Background

[0001] Inflatable dunnage bags are used to stabilize and limit movement of cargo during transportation of cargo containers. A typical dunnage bag includes an airtight inner bladder enclosed within an outer bag that is formed from either paper or plastic. The dunnage bag also includes a valve that enables inflation and deflation of the inner bladder. The valve is attached to the outer bag (and in some cases the inner bladder) and in fluid communication with the interior of the inner bladder. Generally, after some or all of the cargo is loaded into a cargo container, an uninflated dunnage bag is positioned in a void between the cargo. An operator then connects an inflator to the valve of the dunnage bag and uses the inflator to direct pressurized air into the bladder of the dunnage bag to inflate the dunnage bag to a desired pressure. The inflated dunnage bag fills the void between the cargo to limit lateral movement of the cargo during transit.

Summary [0002] Various embodiments of the present disclosure provide a valve configured to enable the inflation and deflation of an inflatable object, such as a dunnage bag.

[0003] One embodiment of the valve of the present disclosure comprises a valve body defining a gas passageway therethrough and comprising a sealing surface; and a sealer mounted to the valve body and comprising a first sealing wing and a sealing surface. The first sealing wing is movable relative to the valve body between closed and open positions. When the first sealing wing is in its closed position, the sealing surface of the sealing ring sealingly engages the sealing surface of the valve body. A perimeter of the sealer is thinner than a portion of the sealer positioned radially inward from the perimeter.

[0004] Another embodiment of the valve of the present disclosure comprises a valve body defining a gas passageway therethrough and comprising a sealing surface; and a deformable sealer mounted to the valve body and comprising a central portion and sealing ring extending radially outward from and integrally formed with the central portion. The sealing ring comprises a sealing surface and an opposing outer surface. A first part of the central portion and a first part of the sealing ring form a first sealing wing and a second part of the central portion and a second part of the sealing ring for a second sealing wing. The sealer defines a first living hinge adjacent the first sealing wing and a second living hinge adjacent the second sealing wing. The first and second sealing wings are pivotable relative to the valve body and about the first and second living hinges, respectively, between respective closed and open positions. When the first and second sealing wings are in their closed positions, the sealing surface of the sealing ring sealingly engages the sealing surface of the valve body.

Brief Description of the Figures

[0005] Figures 1 and 2 are top and bottom perspective views of one example embodiment of a valve of the present disclosure in its closed configuration.

[0006] Figure 3 is an exploded bottom perspective view of the valve of Figure 1.

[0007] Figures 4A and 4B are cross-sectional views of the valve of Figure 1 in its closed and open configurations, respectively, taken substantially along line 4—4 of Figure 1.

[0008] Figure 5 is a top perspective view of the valve body of the valve of Figure 1.

[0009] Figures 6 and 7 are top and bottom plan views of the valve body of Figure 5.

[0010] Figure 8 is a cross-sectional view of the valve body of Figure 5 taken substantially along line 8—8 of Figure 6. [0011] Figures 9 and 10 are top and bottom perspective views of the sealer of the valve of Figure 1.

[0012] Figure 11 is a cross-sectional view of the sealer of Figure 9 taken substantially along line 11—11 of Figure 10. Detailed Description

[0013] While the systems, devices, and methods described herein may be embodied in various forms, the drawings show and the specification describes certain exemplary and non-limiting embodiments. Not all of the components shown in the drawings and described in the specification may be required, and certain implementations may include additional, different, or fewer components. Variations in the arrangement and type of the components; the shapes, sizes, and materials of the components; and the manners of connection of the components may be made without departing from the spirit or scope of the claims. Unless otherwise indicated, any directions referred to in the specification reflect the orientations of the components shown in the corresponding drawings and do not limit the scope of the present disclosure. Further, terms that refer to mounting methods, such as coupled, mounted, connected, etc., are not intended to be limited to direct mounting methods, but should be interpreted broadly to include indirect and operably coupled, mounted, connected, and like mounting methods. This specification is intended to be taken as a whole and interpreted in accordance with the principles of the present disclosure and as understood by one of ordinary skill in the art.

[0014] Various embodiments of the present disclosure provide a valve configured to enable the inflation and deflation of an inflatable object. The valve of the present disclosure is described below as being attached to (and usable to inflate/deflate) a dunnage bag (not shown) that includes an airtight plastic inner bladder enclosed within an outer paper or plastic (such as a polywoven) bag. This is merely one example inflatable object with which the valve may be used, and the valve may be used in connection with any other suitable inflatable object.

[0015] Referring now to the drawings, Figures 1—11 illustrate one example valve 10 of the present disclosure. As best shown in Figures 4A and 4B, the valve 10 has a longitudinal axis AVALVE and includes a valve body 100 and a sealer 200 mounted to the valve body 100 and movable between a closed configuration (Figure 4A) and an open configuration (Figure 4B). The valve body 100 defines a gas passageway therethrough (not labeled). When the sealer 200 is in its closed configuration, it sealingly engages the valve body 100 and prevents gas from flowing through the valve body 100 via the gas passageway. In this scenario the valve 100 is in a closed configuration. When the sealer 200 is in its open configuration, it does not (completely) sealingly engage the valve body 100 and enables gas to flow through the valve body 100 via the gas passageway. In this scenario the valve 100 is in an open configuration. Accordingly, the configuration of the sealer 200 relative to the valve body 100 controls whether the valve 100 is in its open configuration or its closed configuration and thus controls the flow of gas through the valve body 100 via the gas passageway.

[0016] The valve body 100 is best shown in Figures 5—8 and is configured to support the sealer 200, is configured to attach the valve 100 to the dunnage bag, and defines the gas passageway. The valve body 100 includes a generally annular wall 110; an annular lip 120; an annular retaining ring 130; an annular attachment flange 140; a sealer support 150, an annular sealing seat 160; and standoffs 170a, 170b, and 170c.

[0017] The wall 110 has a cylindrical inner surface 114 that, along with the gas-passage openings 150a— 150d defined by the stem supporter 150 (described below), defines the gas passageway. The lip 120 extends radially outwardly (relative to AVALVE) from the wall 110 near the top of the wall 110. The lip 120 is sized, shaped, positioned, and otherwise configured to be engaged by a suitable inflator (not shown) to removably attach the inflator to the valve body 100. The retaining ring 130 extends radially outwardly (relative to AVALVE) from the wall 110 near the bottom of the wall 110. The attachment flange 140 is axially below and spaced-apart (relative to AVALVE) from the retaining ring 130 and extends radially outwardly (relative to AVALVE) from the wall 110. The attachment flange 140 has opposing upper and lower surfaces 142 and 144.

[0018] The stem supporter 150 supports the sealer 200 and, along with the wall 110, defines the gas passageway. The stem supporter 150 includes an outer ring 152 extending radially inwardly (relative to AVALVE) from the inner surface 114 of the wall 110, a sealer-mounting arm 154 extending across the diameter of the outer ring 152 and through AVALVE, and first and second connecting arms 156 and 158 transverse to the sealer-mounting arm 154 and connecting the sealer-mounting arm 154 to the outer ring 152. Sealer-mounting openings 154a and 154b are defined through the sealer-mounting arm 154 and configured to enable the sealer 200 to be mounted to the sealer-mounting arm 154, as described below. The outer ring 152, the sealer mounting arm 154, and the connecting arms 156 and 158 define four radially spaced- apart gas-passage openings 150a, 150b, 150c, and 150d that, along with the wall 110, define the gas passageway. The sealing seat 160 is defined on an underside of the valve body 100, is generally flat, and is configured to be sealingly engaged by the sealer 200 (described below) when the sealer 200 is in its closed configuration to prevent gas from flowing through the valve body 100 via the gas passageway In certain embodiments the sealing seat 160 is polished to improve the sealing engagement of the sealer 200 with the sealing surface 160 (described below). The standoffs 170a— 170c are radially spaced-apart and extend axially downward (relative to AVALVE) from the lower surface 144 of the attachment flange 140. The standoffs are sized, positioned, and otherwise configured to prevent the inner bladder from being sucked onto the underside of the valve body and blocking the gas passageway during deflation of the dunnage bag.

[0019] In this example embodiment, the valve body 100 is a one-piece molded plastic component such that the wall 110, the lip 120, the retaining ring 130, the attachment flange 140, the sealer support 150, the sealing seat 160, and the standoffs 170a— 170c are integrally formed with one another. In other embodiments the valve body may be formed from via any suitable manufacturing process, from any suitable material, and from any suitable quantity of pieces connected to one another.

[0020] The sealer 200 is mounted to the valve body 100 and generally forms first and second sealer flaps 200a and 200b pivotable about respective living hinges (described below) between open and closed positions to control whether the sealer 200 — and by extension the valve 10 — is in its open configuration or its closed configuration, thereby controlling the flow of gas through the valve body 100 via the gas passageway. As best shown in Figures 4 and 9—11, the sealer 200 includes a generally disc-shaped central portion 210, an annular sealing ring 220, and two mounting projections 230a and 230b. Certain portions of the central portion 210 and the sealing ring 220 form the first sealer flap 200a, while other portions of the central portion 210 and the sealing ring 220 form the second sealer flap 200b.

[0021] The central portion 210 is shaped and otherwise configured such that the sealer flaps 200a and 200b are pivotable between their respective open and closed positions, as described below. Specifically, the central portion 210 includes a rib 212 extending across the diameter of the central portion 210 (and intersecting AVALVE). The rib 212 has a thickness tl and has a generally semicircular cross-section (though its cross-section may take any suitable shape). First and second recessed portions 214a and 214b are positioned on either side of the rib 212 and both have a thickness t2 that is less than tl. A first body portion 216a is positioned adjacent the first recessed portion 214a, and a second body portion 216b is positioned adjacent the second recessed portion 214a. The first and second body portions 216a and 216b are generally semicircular (best shown in Figure 10) and have a thickness t3 that is greater than t2 (and, in this example embodiment, greater than tl). By virtue of their reduced thickness relative to the rib 212 and the first and second body portions 216a and 216b, the first and second recessed portions 214a and 214b act as living hinges that enable the first and second sealer wings 200a and 200b to pivot, as described below. In other embodiments the central portion does not include the rib and includes one recessed portion extending between the first and second body portions.

[0022] The sealing ring 220 is configured to sealingly engage the sealing surface 160 of the valve body 110 to prevent the flow of gas through the gas passageway. The sealing ring 220 includes a generally flat sealing surface 222 and an opposing outer surface 224. As best shown in Figure 11, the thickness of the sealing ring 220 varies moving radially outward from the central portion 210 (and radially outward from AVALVE). Specifically, the sealing ring 220 tapers from a thickness t4 adjacent the central portion 210 to a thickness t5 that is less than t4 at the perimeter of the sealing ring 220. In this example embodiment, the sealing ring 220 does not taper at a constant rate moving radially outward from the central portion 210 (though it may do so in other embodiments).

[0023] As best shown in Figure 11, the first body portion 216a of the central portion 210 and the portion of the sealer 200 on one side of the rib 212 (and on one side of AVALVE) together form the first sealer wing 200a. The second body portion 216a of the central portion 210 and the portion of the sealer 200 on the other side of the rib 212 (and on the other side of AVALVE) together form the second sealer wing 200b. By virtue of the sealer 200 being formed from a deformable material (such as an elastomeric material) and of the first and second recessed portions 214a and 214b forming living hinges, the first and second sealer wings 200a and 200b are pivotable about these living hinges between their respective closed positions (Figure 4A) in which the sealing surface 222 of the sealing ring 220 sealingly engages the sealing surface 160 of the valve body 110 and their respective open positions (Figure 4B) in which the sealing surface 222 is (mostly or entirely) disengaged from the sealing surface 160. In this example embodiment, the sealer 200 is configured (and in particular, is made of a suitable material) such that the first and second sealer wings 200a and 200b are biased to their closed positions, though this may not be the case in other embodiments.

[0024] The mounting projections 230a and 230b extend axially upwardly (relative to AVALVE) from the central portion 210 and generally above the rib 212. The mounting projections 230a and 230b include respective cylindrical shafts 232a and 232b and respective frustoconical heads 234a and 234b atop the shafts 232a and 232b.

[0025] In this example embodiment, the sealer 200 is a one-piece molded elastomeric (such as silicon rubber) component such that central portion 210, the sealing ring 220, and the mounting projections 230a and 230b are integrally formed with one another. In other embodiments the sealer may be formed from via any suitable manufacturing process, from any suitable material, and from any suitable quantity of pieces connected to one another.

[0026] To assemble the valve 10, the heads 234a and 234b of the mounting projections 230a and 230b of the sealer 200 are inserted into and through the sealer mounting openings 154a and 154b of the sealer-mounting arm 154 of the sealer support 150 of the valve body 100. Thee frustoconical shape of the heads prevents the sealer 200 from being unintentionally removed from the valve body 100.

[0027] To attach the valve 10 to the dunnage bag (not shown), the upper surface 142 of the attachment flange 140 of the valve body 100 is attached to an inner surface of the inner bladder of the dunnage bag in an airtight manner, such as via heat sealing. The inner bladder and the outer bag are positioned between the attachment flange 140 and the retaining ring 130 of the valve body 100. Accordingly, when the valve 10 is attached to the dunnage bag, the attachment flange 140 and the portions of the valve body 100 below it are inside the inner bladder, and the portions of the valve body 100 above the retaining ring 130 are generally external to the dunnage bag.

[0028] To inflate the dunnage bag, an operator attaches an inflator (not shown) to the lip 120 of the valve body 100 of the valve 10. The operator then switches the inflator on. The inflator directs pressurized gas into the gas passageway. As shown in Figure 4B, this forces the first and second sealer wings 200a and 200b of the sealer 200 to move from their respective closed positions to their respective open positions, enabling the gas to flow into and inflate the inner bladder via the gas passageway. Once the pressure inside the inner bladder reaches a desired pressure, the operator switches the inflator off. When this occurs, the air pressure inside the inner bladder forces the first and second sealer wings 200a and 200b to move to their respective closed positions, thereby causing the sealing surface 222 of the sealing ring 220 of the sealer 200 to sealingly engage the sealing surface 160 of the valve body to prevent air from leaking out of the inner bladder via the gas passageway. To deflate the dunnage bag, in certain embodiments the operator attaches a deflator cap (not shown) to the lip 120 of the valve body 100. The deflator cap includes projections that extend into the gas passageway and force the first and second sealer 200a and 200b to move from their respective closed positions to their respective open positions, which enables the gas to escape the inner bladder via the gas passageway.

[0029] The valve of the present disclosure improves upon known valves. Using living hinges to enable the sealing wings to pivot between their closed and open positions based on pressure differential renders the valve cheaper to produce and easier to assemble than certain known valves that construct hinges using several intricate components. For instance, unlike many known valves, the valve of the present disclosure does not include a metal spring to bias the valve to its closed configuration or spring-retaining components to retain the spring in place. It also eliminates the need for a sealing cap (and associate gasket) to prevent air leakage. This simplifies the design and cost with the added bonus of reduced waste. Additionally, the cross-sectional profile of the sealer ensures the sealer adequately seals the inner bladder in both low- pressure and high-pressure scenarios. Specifically, the fact that the sealer is relatively thin near its perimeter ensures that the sealer will sealingly engage the valve body even at relatively low pressures because minimal force is required to retain the sealer in its closed configuration. And the fact that the sealer is relatively thick in the center ensures that the center of the sealer will not bulge outward at relatively high pressures and cause the sealer to break its seal with the valve body.