Flap Valve Retainer Structure for Secure Dispenser Tube Fit
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Solution Overview
Problem
Existing flap valves in pump dispensers are prone to inadvertent dislodgement from their fitment within the pump dispenser body, particularly in large-volume applications, leading to potential operational issues and product leakage.
Innovation Solution
A one-piece flap valve design featuring a retaining mechanism with radially extending prongs that resist inward displacement, ensuring secure engagement within the dispenser tube, combined with a flexible hinge for assembly in a single injection molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional flap valve design without additional retaining features is used, then the manufacturing process is simple and cost-effective, but the valve is prone to inadvertent dislodgement from the pump dispenser body
Solution Approach 1:
The retaining mechanism is segmented into multiple discrete prongs (at least two, preferably three or four) that are distributed around the circumferential wall. This segmentation allows each prong to independently engage with corresponding features on the pump dispenser body, providing redundant retention points that enhance reliability while maintaining manufacturing simplicity through injection molding
Solution Approach 2:
The prongs are integrated within the body structure of the flap valve, with the retaining mechanism nested inside the circumferential wall structure. The prongs extend from the inner surface of the circumferential wall outward, creating a nested configuration where the retention features are contained within the overall valve assembly without adding external complexity
2Ease of manufacture
If multiple separate parts are used to create the flap valve, then the valve can be designed with complex features like internal valve seats, but the manufacturing cost and assembly complexity increase
Solution Approach 1:
The invention merges multiple functional components into a single integrated body structure that can be manufactured in one injection molding operation. The body includes the circumferential wall, the internal valve seat formation, and the retaining prongs all as unified features of a single molded part, eliminating the need for separate manufacturing steps or assembly operations
Solution Approach 2:
The internal valve seat is created through a dimensional feature formed during injection molding, where the mold cavity itself creates the recessed seat area. This approach uses the molding process's inherent dimensional capabilities to create complex internal geometries without requiring additional machining or assembly steps
3Reliability
If the flap valve legs are allowed to displace radially inward easily, then the installation process is simple, but the valve becomes loose and prone to dislodgement during operation
Solution Approach 1:
The prongs are pre-configured with engagement features (such as enlarged ends or hooked shapes) that automatically engage with corresponding features on the pump dispenser body upon insertion. This preliminary anti-action prevents the legs from displacing radially inward beyond the intended engagement position, securing the valve during installation without requiring additional fastening operations
Data Source
AI summary
A one-piece flap valve (150) comprising first and second portions hingedly connected to one another by a flexible strip, the first portion having a hingeable internal valve flap (152) and the second portion comprising an at least partially annular valve seat (154). The first and second portions being socket-fitted together by relative movement, such that the valve seat (54, 154) is spanned by the flap (152), the second portion comprising first and second legs (121a, 121b) having first and second locking lugs (127a, 127b) extending radially outwardly therefrom, the locking lugs for location within locking apertures (125a, 125b) of a tube body (10) of a dispenser. The flap valve (150) comprising a retaining mechanism configured and arranged such that once the flap valve is installed in a tube body of a dispenser, the retaining mechanism resists against radially inward displacement of the first and second legs.