Vehicle pressure relief valve having peripherally secured flaps and method of manufacturing the same

1. A pressure relief valve for relieving air pressure from a passenger compartment of a vehicle, the pressure relief valve comprising:

a base having a peripheral portion, a central opening extending through the base; and

a plurality of flaps for closing the central opening of the base, each flap having an outer end connected with the peripheral portion of the base and an inner end that is movable relative to the peripheral portion and the other flaps for enabling airflow through the central opening;

each flap having opposite surfaces against which air pressure acts, differential air pressure acting on the opposite surfaces causing the flap to move about a hinge to enable airflow through the central opening, the hinge comprising a narrow portion of material formed between slots in the flap,

the plurality of flaps being formed in a single sheet of flexible material, the outer ends of the plurality of flaps being interconnected to collectively form an undivided outer periphery of the sheet of flexible material, the inner ends of the plurality of flaps forming a central portion of the sheet of flexible material and being movable relative to the outer periphery.

2. The pressure relief valve of claim 1 wherein the peripheral portion of the base includes first alignment members and the outer periphery of the sheet of flexible material includes second alignment members that are adapted to cooperate with the first alignment members for positioning the sheet of flexible material relative to the base.

3. A method of forming a pressure relief valve for relieving air pressure from a passenger compartment of a vehicle, the method comprising the steps of:

providing a base having a peripheral portion and a central opening that extends through the base;

closing the central opening of the base with a plurality of flaps;

connecting an outer end of each flap with the peripheral portion of the base;

forming the plurality of flaps in a single sheet of flexible material;

maintaining an outer periphery of the sheet of flexible material undivided so that the outer ends of the plurality of flaps are interconnected;

forming inner ends of the plurality of flaps in a central portion of the sheet of flexible material; and

enabling airflow through the central opening by causing the inner end of each flap to move relative to the peripheral portion and the other flaps due to differential air pressure acting on opposite surfaces of the flap.

4. The method of claim 3 wherein the step of providing a base having a peripheral portion and a central opening further includes the step of injection molding the base.

5. The method of claim 3 wherein the step of providing a base having a peripheral portion and a central opening further includes the steps of providing a support portion of the base that divides the central opening into a plurality of flow openings, and associating a flap of the plurality of flaps with at least one flow opening for closing the at least one flow opening and for moving to enable airflow through the at least one flow opening.

6. The method of claim 5 further including the steps of supporting, with the support portion of the base, the inner end of each flap in a closed condition closing the at least one flow opening, enabling movement of the inner end of each flap in a first direction relative to the support portion, and preventing movement of the inner end of each flap in a second direction, opposite the first direction, relative to the support portion for enabling airflow through the at least one flow opening in only the first direction.

7. The method of claim 5 wherein the steps of providing a base having a peripheral portion and providing a support portion on the base further include the step of molding the base, including the peripheral portion and the support portion, from a homogenous material so that the base is a monolithic structure that is free from any connecting devices and has a uniform density throughout.

8. The method of claim 3 wherein the step of closing the central opening of the base with a plurality of flaps further includes the step of forming at least one hinge in each flap to connect the inner end of the flap with the outer end of the flap for enabling movement of the inner end relative to the outer end.

9. The method of claim 8 wherein the step of forming at least one hinge in each flap includes the step of cutting slots through the flap to form at least one narrow portion of material between slots.

10. The method of claim 3 wherein the step of closing the central opening of the base with a plurality of flaps further includes the step of forming the plurality of flaps from a material having a tendency to return the flaps to a closed condition closing the central opening of the base so as to form a pressure relief valve that is independent of gravity.

11. The method of claim 3 further including the steps of providing first alignment members on the peripheral portion of the base, and providing second alignment members, that are adapted to cooperate with the first alignment members for positioning the sheet of flexible material relative to the base, on the outer periphery of the sheet of flexible material.

12. The method of claim 3 further including the step of molding a rim onto the peripheral portion of the base for fixedly securing the outer end of each flap to the peripheral portion of the molded base.

13. The method of claim 12 wherein the step of molding a rim further includes the step of forming a locking portion on the rim that is adapted to secure the pressure relief valve to a panel of the vehicle and is further adapted to seal against the panel of the vehicle.

14. A pressure relief valve for relieving air pressure from a passenger compartment of a vehicle, the pressure relief valve comprising:

a base having a peripheral portion, a central portion, and a support portion interposed between the peripheral portion and the central portion, the support portion defining inner and outer flow openings extending through the base; and

a plurality of flaps for closing the inner and outer flow openings of the base, each flap having an outer end connected with the peripheral portion of the base and an inner end that is movable relative to the peripheral portion and the other flaps for enabling airflow through the inner and outer flow openings,

each flap having opposite surfaces against which air pressure acts, differential air pressure acting on the opposite surfaces causing the flap to move to enable airflow through the inner and outer flow openings.