Valve for a Dispensing Container

Abstract

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.

What is claimed is: 
     
         1 . A method of manufacturing a co-injection molded valve, the method comprising:
 depositing a first injection material from a first injection nozzle into a first mold cavity to form a valve frame, the valve frame comprising a radial ledge and a radial wall extending from the radial ledge; and   depositing a second injection material from a second injection nozzle into a second mold cavity to form a valve head, the valve head comprising a valve head portion, a sleeve portion, a hinge portion, and a peripheral sealing flange.   
     
     
         2 . The method of  claim 1 , wherein the first injection material is polypropylene. 
     
     
         3 . The method of  claim 1 , wherein the second injection material is a thermoplastic elastomer. 
     
     
         4 . The method of  claim 1 , wherein the valve frame further comprises an access window, the access window configured to permit passage of the second injection nozzle through the valve frame. 
     
     
         5 . The method of  claim 1 , wherein the method further comprises forming one or more valve slits in the valve head portion via at least one of a laser cutting process and a mechanical cutting process. 
     
     
         6 . The method of  claim 1 , wherein the valve head portion is formed with a first thickness, wherein the hinge portion is formed with a second thickness, wherein the sleeve portion is formed with a third thickness, wherein the valve head portion is configured to be operable between an open position and a closed position, and wherein the second thickness is substantially greater than the first thickness and substantially greater than the third thickness, such that the hinge portion, the sleeve portion, and the peripheral sealing flange are stationary as the valve head operates between the closed position and the open position. 
     
     
         7 . A method of manufacturing a valve assembly, the method comprising:
 manufacturing a co-injected molded valve, comprising the steps of:
 depositing a first injection material from a first injection nozzle into a first mold cavity to form a valve frame, the valve frame comprising a radial ledge and a radial wall extending from the radial ledge, and 
 depositing a second injection material from a second injection nozzle into a second mold cavity to form a valve head, the valve head comprising a valve head portion, a sleeve portion, a hinge portion, and a peripheral sealing flange; 
   injection molding a closure body to form a main closure body that includes a central raised portion that forms a central aperture, the central aperture configured to receive the co-injected molded valve such that the co-injected molded valve protrudes at least partially past the central raised portion, and to form a cap configured to transition between a closed cap position in which the cap in coupled to the main closure body in such a way as to cover the central aperture and an open cap position in which the cap is at least partially removed from the main closure body in such a way as to uncover the central aperture;   positioning the co-injected molded valve in the central aperture such that the co-injected molded valve protrudes at least partially past the central raised portion; and   coupling the co-injected molded valve to the main closure body of the closure body.   
     
     
         8 . The method of  claim 7 , wherein the step of injection molding the closure body further comprises the step of forming a living hinge as an extension of the main closure body and of the cap. 
     
     
         9 . The method of  claim 7 , wherein the step of injection molding the closure body further comprises the step of forming a stopper as a protrusion of the cap, the stopper protruding toward the main closure body and aligning with the co-injected molded valve such that the stopper prevents the valve head from flexing when the cap is in the closed cap position. 
     
     
         10 . The method of  claim 9 , wherein the step of depositing the second injection material from the second injection nozzle into the second mold cavity to form the valve head further comprises forming the valve head in a concave shape. 
     
     
         11 . The method of  claim 10 , wherein the step of injection molding the stopper further comprises injection molding the stopper in a convex shape. 
     
     
         12 . The method of  claim 7 , wherein the step of coupling the co-injected molded valve to the main closure body of the closure body is accomplished by detachably coupling the co-injected molded valve to the main closure body with a snap fit joint. 
     
     
         13 . The method of  claim 7 , wherein the step of coupling the co-injected molded valve to the main closure body of the closure body is accomplished by permanently coupling the co-injected molded valve to the main closure body with an ultrasonic assembly process. 
     
     
         14 . The method of  claim 13 , wherein the ultrasonic assembly process further comprises the steps of converting high frequency electrical energy into high frequency mechanical motion, combining the high frequency mechanical motion converted from the high frequency electrical energy with applied force to generate frictional heat between the closure body and the co-injected molded valve sufficient to form a molecular bond between the closure body and the co-injected molded valve. 
     
     
         15 . A method of manufacturing a co-injection molded valve, the method comprising:
 depositing a first injection material from a first injection nozzle into a first mold cavity to form a valve frame, the valve frame comprising a radial ledge and a radial wall substantially perpendicular to the radial ledge;   depositing a second injection material from a second injection nozzle into a second mold cavity to form a valve head, the valve head comprising a valve head portion, a sleeve portion, a hinge portion, and a peripheral sealing flange;   cooling the first injection material and the second injection material until the valve head is permanently bonded to the valve frame;   ejecting the first injection material and the second injection materials from the respective first mold cavity and second mold cavity; and   forming a valve slit in the valve head portion.   
     
     
         16 . The method of  claim 15 , wherein the step of forming the valve slit in the valve head portion is accomplished by a cutting process. 
     
     
         17 . The method of  claim 15 , wherein the step of forming the valve slit in the valve head portion is accomplished by at least one of a laser blade slitting process and a mechanical blade slitting process. 
     
     
         18 . The method of  claim 15 , wherein the valve head portion is formed with a first thickness, wherein the hinge portion is formed with a second thickness, wherein the sleeve portion is formed with a third thickness, wherein the valve head portion is configured to be operable between an open position and a closed position, and wherein the second thickness is substantially greater than the first thickness and substantially greater than the third thickness, such that the hinge portion, the sleeve portion, and the peripheral sealing flange are stationary as the valve head operates between the closed position and the open position. 
     
     
         19 . The method of  claim 15 , wherein the second injection material is a softer material than the first injection material. 
     
     
         20 . The method of  claim 19 , wherein the first injection material is polypropylene, and wherein the second injection material is a thermoplastic elastomer.