Co-Injected Dispensing Valve Assembly for Recyclable Sealing
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Solution Overview
Problem
Conventional valve assemblies for dispensing containers, often made of silicone, are not recyclable and cannot be co-injected with a strong frame material via injection molding, limiting their recyclability and manufacturing processes.
Innovation Solution
A co-injected valve assembly is fabricated using a two-step injection molding process, where a polypropylene valve frame is combined with a thermoplastic elastomer valve head, allowing for recyclability and reliable operation, with features like radial ledges and peripheral sealing flanges for support and sealing, and optional snap fit or ultrasonic assembly for attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If silicone valve heads are used in conventional valve assemblies, then the valve can be manufactured and assembled, but the valve cannot be co-injected with the frame material and is not recyclable
Solution Approach 1:
The patent changes the material parameter from silicone to thermoplastic elastomer, which enables co-injection with polypropylene frame material while maintaining the required sealing and dispensing functions. This material substitution resolves the incompatibility between silicone and co-injection processes.
Solution Approach 2:
The patent creates a composite valve assembly by co-injecting two different thermoplastic materials (polypropylene for the frame and thermoplastic elastomer for the valve head) in a single molding process, achieving both structural integrity and functional requirements while enabling recyclability.
2Adaptability or versatility
If a two-step injection molding process is used to create a co-injected valve assembly, then recyclability and manufacturing integration are improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent merges the frame and valve head manufacturing into a single co-injection molding process, where both components are formed and bonded together in one operation. This eliminates separate assembly steps and enables recyclability as a single integrated component.
3Ease of operation
If the valve assembly is designed to open reliably under applied force, then dispensing function is improved, but the valve may fail to close reliably without sufficient sealing force
Solution Approach 1:
The patent applies different material properties to different parts of the valve: the thermoplastic elastomer valve head provides local compliance and sealing capability at the sealing surface, while the polypropylene frame provides structural support. This local differentiation enables both easy opening and reliable closing.
Solution Approach 2:
The valve head is designed with a curved, dome-shaped geometry that allows it to flex and deform under applied force for reliable opening, while the curved sealing surface maintains consistent contact pressure for reliable closing and sealing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a recyclable and reliable valve assembly that opens and closes effectively, preventing leakage and ensuring efficient dispensing without requiring excess force, while being environmentally friendly and cost-effective.
Implementation Method 1
The co-injected valve assembly is configured to open reliably when force is applied to the dispensing container. The co-injected valve assembly is further configured to be self-closing in that it closes in a reliable and sealed fashion in the absence of force applied to the dispensing container.
Implementation Method 2
The valve head includes a valve head portion with multiple valve head slits, a sleeve portion, and a peripheral sealing flange. The valve frame is permanently coupled to the valve head and includes a radial ledge and a radial wall that support the peripheral sealing flange of the valve head.
Data Source
AI summary
A valve assembly for a dispensing container includes a closure body detachably coupled to a co-injected valve. The closure body includes a main closure body coupled to a closure cap via a flexible hinge. The co-injected valve includes a valve head and a valve frame. The valve head includes a valve head portion with multiple valve head slits, a sleeve portion, and a peripheral sealing flange. The valve frame is permanently coupled to the valve head and includes a radial ledge and a radial wall that support the peripheral sealing flange of the valve head. The co-injected valve is fabricated via a two-step injection molding process. The first step includes fabricating the valve frame from a first injection material, and the second step includes fabricating the valve member from a second injection material.