초록 ▼

Valves and methods for manufacturing the valves are disclosed. The valves are formed from a plurality of flexible polymer layers. A radio frequency bonding process, or the like, is utilized to form welds between the various layers. In general, a sub-assembly is formed that includes a valve layer bon

Valves and methods for manufacturing the valves are disclosed. The valves are formed from a plurality of flexible polymer layers. A radio frequency bonding process, or the like, is utilized to form welds between the various layers. In general, a sub-assembly is formed that includes a valve layer bonded to a substrate layer. The sub-assembly is bonded to a second element such that a channel is formed between the valve layer and the second element. The channel includes an inlet, an outlet, and a pair of weld beads located in the inlet that place the inlet in an open configuration.

대표청구항 ▼

1. A method of manufacturing a valve from a plurality of flexible polymer layers, the method comprising steps of:constructing a first sub-assembly by forming a first substrate weld between a first valve layer and a first substrate layer, said first valve layer having an inlet portion and an outlet p

1. A method of manufacturing a valve from a plurality of flexible polymer layers, the method comprising steps of:constructing a first sub-assembly by forming a first substrate weld between a first valve layer and a first substrate layer, said first valve layer having an inlet portion and an outlet portion; aligning said first sub-assembly with a second element such that said first valve layer is positioned between said first substrate layer and said second element; and bonding said first valve layer with said second element by forming a pair of spaced channel welds between said first valve layer and said second element, said channel welds defining a channel located between said first valve layer and said second element and between said channel welds, said channel having an inlet adjacent to said inlet portion and an outlet adjacent to said outlet portion. 2. The method of manufacturing a valve of claim 1, further including a step of forming a second sub-assembly to be said second element, said second sub-assembly being constructed by forming a second substrate weld between a second valve layer and a second substrate layer.3. The method of manufacturing a valve of claim 1, further including a step of forming said second element from a second substrate layer.4. The method of manufacturing a valve of claim 1, wherein said step of constructing said first sub-assembly includes locating said first substrate weld adjacent to said inlet portion.5. The method of manufacturing a valve of claim 1, wherein said step of constructing said first sub-assembly includes forming said first substrate weld with an RF welding process having an RF die.6. The method of manufacturing a valve of claim 5, wherein said step of constructing said first sub-assembly includes inhibiting formation of weld beads adjacent to said first substrate weld by incorporating a weld flow director into said RF die.7. The method of manufacturing a valve of claim 1, wherein said step of bonding said first valve layer with said second element includes spacing said channel welds away from said outlet portion, said first valve layer thereby being unbonded to said second element at said outlet portion.8. The method of manufacturing a valve of claim 1, wherein said step of bonding said first valve layer with said second element includes forming said channel welds with an RF welding process having a pair of RF dies.9. The method of manufacturing a valve of claim 8, wherein said step of bonding said first valve layer with said second element includes inhibiting formation of weld beads adjacent to at least a portion of said channel welds by incorporating a pair of weld flow directors into said pair of RF dies.10. The method of manufacturing a valve of claim 9, wherein said step of bonding said first valve layer with said second element includes facilitating formation of a pair of inlet weld beads in said inlet by locating a gap in an area of said pair of weld flow directors corresponding with said inlet, said inlet weld beads placing said inlet in an open configuration.11. The method of manufacturing a valve of claim 1, wherein said step of bonding said first valve layer with said second element includes forming of a pair of inlet weld beads in said inlet.12. The method of manufacturing a valve of claim 1, wherein said step of constructing said sub-assembly includes positioning a blocking material between said first valve layer said first substrate layer, said blocking material preventing formation of additional bonds between said first valve layer and said first substrate layer during said step of bonding said first valve layer with said second element.13. The method of manufacturing a valve of claim 1, wherein said step of bonding said first valve layer with said second element includes joining said channel welds at said outlet portion, and forming an outlet aperture in said first valve layer.14. A method of manufacturing a valve from a plurality of flexible polymer layers, including a first valve layer, a first substrate layer, a second valve layer, and a second substrate layer, the method comprising steps of:constructing a first sub-assembly by forming a first substrate weld between said first valve layer and said first substrate layer, said first valve layer having a first inlet portion and a first outlet portion; constructing a second sub-assembly by forming a second substrate weld between said second valve layer and said second substrate layer, said second valve layer having a second inlet portion and a second outlet portion; aligning said first sub-assembly with said second sub-assembly such that said first valve layer is overlaying and adjacent to said second valve layer and said substrate layers encompass said valve layers; and bonding said first valve layer with said second valve layer by forming a pair of spaced channel welds between said valve layers, said channel welds defining a channel located between said valve layers and between said channel welds, said channel having an inlet adjacent to said inlet portions and an opposite outlet adjacent to said outlet portions. 15. The method of manufacturing a valve of claim 14, wherein said steps of constructing said sub-assemblies include locating said substrate welds adjacent to said inlet portions of said valve layers.16. The method of manufacturing a valve of claim 14, wherein said steps of constructing said sub-assemblies include forming said substrate welds with an RF welding process having an RF die.17. The method of manufacturing a valve of claim 16, wherein said steps of constructing said sub-assemblies include inhibiting formation of weld beads adjacent to said substrate welds by incorporating a weld flow director into said RF die.18. The method of manufacturing a valve of claim 14, wherein said step of aligning said sub-assemblies includes locating said first inlet portion adjacent to said second inlet portion, and locating said first outlet portion adjacent to said second outlet portion.19. The method of manufacturing a valve of claim 14, wherein said step of bonding said first valve layer with said second valve layer includes spacing said channel welds away from said outlet portions, said valve layers thereby being unbonded to each other at said outlet portions.20. The method of manufacturing a valve of claim 14, wherein said step of bonding said first valve layer with said second valve layer includes forming said channel welds with an RF welding process having a pair of RF dies.21. The method of manufacturing a valve of claim 20, wherein said step of bonding said first valve layer with said second valve layer includes inhibiting formation of weld beads adjacent to at least a portion of said channel welds by incorporating a pair of weld flow directors into said pair of RF dies.22. The method of manufacturing a valve of claim 21, wherein said step of bonding said first valve layer with said second valve layer includes facilitating formation of a pair of inlet weld beads in said inlet by locating a gap in an area of said pair of weld flow directors corresponding with said inlet, said inlet weld beads placing said inlet in an open configuration.23. The method of manufacturing a valve of claim 14, wherein said steps of constructing said sub-assemblies include positioning a blocking material between said valve layers and said substrate layers, said blocking material preventing formation of additional bonds between said valve layers and said substrate layers during said step of bonding said first valve layer with said second valve layer.24. The method of manufacturing a valve of claim 14, wherein said step of bonding said first valve layer with said second valve layer includes joining said channel welds at said outlet portions, and forming an outlet aperture in said first valve layer.25. A method of manufacturing a valve from a plurality of flexible polymer layers, including a first valve layer, a first substrate layer, a second valve layer, and a second substrate layer, the method comprising steps of:constructing a first sub-assembly by forming a first substrate weld between said first valve layer and said first substrate layer, said first valve layer having a first inlet end and an opposite first outlet end; constructing a second sub-assembly by forming a second substrate weld between said second valve layer and said second substrate layer, said second valve layer having a second inlet end and an opposite second outlet end; aligning said first sub-assembly with said second sub-assembly such that said first valve layer is overlaying and adjacent to said second valve layer and said substrate layers encompass said valve layers; and bonding said first valve layer with said second valve layer by forming a pair of spaced channel welds between said valve layers and forming a pair of inlet weld beads, said channel welds defining a channel located between said valve layers and between said channel welds, said channel having an inlet adjacent to said inlet ends and an opposite outlet adjacent to said outlet ends, said inlet weld beads being located within said inlet to place said inlet in an open configuration. 26. The method of manufacturing a valve of claim 25, wherein said steps of constructing said sub-assemblies include locating said substrate welds adjacent to said inlet ends of said valve layers.27. The method of manufacturing a valve of claim 25, wherein said steps of constructing said sub-assemblies include forming said substrate welds with an RF welding process having an RF die.28. The method of manufacturing a valve of claim 27, wherein said steps of constructing said sub-assemblies include inhibiting formation of weld beads adjacent to said substrate welds by incorporating a weld flow director into said RF die.29. The method of manufacturing a valve of claim 25, wherein said step of aligning said sub-assemblies includes locating said first inlet end adjacent to said second inlet end, and locating said first outlet end adjacent to said second outlet end.30. The method of manufacturing a valve of claim 25, wherein said step of bonding said first valve layer with said second valve layer includes spacing said channel welds away from said outlet ends, said valve layers thereby being unbonded to each other at said outlet ends.31. The method of manufacturing a valve of claim 25, wherein said step of bonding said first valve layer with said second valve layer includes forming said channel welds with an RF welding process having a pair of RF dies.32. The method of manufacturing a valve of claim 31, wherein said step of bonding said first valve layer with said second valve layer includes inhibiting formation of weld beads adjacent to at least a portion of said channel welds by incorporating a pair of weld flow directors into said pair of RF dies, said weld flow directors having a gap in an area of said pair of weld flow directors corresponding with said inlet to form said inlet weld beads.33. The method of manufacturing a valve of claim 25, wherein said steps of constructing said sub-assemblies include positioning a blocking material between said valve layers and said substrate layers, said blocking material preventing formation of additional bonds between said valve layers and said substrate layers during said step of bonding said first valve layer with said second valve layer.34. The method of manufacturing a valve of claim 25, wherein said step of bonding said first valve layer with said second valve layer includes joining said channel welds at said outlet end, and forming an outlet aperture in said first valve layer.35. A method of manufacturing a valve from a plurality of flexible polymer layers, including a first valve layer, a first substrate layer, a second valve layer, and a second substrate layer, the method comprising steps of:constructing a first sub-assembly by forming a first substrate weld between said first valve layer and said first substrate layer with a first RF die that includes a first weld flow director to inhibit formation of weld beads adjacent to said first substrate weld, said first valve layer having a first inlet end and an opposite first outlet end; constructing a second sub-assembly by forming a second substrate weld between said second valve layer and said second substrate layer with a second RF die that includes a second weld flow director to inhibit formation of weld beads adjacent to said second substrate weld, said second valve layer having a second inlet end and an opposite second outlet end; aligning said first sub-assembly with said second sub-assembly such that said first valve layer is overlaying and adjacent to said second valve layer and said substrate layers encompass said valve layers; and bonding said first valve layer with said second valve layer by forming a pair of spaced channel welds between said valve layers and forming a pair of inlet weld beads, said channel welds and said inlet weld beads being formed by a pair of RF dies having a pair of weld flow directors, said channel welds defining a channel located between said valve layers and between said channel welds, said channel having an inlet adjacent to said inlet ends and an opposite outlet adjacent to said outlet ends, said inlet weld beads being located within said inlet to place said inlet in an open configuration, said weld flow directors having a gap in an area of said pair of weld flow directors corresponding with said inlet to form said inlet weld beads. 36. The method of manufacturing a valve of claim 35, wherein said steps of constructing said sub-assemblies include locating said substrate welds adjacent to said inlet ends of said valve layers.37. The method of manufacturing a valve of claim 35, wherein said step of aligning said subassemblies includes locating said first inlet end adjacent to said second inlet end, and locating said first outlet end adjacent to said second outlet end.38. The method of manufacturing a valve of claim 35, wherein said step of bonding said first valve layer with said second valve layer includes spacing said channel welds away from said outlet ends, said valve layers thereby being unbonded to each other at said outlet ends.39. The method of manufacturing a valve of claim 35, wherein said steps of constructing said sub-assemblies include positioning a blocking material between said valve layers and said substrate layers, said blocking material preventing formation of additional bonds between said valve layers and said substrate layers during said step of bonding said first valve layer with said second valve layer.40. The method of manufacturing a valve of claim 35, wherein said step of bonding said first valve layer with said second valve layer includes joining said channel welds at said outlet end, and forming an outlet aperture in said first valve layer.41. A method of manufacturing a valve from a plurality of flexible polymer layers, including a valve layer, a first substrate layer, and a second substrate layer, the method comprising steps of:constructing a sub-assembly by forming a substrate weld between said valve layer and said first substrate layer, said valve layer having an inlet portion and an outlet portion; aligning said sub-assembly with said second substrate layer such that said valve layer is positioned between said substrate layers; and bonding said valve layer with said second substrate layer by forming a pair of spaced channel welds between said valve layer and said second substrate layer, said channel welds defining a channel located between said valve layer and said second substrate layer and between said channel welds, said channel having an inlet adjacent to said inlet portion and an opposite outlet adjacent to said outlet portion. 42. The method of manufacturing a valve of claim 41, wherein said step of constructing said sub-assembly includes locating said substrate weld adjacent to said inlet portion of said valve layer.43. The method of manufacturing a valve of claim 41, wherein said step of constructing said sub-assembly includes forming said substrate weld with an RF welding process having an RF die.44. The method of manufacturing a valve of claim 43, wherein said step of constructing said sub-assembly includes inhibiting formation of a weld bead adjacent to said substrate weld by incorporating a weld flow director into said RF die.45. The method of manufacturing a valve of claim 41, wherein said step of bonding said valve layer with said second substrate layer includes spacing said channel welds away from said outlet portion, said valve layer thereby being unbonded to said second substrate layer at said outlet portion.46. The method of manufacturing a valve of claim 41, wherein said step of bonding said first valve layer with said second substrate layer includes forming said channel welds with an RF welding process having a pair of RF dies.47. The method of manufacturing a valve of claim 46, wherein said step of bonding said first valve layer with said second substrate layer includes inhibiting formation of weld beads adjacent to at least a portion of said channel welds by incorporating a pair of weld flow directors into said pair of RF dies.48. The method of manufacturing a valve of claim 47, wherein said step of bonding said first valve layer with said second substrate layer includes facilitating formation of a pair of inlet weld beads in said inlet by locating a gap in an area of said pair of weld flow directors corresponding with said inlet, said inlet weld beads placing said inlet in an open configuration.49. The method of manufacturing a valve of claim 41, wherein said step of constructing said sub-assembly include positioning a blocking material between said valve layer and said first substrate layer, said blocking material preventing formation of additional bonds between said valve layer and said first substrate layer during said step of bonding said first valve layer with said second substrate layer.50. The method of manufacturing a valve of claim 41, wherein said step of bonding said valve layer with said second substrate layer includes joining said channel welds at said outlet portion, and forming an outlet aperture in said valve layer.51. A method of manufacturing a valve from a plurality of flexible polymer layers, including a valve layer, a first substrate layer, and a second substrate layer, the method comprising steps of:constructing a sub-assembly by forming a substrate weld between said valve layer and said first substrate layer, said valve layer having an inlet end and an opposite outlet end; aligning said sub-assembly with said second substrate layer such that said valve layer is positioned between said substrate layers; and bonding said valve layer with said second substrate layer by forming a pair of spaced channel welds between said valve layer and said second substrate layer and forming a pair of inlet weld beads, said channel welds defining a channel located between said valve layer and said second substrate layer and between said channel welds, said channel having an inlet adjacent to said inlet end and an opposite outlet adjacent to said outlet end, said inlet weld beads being located within said inlet to place said inlet in an open configuration. 52. The method of manufacturing a valve of claim 51, wherein said step of constructing said sub-assembly includes locating said substrate weld adjacent to said inlet end of said valve layer.53. The method of manufacturing a valve of claim 51, wherein said step of constructing said sub-assembly includes forming said substrate weld with an RF welding process having an RF die.54. The method of manufacturing a valve of claim 53, wherein said step of constructing said sub-assembly includes inhibiting formation of a weld bead adjacent to said substrate weld by incorporating a weld flow director into said RF die.55. The method of manufacturing a valve of claim 51, wherein said step of bonding said valve layer with said second substrate layer includes spacing said channel welds away from said outlet end, said valve layer thereby being unbonded to said second substrate layer at said outlet end.56. The method of manufacturing a valve of claim 51, wherein said step of bonding said first valve layer with said second substrate layer includes forming said channel welds with an RF welding process having a pair of RF dies.57. The method of manufacturing a valve of claim 56, wherein said step of bonding said first valve layer with said second substrate layer includes inhibiting formation of weld beads adjacent to at least a portion of said channel welds by incorporating a pair of weld flow directors into said pair of RF dies.58. The method of manufacturing a valve of claim 51, wherein said step of constructing said sub-assembly include positioning a blocking material between said valve layer and said first substrate layer, said blocking material preventing formation of additional bonds between said valve layer and said first substrate layer during said step of bonding said first valve layer with said second substrate layer.59. The method of manufacturing a valve of claim 51, wherein said step of bonding said valve layer with said second substrate layer includes joining said channel welds at said outlet end, and forming an outlet aperture in said valve layer.