Co-molded Closure Valve with Variable-Volume Pouch
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Solution Overview
Problem
Existing devices with one-way valves and variable-volume storage chambers require separate manufacture and assembly of multiple components, leading to increased costs and complexity, including the need for sterilization of these components before assembly.
Innovation Solution
A device comprising a semi-annular, relatively rigid valve seat and a flexible valve cover forming a normally closed axially and angularly extending valve seam, where the valve cover and seat define different degrees of interference, allowing fluid passage when pressure is exceeded, integrated with a method of injection molding a support and blow molding a flexible pouch for the storage chamber, enabling assembly into a single, easily sterilized unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate manufacture and assembly of multiple components (one-way valve, closure, variable-volume storage chamber, housing) are used, then device functionality is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the closure and one-way valve into a single integrated component manufactured via co-molding. The closure body and valve member are formed as one piece, eliminating separate assembly steps and reducing the total number of components while maintaining the one-way valve functionality and closure sealing capability.
Solution Approach 2:
The integrated closure component serves multiple functions simultaneously: it acts as a closure to seal the container, contains the one-way valve mechanism for controlled dispensing, and provides structural support. This multi-functionality reduces the need for separate dedicated components for each function.
2Productivity
If multiple separate components are manufactured and assembled, then device assembly is possible, but assembly time and cost increase
Solution Approach 1:
By co-molding the closure and valve into a single integrated component, the patent eliminates multiple assembly operations. The single-piece construction means no assembly time is required for joining the closure and valve, directly improving productivity and reducing manufacturing cycle time.
3Reliability
If multiple separate components are used, then device functionality is achieved, but sterilization complexity and cost increase
Solution Approach 1:
The integrated closure-valve component reduces the number of separate parts requiring sterilization. With fewer components, the sterilization process becomes simpler and more reliable, as there are fewer interfaces and assembly points where contamination could occur during the sterilization process.
4Ease of manufacture
If separate components are manufactured, then device assembly is possible, but manufacturing cost increases
Solution Approach 1:
The co-molding process creates the closure and valve from a single material injection, eliminating the need for separate materials, fasteners, and bonding agents that would be required for assembled components. This reduces total material consumption and simplifies the manufacturing process.
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
This solution reduces the number of components needed, simplifies assembly, and allows for efficient sterilization, resulting in a cost-effective, high-quality product with enhanced functionality and reduced material usage, while maintaining hermetic seals and preventing bacterial ingress.
Implementation Method 1
The valve cover and valve seat define a first degree of interference therebetween at the inlet, and a second degree of interference therebetween at the outlet that is less than the first degree of interference
Implementation Method 2
a flexible valve member superimposed on the valve seat... The valve cover is movable in response to fluid at the inlet exceeding a valve opening pressure between (i) a normally closed position... and (ii) a second position with at least a portion of the valve cover spaced away from the valve seat
Data Source
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AI summary
A device includes a first part having a co-molded first support, valve cover and elastic actuator, and a second part having an injection molded second support, valve seat, and variable- volume storage chamber pre-form. The pre-form is blow molded into a flexible pouch defining the variable-volume storage chamber. The one-way valve includes a semi-annular, curvilinear, relatively rigid valve seat defining axially-extending, opposing first marginal portions, and an axially-extending first mid-portion angularly extending between the opposing first marginal portions. A flexible valve member is superimposed on the valve seat and defines axially- extending, opposing second marginal portions fixedly secured on or adjacent to respective first marginal portions of the valve seat, and an axially-extending second mid-portion angularly extending between the opposing first marginal portions and superimposed onto the first mid- portion of the valve seat. The flexible valve cover and valve seat form a normally closed axially and angularly extending valve seam therebetween.