Patent Publication Number: US-10323760-B2

Title: Decompression air valve

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 15/593,718, filed May 12, 2017, and claims priority to Chinese Application Serial No. 201610316878.5, filed May 12, 2016, the disclosures of which are hereby expressly incorporated by reference herein in their entireties. 
    
    
     FIELD OF THE DISCLOSURE 
     The present disclosure relates to a valve for use with an inflatable product. More particularly, the present disclosure relates to a combined inflation and decompression valve for use with an inflatable product, and to a method for using the same. 
     BACKGROUND OF THE DISCLOSURE 
     Traditional air valve assemblies of the type for use with inflatable products (such as mattresses, chairs, pools, spas, floats, etc.) include fill valve components. However, such conventional air valve assemblies typically do not provide for an automatic decompressing function, such that when the product is over inflated, air in the air chamber cannot exhaust out. As a result, if the internal portion of the product is in an over inflated state (i.e., has an internal pressure greater than a decompression value), and if the product is pressed by sufficient external force, it may burst or explode. 
     Prior attempts to combine an air valve and a decompression valve, have resulted in a simple decompression function as the internal portion of the product is over inflated. However, when the decompression valve is open to deflate, it does not automatically close in response to a reduction of air pressure. Additionally, the internal components of the decompression valve may shake or rattle as a result of air flowing when open, and thus may tend to break. 
     SUMMARY OF THE DISCLOSURE 
     The present disclosure provides a valve assembly configured for use with an inflatable product, such as a mattress, chair, pool, spa, float, or another suitable inflatable product. The valve assembly includes a first valve component that serves as an air inlet for inflation of inflatable product, and a second valve component that serves as an air outlet for deflation or decompression of inflatable product. 
     According to an embodiment of the present disclosure, an air valve assembly includes an air valve component and a decompression valve component. The air valve component includes an outer body defining an internal receiving chamber, and an air valve in fluid communication with the internal receiving chamber, the outer body including an air hole fluidly connecting the internal receiving chamber and an air chamber of an inflatable product. The decompression valve component is received within the internal receiving chamber and supported for longitudinal movement within the internal receiving chamber between a sealed state and an open state. The decompression valve component seals the air valve of the air valve component from the air hole of the outer body in the sealed state. The decompression valve component fluidly connects the air valve of the air valve component and the air hole of the outer body in the open state. The decompression valve component includes a decompression passage fluidly connecting the air chamber and atmosphere. A sealing portion is configured to close the decompression passage in the sealed state, and a limit portion is operably coupled with the sealing portion. When air pressure within the internal receiving chamber is greater than a decompression value, the sealing portion and the limit portion move relative to each other, and the sealing portion abuts the limit portion to move the decompression valve component from the sealed state to the open state. 
     According to another embodiment of the present disclosure, an air valve assembly includes an outer body defining an internal receiving chamber and having a plurality of air holes fluidly coupling the internal receiving chamber and an air chamber of an inflatable product. An air outlet is supported by the body and is configured to provide selective communication between the air chamber and atmosphere. An air valve device is supported by the outer body and fluidly coupled to the air chamber through the air holes of the outer body and the internal receiving chamber. The air valve device includes a valve rod and a seal supported by the valve rod, the valve rod being movable between a sealed state and an open state. The seal cooperates with the outer body to block air flow in the sealed state, and the seal is in spaced relation to the outer body to define a passageway between the seal and the outer body in the open state. The valve rod is biased toward the sealed state. A decompression valve device is supported by the outer body and is fluidly coupled to the air chamber through the air holes of the outer body and the internal receiving chamber. The decompression valve device includes a valve base received within the internal receiving chamber, the valve base defining an internal chamber extending between a first end and a second end. The first end of the valve base includes a decompression opening in fluid communication with the air outlet, and the second end of the valve base is fluidly coupled to the air chamber through the air holes of the outer body and the internal receiving chamber. A valve body and a seal are supported within the internal chamber of the valve base. The valve body is supported for movement relative to the seal between a sealed state and an open state. Air pressure inside the air chamber less than or equal to a decompression value causes the valve body and the seal to be in the sealed state where air flow is blocked through the decompression opening. Air pressure inside the air chamber greater than a decompression value causes the valve body and seal to be in the open state where air flow is permitted through the decompression opening. 
     According to yet another embodiment of the present disclosure, an air valve assembly includes an outer body defining an internal receiving chamber and having a plurality of air holes fluidly coupling the internal receiving chamber and an air chamber of an inflatable product. An air outlet is supported by the body and is configured to provide selective communication between the air chamber and atmosphere. An air valve device is supported by the outer body and is fluidly coupled to the air chamber through the air holes of the outer body and the internal receiving chamber. The air valve device includes a seal movable between a sealed state and an open state. The seal cooperates with the outer body to block air flow in the sealed state, and the seal is in spaced relation to the outer body to define a passageway between the seal and the outer body in the open state. A decompression valve device is supported by the outer body and is fluidly coupled to the air chamber through the air holes of the outer body and the internal receiving chamber. A decompression valve device is supported by the outer body and is fluidly coupled to the air chamber through the air holes of the outer body and the internal receiving chamber. The decompression valve device includes a valve base received within the internal receiving chamber, the valve base defining an internal chamber extending between a first end and a second end, the first end including an upper wall having a decompression opening in fluid communication with the air outlet, and the second end fluidly coupled to the air chamber through the air holes of the outer body and the internal receiving chamber. A valve body is supported within the internal chamber of the valve base, the valve body including an upper wall having a valve body opening in fluid communication with the decompression opening. A valve spool and a valve body seal are operably coupled to the valve body, the valve body seal supported by the valve spool and configured to selectively block the valve body opening. A valve body spring is received within the internal chamber of the valve base and biases the valve body away from the upper wall of the valve base and toward the valve body seal. The valve body is supported for movement relative to the valve body seal between a sealed state and an open state. A valve spool spring biases the seal toward the valve body opening. A limit portion is operably coupled with the seal, wherein air pressure inside the air chamber less than or equal to a decompression value causes the valve body and the valve body seal to be in the sealed state where air flow is blocked through the valve body opening and the decompression opening. Air pressure inside the air chamber greater than a decompression value causes the valve body seal to abut the limit portion and move the valve body relative to the valve body seal from the sealed state to the open state where air flow is permitted through the valve body opening and the decompression opening. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein: 
         FIG. 1  is an exploded perspective view of an illustrative valve assembly of the present disclosure, including an air valve component and a decompression valve component; 
         FIG. 2  is a longitudinal cross-sectional view of the air valve assembly of  FIG. 1 ; 
         FIG. 3  is a longitudinal cross-sectional view of the air valve component of the air valve assembly of  FIG. 1 ; 
         FIG. 4  is a longitudinal cross-sectional view of the decompression valve component of the air valve assembly of  FIG. 1 ; 
         FIG. 5  is a longitudinal cross-sectional view of the air valve assembly of  FIG. 1 , showing an external wall of the air chamber sealingly coupled to the outer body; 
         FIG. 6  is a longitudinal cross-sectional view of a further illustrative valve assembly of the present disclosure, showing a different configuration limit portion; 
         FIG. 7  is a longitudinal cross-sectional view of a further illustrative valve assembly of the present disclosure, showing a different configuration decompression valve component; and 
         FIG. 8  is a longitudinal cross-sectional view of another illustrative valve assembly of the present disclosure, showing an external wall of the air chamber sealingly coupled to the outer body. 
     
    
    
     Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate exemplary embodiments of the invention and such exemplifications are not to be construed as limiting the scope of the invention in any manner. 
     DETAILED DESCRIPTION OF THE DRAWINGS 
     An illustrative decompression air valve assembly  100  of the present disclosure is shown in  FIGS. 1-5 . With reference to  FIG. 5 , air valve assembly  100  is configured for use with an inflatable product  4 , such as a mattress, chair, pool, spa, float, or another suitable inflatable product. Inflatable product  4  may include an external or outer wall  41  that defines one or more air chambers  42 . Valve assembly  100  includes a first or fill/deflation air valve component or device  1  that serves as an air inlet for inflation/deflation of inflatable product  4 , and a second or decompression valve component or device  2  that serves as an air outlet for deflation or decompression of inflatable product  4  by venting to atmosphere  102 . 
     With further reference to  FIGS. 1-4 , the air valve component  1  of the valve assembly  100  illustratively includes an outer body defined by an upper body  11  and a lower body  12 . In the illustrated embodiment of  FIG. 2 , upper body  11  is threadably coupled to lower body  12 . Upper body  11  includes an air valve  111 . As shown in  FIG. 3 , upper body  11  also includes one or more internal ribs  114  that define an internal passageway  112 , and a groove  113  surrounding internal passageway  112 . As shown in  FIG. 2 , lower body  12  defines an internal accommodating or receiving chamber  121  and one or more air holes  122  in the side wall  123  and/or the bottom wall  124  of lower body  12  that allow air to pass through lower body  12  between internal receiving chamber  121  of lower body  12  and air chamber  42  of inflatable product  4  ( FIG. 5 ). 
     As shown in  FIG. 2 , the second or decompression valve component  2  includes a decompression passage  210  selectively connecting the air chamber  42  to atmosphere  102 . More particularly, the decompression valve component  2  is received in the internal chamber  121  of lower body  12  and is configured to selectively close the decompression passage  210 . The second valve component  2  includes a sealing portion having a valve base  21 , a valve body  22 , and a valve spool component  23 . The valve base  21  includes an internal chamber  211  that is aligned with and fluidly communicates with internal receiving chamber  121  and air holes  122  of lower body  12  and hence with air chamber  42 . 
     As shown in  FIG. 3 , a valve rod  212  extends upward from valve base  21  through internal passageway  112  of upper body  11  and away from internal chamber  211 . A valve spring  213  is disposed around valve rod  212 . A lower end of valve spring  213  is retained by being received in groove  113  of upper body  11 , and an upper end of valve spring  213  is retained by being received beneath a screw  214  and a nut  215 . Under the force of valve spring  213 , nut  215  of the second valve component  2  is biased upward relative to upper body  11 . A seal  216  (e.g., an O-ring) may be provided around valve rod  212  between the upper end of valve base  21  and the lower end of upper body  11 . 
     The first air valve component  1  may have a normally sealed state or position and an open state or portion. In the sealed state, valve spring  213  lifts valve base  21  and seal  216  upward and into sealed engagement with upper body  11 . In this sealed state, seal  216  blocks communication between air valve  111  in upper body  11  and internal chamber  121  in lower body  12 . In the open state, a user manually presses nut  215  downward to compress valve spring  213 . Valve base  21  and seal  216  also move downward and away from upper body  11  to define a passageway between the valve base  21  and the upper body  11 , which places air valve  111  in upper body  11  in fluid communication with internal chamber  121  in lower body  12 . The second valve component  2  may be placed in the open state when inflating or deflating the air chamber  42  of the inflatable product  4  ( FIG. 5 ). 
     Valve body  22  and valve spool component  23  are received in internal chamber  211  of valve base  21 , as shown in  FIG. 4 . With reference to  FIGS. 1 and 2 , the upper end of internal chamber  211  is in fluid communication with one or more one-way decompression holes  217  supported by a lateral upper wall  220  of the valve base  21 , and the lower end of internal chamber  211  is in fluid communication with the internal receiving chamber  121  and the air holes  122  of the lower body  12 . Valve body  22  defines a valve body opening or hole  221  in its upper end. Valve spool component  23  includes a valve spool  231  and a sealing element or seal  232  positioned between an upper surface of valve spool  231  and a lower surface of valve body  22  near hole  221 . A limit portion or projection, such as a post or thimble  218 , extends downwardly from valve base  21  into internal chamber  211 , through hole  221 , and toward valve spool component  23 . A first, or valve body spring  219  is positioned in internal chamber  211  of valve base  21 . An upper end of spring  219  abuts the upper wall  220  of the valve base  21 , and a lower end of spring  219  abuts the valve body  22 . 
     A second, or valve spool spring  233  is illustratively positioned between valve body  22  and valve spool component  23 . A flexible bellows  234  is received within the internal chamber  211  of the valve base  21  and includes a first end coupled to the valve body  22  through a retainer  236 . An end cap  238  is threadably coupled to the second end of the valve base  21 . A second end of the bellows  234  is coupled to the end cap  238 , such that the bellows  234  extends and retracts in response to longitudinal movement of the valve body  22  within the internal chamber  211  of the valve base  21 . 
     With reference to  FIGS. 1, 4 and 5 , the second valve component  2  may have a normally sealed state or position and an open state or position. In the sealed state of the second valve component  2 , the pressure inside the air chamber  42  of the inflatable product  4  ( FIG. 5 ) forces valve spool  231  and seal  232  upward and into sealed engagement with valve body  22 . In this state, seal  232  closes hole  221  to block airflow through internal chamber  211  of valve base  21 . 
     When air pressure in the air chamber  42  of the inflatable product  4  is lower than a decompression value, the valve body  22  resets under the action of the valve body spring  219 . More particularly, the valve body spring  219  pushes downwardly against the valve spool spring  233  and drives the sealing element  232  to again close the hole  221 . Characteristics of the valve body spring (e.g., spring constant (elasticity), length, etc.) may be set based upon the desired decompression value of air pressure. As such, the second valve component  2  automatically seals after decompression. When the air pressure of the air chamber  42  is lower than the decompression value, the elastic force of the valve body spring  219  causes the valve body  22  and the valve spool component  23  to move away from the thimble  218 . 
     In the open state of the second valve component  2 , the pressure in the air chamber  42  of the inflatable product  4  increases, and valve body  22  and the valve spool component  23  move towards the thimble  18  under the increased air pressure. When the thimble  218  abuts against the sealing element  232 , the valve spool spring  233  is compressed. When the air pressure of the air chamber  42  is less than or equal to the decompression value, the thimble  218  abuts against the sealing element  232 , thereby sealing the hole  221 . When the air pressure of the air chamber is greater than the decompression value, the valve body  22  keeps moving, the valve spool component  23  stops moving by the limiting of the thimble  218 , so that the valve spool component  23  separates from the valve body  22 , the decompression hole  217  is connected to the air chamber  42  to exhaust air out from the air chamber  42  of the inflatable product  4  (i.e., automatically decompressing). 
     During automatic decompression, the valve spool component  23  is continuously abutted against, and has its upward movement limited by, the thimble  218 . As such, the valve spool component  23  does not move up and down under flowing air, so that the service life of the valve spool component  23  may be effectively lengthened. 
     Therefore, when the air pressure of the air chamber  42  is lower than the decompression value, the valve spool component  23  is forced upwardly by the valve spool spring  233  and the air pressure of the air chamber  42 , such that the sealing element  232  abuts against the valve body  22  and seals the hole  221 . When the air pressure of the air chamber  42  is greater than the decompression value, due to the relatively weak elastic force of the valve spool spring  233 , the sealing element  232  is configured to open quickly for decompression (i.e., has a quick response time). Furthermore, when the air pressure of the air chamber  42  reduces to below the decompression value, as the elastic force of the valve spool spring  233  is far lighter than the elastic force of the valve body spring  219 , the valve spool spring  233  resets quickly under the action of the valve body spring  219 , thus stopping decompressing quickly and reducing the likelihood of over decompressing air in the air chamber  42 . 
     In the illustrative embodiment shown in  FIGS. 1 and 2 , an air valve cover  3  is inserted in the air valve  111 . The air valve cover  3  includes an air outlet  31 , which is connected to the decompression hole  217  by the internal passageway  112  of the upper body  11 . Air is configured to selectively flow out of the decompression hole  217  and then the air outlet  31  by operation of the decompression valve component  2 . More particularly, the second or decompression valve component  2  includes decompression passage  210  selectively connecting the air chamber  42  to atmosphere  102 . The decompression passage  210  illustratively extends from the air chamber  42 , through the internal chamber  121  of the lower body  12 , the internal chamber  211  of the valve base  21 , the decompression holes  217 , and through the internal passageway  112  of the upper body  11  to the air outlet  31 . 
     In the illustrative embodiment shown in  FIG. 5 , the outer wall  41  of the air chamber  42  is illustratively positioned in an abutting relationship between the upper body  11  and the lower body  12 . More particularly, the outer wall  41  is illustratively sealed with the upper body  11  and the lower body  12  by the abutting force between the upper body  11  and the lower body  12 . 
     It should be noted that, the limit portion (e.g., the thimble  218 ) of the illustrative embodiment of  FIGS. 1-5  is shown disposed at the top end of the internal chamber  211 . More particularly, the thimble  218  may extend downwardly from the upper wall  220  of the valve body  22  ( FIG. 4 ). As needed, the thimble  218  can be disposed at other positions for releasing the sealing relationship of the valve spool component  23  and the valve body  22  when the air pressure increases. With reference to the illustrative embodiment of  FIG. 6 , the thimble  218  may extend upwardly from the valve spool component  23 . 
     Referring now to the illustrative embodiment of  FIG. 7 , the second or decompression valve component  2  comprises valve base  21 , valve body  22  and valve spool component  23 . Valve body  22  is received within first chamber  211   a  of valve base  21 , while the valve spool component  23  is received within second chamber  211   b . The first chamber  211   a  and second chamber  211   b  are fluidly connected with each other, via a connecting passageway  222 , and with the internal chamber  121  (see  FIG. 2 ). More particularly, one end of the second chamber  211   b  is fluidly connected to the air chamber  42  via the internal chamber  121 , and the valve spool component  23  is disposed in the second chamber  211   b . The valve spool component  23  abuts against and closes the connecting portion between the first chamber  211   a  and the second chamber  211   b  by the air pressure in the air chamber  42 . 
     The valve body  22  is disposed in the first chamber  211   a , one end of the first chamber  211   a  is connected to the internal receiving chamber  121 , so that the valve body  22  moves in the first chamber  211   a  by the influence of the air pressure in the air chamber  42 . The other end of the first chamber  211   a  is disposed with decompression holes  217  connected to the air valve  111 . The decompression holes  217  and the air chamber  42  are separated by the valve body  22 . The valve body  22  is further disposed with a limit portion  218 , such as a post or thimble. More particularly, the limit portion  218  may comprise a thimble disposed at the top end of the internal wall of the valve body  22  along the length direction of the valve body  22 . 
     When air pressure in the air chamber  42  increases, the valve body  22  moves toward the valve spool component  23  by the air pressure. When air pressure in the air chamber  42  reaches the decompression value, the limit portion  218  abuts against the valve spool component  23 . When the air pressure in the air chamber  42  is higher than the decompression value, the valve spool component  23  moves away from the connecting passageway  222  of the first chamber  211   a  and the second chamber  211   b  under the limit action of the limit portion  218 . The decompression hole  217  connects the second chamber  211   b  and the air chamber  42  to exhaust in the air chamber  42  out from the valve assembly  100 . 
     As shown in the illustrative embodiment of  FIG. 8 , external wall  41  of the air chamber  42  includes a lower surface sealed to the upper surface of the lower body  12  by high-circle welding or gluing. The external wall  41  of the air chamber  42  includes an upper surface illustratively sealed by the abutting force between the air valve cover  3  and the lower body  12 . In other illustrative embodiments, the air valve cover  3  does not apply an abutting force to lower body  12  and, in fact, has holes to allow air to escape when the over pressure condition occurs. The remaining components of this illustrative embodiment are substantially similar to those of the illustrative embodiment of  FIGS. 1-5 . 
     While this invention has been described as having exemplary designs, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.