BEN-DOR RIMON (IL)
DAGAN MEIR (IL)
WO2015080119A1 | 2015-06-04 | |||
WO2002015670A2 | 2002-02-28 |
US20120256017A1 | 2012-10-11 | |||
US20090212135A1 | 2009-08-27 | |||
US20140246520A1 | 2014-09-04 | |||
US20130248616A1 | 2013-09-26 | |||
US8998112B2 | 2015-04-07 |
C L A I M S 1. A pressure regulated integral drip emitter, that is formed wherein it comprise - body component and cover component which are formed, each one, in a substantially rectangle configuration, having a lengthwise axis, wherein from the instant of their pinning one to the other and installing said assembled drip emitter inside the hose, the lengthwise axis of said rectangle configuration, as said, is turned in parallel to the flow direction; and said body component is formed in a bi-level configuration on the two sides of a common wall, wherein - at the first level, on its one side which is turned towards the interior of the hose from the instant of installing the drip emitter in it, is formed with a bracket which is suited to affixing said cover component from the instant of pinning them, as said, one to the other, and with a water passage, and compensation space; and - at the second level, on its other side that is suited to affixing to the interior wall of the hose from the instant of installing the drip emitter in it, is formed with an elongated exit pool that extends along the body component, and with baffle's labyrinth, for reducing the water pressure, that extends around the circumferential of said exit pool wherein it is separated from it; and - with a first water passage opening that routes the water flow from said water passage that is formed in said first level through said common wall, to one end of said baffle's labyrinth that is formed at said second level; and- with a second water passage opening that is formed at a second end of said baffle's labyrinth and routes the water flow whose pressure was reduced from the instant of their passing through said baffle's labyrinth, through said common wall, back to said first level unto said compensating space; and - with a third water passage opening that is formed at said compensating space and routes the water flow that was routed through said second water passage opening, through said common wall, back to said second level and into said exit pool, and - said cover component is formed with a filtering sector that from the instant of affixing said cover component to said bracket that is formed in the first level of said body component, from affixing them, as said, one to the other, is positioned over said water passage that is formed at said first level, and in a manner that filtered water passage is enabled from the hose to said water passage; and - wherein said integral drip emitter is characterized in that - said cover component is produced by a bi-component injection into a mold, and is formed also with a sector of an elastomer material; and - wherein from the instant of affixing said cover component to said bracket that is formed at said first level of said body component, from the instant of pinning them one to the other, as said, the elastomer material sector is positioned above said compensating space, and in a manner that bending said elastomer material sector is enabled, due water pressure prevailing in the hose, towards said third water passage opening, and thus the pressure compensating action is executed. 2. A drip emitter in accordance with claim 1 wherein; - the drip emitter is a unit-part, wherein said body component and cover component are fabricated through bi-component injection into one mold, and wherein from the beginning they are pinned one to the other via an integral hinge and hence constitute a unified part; and- wherein from the instant of turning of said body component and cover component, one relative to the other by 180° around said integral hinge, said body component and cover component are pinned one to the other. 3. A drip emitter in accordance with claim 2, wherein - said integral hinge is formed at said first level and connects said body component to said cover component wherein it extends along the longer edge of said rectangle configuration. 4. A drip emitter in accordance with claim 2, wherein - said integral hinge is formed in said first level and connects said body component to said cover component wherein it extends along a shorter edge of said rectangle configuration. 5. A drip emitter in accordance with claim 1, wherein - said bracket that is suited to affixed inside it said cover component from their being pinned as said, of the body component to the cover component, one to the other, formed as at least one rib that is protruding from said common wall into said first level, in a manner that said cover component is suited to lean on it, and as a circumferential rib, one at least, that extends around said first level in a manner that said cover component is suited to be embraced by it. 6. A drip emitter in accordance with claim 5, wherein - said water passage is formed as a gap that extends inside said first level, between said common wall to said cover component, from the instant of it leaning as said on said protruding rib. 7. A drip emitter in accordance with claim No. 1 wherein - said bracket that is suited to affix inside it said cover component from the instant of having them pinned as said, the body component to the cover component, one to the other, is formed as a bracket to an under-cut type of connector that exists between it and said cover component. 8. A drip emitter in accordance with claim 1, wherein - said cover component is formed with a protrusion having a tip, that from the instant of affixing the drip emitter to the inner wall of the hose, said tip is suited to be attached too unto the inner wall of the hose. 9. A drip emitter in accordance with claim No. 1 wherein - said compensating space is formed as a cell endowed with a circumferential wall that extends in a round configuration around said third water passage opening and at a distance from it, wherein it protrudes from said common wall into the said first level. 10. A drip emitter in accordance with claim 1, wherein - said body component at the first level, on its one side that is turned towards the interior of the hose from the instant of installing said drip emitter in it, is formed in an arched configuration that extends along the shorter edge of said rectangle configuration for being suited to the radius of the internal wall of the hose in which the drip emitter is intended to be installed; and - formed with an exit pool that extends along said lengthwise axis, in a symmetrical configuration, and along a substantial part of said body component; and - said baffle's labyrinth extends on the two sides of said elongated exit pool and is formed with flow passages at two ends of said body component, that are routing the water which arrives from the one end of said labyrinth through the labyrinth's sector that extends along one side of said exit pool to a sector of said labyrinth that extends along the second side of said exit pool, and back to a second end of said labyrinth that is positioned, it too, on said one side of said exit pool. 11. A drip emitter in accordance with claim 1, wherein - said third water passage opening is formed as a hollow stem which protrudes from said common wall into said compensating space and at its tip is formed with a widthwise slot for leaving a water passage from said second water passage opening to said third water passage opening also at the time of bending said elastomer material for contact with said stem's tip. 12. A drip emitter in accordance with claim 1, wherein - said elastomer material sector is fabricated by injection of material, which is thermoplastic Vulcanizate (TPV). 13. A drip emitter in accordance with claim 9, wherein - said elastomer material sector is formed in a configuration of a round disc whose circumference extends beyond said circumferential wall of said compensating space. 14. A drip emitter in accordance with claim 1, wherein - said elastomer material sector is formed in a thinner width by comparison to the thickness of said cover component that is injected from another material, and in a manner, that the circumferential edge of said elastomer material sector connects with a matching bracket that is formed in said another material. 15. A drip emitter in accordance with claim 1, wherein - said filtering sector is formed in a configuration of plurality of passages over a sector of said cover component. 16. A drip irrigation hose that includes at least one drip emitter in accordance with any of claims 1-15. 17. A mold for fabricating a drip emitter in accordance with any of claims 2-15, which comprise- an immobile assembly and a mobile assembly which are suited to form the drip emitter, using bi- component injection and a core back technology; and - wherein the mold is characterized in that it comprise in addition - first pusher means which is positioned in said immobile assembly of the mold and suited to turn slightly erect said cover component of the injected drip emitter, while propelling it into a rotational motion around its integral hinge; and - pinning means which is suited to complete the rotation around of the cover component of the drip emitter by 180° around the integral hinge, and to iron the cover component unto the emitter's body component and affix them together one to the other; and - second pusher means that is positioned in the immobile assembly of the mold and suited to extract the assembled drip emitter from inside the immobile assembly of the mold. 18. A method for fabricating by injection into a mold and assembling inside said mold of a drip emitter in accordance of any of claims 2-15, which comprises the steps of - providing an injection mold comprise an immobile assembly and a mobile assembly which are suited to form by bi-component injection using core back technology, at least one of said drip emitters; first pusher means which is positioned in said immobile assembly of the mold and suited to erect the cover component of the drip emitter being injected, and to propel it to rotational movement around its integral hinge; pinning means which is suited to complete the turnaround of the cover component of the drip emitter by 180° around the integral hinge, and to iron said cover component unto the emitter's body component and to pin them one to the other; and second pusher means which is positioned in the immobile assembly of the mold and suited to extract the assembled drip emitter from inside said immobile assembly of the mold; and - injecting said drip emitter in a mold and opening it after it, while leaving the drip emitter being injected as a unit-part, wherein their body component and cover component were fabricated by bi-component injection into a mold, wherein they are connected one to the other by an integral hinge and hence constitute one unified part, but - said body component and cover component are still found in a spreading state and it is still required to turn them one relative to the other, by 180° around the integral hinge for assembling the drip emitter; and - propelling the cover component of the drip emitter into a motion around said integral hinge towards the body sector, before pinning them one to the other, using said first pusher means; and - completing turning of the cover component of said drip emitter by 180° around the integral hinge, while ironing said cover component into the body component and pinning them one to the other through said pinning means; and extracting the assembled drip emitter from said immobile assembly of the mold using said second pusher means for this purpose. A pressure regulated integral drip emitter which is fabricated using bi-component injection into a mold of one material which is HD polyethylene and second elastomer material, wherein it is formed also with a sector of said second elastomer material for the requirements of its pressure compensating mechanism; and— wherein said integral drip emitter is characterized in that said second elastomer material is Thermoplastic Vulcanizate (TPV). |
Field of the Invention -
The various embodiments described herein generally refer to discrete, pressure compensated, integral drip emitters, and means to manufacture them.
Background of the invention -
Discrete integral drip emitters are well known and recognized (familiar), namely drip emitters that are adapted for attachment - each one of them, inside a hose (pipe or conduit) and along its length - in various distances one from the other, wherein they are attached to the inner wall of the hose and are pressure compensated or pressure regulated. Namely - comprise a mechanism for compensating (or regulating) the pressure of the water that are made to flow through the hose, in a manner such that the occurrence of pressure variations inside the length of the hose would not influence the volumetric flow rate of the water emitted by them towards the area designated to be irrigated by them. A typical compensating mechanism is based on employing an elastomeric membrane (diaphragm) that is packed as a distinct part (component) in the structure of the drip emitter. As a consequence, an integral drip emitters of the pressure compensating (regulating) type are generally made of plurality of (sub) parts (include more than a single part - mostly two or three parts) - for example a housing or body part, cover part and the said membrane (diaphragm) part that is located between them. All of them assembled together to provide the integral, pressure compensating (regulating) drip emitter, following after the manufacturing of each part separately. The assemblage of an integral, pressure compensating (regulating) drip emitter made of two or three parts, is taking place as said, following after the earlier manufacturing of the different parts from which the emitter as said is constructed, in a way that naturally required separate manufacturing processes and manufacturing means for each of the different and distinct parts and the assemblage of the drip emitter from its different parts in an additional assembly process (all this before we even considered the insertion of the drip emitter into the interior of the hose and attaching it as said, as an integral type of drip emitter, inside the hose).
Due to the large number of parts, the various number of manufacturing tools required for them and the manufacturing processes we pointed hereinabove, in a manner that dictate manufacturing and assemblage rather long time period and significant cost, during the last years, efforts were made to develop integral, discrete, regulated drip emitters that are constructed as "unit-part" device (herein after it means - drip emitters that are uni-part or in other words - single unit, part, member, element, and to be distinguished from multi parts drip emitters).
For example - patent US 5,203,503 whose title is Drip Irrigation lines, instructed the professionals about integral drip emitters, that are discrete, regulated and a unit-part device. According to this publication, integral regulated drip emitters were fabricated by pressure injection molding and were characterized in that that a plurality of different materials were injected molded by separate casting "shots" into a single common manufacturing mold wherein at least one of the materials was an elastomeric material as is required for executing the compensating activity of the drip emitter. The problem is that the compensating mechanism described in this publication, call for compensation done on a narrow passage slot that is delineated by the internal surface of the hose's wall and positioned between the water outlet from the pressure reducing means (the labyrinth), and the exit pool (the space unto which an opening is linked and through which water are dripping unto the surface designated to be irrigated). This compensating mechanism is relatively not an efficient one (as compared to other pressure compensation mechanisms known in the field wherein an elastomeric membrane is band towards a labyrinth in which the water are flow in the drip emitter in order to reduce the prevailing pressure of the flowing water, or towards a water passage opening wherein the water pressure has already been reduced). Furthermore, a discrete drip emitter as per this publication is characterized by a single level, arranged in a row configuration - the pressure reducing mechanism (namely the labyrinth) is positioned wherein behind it, in a row and at the same level - the compensation slot is found and following the compensation slot there is positioned in a row and in the same level - the exit pool. A single level in a row configuration that naturally, geometrically limiting the size of the exit pool (as much as it is wanted to save raw material and thus reduce, as much as possible, the dimensions of the drip emitter), and leads to setting high accuracy requirements in all that is related to forming the water outlet opening from the pipe (and in a manner that compels high costs). Not to mention the fact that opposite a drip emitter formed with an exit pool that is geometrically relatively small, it is difficult to form a water outlet opening at the wall of the hose that is in the form of a slit and all the more so as in the form of a rather elongated slit as it is sometimes preferred for irrigation tasks. An additional example is found in a publication of an application for a patent WO 99/02273 whose title is Unibody pressure-Compensating Emitter. The publication described, inter alia, integral discrete drip emitters, that are liable to be manufactured by sequential molding from two different materials. Here once more, what is described in this publication are drip emitters with a configuration of in a row single level and wherein the compensation mechanism consists of a compensation mechanism on a slot - with all the drawbacks we pointed at above (in the case of US 5,203,503 publication).
An additional example is provided by patent US 8,998,112 whose title is Bi-Component Drip Emitter. Similarly to the two examples presented above, also this publication describes a compensated, discrete, integral drip emitters that are fabricated by pressure injection molding of two different materials into a mold and formed in a row and single level configuration (with all the drawbacks that we have pointed at above), wherein the difference is found in the specific compensation mechanism - in the above quoted patent; the compensation mechanism is formed as a mechanism wherein with an increase of the water pressure in the hose, is based on bending of the bottom of the drip emitter as a "membrane" towards the labyrinth while closing a flow passage that usually exist between them, or on bending of the labyrinth itself (as a kind of a membrane) towards the hose inner wall, while closing the flow passage that usually located between them.
At the same time, efforts to develop compensating integral drip emitters that are one-part (as defined above as uni, single part) are under way, not only through fabricating the drip emitters from two different materials (as was reported in the examples quoted above) but also in an approach of fabricating the complete (total) drip emitter, inclusive of its compensation mechanism, from a unified elastomer material.
Examples of this approach can be found in the publications of patent applications WO 2015/080115 ;WO 2015/080116 ;WO 2015/080119 ;WO 2015/080126 ;WO 2015/080127 ; WO 2015/093246 ;WO/2015/098412 ;and - WO 2015/105082. The problem is that the limitations of the unified elastomer material leads unto relatively non efficient compensation mechanisms (by comparison to the compensation mechanisms known in this field - e.g., bending an elastomer membrane towards the labyrinth in which the water flows in the emitter, for reducing the pressure of the prevailing water pressure or towards a water passage opening of the water whose pressure was already reduced). It is to be noted that the cited publications indicate a production and assembling capability of the drip emitter in unit-part and from said unified material as said while using an integral hinge as the specific means that enables unifying and integrating the drip emitter cover with the drip emitter body (see for example in publication WO 2015/080115; Fig. No. 5a). But, any professional in this field knows that an integral hinge as a connecting means were already implemented in the construction of discrete, compensating integral drip emitters (although in multi-parts drip emitters), (see for example patent US 6,250,571 whose title is Drip Irrigation Emitter, the compensating integral drip emitter that is made of two parts that is illustrated there in Figure No. 10b, and in patent US 6,568,607 whose title is Emitter - the integral compensating emitter assembled from two parts that was illustrated there in Figure No. 6).
Thus, at a period that was before the present invention, the professionals in the current domain were faced with the challenge of providing a solution to the need of reducing the time duration and production costs as required for the manufacturing and assemblage of discrete, pressure compensating (regulating), integral drip emitters, that are assembled from a plurality of parts (multi-parts), but without sacrificing for this end the required pressure compensating performance, and while relieving the accuracy requirements facing the means for forming the opening at the wall of the hose, in a manner that would form the opening exactly opposite the exit pool of the drip emitter, and enables also forming of said water outlet opening at the wall of the hose that is in a configuration of a rather elongated slit.
Summary of the Invention - The invention, the subject matter of this patent application presents a solution for the said need, to reduce the time and the production costs of discrete, pressure compensating integral drip emitters, that are assembled from plurality of separate parts (multi-parts), but without sacrificing the required compensation results and while getting some relaxation of the required accuracy values that challenged the forming means implemented for forming the water outlet openings in the hose wall, in a manner that would form the opening exactly opposite the exit pool of the drip emitter and would also enable forming of an exit opening at the wall of the hose that is in the configuration of an elongated slit.
In one aspect of the invention, the invention is embodied in an integral, pressure regulated drip emitter, formed wherein it comprises a body component and a cover component that are formed - each one of them, in a substantially rectangle configuration endowed with a lengthwise axis, wherein from the instant of attaching them together and the installation of the assembled drip emitter inside the hose, the length wise axis of the rectangle configuration as said, is turned in parallel to the direction of the flow. The body component is formed in a bi- level configuration on the two sides of a common wall, wherein in the first level, on its one side that is turned towards the inner side of the hose from the instant of installing the drip emitter in it, is formed with a bracket that is suited to affix the cover component on it from the instant of attaching them as said, one to the other, with a water passage, and with a compensating space. In the second level, on its second side that is suited to being attached to the inner side of the wall of the hose from the instant of installing the drip emitter in it, it is formed with an elongated exit pool that extends along the body component and with a baffle's labyrinth, for reducing the water pressure, that extends around the circumference of the exit pool wherein it is separated from it. The body component is formed with first water passage that routes (leads) the water flow from a water passage that is formed in the first level, through the common wall, to a one end of the baffle's labyrinth that is formed in the second level. The body component is formed also with a second water passage opening that is formed at the other end of the baffle' s labyrinth, and leads the flow of the water that its pressure was reduced while flowing through the baffle's labyrinth and through the common wall back to the first level unto the compensating space. A third water passage opening is also formed in the body component - at the compensating space, and leads the water flow that was routed through the second water opening passage, through the common wall, back to the second level and into the exit pool. The cover component is formed with a filtering sector, that from the instant of affixing the cover component to the bracket that is formed in the first level of the body component, from the instant of coupling them one to the other as said, the filtering sector is positioned above the water passage that is formed at the first level, and in a manner that enables passage of filtered water from the hose to the water passage.
A pressure regulated integral drip emitter in accordance with the invention is characterized by that that the cover component is fabricated by bi-component (materials) injection to a mold, wherein it is formed also with a sector of elastomer material. From the instant of affixing the cover component to the bracket that is formed in the first level of the body component, from the instant of coupling them together as said one to the other, the elastomer material sector of the cover component is positioned over the compensating space and in a manner that enables bending of the elastomer material sector, due to the water pressure prevailing in the hose, towards the third water passage opening and thus the compensating action is performed. As per another and additional aspect of the invention, the invention is embodied by a pressure regulated integral drip emitter that is a unit-part (single part /member/ element) - the body component and the cover component of the drip emitter are manufactured by a bi-component (materials) injection to a one single mold, wherein they are linked together one to the other through an integral hinge and constitute a unified part (unibody). From the instant of manufacturing them as a single unified part with an integral hinge as said, then from the instant of turning the cover component relative to the body component or vice versa, one relative to the other, by 180° around the integral hinge, the body component and the cover component are attached (coupled) one to the other.
Another aspect of the invention is embodied in a drip irrigation hose (lateral) that includes at least one drip emitter in accordance with the invention.
In yet an additional aspect of the invention, the invention is embodied by production means - by a mold for producing a drip emitter in accordance with the invention. A mold that comprise an immobile assembly and a mobile one, that are suited to forming by bi- components injection a one -part drip emitter in accordance with the invention, by core back technology. Wherein the mold is characterized by that that it comprise in addition a first pusher means that is positioned in the immobile assembly of the mold and suited to raise a little and erect the cover component of the injected drip emitter, while propelling it to a rotational motion around the integral hinge; a pinning together means that is suited to complete the rotating of the cover component by 180° around the integral hinge and to "iron" the cover component to the body component and pin them together one to the other; and second pusher means that is positioned in the immobile assembly of the mold and suited to extract the assembled drip emitter from inside the immobile assembly of the mold.
As per an additional aspect, the invention is embodied in a manufacturing (production) method - in a method for production by injection into a mold and assembling a one-part drip emitter inside the mold in accordance with the invention. A method that comprise the steps of - providing a mold as said; a step of injecting the drip emitter into the mold and opening the mold after it, while leaving the injected drip emitter as a unit-part drip emitter - wherein the body component and its cover component were produced using a bi-components injection to the mold, wherein they are connected one to the other through an integral hinge and hence constitute one unified part, but (however) the body component and the cover component are found in a "spreading" condition (i. e. "open state") one next to the other and their turning around the integral hinge by 180 is still required for the sake of assembling the drip emitter
(bringing them to "closed" state); a step of propelling the cover component of the drip emitter into movement around the integral hinge of the body sector, before they are pinned together one to the other - by the first pusher means; step of completing the turning of the cover component of the drip emitter by 180° around the integral hinge, while ironing the cover component unto the body component and affixing them together one to the other by a pinning means; and the step of extracting the drip emitter from the immobile assembly mold using the second pusher means.
Finally, the invention is embodied in the specific elastomer material that is used (embedded) for injecting the elastomer material sector in a pressure regulated integral drip emitter, which is bi- component, that might be a unit-part drip emitter as said— Thermoplastic Vulcanizate (TPV).
Still other aspects, embodiments, and advantages of these exemplary aspects and embodiments are discussed in detail below. Embodiments disclosed herein may be combined with other embodiments in any manner consistent with at least one of the principles disclosed herein, and references to "an embodiment," "some embodiments," "an alternate embodiment," "various embodiments," "one embodiment" or the like are not necessarily mutually exclusive and are intended to indicate that a particular feature, structure, or characteristic described may be included in at least one embodiment. The appearances of such terms herein are not necessarily all referring to the same embodiment.
Brief Description of the Drawings -
Various aspects of at least one embodiment are discussed below with reference to the accompanying figures, which are not intended to be drawn to scale. The figures are included to provide illustration and a further understanding of the various aspects and embodiments, and are incorporated in and constitute a part of this specification, but are not intended as a definition of the limits of the invention. In the figures, each identical or nearly identical component that is illustrated in various figures is represented by a like numeral. For purposes of clarity, not every component may be labeled in every figure. In the figures:
Figure No. 1 constitutes a view in perspective from one angle of an example of a bi- components, unit-part drip emitter in accordance with the invention wherein the body component and the cover component of the drip emitter that are connected one to the other through an integral hinge, are illustrated in a spreading state ("open" state) - prior to their turning one relative to the other by 180° around the integral hinge, for their being pinned one to the other (in other words - a view of a unit-part drip emitter given after its production stage by a bi-components injection).
Figure No. 2 constitutes a view in perspective from another angle of the exemplifying drip emitter that is illustrated in figure No. 1 , in a spreading state ("open" state).
Figure No. 2a constitutes a view in perspective of an additional example of bi-components unit- part drip emitter in accordance with the invention, that similarly to the drip emitter that is illustrated in figure No. 1 , is also found in a partially "open" state, but that as now different from it - its integral hinge is formed wherein it is extending along a shorter edge of the rectangle configuration of the drip emitter.
Figure No. 2b constitutes a local schematic view in cross section of an integral hinge of the kind that is formed in a bi-components, unit-part drip emitter in accordance with the invention (like the drip emitters which are illustrated in figures No.l and 2a) , in the open state.
Figure No. 2c constitutes a local schematic view in cross section (that is marked in figures No. 13 as 2c - 2c), of the integral hinge of the kind that is formed in a bi-components, unit- part, drip emitters in accordance with the invention (as the example drip emitters which are illustrated in figures No. 1 and No. 2a), in the closed state.
Figure No 3 is a top view of an example drip emitter which was illustrated in Figures No. 1 , in a spreading state ("open" state). Figure No. 4 is a lower view of an example drip emitter which is illustrated in Figurer No. 1, in a spreading state ("open" state).
Figure No. 5 is a side view of an example drip emitter which is illustrated in figure No. 1.
Figure No. 6 is a view in perspective from one angle of the exemplifying bi-components unit- part drip emitter which is illustrated in Figure No. 1, wherein the body component and the cover component of the drip emitter that are connected one to the other by an integral hinge, are illustrated in the "closed' state - following after their turn one to the other by 180° around the integral hinge, and pinning them one to the other (in other words - shows the unit-part drip emitter after the step of its assembly, and in the condition wherein the emitter is ready to be installed on an inner wall of a hose).
Figure No 7 is a view in perspective from a different angle of the exemplifying drip emitter which is illustrated in Fig. No. 6, in the closed state.
Figure No. 8 is a top view of the exemplifying drip emitter that is illustrated in Fig. No. 6, in a closed state.
Figure No. 9 is a view from below of the exemplifying drip emitter that is illustrated in Fig. No. 6, in a closed state.
Figure No. 10 is a view in cross section that is marked a-a in figure. No. 8.
Figure No. 11 is a side view of the exemplifying drip emitter that is illustrated in No. 6, in the closed condition.
Figure No. 12 is a cross section view which is marked b-b in Fig. No. 10.
Figure No. 13 is a view of the cross section which is marked c-c in Fig. No. 10.
Figure No. 13a is a local view by cross section of an under-cut type of connector which is embodied for the requirements of affixing of the cover component to the body component of the drip emitter which is illustrated in Fig. No. 1 and No. 6, in a condition of prior to affixing.
Figure No. 13b is local view in cross section of an under-cut type of connector which is embodied for the requirements of affixing cover component to the body component in the drip emitter that is illustrated in Fig.No.l and No. 6, in the pinning condition. Figure No. 13c is a view in perspective of an additional exemplifying bi-component unit-part drip emitter in accordance with the invention, which is like the example drip emitter which is illustrated in Fig. No. 6, also illustrated in the closed condition, but different from it, in which its cover component is formed with a bulge whose tip is suited to being affixed to the inner wall of the hose (which is not illustrated).
Figure No. 13d is a view in cross section d-d which is illustrated in Fig. No. 13c.
Figure No. 13e is a view in perspective of an additional exemplifying bi-component unit-part drip emitter in accordance with the invention, which is like the example drip emitter which is illustrated in Fig. No. 6 and 13c, also illustrated in the closed condition, but different from them, in which its cover component is formed with an under-cut type of connectors whose tips are suited to being affixed to the inner wall of the hose (which is not illustrated).
Figure No. 13f is a view in cross section dl-dl which is illustrated in Fig. No. 13e.
Figure No. 13g is a view in cross section d2-d2 which is illustrated in Fig. No. 13e.
Figure No. 14 is a view in perspective of the unit-part drip emitter which is illustrated in Fig. No. 1 and No. 6, wherein it is affixed to the inner wall of a hose.
Figure No. 15 is a cross section view of the drip emitter which is illustrated in Fig. No. 14 wherein it is affixed to the inner wall of a hose and wherein a pressure compensation is taken place.
Figure No.16 is a schematic view in perspective of mold assemblies for production by injection and assembling inside the mold of the bi-component, unit-part drip emitter, which is illustrated in Fig. No. 1 and No. 6.
Figure No. 16a is a schematic view of the mold assemblies which are illustrated in Fig. No. 16 wherein they are presented one next to the other.
Figure No. 17 constitutes a schematic view in cross section of the mold which is illustrated in Fig. No. 16 in the open state (prior to injection).
Figure No. 18 is a schematic view in cross section of the mold that is illustrated in Fig. No. 16 in closed state (prior to injection).
Figure No. 19 is a schematic view in cross section of the mold which is illustrated in Fig. No. 16 in a closed state after injection of the first material. Figure No. 20 is a schematic view in cross section of the mold which is illustrated in Fig. No. 16 in a closed state and after retreat of the core, before injecting the second material - the elastomeric material.
Figure No. 21 is a schematic view in cross section of the mold which is illustrated in Fig. No. 16 at a closed state after injection the second material - the elastomeric material.
Figure No. 22 is a schematic view in cross section of the mold which is illustrated in Fig. No.16 at an open state following injecting the two materials (the injected drip emitter is formed in a spreading state (in an "open" state) inside the immobile assembly of the mold).
Figure No. 23 is a schematic view in cross section of the mold which is illustrated in Fig. No. 16 in a state of propelling the cover component for a movement around the integral hinge and towards the body component before they are affixed one to the other.
Figure No. 24 is a schematic view in cross section of the mold which is illustrated in Fig. No. 16 in a state of affixing the body component to the cover component (the drip emitter is assembled to its "closed" condition).
Figure No. 25 is a schematic view in cross section of the mold which is illustrated in Fig. No. 16 in a state of extracting the assembled drip emitter from within the mold.
Figure No. 26 is a view in perspective of yet another exemplifying bi-component drip emitter in accordance with the invention, a drip emitter that is assembled from two separate parts - body component and cover component, wherein the cover component is the only one which is produced by bi-component injection (and includes an elastomer sector).
Figures No. 27a - 27c are schematic views in cross section depicting in sequence the stages following the injection molding of an additional exemplifying bi-component unit -part drip emitter in accordance with the invention of the type illustrated Fig. No. 13e - 13g, wherein the extracting of the drip emitter from within the mold provide for a space as required for pinning the cover component to the body component through the under-cut type of connectors, at a later stage.
Figures No. 28a - 28b are schematic views in cross section depicting an example of a core back technology as implemented for the injection of the second material - the elastomeric material, in the manufacturing of bi-component unit-part drip emitter in accordance with the invention. Detailed Description -
It is to be appreciated that embodiments of the and apparatuses and method discussed herein are not limited in application to the details of construction and the arrangement of components set forth in the following description or illustrated in the accompanying drawings. The apparatuses and methods are capable of implementation in other embodiments and of being practiced or of being carried out in various ways. Examples of specific implementations are provided herein for illustrative purposes only and are not intended to be limiting. In addition, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use herein of "including," "comprising," "having," "containing," "involving," and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. References to "or" may be construed as inclusive so that any terms described using "or" may indicate any of a single, more than one, and all of the described terms.
Furthermore, it will be appreciated that for simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements; in addition, numerous specific details are set forth in order to provide a thorough understanding of the embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein may be practiced without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as not to obscure the embodiments described herein. In addition, the description is not to be considered as limiting the scope of the embodiments described herein.
Referring to Fig. No. 1 and No. 2. Fig. No. 1 constitutes a view in perspective from one angle of an exemplifying drip emitter 10 in accordance with the invention. Drip emitter 10 constitutes an integral drip emitter, namely - one that is suited to being installed inside a hose wherein it is affixed to its inner wall (and see when referring to figures No. 14 and No. 15). Drip emitter 10 consists a single unit-part (above and below in the meaning of single unit/part/member/element), wherein body component 15 and cover component 20 of drip emitter 10 are connected one to the other by integral hinge 25. In Fig. No. 1 , drip emitter 10 which is illustrated in the spreading state ("open" state ) - prior to the turning of body component 15 and cover component 20 of drip emitter 10 one relative to the other by 180° around integral hinge 25, in order to have them pinned one to the other (in other words - Fig. No. 1 is the view of unit-part drip emitter 10 in the spreading state following its production stage through bi-components injection (as would be explained later below when referring to figures No. 16 to No. 25)). Fig. No. 2 is a view in perspective from another angle of drip emitter 10 that is illustrated in Fig. No. 1, in the spreading state ("open" state).
Thus, any professional would understand that drip emitter 10 is a unit-part, wherein body component 15 and cover component 20 are liable to be produced by bi -component injection into one (single) mold (as said, would be described below when referring to figures No. 16 to No. 20), wherein they are connected one to the other by an integral hinge 25 and constitute a unified part and wherein from the instant of the turning of body component 15 and cover component 20 of drip emitter 10, one relative to the other as said, by 180° around the integral hinge 25, the body component 15 and cover component 20 are being affixed one to the other.
Reference is given to figures No. 6 and No. 7. Fig. No. 6 is a view in perspective from one angle of drip emitter 10 that is illustrated in Fig. No.l, wherein body component 15 and cover component 20 of drip emitter 10 that are connected one to the other through an integral hinge 25, are illustrated in a state "closed" - subject to their turning one relative to the other by 180° around integral hinge 25, and affixing them one to the other (in other words - shows a view of unit- part drip emitter 10 a stage after its assembly, and in the stage it prevails following after the stage of its assembly it is ready to be installed on an internal wall of a hose, as would be described when referring to figures No. 14 and No. 15). Fig. No. 7 is a view in perspective from another angle of drip emitter 10 that is illustrated in figure No. 6, in a closed state.
In order to learn about the various components that are embedded in the structure of drip emitter 10 and the reciprocal relations between them, reference is being made to figures No. 2b and No. 2c as well as to figures No. 3 to No. 5, No. 8 to No. 13 and No.'s 13a to No. 13d.
Figure No. 2b is a local schematic view in cross section of integral hinge 25 of the kind that is formed in drip emitter 10, and every professional would understand, that a similar hinge might be formed in other bi-components, unit-part drip emitters in accordance with the invention (as per an additional example - see below when referring to Fig. No. 2a). Integral hinge 25 is formed with a weakening dent 27 along its length (in the illustrated example - as a dent having an arched cross section), in a manner that enables propelling the components which are connected by it, in a rotational movement one relative to the other, around dent 27. In figure No. 2b, hinge 25 is illustrated in the open state, wherein it bridges between the body component and cover component before they are pinned one to the other by rotating them one relative to the other around the hinge. Fig. No. 2c, contrary to it, is a local schematic view in cross section of integral hinge 25 depicted in a closed state - after affixing body component to the cover component, namely - after completing propelling them in rotation one to the other, around the hinge (local view that is marked in Fig. No. 13 as cross section 2c-2c).
Fig. No. 3 constitutes atop view of drip emitter 10 depicted in an open state. Fig. No. 4 constitutes a view from below of drip emitter 10 depicted in an open state. Fig. No. 5 constitutes a side view of drip emitter 10 depicted in an open state. Fig. No. 8 constitutes a top view of drip emitter 10 depicted in a closed state. Fig. No. 9 constitutes a view from below (under) drip emitter 10 depicted in a closed state. Fig. No. 10 constitutes a view in cross section that is marked a-a in Fig. No. 8. Fig. No. 11 constitutes a side view of drip emitter 10 depicted in a closed state. Fig. No. 12 constitutes a view of cross section that is marked b-b in Fig. No. 10. Fig. No. 13 constitutes a view in cross section that is marked c-c in Fig. No. 10.
Drip emitter 10 is characterized by the rectangle configuration that characterizes both body component 15 and cover component 20, and (anyway) the entire drip emitter, as it is formed from the instant of affixing them one to the other. Namely - the treated is a discrete integral drip emitter, of the type that is called at times "boat" type of drip emitter (a drip emitter that is affixed at times to an inner wall of the hose over less than half its inner circumference, to distinguish it from cylindrical shaped integral drip emitters). In drip emitter 10 both the body component 15 and the cover component 20 are formed, each one of them, in a substantially rectangle configuration, having a lengthwise axis. See in Fig. No. 3 - length axis 29 of body component 15 and length axis 31 of cover component 20. From the instant of pinning together the components one to the other, the axes are unified by over lapping (becoming congruent) one with the other unto forming a common lengthwise axis. See in figures No. 6 and No. 7 - the common lengthwise axis 33. From the instant of assembling drip emitter 10 that is installed inside a hose (see below and where referring to figures No. 14 and No. 15), the common lengthwise axis 33 of the rectangle configuration as said, directed in parallel to the direction of the flow in the hose.
Body component 15 is formed in a bi-levels configuration on the two sides of a common wall 35 (see the common wall as it appears in cross section in Fig. No. 10). In the illustrated example, common wall 35 is formed in an arched configuration in cross section, in a manner that in the illustrated example, helps in keeping the thickness and distribution of the material uniform along the body component of the drip emitter.
The first level 37 is formed on the side of the body component that from the instant of installation of drip emitter 10 in the hose is turned towards the interior of the hose. First level 37 (see in Fig. No. 4) is formed with a bracket 39 that is suited to affix cover component 20 in it (from the instant of pinning together as said body component 15 and cover component 20 one to the other). First level 37 is formed also with a water passage 41 and with a pressure compensation space 43.
The second level 45 is formed on the other side of the body component that is suited to be affixed to the internal wall of the hose from the instant of installing the drip emitter inside it. Second level 45 (see in figures No. 3 and No. 8), is formed with an elongated exit pool 47 that extends along the length of body component 15 and with baffle's labyrinth 49 for reducing the water pressure, that extends around the circumference of exit pool 47 while it is separated from it.
Body component 15 (see in Fig. No. 4) is formed with a first water passage opening 51 that guides the water flow from a water passage 41 which is formed in first level 37, through common wall 35, towards (see in figures No. 3 and No. 8), one end 53 of baffle's labyrinth 49 that is formed in second level 45.
Body component 15 (see in Fig. No. 3 and No. 8), is formed with a second water passage opening 55 which is formed at a second end 57 of baffle's labyrinth 49 and leads the flow of the water whose pressure was reduced from the instant of passing through baffle's labyrinth 49, through common wall 35, back to first level 37 (see in Fig. No. 4), and into pressure compensating space 43.
In accordance with the illustrated example, baffle's labyrinth 49 extends on the two sides of elongated exit pool 47 in a kind of symmetric geometry that is conformal relative to the exit pool and formed with flow passages on the two ends of the body component, that are leading the water that arrives from one end 53 of the labyrinth through a sector of the labyrinth that extends on a one side of the exit pool, to a sector of the labyrinth that extends on its other side of the exit pool and back to a second end 57 of the labyrinth that is also positioned on a one side of the exit pool. Nevertheless, any professional would understand that what is treated is only an example and the geometry of the labyrinth relative to the exit pool is liable to be another and different (for example - forming baffle's labyrinth that extends only on a one side of the exit pool).
Body component 15 (see in Fig. No. 4) is formed with a third water passage opening 59 that in formed in the compensating space 43 and routes the water flow that was routed through second water passage opening 55 through common wall 35 (see figures No. 3 and No. 8) back to second level 45 to the exit pool 47.
Cover component 20 is formed with a filtering sector 61. From the instant of affixing cover component 20 to bracket 39 that is formed in first level 37 of body component 15, from the instant of pinning them one to the other as said (see figures No. 10 and No. 13), filtering sector 61 is positioned above water passage 41 that is formed in first level 37, and in a manner that filtered water passage is enabled from the hose (that is not illustrated) to water passage 41. In accordance with the illustrated example, filtering sector 61 is formed in a configuration of plurality of passages 62 over a sector of cover component 20.
As we have pointed at above, drip emitter 10 is, as said, an integral unit-part drip emitter - integral hinge 25 connects from the beginning, already at its early injection production stage, body component 15 to cover component 20 and turns them into a unified part from the beginning.
In drip emitter 10 as it was described above while referring to the accompanying figures, integral hinge 25 is formed in first level 37 and connects body component 15 to cover component 20, wherein it extends along the longer edge of the rectangular configuration that characterizes the components (the body and the cover) and the complete drip emitter that is formed from the instant of pinning them together one to the other. But, every professional would understand that what is treated is only an example and that an integral drip emitter, which is pressure regulated, and unit-part in accordance with the invention might be formed wherein its integral hinge is formed in another location. Reference is given to Fig. No. 2a. Fig. No. 2a.is a view in perspective of an exemplifying unit-part drip emitter 210 in accordance with the invention, that similarly to said drip emitter 10 as illustrated in Fig. No.l , also drip emitter 210 is illustrated in the open state (partly), but as different from drip emitter 10 as it appears in drawing No. 1 , the integral hinge 225 in drip emitter 210, is formed at the first level 237, wherein it extends along the shorter edge of the rectangle configuration of the drip emitter. Drip emitter 10, as well as drip emitter 210, the subject matter of Fig. No. 2a, are also pressure compensating drip emitters, namely - drip emitters that include an elastomer component for the sake of the compensation function. Drip emitters 10 and 210, are characterized by that that even though they are unit-part, as said, the compensation means (the elastomer component) is embodied while embedded in their unit-part construction.
As compensating drip emitters, drip emitters in accordance with the invention are fabricated from two components - a relatively rigid component, for example - made by injection of HD polyethylene, and from an elastomer component, for example - made by injection of material that is from the "family" of Thermoplastic Vulcanizate (TVP), (as an example for a material from this "family" there is the thermoplastic elastomer TPSiV R 4100-60A supplied by Dow Corning company. Any professional would appreciate the fact that additional elastomer materials, but other and different, were included in the previous prior art which dealt with drip emitters that similar to the current invention, they too were described as unit-part drip emitters and were designated for fabrication by bi-component injection. These materials include, inter alia, thermoplastic elastomers (TPE), such as Santoprene R , thermoplastic polyurethane and thermostatic polymers (such as silicone or nitrile rubber (NBR)).
Thus for example, in drip emitter 10, cover component 20 is produced by bi-component injection into a mold (as would be explained below when referring to figures No. 16 to No. 20), wherein it is formed also with a sector 63 of elastomer material.
From the instant of affixing, cover component 20 to bracket 39 that is formed in the first level 37 of body component 15, from the instant of pinning them together one to other (see Fig. No. 10 and No. 12), the elastomer material sector 63 is positioned over compensating space 43 that is formed in first level 37, and in a manner that it enables bending of the elastomer material sector 63, due to the prevailing water pressure in the hose (that is not illustrated), towards third water passage opening 59, and so is the compensating action executed (as would be explained in more detail below and when referring to Fig. No. 15).
According to the illustrated example, (see Fig. No. 4 and No. 12), third water passage opening 59 is formed as a hollow stem (reed) that protrudes from common wall 35 into compensating space 43, and at its tip exists a widthwise slot 60 for allowing water passage from the second water passage opening 55 to the third water passage 59, and this, also when bending the elastomer material sector 63 to a contact with the stem tip. In the illustrated example; elastomer material sector 63 is formed in the configuration of a round disc but any professional would understand that the configuration of the elastomer material sector could be other and different, (for example - square or rectangle). More in according to the illustrated example (see Fig. No. 4), compensating space 43 is formed as a cell having a circumferential wall 44 that extends in a round configuration around third water passage 59 and at a distance from it, wherein it protrudes from common wall 35 into the first level 37, but any professional would understand that what is considered is solely an example and the compensating space can be formed in another and different configuration (for example - as a space with square or rectangle cross section).
In accordance with the illustrated example, the circumference of the disk shape configured elastomer sector 63 extends beyond the circumferential wall 44 of compensating space 43.
Additionally in accordance with the illustrated example; elastomer material sector 63 is formed as thin by comparison to the thickness of the rest of cover component 20 that is injected from the other material (for example - polyethylene HD), (see in Fig. No. 12), and in a manner that the circumferential edge of elastomer sector 63 is integrally connected with matching bracket 65 that is formed by the other material (for example - polyethylene HD), from which the rest of cover component 20 is made.
Every professional would understand that the elastomer sector of drip emitters in accordance with the invention is liable to be formed by injection with varying cross sections in its shape and thickness in order to suit the sinking (bending) geometries that are expected from it due to pressure differences prevailing on its two sides.
Bracket 39 that as said is suited to establish (affix) in it cover component 20 from the instant of connecting (pinning) as said, of component body 15 to cover component 20, one to the other, is formed in accordance with the illustrated example, (see in Fig. No. 4), as a plurality of ribs 67 that protrude from common wall 35 into the inside of first level 37. Cover component 20 is suited to lean on ribs 67. Concurrently, circumferential rib 71 extends around first level 37 in a manner that cover component 20 is suited to be embraced by it.
Water passage 41 (see in Fig. No. 13) is (hence) delineated as a space that extends inside first level 37 between common wall 35 to cover component 20, from the instant of driving it to lean as said on protruding ribs 67 (see in Fig. No. 4). What is presented is solely an example, and any professional in this field will understand that it is possible to form the flow passage by another and different configuration of ribs. Bracket 39 that is suited to affixing in it cover component 20 from the instant of pinning them as said, of body component 15 to cover component 20, one to the other, is formed according to the illustrated example as a bracket to an under-cut type of connector 73 (see Fig. No. 13) that exist between it and cover component 20. Reference is given to Fig. No. 13a and 13b. Fig. No. 13a is a local view in cross section of under-cut connector 73 in a state of pre (prior to) pinning. Fig. No. 13b is a local view in cross section of under-cut connector 73 in a pinning state. Any professional would understand that a proper design of under-cut connector 73 could insure the sealing of compensation space 43 as it is illustrated in Fig. No. 12 - from the instant of "slamming" the cover component to the body component by using under-cut connector, on (the surface of) protruding edge 44 that extends around the circumference of compensating space 43, elastomer material sector 63 (at its circumferential edge) is biased (under traction) by pressure in a manner that ensures the sealing of compensating space 43 and its insulation as required, from the water pressure that prevails in the hose. Any professional would also understand that "slamming" the cover component unto the body component in a unit-part drip emitter in accordance with the invention using an under-cut connector for this purpose, is liable to be embodied using a connector as said, that would be different in its components (for example - by means of reversal of applying the male and female designations to the body and cover components).
This and more, it is feasible to ensure the pinning of the cover component unto the body component in drip emitters in accordance with the invention, also by affixing the cover component (in addition to the body component of the drip emitter) to the wall of the hose (for example and as it is customary in the fields of producing integral drip irrigation laterals, while exploiting the heat prevailing in the inner wall of the hose that emerged from the extrusion head and soldering the drip emitter on it). Reference is given to Fig. No. 13c and 13d. Fig. No. 13c is a view in perspective of exemplifying drip emitter 310 wherein it too, similarly to the above cited drip emitters 10 and 210, is a bi-components unit -part. Drip emitter 310, similarly to drip emitter 10 that is illustrated in Fig. No. 6, it too is illustrated in the closed state, but as distinguished from it, its cover component is formed with a protrusion 381 that produces, together with cover component' s plane 320, a configuration similar in cross section to the letter 'L', whose tip 383, is suite - it too, also to be pinned unto the inner wall of the hose (not illustrated). Fig. No. 13d is a view in cross section that is marked d-d in Fig. No. 13c. Reference is being made to Figures No. 13e - 13g. Figure 13e is a view in perspective of an additional exemplifying bi-component unit-part drip emitter 1310 in accordance with the invention, which is like the example drip emitter 10 and 310 which is illustrated in Fig. No. 6 and 13c, also illustrated in the closed condition, but different from them, in which its cover component 1320 is formed with an under-cut type of connectors 1381 and 1385, whose tips (respectively) - 1383 and 1387, are suited to being affixed to the inner wall of the hose (which is not illustrated). Figure No. 13f is a view in cross section dl-dl which is illustrated in Fig. No. 13e and Figure No. 13g is a view in cross section d2-d2 which is illustrated in Fig. No. 13e. any professional will understand that in accordance with this embodiment, the under- cut type of connectors are formed on both the shorter and the longer edges of the rectangle shaped emitter, and not only they are locking the emitter's body component 1315 unto the cover component 1320, but in addition, the under-cut connector tips are weldable to the inner side of the hose wall upon installation (and therefore affixing the body component too to the hose's wall).
Drip emitters in accordance with the invention are, as said, compensating integral drip emitters. Drip emitters in accordance with the invention are liable to be formed with additional familiar configurational aspects -already known in the past as instilling advantages also in these aspects of compensating integral drip emitters. So for example, drip emitters 10, 210 and 310 on which we pointed at above, are formed in a manner that their body components in the first level, on their one side that is turned towards the interior of the hose from the instant of installing the drip emitter in the hose, are formed in an arched configuration that extends along the shorter edge of the emitter's rectangle configuration, for the sake of adapting to the radius dimension of the hose's inner wall in which the drip emitter is said to be attached. See for example in Fig. No.11 - the arched layout of the body component 15 in drip emitter 10, and in Fig. No. 13d - the arched layout of body of body component 320 and tip 383 of protrusion 381.
Reference is given to Fig. No. 14 and No. 15. Fig. No. 14 is a view in perspective of drip emitter 10 wherein it is affixed as an integral drip emitter to the internal wall 403 of hose 405. Fig. No. 15 is a view in cross section of drip emitter 10 wherein it is affixed on internal wall 403 of hose 405 and when pressure compensation is performed there. Every professional would appreciate the fact that drip emitters in accordance with the invention, as drip emitters 10, 210 and 310 at which we pointed above, enable their embodiment as integral drip emitters that are installed inside a hose, wherein they are affixed to its internal wall, by means and technologies that are already known before. The professionals would also appreciate the fact that for these drip emitters in accordance with the invention, assigning a relatively large area to filtering sectors (61 in the illustrated example dipper 10) is enabled, in a manner that it extends the operating life span of the compensating mechanisms. This and more, the professionals would appreciate the fact that the compensating mechanism that is embodied in drip emitters in accordance with the invention, is a differential compensating mechanism already proven. Even though we are treating bi-component drip emitters, the compensating mechanism that is embodied in drip emitters in accordance with the invention, the compensating mechanism is based on bending a membrane (diaphragm), (elastomer sector 63 in the illustrated example drip emitter 10), inside a dedicated compensating cell (compensating space 43 in the illustrated drip emitter 10), towards the water exit (third water passage opening 59 and widthwise slot 60 in the illustrated drip emitter 10), wherein on its one side of the elastomer sector 63 prevails the water pressure that is in the hose, and on the second side- the reduced water pressure after water flow passed in the baffle's labyrinth. Finally, drip emitters in accordance with the invention are formed with a rather elongated exit pool that extends along its lengthwise axis (see for example, in the subject of drip emitter 10, in Fig. No. 6), along a substantial part of the body component. Any professional would appreciate the fact that such an elongated configuration facilitates significantly the accuracy requirements in the stage of forming water exit opening in the wall of the hose opposite the exit pool and enables implementing exit openings in a configuration of a thin and elongated slit (slit 407 in the illustrated drip emitter 10).
Drip emitters in accordance with the invention, as the exemplifying drip emitters 1, 20 and 310 at which we pointed at above, are liable to be manufactured using bi-components injection (multi material injection technology) and to be assembled while still in the injection mold. Reference is given to Fig. No. 16 to No. 25. Fig. No. 16 is a schematic view in perspective of the assembles of mold 505 - the stationary assembly 507 and the mobile assembly 509, for production by injection and for assembly inside the mold of drip emitter 510 (that is not illustrated). Any professional would understand that drip emitter 510 is a compensating integral drip emitter, bi-component, unit -part that is substantially similar to drip emitter 10 (that is illustrated for example in Fig. No. 1 and No. 6). Fig. No. 16a is a schematic view of the assemblies of mold 505 that is illustrated in Fig. 16 wherein they are displayed one next to the other. Fig. No. 17 is a schematic view in cross section of mold 505 depicted in an open state (before injection). Fig. No. 18 is a schematic view in cross section of mold 505 depicted in closed state (before injection). The mobile assembly 509 advanced in motion in the direction of arrow 512.
Every professional would appreciate the fact that in mold 505 is implemented the core back technology or the core toggle, a technology that is already known from earlier times as a technology which is applicable for the need of production by injection of an integral parts made from multi components (materials). Core 514 is propelled in the direction of arrow 516 for isolating the cavity that is designated for injecting the elastomer material sector, and separating it from the rest of the mold's cavities. Any professional would understand that core 514 is likely to be formed as a full body that from the instant of propelling it, as said, fills the entire cavity (as per the illustrated example), or as just separating (divider) having a thin separation means that from the instant of being positioned, it does not fill the entire cavity (as seen in the illustrated example), but does separate and prevents passage of the first injected material. The core might also be formed with shaped surface area in accordance with the configuration of the elastomer sector (as per the illustrated example and solely for the sake of explanation - the treated subject is forming a rather flat elastomer sector having a uniform thickness that is connected to an opening that would be formed in the cover component). Fig. No. 19 is a schematic view in cross section of the mold that is illustrated in Fig. No. 16 depicted in closed state following after the injection of the first material 518 (illustrated in full black color). As said, the first material might be HD polyethylene. Attention is given to the forming by injection at this stage, both of the body component as well as the integral hinge and also the emitter's cover component, except than to the elastomer material sector (due to the presence of core 514, injection of the first material, forms as said, an opening in the cover component). Fig. No. 20 is a schematic view in cross section of mold 505 depicted in a closed state and after retreat of core 514, just before injection of the second material - the elastomer material. In this state, core 514 is retreated in the direction of arrow 517, cavity 523 is exposed in the required dimension (to the extent of the thickness allocated to the elastomer sector), and the feeding ditch of the melted elastomer material 526 is connected to the now open cavity 523 in preparation to the expected passage of the melted elastomer material into the cavity. Fig. No. 21 is a schematic view in cross section of mold 505 depicted in a closed state following after injecting the second material - the elastomer material 527. As said, the elastomer material is liable to be Thermoplastic Vulcanizate (TPV). Fig. No. 22 is a schematic view in cross section of mold 505 depicted in an open state after injecting of the two different materials 518 and 523. At this stage, the mobile assembly 509 was retreated, it too, in the direction of arrow 529. Inside immobile assembly 507 there was actually left drip emitter 510 formed as a unit-part, where its body component and cover component were fabricated in bi-component injection into one single mold 505, wherein they are connected one to the other through an integral hinge and hence constitute a unity part. However, the body component and cover component are found in spreading state ("open" state) and their turning is still required one towards the other by 180° around the integral hinge for assembling drip emitter 510 (bringing it to the "closed" state). Fig. No. 23 is a schematic view of mold 505 depicted in a state of propelling cover component 520 of drip emitter 510 that as said, was just recently injected, to motion around its integral hinge 525, towards body component 515, prior to them being pinned together one to the other. First pusher means 529 that is positioned in the immobile assembly 507 of the mold is propelled for motion in the direction of arrow 533, in a manner that slightly erects cover component 520 and propels it to a rotational motion around integral hinge 525. Simultaneously unto gap 533 that there is produced in the mold upon retreating of mobile assembly 509, is advanced pinning means 535 which is propelled in parallel to the surface area of immobile assembly 507 and perpendicular to the direction of the motion of the first pusher means (in the direction of arrow 537). Pinning means 535 which is illustrated in a schematic configuration propelled to motion in parallel to immobile assembly area 507 and perpendicular to first pusher means 531 (in the direction of arrow 537). Pinning means 535 is illustrated in a schematic configuration as said, as a plane having an end which leans at its tip, but any professional will understand that what is presented is a schematic illustration, and the pinning means can be formed with other and different mechanism, for example - as a wheel, a gripper or another manipulator. This and more, professionals in the field of molds design, are apt to remember that technology and means like those are implemented for example, in production by injection of tube's corks, wherein their closing component is connected to their bracket component via an integral hinge and for shutting (closing) the closing component on the bracket, even before extracting them from the mold. Fig. No. 24 is a schematic view in cross section of mold 505 depicted in a state of pinning body component 515 of drip emitter 510 to cover component 520. First pusher means 531 that as said is positioned in immobile assembly 507 of the mold is retreated back by motion in the direction of arrow 539, wherein simultaneously - pinning means 535 continues to be advanced to movement in the direction of arrow 537, and thus completes the turn of cover component 520 of the drip emitter 510 by 180° around integral hinge 525, and "irons" the cover component to the body component and affixes them one to the other. Fig. No. 25 is a schematic view in cross section of mold 505 depicted in a state of extracting drip emitter 510 which is already assembled from inside the mold. In this stage, in which the assembly of the drip emitter, as said, was accomplished still inside the mold of its manufacturing, pinning means 535 which is not illustrated was retreated backwards, and second pusher means 539 that is positioned in an immobile assembly 507 of the mold, is propelled for motion in the direction of arrow 541, in a manner which extracts drip emitter 510 from inside the immobile assembly of the mold, and enables the emptying of the mold and making it ready for an additional cycle of injection bi-components, and assembling the injected drip emitter already inside the mold as said.
Any professional would understand that a mold, as said, might include a large number of injection cavities, in a manner that would enable production through bi-component injection, and assembling as said, in parallel, of a large number of pressure regulated integral drip emitters in accordance with the invention, which are unit-part.
We have pointed above while referring to the accompanying figures implementing the invention in a pressure regulated, integral drip emitter, that is a unit -part - body component and cover component of the drip emitter produced by bi-component injection into one mold, wherein they are connected one to the other hence via integral hinge and constitutes one unified part. However, the invention is liable to be implemented also in a pressure regulated, integral drip emitter, which is assembled from two separate parts. Reference is made to Fig. No. 26. Fig. No. 26 is a view in perspective of exemplifying bi-component drip emitter 410 in accordance with the invention. We are referring to a two-part drip emitter - the body component 415 and the cover component 420 are separated parts one from the other (and assembled one to the other at a second stage), wherein the cover component 420 alone is fabricated by bi-components of relatively rigid material injection on the side of elastomer material sector 463.
Any professional would understand that also pressure regulated, bi- components, integral drip emitters, that are assembled from two separate parts as the example drip emitter 410, is given to fabrication by bi- components via multi material injection, and to assemble already inside the injection mold, and this by using mechanical manipulator which for example, would propel the cover component that was injected using bi-components (materials), as said, for affixing on the body component which was injected on its side by the same mold, but separated from it.
Reference is being made to Figures No. 27a - 27c. Figures No. 27a - 27c are schematic views in cross section depicting in sequence the stages following the injection molding of an additional exemplifying bi-component unit-part drip emitter 2710 in accordance with the invention of the type illustrated Fig. No. 13e - 13g, wherein the extracting of drip emitter 2710 from within mold 2705 provide for a space as required for pinning cover component 2720 to body component 2715 through the under-cut type of connectors, at a later stage. In this embodiment, a single pusher means 2739 that is positioned in an immobile assembly 2707 of the mold, is propelled for motion in the direction of arrow 2741 (see Fig. 27c), in a manner which extracts drip emitter 2710 from inside the immobile assembly of the mold, and enables the emptying of the mold and making it ready for an additional cycle of bi-component injection.
We mentioned hereinabove the 'core back' term as a technology which is applicable for producing the cover component portion of an emitter in accordance with the invention as a bi- component portion (made of both relatively rigid portion and an elastomeric material portion). The core back technology as said, is well known in the art and reference is being made to Figures No. 28a - 28b which are schematic views in cross section, depicting an example of a core back technology as implemented for the injection of the second material - the elastomeric material, in the manufacturing of bi-component unit-part drip emitter in accordance with the invention. The first "shot" of the relatively rigid material is depicted in Fig. 28a, wherein core 2801 is in a position closing the way to any of the relatively rigid material (depicted in full black) to invade the cavity occupied at this stage by the core, which is intended for the elastomer material. The second "shot" is depicted in fig. 28b wherein following the first "shot", core 2801 is retracted ("core back" ) moving in the direction of arrow 2803, and exposing cavity 2895 to be filled by the hot melted elastomer material to be injected through static nozzle (gate) 2807. As said above, any professional in the mold design filed will understand that the core might be shaped as a divider in a way that although blocking the hot melt of the first material entering the cavity allocate for the elastomer material, is not occupying the all space of the cavity before retreating (as the case in the depicted example). Thus, to the invention that is the subject matter of this patent application, different embodiments - as a pressure regulated, bi-components, integral drip emitter that might also be unit-part; like a drip irrigation hose (lateral) in which there is included such drip emitters; as an injection mold means that enables fabrication and assembly of the drip emitter as a unit- part drip emitter when still inside this injection mold; as a method that implements the fabrication of the drip emitter within this mold; and as specific elastomer material which is implemented for injecting in a pressure compensated, bi-components, integral drip emitter which is liable even to be a unit-part drip emitter as said. In every embodiment, the invention presents a solution to said required need, to reduce time and cost of the fabrication of discrete, pressure compensating integral drip emitters that are multi parts devices, and in a manner which does not sacrifice for this its required pressure compensating performance, and while facilitating the accuracy requirements that challenged the forming means utilized to form the opening at the hose's wall, in a manner that forms the opening exactly opposite the drip emitter's exit pool and would also enable forming the water exit opening at the hose's wall, in the configuration of a rather elongated slot.
While the applicant's teachings are described herein in conjunction with various embodiments or illustrative purposes, it is not intended that the applicant's teachings be limited to such embodiments. On the contrary, the applicant's teachings described and illustrated herein encompass various alternatives, modifications, and equivalents, without departing from the embodiments, the general scope of which is defined in the appended claims.
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