Penetrable membrane structure and coupler incorporating the same in a fluid path
A penetrable membrane structure for incorporation in a flow path of a coupling includes a body having a first face and an opposite second face, one of the first and second faces including at least one major portion and at least one minor portion. The major portion includes a major thickness between the first and second faces that is greater than a minor thickness of the minor portion, and the minor portion forms a channel transversely extending into one of the first or second faces, the channel of the minor portion including sidewalls each adjacent to the major portion. The sidewalls of the channel extend toward each other in a converging configuration.
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This application claims the benefit of U.S. Patent Provisional Application Ser. No. 60/608,792, filed on Sep. 9, 2004 and entitled “Penetrable Membrane Structure and Coupler Incorporating the Same in a Fluid Path,” the entirety of which is hereby incorporated by reference.
TECHNICAL FIELDEmbodiments of the invention relate to penetrable membrane structures for sealing a fluid path in a coupling before use and being puncture ready for enabling flow through the fluid path during use. More particularly, embodiments of the present invention relate to couplers having a penetrable membrane in a fluid path with the principles described.
BACKGROUNDThe use of a penetrable membrane as applied to various products is well known. In particular, penetrable membranes have been used in various disposable food product packages such as, for example, juice containers and the like. Typically, such penetrable membranes are disposed over a container opening to seal the same. The penetrable membrane may be broken by using another instrument to puncture through the penetrable membrane, thereby allowing access to contents in the container.
U.S. Pat. No. 4,436,125 to Blenkush, commonly assigned with the instant application herein and incorporated by reference, discloses a coupling having an insert that includes a penetrable membrane seal 28.
Another configuration of an insert 10 with a penetrable membrane incorporated therein is provided in the penetrable membrane structure 20 of
As shown in
Dimensionally, the major portions 22A each may include sections being spaced about 60 degrees apart, and a molded thickness of 0.010±0.001 or 0.002 inches. The minor portions 22B may include a molded thickness of 0.006±0.001 inches. The bridge portions 24 each typically form a 30 degree wedge extending outward from the second side 23. The bridge portions 24 each may include a width of about 0.009 inches and a height of about 0.019 inches. The center portion 28 may include a diameter of about 0.056 inches and a thickness of about 0.034 inches. The central depression 26 may include a diameter of about 0.080 inches and a thickness being substantially similar to the thickness of the minor portions 22B. The penetrable membrane diameter 20 may include a total diameter of about 0.257 inches.
In the injection molding process forming the penetrable membrane 20, a mold tool 30 illustrated in
The above penetrable membrane arrangements, however, have several limitations. Such limitations in these previous designs include manufacturing shortcomings that also have resulted in performance problems when such penetrable membranes are in use.
For example, membrane thickness through the thinnest areas (the pie shaped cuts designed to tear) has been limited to 0.007 inches, when using the LDPE material. The force required for rupturing the membrane with, for example, a mating coupler body, has exceeded 20 lbs. In such bag-in-box product applications, such a required force can be considered excessive.
Such previous designs, as described above, have encountered problems during the injection molding process, wherein the minor portions 22B and central depression 26 included excessive distances for the injection molding to form the thinner wall portions. The LDPE material has had a tendency to cool and solidify as it flowed under pressure into the thin wall areas of the membrane, such as the minor portions 22B and the central depression. Such a membrane structure has caused incomplete molding and pinhole leaks in the membrane at the thin wall areas when using typical molding techniques. In order to promote flow of the LDPE material during the molding process and compensate for these larger distances, excessively high temperatures for the LDPE material (370 degrees F.) and mold tool temperatures (120 degrees F.) were required. Likewise, injecting, packing and holding pressures have become excessive.
As a result, such high temperatures and pressures can have the effect of burning the LDPE material, degrading the material, and may cause excessive flash on the finished part. Additionally, high pressures and temperatures cause unanticipated thermal and mechanical distortion of the mold tool, and can result in dimensional non-conformance of the finished part. Finally, the requirement of higher temperatures and pressures have required longer molding cycle times, which results lower production rates and increased costs of the molded article.
SUMMARYEmbodiments of the invention relate to penetrable membrane structures for sealing a fluid path in a coupling before use and being puncture ready for enabling flow through the fluid path during use. More particularly, embodiments of the present invention relate to couplers having a penetrable membrane in a fluid path with the principles described.
According to one aspect, a penetrable membrane structure for incorporation in a flow path of a coupling includes a body having a first face and an opposite second face, one of the first and second faces including at least one major portion and at least one minor portion, the major portion including a major thickness, defined between the first and second faces, that is greater than a minor thickness of the minor portion, and the minor portion forming a channel transversely extending into one of the first or second faces, the channel of the minor portion including sidewalls each adjacent to the major portion. The sidewalls of the channel extend toward each other in a converging configuration.
According to another aspect, an insert configured to be coupled to a coupling device includes an insert body including a first end and a second end and defining a flow passage therethrough, the first end including a fitment structure. The insert further includes a penetrable membrane coupled at an opening defined at the second end of the insert body, the penetrable membrane being configured to seal the opening and to be punctured by the coupling device to allow flow through a fluid path between the insert and the coupling device. The penetrable membrane includes a body having a first face and an opposite second face, one of the first and second faces including at least one major portion and at least one minor portion, the major portion including a major thickness, defined between the first and second faces, that is greater than a minor thickness of the minor portion, and the minor portion forming a channel transversely extending into one of the first or second faces, the channel of the minor portion including sidewalls each adjacent to the major portion. The sidewalls extend toward each other in a converging configuration.
According to another aspect, a method of forming a penetrable membrane structure includes: providing a mold tool, the mold tool comprising a plurality of major mold sections each separated by a minor mold section, wherein each of the minor mold sections extends to a single central junction, and wherein each of the minor mold sections includes first and second surfaces converging at an angle with respect to one another; and injecting plastic material to form the penetrable membrane structure using the mold tool.
These and other various advantages and features of novelty are pointed out in the following detailed description. Reference should also be made to the drawings, which form a further part hereof, and to accompanying descriptive matter, in which there are illustrated and described specific example embodiments.
DESCRIPTION OF THE DRAWINGSLike reference numbers generally indicate corresponding elements in the Figures.
One example embodiment of a penetrable membrane structure 120 is provided in
In
As shown in
In the illustrated embodiments, the major portions 122A each may include sections spaced about 60 degrees apart, and a molded thickness of 0.020±0.002 inches. The minor portions 122B may include a molded thickness of 0.003±0.001 inches. The thickness of the minor portions 122B is defined from an endpoint of the converging sidewalls 124 to the other of the first or second face. The channels of the minor portions 122A may include wedge portions formed at a 90 degree angle. The penetrable membrane structure may include a total diameter of about 0.257 inches. In another example, the penetrable membrane structure may include a total diameter of about between 1.22 and 1.26 inches.
In the injection molding process forming the penetrable membrane 120, a mold tool 230 illustrated in
The penetrable membrane structure 120 provides a membrane thickness through the thinnest walls that can be achieved as low as 0.002 inches, while using molding process parameters that generally fall within a material manufacturer's recommendations. Achieving a thinner wall of 0.003±0.001 inches compared to 0.007 inches in previous designs is desirable since it reduces the force required to rupture the membrane. A reduced force is desirable since it makes it easier for a user to interconnect a mating coupler or connector body. In one example, the force required to rupture the redesigned membrane is approximately 14 lbs., providing for at least a 30% reduction in force as compared to previous designs. Material and tool temperatures may average 50 degrees F. lower than that required in previous designs.
The penetrable membrane structure 120 further avoids pinhole leaks, and the risk of burning the material during injection molding is substantially reduced. Additionally, the cycle time can be reduced by ⅓ (as much as from 30 seconds to 20 seconds), thereby reducing the cost of manufacturing the membrane structure. The penetrable membrane structure provides improved quality due to the greater consistency of the molded parts that are not subjected to the stresses of higher temperatures and pressures. Since the mold tool runs within temperatures contemplated for the mold tool, the penetrable membrane structure can conform to desired dimensional specifications.
It is noted that, although the penetrable membrane as described herein is suited for use in an insert for a coupling device, penetrable membrane structures in accordance with the principles of the present invention may be suitable for incorporation into larger assemblies, including but not limited to a fluid dispensing system, such as but not limited to bag-in-box dispensing applications. Further, the penetrable membrane structure is also suitable for incorporation as a puncture seal in couplings providing part-free sealing surfaces.
The above specification provides a complete description of the composition, manufacture and use of the improved penetrable membrane in accordance with the principles of the present invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.
Claims
1. A penetrable membrane structure for incorporation in a flow path of a coupling, the penetrable membrane structure comprising:
- a body having a first face and an opposite second face, one of the first and second faces including at least one major portion and at least one minor portion, the major portion including a major thickness, defined between the first and second faces, that is greater than a minor thickness of the minor portion, and the minor portion forming a channel transversely extending into one of the first or second faces, the channel of the minor portion including sidewalls each adjacent to the major portion;
- wherein the sidewalls of the channel extend toward each other in a converging configuration.
2. The penetrable membrane structure of claim 1, further comprising a plurality of major portions.
3. The penetrable membrane structure of claim 1, further comprising a plurality of minor portions, wherein each of the minor portions extends to a central junction of the body of the penetrable membrane structure.
4. The penetrable membrane structure of claim 1, wherein the major thickness of the major portion is 0.012±0.002 inches.
5. The penetrable membrane structure of claim 1, wherein the minor thickness of the minor portion is 0.003±0.001 inches.
6. The penetrable membrane structure of claim 1, wherein the minor thickness of the minor portion is defined from an end point of the converging sidewalls extending into one of the first or second face to the other one of the first and second faces.
7. The penetrable membrane structure of claim 1, wherein the sidewalls of the channel are formed as converging beveled wall portions.
8. The penetrable membrane structure of claim 1, wherein the sidewalls of the channel converge to a single point in a wedge shape.
9. The penetrable membrane structure of claim 8, wherein one of the sidewalls of the wedge shape extends at a ninety degree angle with respect to another of the sidewalls.
10. An insert configured to be coupled to a coupling device, the insert comprising:
- an insert body including a first end and a second end and defining a flow passage therethrough, the first end including a fitment structure; and
- a penetrable membrane coupled at an opening defined at the second end of the insert body, the penetrable membrane being configured to seal the opening and to be punctured by the coupling device to allow flow through a fluid path between the insert and the coupling device, wherein the penetrable membrane includes: a body having a first face and an opposite second face, one of the first and second faces including at least one major portion and at least one minor portion, the major portion including a major thickness, defined between the first and second faces, that is greater than a minor thickness of the minor portion, and the minor portion forming a channel transversely extending into one of the first or second faces, the channel of the minor portion including sidewalls each adjacent to the major portion; wherein the sidewalls extend toward each other in a converging configuration.
11. The insert of claim 10, wherein the penetrable membrane structure further comprises:
- a plurality of major portions; and
- a plurality of minor portions, wherein each of the minor portions extends to a central junction of the body of the penetrable membrane structure.
12. The insert of claim 10, wherein the major thickness of the major portion is 0.012±0.002 inches.
13. The insert of claim 10, wherein the minor thickness of the minor portion is 0.003±0.001 inches.
14. The insert of claim 13, wherein the sidewalls of the channel of the penetrable membrane structure converge to a single point in a wedge shape, wherein one of the sidewalls of the wedge shape extends at a ninety degree angle with respect to another of the sidewalls.
15. The insert of claim 10, wherein the sidewalls of the channel of the penetrable membrane structure converge to a single point in a wedge shape, wherein one of the sidewalls of the wedge shape extends at a ninety degree angle with respect to another of the sidewalls.
16. A method of forming a penetrable membrane structure, the method comprising:
- providing a mold tool, the mold tool comprising a plurality of major mold sections each separated by a minor mold section, wherein each of the minor mold sections extends to a single central junction, and wherein each of the minor mold sections includes first and second surfaces converging at an angle with respect to one another; and
- injecting plastic material to form the penetrable membrane structure using the mold tool.
17. The method of claim 16, wherein providing further comprises forming each of the minor mold sections of the mold tool so that a minor thickness of the penetrable membrane structure is 0.003±0.001 inches.
18. The method of claim 17, wherein providing further comprises forming each of the minor mold sections so that the first surface converges at a ninety degree angle with respect to the second surface.
19. The method of claim 16, wherein providing further comprises forming each of the minor mold sections so that the first surface converges at a ninety degree angle with respect to the second surface.
20. The method of claim 16, wherein injecting further comprises injecting a low-density polyethylene to form the penetrable membrane structure using the mold tool.
Type: Application
Filed: Sep 9, 2005
Publication Date: Mar 9, 2006
Applicant: Colder Products Company (St. Paul, MN)
Inventor: Charles deCler (Edina, MN)
Application Number: 11/223,091
International Classification: B65B 1/04 (20060101);