Multi-port free flow valve and element

A multi-port valve comprising:

• a parent valve casing having an unobstructed straight-through bore flow axis and an outlet for receiving a first child valve casing wherein said first child valve casing has an unobstructed straight-through bore flow axis perpendicular to the flow axis of the parent valve casing;
• a single-piece removable cylindrical flexible element for communicating fluid through said valve, the flexible element having tolerance-fitted connections seamlessly joining the fluid communication paths of said parent and first child valve casings to form connection ports at each exposed end of said parent and first child valve casings;
• and
• a manual or pneumatic actuator for each said parent and first child valve casings.

A multi-port valve comprising:

• a series of valve casings having unobstructed straight-through bore flow axes and outlets for receiving additional valve casing wherein each connection of valve casings is at 90 degree angles such that the flow axis of each valve casing in said series is perpendicular to the flow axis of the preceding valve casing in said series, and wherein the first valve casing in said series has two identical ports, wherein the second valve casing in said series is connected via an outlet in the side of said first valve casing via a tapered end that locks into said first valve casing outlet, and each valve casing connected in said series thereafter to each preceding valve casing has a tapered end to connect to the outlet of the preceding valve casing in said series, and wherein the last valve casing in said series is a terminal valve casing with no side outlet;
• a single-piece removable cylindrical flexible element for communicating fluid through said series that has tolerance-fitted connections seamlessly joining the fluid communication paths of said parent and each child valve casing to form connection ports at each exposed end of said valve casings;
• and
• a manual or pneumatic actuator for each said valve casings.

A method for molding a flexible element comprising:

• joining the internal bore of two or more cylindrical tubes together with at least one premolded thermoset connector, wherein said thermoset connector is comprised of hollow ends,
• placing at least one mandrel with one threaded end into each of said hollow ends of said at least one thermoset connector, whereby a seamless bore is created for fluid flow;
• placing said joined tubes into a mold with the desired number of cavities for molded-in gasket end connections and the overall assembly configuration, wherein said configuration can be a reducer, cross, T or Y shape;
• injecting liquid silicone into the mold cavities to join the tubing together and to mold the flexible element end connections with integrated gaskets in a single step;
• heating and curing the liquid injection silicone;
• removing the molded assembly from mold;
• and
• removing said at least one threaded mandrel and said attached at least one thermoset connector with a threaded extraction rod.