Flexible Membrane Check Valve for Faster Inflatable Packaging
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Solution Overview
Problem
Conventional inflatable packaging systems face issues with misalignment of pre-printed check valve features due to heat sealing, requiring specialized equipment and resulting in restricted fluid flow and longer inflation times.
Innovation Solution
A check valve design that eliminates the need for pre-printing and specialized registration, using flexible membranes bonded to form an impermeable barrier, allowing for higher fluid flow rates and faster inflation by eliminating the need for continuous seals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pre-printed check valve features are used in conventional inflatable packaging systems, then the manufacturing process can be simplified, but misalignment occurs due to heat sealing causing plastic deformation and expansion/contraction of sheets
Solution Approach 1:
The check valve features are pre-formed on the plastic sheet before heat sealing occurs. This preliminary action ensures that the valve features are already in their correct positions and configurations before the heat sealing process causes any plastic deformation or sheet expansion/contraction, thereby preventing misalignment issues
Solution Approach 2:
The check valve is designed as a separate, distinct feature formed within the plastic sheet structure itself, rather than relying on continuous seals or externally applied components. This segmentation allows the valve feature to be independently formed and positioned, making it resistant to misalignment during the heat sealing process
2Ease of manufacture
If pre-printing and specialized registration equipment are used, then check valve features can be formed, but capital costs and device complexity increase
Solution Approach 1:
The plastic sheet itself serves as the forming medium for the check valve features. The valve features are created through the inherent properties and manipulation of the plastic material during standard manufacturing processes, eliminating the need for separate pre-printing equipment or specialized registration devices
Solution Approach 2:
The invention extracts and eliminates the need for specialized pre-printing and registration equipment from the manufacturing system. By forming check valve features directly within the plastic sheet structure using standard manufacturing processes, the complex and costly specialized equipment is removed entirely
3Reliability
If conventional check valve designs with heat sealing elements are used, then proper connection between inflatable channel, check valve, and air chamber is achieved, but fluid flow is significantly restricted and inflation time increases
Solution Approach 1:
The check valve is formed as an integrated feature within the flexible plastic sheet structure itself, rather than using rigid heat sealing elements or separate valve components. This flexible membrane-based design maintains connection integrity through the inherent flexibility and continuity of the plastic material while significantly reducing flow restriction compared to conventional rigid valve designs
Solution Approach 2:
Instead of using heat sealing elements to create the check valve connection (which restricts flow), the invention inverts the approach by forming the valve feature within the continuous plastic sheet structure. This reverses the conventional methodology and eliminates the flow-restricting heat sealing elements while maintaining reliable connections
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 results in a simpler manufacturing process, reduced capital costs, and inflation times that are at least twice as fast as conventional systems, with improved operational efficiency and reduced material waste.
Implementation Method 1
The check valve is formed from the flexible membrane and defines a valve opening leading into the air chamber. The flexible membrane bonds to the third flexible membrane at a valve bond line to form an impermeable barrier.
Implementation Method 2
The flexible membrane bonds to the third flexible membrane at a valve bond line to form an impermeable barrier.
Data Source
AI summary
The fluid container has a first and second flexible membrane forming at least one chamber, a channel configured to receive pressurized inert gas, and one or more check valve assemblies disposed therebetween. The one or more check valve assemblies is formed from a continuous third flexible membrane folded at an apex, and configured to provide the flow of pressurized fluid in one direction upon inflation, from the channel to the at least one chamber, while restricting flow in the opposite direction. The one or more check valve assemblies are characterized in that they do not require pre-printing or electronic registering, thus allowing for an inflation flow rate of at least twice that of conventional inflatable packaging systems.