in the open position, the valve can be reversed or bent into a closed valve position to enable to the closing of the sealing configurations of the valve petals.  FIG. 7  is a cross-section of a valve  10  reversed or bent into a closed valve position, and  FIG. 10  is a perspective view of the valve in a closed position. As seen in  FIG. 7 , the reversed valve  10  can be kept in place by a substantially rigid skeleton  14  that can be molded or assembled onto the valve to ensure proper functioning of the valve. 
       FIGS. 48-55  show a cross-section of a valve  10  in accordance with the present invention first in an open position and then reversed with the use of a substantially rigid skeleton  14 . As explained above, when the valve is in the open position, different sealing configurations of the valve lips can be achieved before the valve is closed. 
     A valve in accordance with the present invention can alternatively have a locking feature built into the valve, for example, a snap. The valve in this embodiment can be, for example, one component or multiple components. The locking feature can aid in reversing the valve from an open position to a closed position and keep the valve securely in the locking position once reversed. In some embodiments, the locking feature can be the material of the valve. 
     In other embodiments of the present invention, a valve can be molded in a functional direction with the use of molding cores and overmolding. Referring to  FIG. 17 , a side view of a core  20  for valve configuration is shown. As seen in  FIG. 18 , a valve body  22  can be molded onto the core  20 .  FIG. 19  shows the molded valve body  22  removed from the core.  FIGS. 20-22  show a second core  21  entering the molded valve body  22 . As seen in  FIG. 23 , the second core  21  can bend or preload part of the substantially rigid molded valve body  22 . Referring to  FIG. 24 , the sealing portion  24  can be molded when the second mold  21  is inside of the molded valve body  22 . 
       FIG. 25  shows the molded valve body and the sealing portion before the bent or preloaded part of the substantially rigid part of the valve body is released. In  FIG. 26 , the bent or preloaded part of the substantially rigid part of the valve body is released and the valve is in a closed position. 
     Referring to  FIGS. 27-31 , a side view a molded valve body and sealing portion are shown. When the sealing portion is under pressure, the sealing portion opens. When pressure is released, the sealing portion returns to a closed position. 
     An alternate embodiment of a molded valve body and sealing portion is shown in  FIGS. 32-35 . In this embodiment, the sealing portion includes a center opening with a trap feature. As seen in  FIG. 32 , the sealing portion starts in a closed position. When under pressure, the sealing portion opens, and when the pressure is released, the sealing portion returns to a closed position. 
     When an overmolding process as described above is incorporated into methods in accordance with the present invention, shrinkage of the overmolded material may occur and provide for additional advantages of extra compression and/or sealing in the valve. For example, a second shot of molded plastic material may be used to strengthen the valve body to ensure that the valve remains in its working configuration. Those of skill in the art will know that if the proper material for the second shot is used and shrinkage of the second shot material is calculated correctly, the sealing petals can meet from this feature alone. Similarly, if the area of the steel portion or core that separates the sealing petals in the first molding is overcome by the shrinkage of the material from the second molding, then those of skill in the art will know that it is possible to make the valve opening seal only by using this process. 
     Other methods of securing the valve in its sealing position include, for example, snap assembly, coining, or using adhesives, or welding techniques to join the valve to a support frame, such as a cap, or a retaining ring for later assembly in various products needing a valve structure. 
     In embodiments of the present invention, a valve is molded with a core having a reversed dome where the angle of the steel or core forming the valve portion is calculated to seal when the valve is reversed in its assembly position. The position of the reversed dome arch makes the sealing of the valve structure possible in a closed position. 
     Support ribs of a substantially rigid material can be molded to an area near the sealing petals. Such support ribs can enhance the sealing, opening, and closing of the valve. In alternate embodiments, a support structure or skeleton of a substantially rigid material can be molded onto the valve or the valve can be molded onto a substantially rigid skeleton. Such a support skeleton can aid in controlling the sealing petals and the functioning of the valve when in use. Specifically, a support skeleton can ensure that the sealing petals of the valve return to a closed position even when the thickness of the petals is thin. A support skeleton can also ensure that the valve does not return to its reversed position if it had been molded in the reversed position. Substantially rigid materials that can be used for support ribs or a support skeleton, include, for example, a polypropylene. 
     Referring to  FIG. 10 , a substantially rigid skeleton material  14  is shown. In embodiments of the present invention, the substantially rigid skeleton can be a substantially rigid housing. When a substantially rigid skeleton or housing is employed, the substantially rigid skeleton can be bent or reversed in a mold before molding the valve material as seen in  FIG. 11 . Then, the valve material can be molded, and, upon ejection from the mold, the valve can close. After the valve is molded onto to the substantially rigid skeleton, the skeleton can regain its original molded position and create the finished valve when released from the mold. 
     Embodiments of the present invention in which a valve is molded onto a substantially rigid skeleton are shown in  FIGS. 36-47 .  FIG. 36  is a side view of a core  30  for valve configuration. In  FIGS. 37-39 , a substantially rigid skeleton  32  is molded onto the core  30  and then released from the core.  FIG. 40  is a side view of the substantially rigid skeleton  32  after molding on the core is complete. 
     As seen in  FIG. 41 , a second core  31  can enter the substantially rigid skeleton  32 . Referring to  FIGS. 42-43 , when the second core  31  enters the substantially rigid skeleton  32 , the second core  31  can bend or preload part of the substantially rigid skeleton  32 . After a portion of the substantially rigid skeleton is bent or preloaded with the second core, a sealing portion  34  can be molded onto the preloaded substantially rigid skeleton  32  and the second core  31  as seen in  FIG. 44 . Then, the second core can be removed from the substantially rigid skeleton  32  and the sealing portion  34 . 
       FIG. 45  shows a side view of the substantially rigid skeleton  32  and the sealing portion  34  before the preloaded part of the substantially rigid skeleton is released. In  FIG. 46 , the preloaded part of the substantially rigid skeleton  32  is partially released, and in  FIG. 47 , the preloaded part of the substantially rigid skeleton  32  is fully released. When the substantially rigid part of the molded skeleton is released, the valve achieves a closed position. 
     The spring effect of the support skeleton can be improved to ensure that it will return to its molded position when the preload is released after molding a flexible sealing material and thus, completing the valve. Such improvements can be achieved by adding, for example, glass fiber or other enhancement fillers into the support skeleton. 
     A substantially rigid skeleton in accordance with the present invention preferably are made from materials that can adapt to the heat and high temperature that will surround the skeleton when it is overmolded with, for example, LSR (Liquid Silicone Rubber), natural rubber, or any other material that must be baked or heated to solidify. The substantially rigid skeleton can work in hostile surroundings. 
     In embodiments of the claimed invention, the sealing petals of the valve can be molded in an open position and then formed in a closed position before a second molding. In such embodiments, a substantially rigid skeleton of the second molding can enable the valve to stay in a closed position when ejected from the mold.  FIG. 12  is a top view of the valve in a closed position with a substantially rigid skeleton, and  FIG. 13  is a side view of the valve in a closed position with the substantially rigid skeleton supporting the sealing area of the valve. The support of the substantially rigid skeleton helps to control the opening and closing function of the valve and also enables a thinner wall thickness of the sealing area. 
     In some embodiments, the flow direction of the valve can be in the same direction as the valve when the valve is reversed. In other embodiments, the flow direction of the valve can be in the opposite direction. 
     Embodiments of the present invention include sealing petals that have support ribs on the back side, the front side, and/or on the inside of the sealing area. Such support ribs can give the sealing petals strength as well as minimize the use of expensive sealing and valve material by allowing for thinner wall thickness compared to the amount of material and wall thickness traditionally required in valves known by those of ordinary skill in the art to give the necessary sealing effect. 
     A valve in accordance with the present invention can be molded from two dissimilar or different materials that do not bond in the molding process. In such embodiments, a valve function can be created in at least one of the contact points between the two materials. The pressure from the flow direction will then either make the valve open or close depending on the intended function of the valve.  FIG. 5  is a cross-section of a valve  10  with a sealing area consisting of a substantially rigid material  12  and a flexible elastomer, rubber or silicone based material  13 . 
     Referring to  FIG. 14 , a top view of a valve configuration is shown where the sealing area is created between the edges of the substantially rigid skeleton material  14  and the sealing material  15 .  FIG. 15  is a side view of the valve configuration shown in  FIG. 14 . An overlapping stop of the substantially rigid skeleton  14 ′ can create a directional valve that can only open in one direction and can be sealed extremely tight when the flow reverses. In this embodiment, the opening in the sealing area is larger, which allows for larger flow volumes as seen in  FIG. 16 . Additionally, the round sealing properties allow for better sealing properties when other devices are connected through the valve. In this embodiment of the present invention, it is preferred to have multiple attachment points (not shown) between the substantially rigid skeleton and the sealing material. 
     In embodiments where the sealing properties of the valve are not of high importance, a valve can be made using a substantially rigid material alone or with a blend of substantially rigid and elastomeric materials. When a substantially rigid material is used, it is possible to build a locking feature into a valve keeping the valve structure in place when reversed to its sealing position. Such valves could be used in connection with, for example, containers and closures in a one component material configuration with a valve structure. 
     A substantially rigid skeleton can also be molded with a spring feature by, for example, adding glass fiber reinforcement into the material blend (e.g. polypropylene) and then overmolding the preloading or reversed skeleton structure into, for example, a flip top can with a hinge material such as, for example, polypropylene without glass fiber reinforcement. Such processes can keep the materials used in the same category for, for example, recycling purposes. Different material combinations can also be used for performance or cost reasons, for example. 
     Embodiments of the present invention include a valve comprising at least one material, having a valve opening molded in an open position and with a design that enables the valve to be reversed and/or released into a closed working position before the intended use of the valve. 
     Further embodiments include a valve comprising a substantially rigid support structure and/or skeleton of a substantially rigid material, for example a plastic or a metal. Part or all of the support structure can be bent and/or preloaded in a mold before a valve material is introduced into the mold. Then, the valve material can be reversed into a sealing position when it is ejected from the mold. The support structure can help to control the sealing lips of the valve and the valve structure when the valve is in use. 
     Other embodiments include a valve comprising a substantially rigid support structure and/or skeleton and a valve material molded together. The support structure can help to support the valve material and control the sealing lips and the valve structure when the valve is in use. 
     Even further embodiments of the present invention include molding a valve in which the sealing lips of the valve have grooves and/or protrusions that interlock in the sealing area. The grooves and/or protrusions can create sealing traps to enhance the sealing feature of the valve. 
     Other embodiments include molding a valve where the sealing lips have a larger sealing surface area as compared to the wall thickness of the surrounding valve material. 
     Some embodiments include molding a valve where the sealing lips have support ribs incorporated in the sealing area. The support ribs can give the sealing portion strength and also minimize the use of material and wall thickness as compared to the amount of material and wall thickness normally needed to provide the necessary sealing effect. 
     In embodiments of the present invention, a valve can be molded from two dissimilar materials that do not bond in the molding process. The valve function can be created by at least one contact point between the two materials. 
     In further embodiments, a valve can be molded where a skeleton of the valve is made from a more rigid material and is bent in a second molding that allows the skeleton to return to its original position after the second molding is complete. Thus, the valve can be closed after the molding process and when ejected from the mold. 
     Some embodiments include an apparatus and/or mold comprising at least one core and/or cavity that has a geometry capable of bending and/or reversing a previously molded part. An externally manufactured part can be affixed or molded to a rigid plastic or a membrane material, for example, elastomer, rubber, or silicone. 
     In other embodiments, an apparatus and/or a mold can comprise at least one core and/or cavity having a geometry capable of being activated and/or moved into a closed molding tool, which can bend and/or reverse a previously molded or an externally manufactured part before a rigid plastic or a membrane material, for example, elastomer, rubber, or silicone, is molded thereto. 
     Further embodiments of the present invention include molding a valve consisting of a substantially rigid material and a sealing material such that the valve sealing portion is created between the two materials, i.e. between a hard and soft/flexible material. 
     Still further embodiments include molding a valve consisting of two materials that do not bond such that the valve portion is created in a dedicated area between the two materials. 
     In some embodiments, a valve can consist of at least two materials that do not bond. The valve portion can be created in a dedicated area between the two materials and include a mechanical bonding in at least one area of the valve to ensure that the valve remains in tact when in use. 
     Embodiments of the present invention include a valve having at least one material having a locking feature built into the valve. The locking feature can keep the valve structure in place and lock by means of the valve&#39;s own structure when the valve is reversed into its sealing position. 
     Further embodiments include a third molding or an applied pressure in the assembly of valve positions. The third molding can be, for example, a valve arm made of a substantially rigid material. 
     Yet even further embodiments include an apparatus and/or a mold comprising at least one core and/or cavity having a geometry capable of bending and/or reversing a previously molded or externally manufactured part. The apparatus can be inserted into a substantially rigid plastic and a membrane material, for example, elastomer, rubber or silicone, can be molded to at least one sealing area of the valve. 
     Other embodiments can include an apparatus and/or a mold comprising at least one core and/or cavity having a geometry capable of bending and/or reversing a previously molded or externally manufactured part. The apparatus can be inserted into a substantially rigid plastic, and a membrane material, for example, elastomer, rubber or silicone can be molded to at least two sealing areas of the valve. The sealing areas can be connected when being filled with the same material, but the sealing areas are not connected for sealing during the molding. 
     The above described embodiments can be incorporated into a valve in accordance with the present invention alone or in combination to create a valve with sealing properties superior to those known by persons of skill in the art. Such valves can be incorporated into a wide variety of products as explained above. 
     From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus or method illustrated herein is intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims.