Compressible Valve Modulating Flow Rates in Pressurized Containers
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Solution Overview
Problem
Pressurized aerosol containers face challenges in achieving optimal flow rates during filling and dispensing, with existing metal valves being non-recyclable and not efficiently modulating flow rates, while plastic containers are desirable for their advantages but lack suitable valve assemblies that are durable, robust, and economical.
Innovation Solution
A compressible valve assembly with a mechanical seal and valve stem, featuring primary and secondary radial openings, a grommet with spring and sealing portions, and a wiper blade, which modulates flow rates by sealing and exposing openings as needed, allowing for increased filling efficiency without affecting dispensing rates, and is recyclable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal valve assembly is used in a pressurized container, then the valve provides reliable components and durable performance, but the container becomes non-recyclable and manufacturing costs increase
Solution Approach 1:
The patent changes the material parameter of the valve assembly from metal to plastic, specifically using polyethylene terephthalate (PET) for the valve body and stem. This material substitution maintains the structural integrity and reliability needed for pressurized containers while enabling recyclability, as plastic components can be separated and recycled with the container material.
Solution Approach 2:
The patent employs composite material construction within the plastic valve assembly, combining PET for structural components with elastomeric materials for sealing elements. This composite approach ensures that the plastic valve achieves the durability and sealing performance previously provided by metal components, while maintaining recyclability through the use of compatible polymer materials.
2Productivity
If the product flow through the valve assembly is increased during filling operation, then the manufacturing process is expedited, but the spray characteristics during dispensing are adversely affected
Solution Approach 1:
The patent segments the flow control function into two distinct phases: a high-flow filling mode and a controlled dispensing mode. The valve assembly includes a filling port that allows unrestricted high-volume flow during manufacturing, while the dispensing orifice provides controlled flow during use. This segmentation enables optimal performance for both filling and dispensing operations without compromising spray characteristics.
Solution Approach 2:
The valve assembly dynamically transitions between two operational states: during filling, the valve is in a high-flow state with the filling port open; during dispensing, it transitions to a controlled-flow state through the dispensing orifice. This dynamic behavior allows the system to optimize flow rates for each specific operation, maintaining productivity during filling while preserving spray characteristics during consumer use.
3Ease of manufacture
If a plastic container with valve assembly is designed for recyclability, then environmental sustainability is improved, but suitable durable and robust valve components become difficult to source
Solution Approach 1:
The patent changes the material parameters of the valve components to use high-strength plastics and polymer composites that can withstand pressurized container conditions. The valve body is constructed from polyethylene terephthalate (PET) with appropriate wall thickness and reinforcement features, while the stem uses high-modulus plastic materials. These parameter changes enable the plastic valve to achieve robustness comparable to metal components while maintaining recyclability.
Solution Approach 2:
The patent uses composite material construction combining PET for the valve body with reinforced structural features and elastomeric materials for sealing components. This composite approach provides the necessary strength, durability, and pressure resistance while ensuring all components are made from recyclable plastic materials. The composite structure allows the plastic valve to meet the mechanical demands previously satisfied by metal components.
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 valve assembly effectively modulates flow rates during filling and dispensing, enhancing manufacturing efficiency while maintaining consistent product dispensing, and is durable, economical, and recyclable, addressing the limitations of existing technologies.
Implementation Method 1
The grommet spring portion is deformable in the longitudinal direction and biases the valve stem
Implementation Method 2
The grommet sealing portion includes a wiper blade located at the sealing portion opening below the primary and secondary sealing sections
Data Source
AI summary
A valve assembly for a pressurized container includes a valve stem and a mechanical seal. The valve stem has an open top portion, a closed bottom portion, at least one primary radial opening, at least one secondary radial opening and a valve stem passageway between the open top portion and both the at least one primary radial opening and the at least one secondary radial opening. The mechanical seal comprises a longitudinal passageway that seals the at least one primary radial opening and the at least one secondary radial opening, respectively, when the valve stem is in a closed position. Longitudinal translation of the valve stem exposes the at least one primary radial opening or both the at least one primary radial opening and the at least one secondary radial opening to the pressurized container when the valve stem is in an open position.