U.S. patent application number 14/451230 was filed with the patent office on 2015-03-19 for elastomeric valve.
The applicant listed for this patent is Jes Tougaard GRAM. Invention is credited to Jes Tougaard GRAM.
Application Number | 20150075001 14/451230 |
Document ID | / |
Family ID | 40522047 |
Filed Date | 2015-03-19 |
United States Patent
Application |
20150075001 |
Kind Code |
A1 |
GRAM; Jes Tougaard |
March 19, 2015 |
ELASTOMERIC VALVE
Abstract
A method for the production of a valve is provided comprising
molding a valve body with a first mold, preloading the valve body
with a second mold, molding a sealing portion in an open position
onto the valve body, and releasing the preloaded valve body. The
sealing portion enters a closed position when the preloaded valve
body is released. When the valve is in use, the sealing portion
opens when under a fluid pressure, and closes when the pressure is
released.
Inventors: |
GRAM; Jes Tougaard;
(Scottsdale, AZ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GRAM; Jes Tougaard |
Scottsdale |
AZ |
US |
|
|
Family ID: |
40522047 |
Appl. No.: |
14/451230 |
Filed: |
August 4, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12247929 |
Oct 8, 2008 |
8793874 |
|
|
14451230 |
|
|
|
|
60978377 |
Oct 8, 2007 |
|
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Current U.S.
Class: |
29/890.127 |
Current CPC
Class: |
Y10T 29/49412 20150115;
B29C 2045/1693 20130101; Y10T 137/7888 20150401; B29L 2031/7534
20130101; Y10T 29/49417 20150115; F16K 15/147 20130101; B29C
45/2628 20130101; B29C 39/021 20130101; Y10T 29/49405 20150115;
B29C 45/1676 20130101; Y10T 137/7885 20150401; B29C 69/004
20130101; B29D 99/0053 20130101; B65D 47/2031 20130101; Y10T
137/7869 20150401 |
Class at
Publication: |
29/890.127 |
International
Class: |
B29D 99/00 20060101
B29D099/00; B29C 69/00 20060101 B29C069/00; F16K 15/14 20060101
F16K015/14 |
Claims
1. A method for the production of a valve comprising: molding a
valve body with a first mold; preloading the valve body with a
second mold; molding a sealing portion in an open position onto the
valve body; and releasing the preloaded valve body wherein the
sealing portion enters a closed position when the preloaded valve
body is released, the sealing portion opens when under a fluid
pressure; and closes when the pressure is released.
2. The method as in the claim 1 further comprising configuring lips
of the sealing portion when the sealing portion is in an open
position.
3. the method of claim 2 wherein configuring the lips of the
sealing portion comprises molding the sealing lips to have a larger
sealing surface than a wall surface of the valve body.
4. The method as in claim 2 wherein configuring the lips of the
sealing portion comprises molding the sealing lips to have at least
one groove and at least one protrusion wherein the groove and the
protrusion interlock when the sealing portion enters the closed
position.
5. The method of claim 2 wherein configuring the lips of the
sealing portion comprises molding the sealing lips with support
ribs in the sealing area.
6. The method as in claim 1 wherein the sealing portion opens on
the sides of the sealing portion when under fluid pressure.
7. The method as in claim 1 wherein the sealing portion opens in
the center of the ceiling portion when under fluid pressure.
8. The method as in claim 1 wherein the sealing portion is made of
a flexible elastomer.
9. The method as in claim 1 wherein the flexible elastomer is one
of rubber or silicone based.
10. The method of claim 1 wherein the valve body comprises a
substantially rigid skeleton.
11. The method of claim 10 wherein the substantially rigid skeleton
is one of a plastic or metal.
12. (canceled)
13. (canceled)
14. (canceled)
15. (canceled)
16. (canceled)
17. (canceled)
18. (canceled)
19. (canceled)
20. A method for the production of a valve comprising: molding a
first part of a valve with a first material; and molding a second
part of the valve with a second material wherein the first material
and the second material are dissimilar materials such that the
first and second materials do not bind to each other and wherein
the first part in the second part are mechanically bound together
at at least one point.
21. The method as in claim 20 wherein the first material is a
substantially rigid material and the second material is a
substantially flexible material.
22. A method for the production of a valve comprising: providing a
preloaded substantially rigid housing; and overmolding the
preloaded substantially rigid housing with a substantially flexible
material wherein the substantially rigid housing is released from
its preloaded state after the substantially flexible material is
overmolded thereon, the substantially flexible material forming a
valve that enters a closed position when overmolded onto the
substantially rigid housing.
23. The method as in claim 22 wherein the substantially rigid
housing is spring-loaded.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] 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
[0002] 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
[0003] 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.
[0004] 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.
[0005] 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
[0006] 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:
[0007] FIG. 1 is a cross-section of a valve in accordance with the
present invention;
[0008] FIG. 2 is a cross-section of a valve sealing lip
configuration with a large sealing surface area in accordance with
the present invention;
[0009] FIG. 3 is a cross-section of a valve sealing lip
configuration incorporating a trap/zipper function in accordance
with the present invention;
[0010] FIG. 4 is a cross-section of a valve sealing lip
configuration incorporating a directional valve function/flow in
accordance with the present invention;
[0011] FIG. 5 is a cross-section of a valve sealing lip
configuration incorporating a substantially rigid material in
accordance with the present invention;
[0012] FIG. 6 is a cross-section of a valve molded in an open valve
position in accordance with the present invention;
[0013] FIG. 7 is a cross section of a valve reversed or bent into a
closed valve position in accordance with the present invention;
[0014] FIG. 8 is a side view of a valve molded in an open valve
position in accordance with the present invention;
[0015] FIG. 9 is a perspective view of a valve reversed or bent
into a closed valve position in accordance with the present
invention;
[0016] FIG. 10 is a substantially rigid skeleton material in
accordance with the present invention;
[0017] FIG. 11 is a preloaded substantially rigid skeleton material
in accordance with the present invention;
[0018] FIG. 12 is a top view of a molded valve in a closed position
in accordance with the present invention;
[0019] FIG. 13 is a side view of a molded valve in a closed
position in accordance with the present invention;
[0020] FIG. 14 is a top view of a directional flow valve in
accordance with the present invention;
[0021] FIG. 15 is a side view of a directional flow valve in
accordance with the present invention;
[0022] FIG. 16 is a side view of a of an open valve made from
non-compatible material in accordance with the present
invention;
[0023] FIG. 17 is a side view of a core for molding a valve in
accordance with the present invention;
[0024] 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;
[0025] FIG. 19 is a side view of a molded valve body in accordance
with the present invention;
[0026] FIG. 20 is a side view of a molded valve body and a second
core in accordance with the present invention;
[0027] FIG. 21 is a side view of a second core entering a molded
valve body in accordance with the present invention;
[0028] FIG. 22 is a side view of a second core in a molded valve
body in accordance with the present invention;
[0029] 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;
[0030] 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;
[0031] FIG. 25 is a side view of the preloaded molded valve body
and a sealing portion in accordance with the present invention;
[0032] 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;
[0033] FIG. 27 is a side view of a molded valve body and sealing
portion in a closed position under pressure;
[0034] 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;
[0035] 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;
[0036] FIG. 30 is a side view of a molded valve body and sealing
portion in a closed position in accordance with the present
invention;
[0037] FIG. 31 is a side view of a molded valve body and sealing
portion in a closed position in accordance with the present
invention;
[0038] 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;
[0039] 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;
[0040] 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;
[0041] 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;
[0042] FIG. 36 is a side view of a core for valve configuration in
accordance with the present invention;
[0043] 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;
[0044] 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;
[0045] 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;
[0046] FIG. 40 is a side view of molded substantially rigid valve
skeleton in accordance with the present invention;
[0047] FIG. 41 is a side view of a second core entering a molded
substantially rigid valve skeleton in accordance with the present
invention;
[0048] FIG. 42 is a side view of a second core in a molded
substantially rigid valve skeleton in accordance with the present
invention;
[0049] 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;
[0050] 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;
[0051] FIG. 45 is a side view of a preloaded molded substantially
rigid valve skeleton and a sealing portion in accordance with the
present invention;
[0052] FIG. 46 is a side view of partially preloaded molded
substantially rigid valve skeleton and a sealing portion in
accordance with the present invention;
[0053] 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;
[0054] FIG. 48 is a cross-section of a valve in an open position in
accordance with the present invention;
[0055] FIG. 49 is a cross-section of a valve in an open position
and a substantially rigid skeleton in accordance with the present
invention;
[0056] FIG. 50 is a cross-section of substantially rigid skeleton
approaching a valve in an open position in accordance with the
present invention;
[0057] FIG. 51 is a cross-section of a substantially rigid skeleton
closing a valve in accordance with the present invention;
[0058] FIG. 52 is a cross-section of a substantially rigid skeleton
closing a valve in accordance with the present invention;
[0059] FIG. 53 is a cross-section of a substantially rigid skeleton
closing a valve in accordance with the present invention;
[0060] FIG. 54 is a cross-section of a substantially rigid skeleton
closing a valve in accordance with the present invention;
[0061] FIG. 55 is a cross-section of a substantially rigid skeleton
holding a valve in a closed position in accordance with the present
invention;
[0062] FIG. 56 is a side view of a valve where the sealing portion
has been closed; and
[0063] 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
[0064] 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.
[0065] 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.
[0066] 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.
[0067] 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.
[0068] 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.
[0069] 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.
[0070] 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.
[0071] 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.
[0072] 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.
[0073] 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.
[0074] 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.
[0075] 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.
[0076] 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.
[0077] 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.
[0078] 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.
[0079] 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.
[0080] 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.
[0081] 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.
[0082] 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.
[0083] 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.
[0084] 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.
[0085] 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.
[0086] 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.
[0087] 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.
[0088] 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.
[0089] 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.
[0090] 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.
[0091] 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.
[0092] 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.
[0093] 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.
[0094] 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.
[0095] 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.
[0096] 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.
[0097] 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.
[0098] 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.
[0099] 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.
[0100] 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.
[0101] 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.
[0102] 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.
[0103] 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.
[0104] 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.
[0105] 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.
[0106] 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.
[0107] 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.
[0108] 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.
[0109] 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's own structure when the valve is
reversed into its sealing position.
[0110] 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.
[0111] 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.
[0112] 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.
[0113] 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.
[0114] 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.
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