BACKGROUND

The present disclosure relates generally to a co-injected valve assembly utilized for the dispensing of flowable product from a dispensing container. A number of consumer goods are sold in such dispensing containers, including, but not limited to, foodstuffs (e.g., ketchup, mustard, honey), personal care products (e.g., shampoos, liquid soaps, lotions), and other household products (e.g., detergents, automotive oils). Conventional valve assemblies for these dispensing containers often include silicone valve heads, which present several drawbacks. Silicone is unable to be co-injected to a strong frame or holder material in an injection molding process, and it is not recyclable. A valve assembly that is recyclable and able to manufactured via a co-injection molding process would therefore be useful.

The co-injected valve assembly of the present disclosure is configured to open reliably when force is applied to the dispensing container. The co-injected valve assembly is further configured to be self-closing in that it closes in a reliable and sealed fashion in the absence of force applied to the dispensing container. The molding process for the valve assembly generally includes the sequential injection of multiple polymeric materials (e.g., thermoplastic elastomers, polypropylene) into multiple cavities within a single mold to form an inseparable valve assembly including a valve head supported by a valve frame.

SUMMARY

One implementation of the present disclosure is a valve assembly for a dispensing container. The valve assembly includes a closure body detachably coupled to a co-injected valve. The closure body includes a main closure body coupled to a closure cap via a flexible hinge. The co-injected valve includes a valve head and a valve frame. The valve head includes a valve head portion with multiple valve head slits, a sleeve portion, and a peripheral sealing flange. The valve frame is permanently coupled to the valve head and includes a radial ledge and a radial wall that support the peripheral sealing flange of the valve head. The co-injected valve is fabricated via a two-step injection molding process. The first step includes fabricating the valve frame from a first injection material, and the second step includes fabricating the valve member from a second injection material.

In some embodiments, the first injection material is polypropylene. In other embodiments, the second injection material is a thermoplastic elastomer.

In some embodiments, the valve head slits are formed via a mechanical cutting process. In other embodiments, the valve head slits are formed via a laser cutting process.

In some embodiments, the valve frame further includes an access window configured to permit passage of an injection molding nozzle used to deposit the second injection material.

In some embodiments, the closure body is coupled to the co-injected valve via at least one of a snap fit assembly process and an ultrasonic assembly process.

In some embodiments, the closure cap further includes a stopper configured to support the valve head when the closure body is in a closed cap position.

In some embodiments, the closure body further includes threads configured to threadably couple the closure body to the dispensing container.

Another implementation of the present disclosure is a co-injection molded valve. The co-injection molded valve includes a valve head and a valve frame. The valve head includes a valve head portion with valve head slits, a sleeve portion, and a peripheral sealing flange. The valve frame is permanently coupled to the valve head and includes a radial ledge and a radial wall configured to support the peripheral sealing flange of the valve head. The co-injected molded valve is fabricated via a two-step injection molding process. The first step includes fabricating the valve frame from a first injection material, and the second step includes fabricating the valve head from a second injection material.

In some embodiments, the first injection material is polypropylene. In other embodiments, the second injection material is a thermoplastic elastomer.

In some embodiments, the valve head slits are formed via a mechanical cutting process. In other embodiments, the valve head slits are formed via a laser cutting process.

In some embodiments, the radial wall includes a retention notch configured to couple the co-injection molded valve to a dispensing container closure body via at least one of a snap fit assembly process and an ultrasonic assembly process.

Yet another implementation of the present disclosure is a method of manufacturing a co-injection molded valve. The method includes depositing a first injection material from a first injection nozzle into a first mold cavity to form a valve frame. The valve frame includes a radial ledge and a radial wall extending from the radial ledge. The method also includes depositing a second injection material from a second injection nozzle into a second mold cavity to form a valve head. The valve head includes a valve head portion, a sleeve portion, and a peripheral sealing flange.

In some embodiments, the first injection material is polypropylene. In other embodiments, the second injection material is a thermoplastic elastomer.

In some embodiments, the valve frame further includes an access window. The access window is configured to permit passage of the second injection nozzle through the valve frame.

In some embodiments, the method further includes forming valve slits in the valve head portion via at least one of a laser cutting process and a mechanical cutting process.

