Abstract:
A valve assembly for a dunnage bag wherein in one embodiment of the valve a valve diaphragm is mounted on a shaft and is supported by a mounting bar such that the valve diaphragm may be reciprocally moved from the closed position to the open position by a simple axial push on the valve shaft. The valve shaft is retained in the mounting bar in an orifice and the shaft diameter is enlarged at its end distant from the valve diaphragm so as to generate a frictional force fit or lock in the open position to facilitate the removal of air from the bag. The valve may be released form the friction lock by the air pressure of a recharged bag and/or by the manual movement of the valve diaphragm and shaft axially toward the open end of the valve assembly. In an alternate embodiment, the valve diaphragm is mounted to a valve stem that it rotationally and axially moveably connected to the valve body. The valve may be frictionally locked in its open or closed position by rotation that valve stem no more than one quarter turn.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application is a continuation-in-part of U.S. patent application Ser. No. 11/202,512 that was filed on Aug. 12, 2005 now U.S. Pat. No. 7,273,065 and entitled “Inflation/Deflation Valve for Cargo Dunnage,” which is hereby incorporated by reference. 

   STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
   Not applicable 
   REFERENCE TO A “MICROFICHE APPENDIX” 
   Not applicable 
   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to inflatable dunnage air bags as are utilized in securing cargo and/or freight in a cargo hold, such as a truck, rail car, aircraft or ship and more particularly, to an inflation valve therefor. 
   2. General Background of the Invention 
   Inflatable air bags are utilized in the cargo transportation industry to secure a load against undue movement during the transportation phase. While cargo is generally loaded as snugly into a vehicle as possible, such as a cargo hold of a truck or rail car, it is frequently of sufficiently irregular shape or varied size, it is not otherwise possible to ensure a tight fit during the loading process 
   The transportation industry has adopted relatively large inflatable bags, often a plastic or rubber so as to be flexible and to readily conform to the irregular shapes of cargo loads. These bags are inserted into observable spaces in a load, and inflated with air to a pressure sufficient to keep the freight from shifting during the movement of transit, whether it be from swaying or being bounced vertically. 
   The dunnage bags are comprised of an inflatable bladder which is enclosed within an outer covering (also a bag) which protects the bladder from wear or puncture. The outer bags are frequently of fabric or paper. Bags may be of a variety of shapes and sizes, such that an appropriate shape or size may be fitted into the several voids that inevitably occur in a loaded container. Once fitted into the void, a bag/bladder is inflated with compressed air to a predetermined pressure level sufficient to prevent or retard the shifting or movement that otherwise occurs in travel. 
   One critical part of the dunnage bag is the valve which enables the rapid, facile inflation and deflation required in the loading and emptying of the container. Conventional construction includes the valve (a thermoplastic material) “welded” to the bladder so as to ensure a secure seal to retain the desired air pressure. The valve includes a generally tubular body portion which defines a conduit for the entry and exhaust of the pressurized air into and out of the bag. Within this tubular body is mounted a valve member which seats on a cooperating seal, usually a ring, the combination of which provides a tight joinder, particularly for the pressurized situation, to retain the pressurized air in the bag providing the desired load security against movement, and shifting. Many conventional valves are spring loaded to the closed position to facilitate the seal of the charged air, allowing also the manual depression against the spring to open the valve for natural deflation. Another common construction incorporates a hinged valve member that securely seats to form a seal. A number of patents are illustrative of the state of the art. 
   U.S. Pat. No. 4,579,141 Arf illustrates a valve for filling and discharging inflatable hollow bodies, in this instance a dinghy. The valve is self closing, as is conventional of valves for dunnage bags. The valve plate is spring loaded, to the closed position by radial leaves which cause the valve plate to bear on a sealing ring, when the valve is in the inactivated state. 
   U.S. Pat. No. 5,651,403 to Andersen shows a valve for sack, such as a dunnage bag, to be filled with pressurized air through a nozzle to the valve. The valve is hinged and opens the filling nozzle in relation to the sealing flange. 
   U.S. Pat. No. 6,823,905 to Smith, et al shows an alternative inflation valve for a dunnage bag having a flapper valve member which is affixed on a chordal segment of the circular valve opening. Opposite end portions of the fixation bar project radially inwardly toward each other so as to define detents for maintaining the valve in the open position. 
   SUMMARY OF THE INVENTION 
   The present invention is directed to a novel valve for a dunnage bag which provides improved functionality by having a piston-like operational structure for the valve diaphragm and shaft enabling secure filling and sealing of the bag against air leakage, yet simple release of the valve diaphragm for facile, rapid emptying of the bag facilitating the removal of the bag when unloading cargo. In an alternative embodiment, the present invention utilizes a valve stem that can be moved axially and rotationally relative to the valve body to provide improved functionality enabling secure filling and sealing of the bag against air leakage, yet simple release of the valve diaphragm for facile, rapid emptying of the bag facilitating the removal of the bag when unloading cargo. 
   Among the further objects of the present invention are the providing of a dunnage bag valve assembly which overcomes the operational drawbacks of many prior art inflation valves. 
   A further object of the present invention is to provide an improved valve assembly which includes a minimized number of operational parts so as to lessen the likelihood of malfunction. 
   A still further object of the present invention is to provide an improved valve assembly for a dunnage bag that may be manually moved to an open condition, in which condition the valve diaphragm is retained open for rapid, complete emptying of the bag of air. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein: 
       FIG. 1  is a pictorial view showing use of a dunnage bag incorporating the present invention. 
       FIG. 2  is a pictorial view of a dunnage bag incorporating the present invention. 
       FIG. 3  is a perspective view of a preferred embodiment of the valve of the present invention 
       FIG. 4  is a side elevation view of the valve illustrated in  FIG. 3 . 
       FIG. 5  is a top view of the valve illustrated in  FIG. 3 , with the cap removed. 
       FIG. 6  is a side elevation view of the valve illustrated in  FIG. 4 , further illustrating opening of the valve for deflation of the dunnage bag. 
       FIG. 7  is a side elevation view of the valve illustrated in  FIG. 3 , with the valve fully open. 
       FIG. 8  is a side elevation view of the valve illustrated in  FIG. 3  showing an alternative embodiment of the valve shaft. 
       FIG. 9  is side elevation view of the valve illustrated in  FIG. 7  showing an alternative embodiment of the valve shaft. 
       FIG. 10  is a side elevation of the valve illustrated in  FIG. 8  showing that application of a hose connected to a pump to inflate the dunnage bag. 
       FIG. 11  is a side elevation view of an alternate embodiment of the dunnage valve in its open position. 
       FIG. 12  is a side elevation view of the alternate embodiment of the dunnage valve in its closed position. 
       FIG. 13  is a side elevation, exploded view of the alternate embodiment of the dunnage valve. 
       FIG. 14  is a partial top elevation of the alternate embodiment of the dunnage valve in its unlocked position. 
       FIG. 15  is a partial top elevation of the alternate embodiment of the dunnage valve in its locked, closed position. 
       FIG. 16  is a partial top elevation of the alternate embodiment of the dunnage valve in its deflation position. 
       FIG. 17  is an exploded pictorial view of the alternate embodiment of the dunnage valve. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
     FIGS. 1 and 2  show generally the application of the dunnage bag in which the present invention has use.  FIG. 1  illustrates a bag B disposed in the cargo area C of a truck trailer T intermediate load articles L 1 , L 2 , L 3 , . . . L y .  FIG. 2  generally illustrates a dunnage bag having a valve V for inflation and deflation. Dunnage bags are used principally in long haul transportation of boxed or crated loads. As known in the art, it is important to secure the load against shifting and other movement which might allow the cargo to become damaged. Dunnage bags have become a very useful tool to be placed into openings between adjacent boxes or crates. 
   In use, the bags are located in the desired space in the cargo container and inflated to a preferred pressure. It is important that the valve assembly  10  attached to the dunnage bag be simple and reliable in use, otherwise the loading process will be delayed. Likewise, it is important that the valve assembly  10  retain a good seal throughout the transit, otherwise the security of the load be compromised. It is an objective of the present invention to provide a valve having as simple a construction as is effective to maintain a proper seal on pressurization, yet permitting a quick and effective discharge of the contained air when the transportation run is terminated and unloading of the cargo is effected. Two general styles of construction are evidenced by the prior art. The first is a hinged valve member, seating on a rib or flange forming a valve seat. the second version is a circular valve which seats on a cooperating circular flange, and is spring loaded in the closed position, thus requiring a continuing activation to exhaust any air loaded into it. Both of the prior art versions of valves are subject to malfunction, and tend to be significantly more expensive that the present invention. The virtue of the present design is its simplicity, being a circular valve that is mounted on a shaft which is easily moveable to the open or closed position. the pressure of the loaded air in pressurizing the dunnage bag retains the valve in the closed position when in use in transit. The frictional engagement of a portion of the mounting shaft on a ring mount retains the valve in the open condition for efficient, expedient emptying of the dunnage bag. The simplicity of the construction provides the low cost and the reliability of the design. As known by those skilled in the art, bags and valves are constructed of various types of polymer materials, frequently thermoplastics. resilient components may also be fabricated of one of several suitable rubbers. 
   Referring now to  FIGS. 3 through 5 , it may be seen that the valve assembly  10  of the present invention includes valve diaphragm  20  which is generally circular in shape and seats on flange  22 , into which mounting bar  24  is disposed. Flange  22  is sealed against valve body  26  which is mounted in bag B and affixed by such as being ultrasonically welded, and preferably additionally disposed into annular groove  30  formed adjacent radial ring flanges  34  and  36 . The integration of the bag B to the body  26  as at flanges  34 ,  36  creates an air-tight seal around the valve assembly  10 . Valve diaphragm  20  is mounted on shaft  38 , as by suitable attachment means as ultrasonic welding, a fastener such as a screw or by an adhesive. the connection between shaft  38  and valve diaphragm  20  may be reinforced as by adding a washer  40  overreaching the contact area between shaft  38  and diaphragm  20 . Washer  40  is preferably of a resilient material however, exhibiting a greater durometer than diaphragm  20 . Shaft  38  and diaphragm  20  are supported in valve assembly  10  by mounting bar  22 , by being slidably received through orifice  39 . As may be best observed in  FIGS. 6 and 7 , shaft  38  has a generally increasing diameter progressing from the end of the attachment of diaphragm  20  and the free end  42 . The diameter for an extent adjacent the free end  42  is sufficiently greater than the orifice  39  in which shaft  38  is mounted. By such means, shaft  38  is retained in orifice  39  however, is free for axial movement as indicated in  FIG. 6  whereby the valve may open and allow air to be added to bag B, or for the bag B to be evacuated as illustrated in  FIG. 7 . Free end  42  may exhibit the continued taper of shaft  38  as illustrated in  FIG. 7 , or have an extended section of a diameter sufficient to retain valve diaphragm  20  in the open position, as illustrated in  FIG. 8  and later discussed. 
   Valve assembly  10  conventionally includes a protective cap  12 , as illustrated in  FIG. 3 . Cap  12  may include a latching handle  14  which engages lugs  16  on body  26  to retain the cap in a tightly fitting relationship when closed. Cap  12  may include such as flat washer  17  which is engaged by the upper surface of an annular seal  18  on valve body  26 . 
     FIG. 8  illustrates an alternative embodiment of valve assembly  10 , wherein shaft includes a cylindrical section  43  which operates in conjunction with mounting bar  24  in retaining valve diaphragm  20  in the open position. In this alternative view, the cylindrical section  43  also includes an optional groove  44  which may receive the edge of bar  24  forming orifice  39  to provide a more positive restraint on the shaft  38  and valve diaphragm  20  to ensure the diaphragm remains in the open position during the evacuation of air from the inside of the bag. 
     FIG. 9  illustrates a still further embodiment of valve assembly  10  herein shaft  38  has disposed thereon a raised ring  46 , which is illustrated in the figure as approximately semi-circular and is generally complementary tin shape to a bar groove  48 , so as to be securely retained therein. Shaft  38  further may include a knob  50  to provide ease in grasping the shaft  38  when it is desirable to release valve diaphragm  20  from the open position, as when getting ready to fill the bag B with air. 
   In operation, a conventional air supply hose H is applied to the opening of valve  10  as illustrated in  FIG. 10 . The flow of air from air pump P into valve body  26  forces valve diaphragm open and the bag B is filled to the desired pressure. the internal pressure of the air contained in the bag B causes the valve diaphragm to seat and seal against loss, as is illustrated in  FIG. 4 . On exhaust, valve assembly is opened as illustrated in  FIG. 6 , by pressing axially inwardly on shaft  38  until the enlarged section  38   e  of shaft  38  frictionally engages the sides of orifice  39  in mounting bar  24 . The valve diaphragm is thereby retained in the open position and the air may exit as illustrated in  FIG. 7 . Valve diaphragm  20  may be released from orifice  39  by an upward pull on shaft  38  or by pressing washer  40  moving the assembly of diaphragm  20  and shaft  38  toward the closed position whereby shaft  38  rides freely in orifice  39 . 
   Referring now to  FIGS. 11 and 12 , an alternative embodiment of the dunnage valve  100  is depicted in its open ( FIG. 11 ) and its closed ( FIG. 12 ) positions. The valve embodies the same basic principles as the former embodiment in that once the dunnage bag is inflated, the valve automatically closes and remains closed due to the pressure inside the bag. In addition, the valve uses friction to maintain an open position for deflating the dunnage bag and can be locked in a closed position. 
   Referring now to  FIG. 17 , the various components of dunnage valve  100  can be seen. Valve  100  is comprised of diaphragm  110 , valve body  120 , and valve stem  150 . Valve body  120  is preferably of a molded, single piece construction. Valve body  120  includes flange  122 , the top side of which is hermetically sealed or conjoined to bag B as shown in  FIG. 3  (note that in  FIG. 3  a different embodiment of the dunnage valve is shown, but the flanges are the similar). Cylindrical wall  124  arises from flange  122  and defines aperture  126 , through which the air for inflating the dunnage bag flows and through which valve stem  150  moves axially to open and close dunnage bag. Upstanding partial cylindrical wall extensions, preferably three,  128  arise from the upper surface of cylindrical wall  124 . Each upstanding partial cylindrical wall extension  128  terminates in an upper surface  130 . Each upper surface  130  slopes away from flange  122 , preferably in a clockwise direction when looking at valve body  120  from above as in  FIG. 14 , to a flat section that terminates in a stop  132  that arises vertically from upper surface  130 . 
   Referring again to  FIG. 17 , valve stem  150  is preferably of a molded, single piece construction. Valve stem  150  includes disc-shaped valve seat  152  that has groove  154  running around its circumference and ridges  156 , preferably three, extending upwardly from the upper surface of valve seat  152 . Opposing valve seat  152  is a pair of concentric rings: inner ring  158  and outer ring  160 . Inner ring  158  has the same outer diameter as valve seat  152  and is connected to valve seat by members  162 , of which there are preferably three. Additionally, the outside diameter of valve seat  152  and inner ring  158  is just smaller than the inside diameter of aperture  126  such that valve seat  152  and inner ring  158  freely slide through aperture  126 . Outer ring  160  is connected to inner ring  158  by a plurality of ribs  164 , preferably three, that are in vertical alignment with members  162 , creating a plurality of arcuate slots  166 , preferably three. Ribs  164  preferably have a length greater than the width of upstanding partial cylindrical wall extensions  128  so that upstanding partial cylindrical wall extensions  128  can pass freely though arcuate slots  166 . 
   Additionally, the minimum height of inner ring  158  is equal to the height of outer ring  160  plus the height of cylindrical wall  124  plus the thickness of flange  122 . Inner ring  158  also has a plurality of ridges  168 , preferably three, on its outer surface spaced away from ribs  164  in a clockwise direction when looking at valve stem  150  from above as in  FIG. 14 . Ridges  168  run vertically down the outer surface of inner ring  158  beginning at the upper edge of inner ring  158  and terminate at a point no farther from the top of inner ring  158  than the height of outer ring  160 . 
   Referring again to  FIG. 17 , diaphragm  110  is preferably made from a flexible, elastomeric material. Diaphragm  110  is removably connected to valve stem  150  by snapping raised circumferential ridge  112  seats into groove  154  on valve stem  150  after valve stem  150  has been passed through aperture  126 . 
   Referring now to  FIG. 11 , in operation a conventional air supply hose H′ is applied to the opening of valve  100  as illustrated in  FIG. 11 . Supply hose H′ should have an outer diameter approximately equal to the inner diameter of inner ring  158  to form an airtight seal. As supply hose H′ is inserted into valve stem  150 , it forces valve  150  into its open position assuming valve  150  is in an unlocked state, as shown in  FIG. 14 . Supply hose H′ is inserted into valve stem  150  until it contacts ridges  156 . Air is then pumped into bag B from air pump P′. The air enters bag B via the gaps between members  162  as shown in  FIG. 11 . Once bag B is filled to the desired pressure, hose H is retracted from valve  100 . As hose H is retracted, valve  100  closes and the pressure within bag B holds valve  100  in a closed position. 
   Once bag B is inflated and hose H′ is removed, valve  100  can be locked in its closed position to prevent inadvertent opening while bag B is in use. This is accomplished by rotating valve stem  150  in a clockwise direction such that the lower surface of each rib  164  slides up the sloped upper surface  130  of one of the plurality of upstanding partial cylindrical wall extensions  128  until ribs  164  impinge on stops  132 . 
   To deflate bag B, valve stem  150  is first rotated counterclockwise from its closed, locked position (shown in  FIG. 15 ) until ribs  164  impinge the clockwise leading edge of upstanding partial cylindrical wall extensions  128  (shown in  FIG. 14 ). Valve  100  is then opened by pressing valve stem  150  into bag B until air is able to escape though the gaps between members  162  (air flow in the opposite direction of the arrows in  FIG. 11 ). Valve  100  can be held in this open position by rotating valve stem clockwise such that ridges  168  engage inner surfaces  134  of upstanding partial cylindrical wall extensions  128  as shown in  FIG. 16 . 
   Those skilled in the art will recognize that numerous equivalent alternative structures may be fabricated utilizing functionally equivalent structure such as alternative resilient materials, attachment mechanisms and cooperative frictional holding techniques as those described and illustrated without departing from the scope and spirit of the invention. 
   The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.