CONFIGURABLE PLUG TO STOP OR SLOW THE FLOW OF A FLUID OR GAS OR FLOWABLE MATERIAL EITHER INWARD OR OUTWARD THROUGH AN OPENING
Aspects of the present invention are directed to a tapered plug. The plug has a bottom base having a geometrical shape. In some embodiments the base has a well-defined geometrical shape, such as a circle, an ellipse, a triangle, a square, a rectangle, a rhombus, and the like. In other embodiments, the shape of the base is not a regular, well-defined shape. In some embodiments, the plug comes to a point at the top, with a shape analogous to a cone, while in other embodiments, the top of the plug is flat. In some embodiments, the plug has a smooth or nearly smooth surface, made of an easily compressible or semi-compressible material. It is for use in stopping or slowing the flow of a fluid or gas or other flowable material through an opening that the plug is inserted into.
This application claims priority to U.S. Application No. 61/672,694 filed Jul. 17, 2012, the contents all of which are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTIONThe present invention is in the field of plugs, and in particular, in the field of configurable plugs to stop or slow the flow of a fluid or gas or flowable material either inward or outward through an opening.
BRIEF SUMMARY OF THE INVENTIONAspects of the present invention are directed to a tapered (and additional shapes as later described) plug. The plug has a bottom base having a geometrical shape. In some embodiments the base has a well-defined geometrical shape, such as a circle, an ellipse, a triangle, a square, a rectangle, a rhombus, and the like. In other embodiments, the shape of the base is not a regular, well-defined shape. In some embodiments, the plug comes to a point at the top, with a shape analogous to a cone or an Egyptian pyramid, while in other embodiments, the top of the plug is flat, with a shape analogous to a Mayan pyramid. In some embodiments, the plug has a smooth or nearly smooth surface, made of an easily compressible or semi-compressible material. It is for use in stopping or slowing the flow of a fluid or gas or other flowable material (such as but not limited to a powder) through an opening (either coming in or going out, for example, with reference to an interior of a vessel, through an opening as the case may be) that the plug is inserted into.
In some embodiments the plug is made of a compressible material such as foam (either open or closed cell) of a certain density and compressibility and slow to fast rebound rate, or a pliable material such as a plastic (or multi-layered plastic filled with a softer material or fluid) or a semi-compressible material such as rubber.
The basic material and manufacturing method of some embodiments of the plug disclosed herein are very similar to those described in the U.S. patent application entitled “Emergency Repair Plug To Slow Down Water Inflow Through An Opening” (US Patent Application No: 2010/0132,605, the relevant sections of which, directed to the manufacture and materials, are incorporated by reference herein. However there are substantial differences disclosed below including sectioning elements, configurability, surface geometry, surface coating, different geometries for the base, different geometries for the tip or head of the plug, different sizes, and different materials.
The plug is segmented longitudinally (parallel to the central axis) into two to eight sections or more (in some ways similar to an orange or a banana.) See
The segmentation is achieved by sectioning elements including grooves or channels (molded into the plug as it is created), slices (either continuous or in a broken series, cut in after molding), or a series of perforations (molded in or cut in). In some embodiments the grooves or channels are produced by raised elements such as fins or vanes protruding into the interior surface of the plug molds. As the plug material sets within the mold these elements leave behind an impression on the plug surface and deeper into the interior of the molded plug equal to the dimensions of these fins or vanes. In other embodiments slices are cut on the surface and as deep into the plug as desired after the plug is removed from the mold. These slices are in continuous or in broken series, and are cut in after molding by means of a conventional knife under pressure, rotary blades, or stamping blades entering the plug either longitudinally or laterally from the side. In some embodiments the sectioning elements are single or a series of perforations. These are molded in by means of pins or posts protruding into the interior surface of the plug molds. In other embodiments the perforations are punched into the surface and as deep into the plug as desired after the plug is removed from the mold. These perforations are in continuous or broken series, and are punched in after molding by means of needles or teeth under pressure, rotary drills, or multiple small blades entering the plug either longitudinally or laterally from the side. The skilled artisan will know that there are many different methods to producing these sectioning elements and that the disclosure is not limited to the several embodiments explained above. In some embodiments, the plug is first manufactured in the form of the slices, but then the slices are attached together by means of a fastening device, such as glue, pins, etc., to form the plug.
These sectioning elements create intentional weak points in the plug material that facilitate separation and tearing along selected dimensions. In some embodiments, a tear is started at a single point of a sectioning element and then further separation and tearing is directed by the groove/channel/cut/perforation. In other embodiments, a tear is started at one end of the plug by pulling in opposite directions across the end of the sectioning element. In still other embodiments, a tear is started at the midpoint or at any point along the groove/channel/cut/perforation by forcing a finger or tool into the sectioning element, and even by pulling in opposite directions across the midpoint, and then continuing this tear in the direction facilitated by the groove/channel/cut/perforation. In some embodiments these sectioning elements are grooves or channels, from 1/16″ deep from the outer surface of the plug to the entire depth of the material as measured from the surface to the central axis, and all the way past the central axis in the case of perforations. In addition to directing the tearing and separation at the outer surface of the plug, these grooves/channels also allow this to occur in three dimensions within the outer surface of the plug, conceptually similar to how the structure of an orange allows it to be segmented in half or in thirds or into many sections. This segmentation allows easier, faster, and more precise tearing of the plug(s) without tools into sections and allows the user to fashion the plug(s) into better shapes for stopping the flow through the particular opening they encounter. For example the shape of a single plug is readily altered by removing section(s) and thereby reducing the plug's girth or diameter and allowing it to fit better into an opening. In some embodiments, a removed section is also used by itself to better fill an opening, such as a longer or narrower opening or crack. In further embodiments, several removed sections are combined to fill a larger opening, such as laying one plug or section against the other for one configuration and reversing one section end-for-end with other sections for another configuration. Multiple plugs are also readily combinable in whole or in part, such as an entire plug plus section(s) of another used together in an even larger opening.
Due to the sectioning elements (groove, slice, or perforation) a wide variety of shapes are created from single or multiple plugs, by hand without tools. This enables separating or tearing plug(s) more precisely and more easily and faster than products currently on the market such as TruPlug (US Patent Application No: 2010/0132,605) that do not have sectioning, and this in turn enables the user to produce a better fit for a variety of opening shapes and sizes including round or irregular openings and also for fitting the ends of or breaches in pipes and round-to-oval lines. This sectioning ability also allows for better and easier insertion than currently available products into the opening to be blocked, and greater holding power against the liquid or gas or flowable material.
Independent of the sectioning, in some embodiments the smooth to nearly smooth surface of the plug is modified to be rough or irregular, such as a sharkskin or sandpaper-like surface, achieved by texturizing the interior of the mold or selecting a coating material that crinkles or puckers on its own after the plug is demolded or post molding processing such as sand/bead blasting or applying a reactive component that reacts with the first coating. In other embodiments a post molding coating consisting of a texturizer (such as sand or plastic granules) and a binder (such as polyurethane or vinyl) is applied (by brush or spray or dipping) to provide the desired texture. Also in some embodiments higher-relief shapes are added, such as embedded cubes or gravel-like texture, and such additions are molded-in (created by the design of the mold cavity) and in other embodiments achieved by adding in separate material(s) at the surface while molding or by adding separate materials into the base plug material that migrate to the plug outer surface during the molding process and in other embodiments by adhering or embedding the separate material to the outside of the plug after molding by applying an adhesive coating to the plug and then dusting on or rolling the plug in a bed of the separate material (like sand on sandpaper.) The skilled artisan will also know that there are many different methods for modifying molded surfaces and that the disclosure is not limited to a specific method.
In some embodiments the plug is made of an impermeable (such as solid rubber and closed cell foam) or permeable (such as open cell foam) material. Permeability is defined with respect to the particular use of the plug. For example, a particular material may be impermeable to liquids but permeable to gases. In general, an “impermeable” material is a material that cuts down the flow of a fluid (whether gas or liquid, depending on the use) by 95% as compared to when the material is not present. Suitable open cell and closed cell foams include Polyurethane (from reaction between a diisocyanate, either aromatic or aliphatic types, and a polyol, typically a polypropylene glycol or polyester polyol, in the presence of catalysts and materials for controlling the cell structure), polyester (by simultaneously cross-linking an unsaturated polyester resin and generating carbon dioxide as a blowing agent), polyether, polyvinyl, polystyrene, Ethafoam, and memory foam (viscoelastic), Suitable solid synthetic rubber and synthetic rubber foams include polyisoprene, polychloroprene/neoprene, polybutadiene/buna, chloro isobutylene isoprene/butyl, chlorosulphonated polyethylene/hypalon, polysiloxane/silicone rubber. Suitable soft plastics include plastisol, alumisol, highly plasticized PVC with phthalates. The foregoing are examples of materials for various embodiments and do not limit the scope of the invention.
When made of a permeable material the sectioning also allows for better (compared to existing products referenced above), faster, and more reliable infiltration of the fluid or gas into the interior of the plug. This is achieved because the sectioning elements penetrate the outer surface of the plug and increases the speed and extent of absorption and permeation into the interior of the plug. This in turn accelerates the equalization of the internal pressure of the foam to the external pressure of the fluid or gas and thereby allowing greater and/or faster expansion of the plug material itself and producing increased holding power and sealing efficiency of the plug inhibiting flow through the opening.
Independent of the sectioning or material, in some embodiments the plug described above also has a surface with a ringed or ridged design. See
Independent of size and location of the ridges, in some embodiments the ridges are stepped or toothed or barbed depending on the degree of undercut (below each ridge as the plug stands on its base) or rounded, square, rectangular or polygonal. See
In some embodiments the ridges are broken or alternated or random around the plug circumference. See
Independent of the sectioning or material of the plug described above, some embodiments have a surface with a spiked or bumped design. See
Independent of shape or surface design, the surface of the above plugs certain embodiments are coated with sticky/high coefficient of friction material such as soft vinyl. Such material tends to adhere to the edges or interior surface of the opening to be plugged and thereby provides increased holding power in the opening, and particularly in an opening with smooth sides where the sticky plug surface coating adheres such as a pipe. Other embodiments are uncoated meaning that the core of the plug is directly exposed to the fluid/gas/flowable material. This direct exposure increases the speed and extent of absorption and permeation into the interior of the plug. This in turn accelerates equalizing the internal pressure of the foam to the external pressure of the fluid or gas and thereby allowing greater and/or faster expansion of the plug material itself and producing increased holding power and sealing efficiency of the plug inhibiting flow through the opening.
Independent of plug design and surface and material, in some embodiments a punt or depression is added to the bottom. See
Because the material absent from a punt allows the user to make the base smaller than would otherwise be possible, this type of collapsible or easily compressible base also facilitates inserting the plug base-first into or through a given size opening and thereafter allowing the base to expand and flare out either within or on the opposite side of an opening from where it is inserted. For example this is useful in stopping or slowing the flow coming from the opposite side of an opening, such as a hole in a tank when applied from outside the tank. In some embodiments the depth of the punt or depression is shallow, while in other embodiments the punt or depression is deep. In some embodiments, the punt or depression comprises a hollow center that extends almost up to the top or tip of the plug. The punt or depression in these embodiments is independent of, or is combined with, a flange at the base. See
Independent of plug design, material, and surface, in some embodiments the plug comprises a lanyard. See
Another embodiment of the plug is a round and another embodiment is an elliptical cylinder where the sides are parallel and the top and bottom edge diameters are square and in another embodiment are rounded. See
Another embodiment of the plug is with a widened and flattened head that is compressed or folded, either by hand or with the aid of a tool and inserted into or through an opening. See
Another embodiment of the plug is with a conical hollow head that is compressed or folded when needed and inserted into or through an opening. See
Independent of sectioning elements, configurability, surface geometry, surface coating, different geometries for the base, different geometries for the tip or head of the plug, and different sizes, in some embodiments the plug utilizes different materials. Those described in the U.S. patent application entitled “Emergency Repair Plug To Slow Down Water Inflow Through An Opening” (US Patent Application No: 2010/0132,605) are limited to polyether and methylene diphenyl diisocyanate or MDI. Some embodiments of the plug disclosed herein use aromatic isocyanates such as but not limited to toluene diisocyanate (TDI) and other embodiments use aliphatic isocyanates such as hexamethylene diisocyanate (HDI) or isophorone diisocyanate (IPDI). Separate from the different isocyanates, various embodiments of the plug disclosed herein use a class of polyethers, such as but not limited to phenyl ether polymers, that contain aromatic cycles in their main chain, one such embodiment using polyphenyl ether (PPE) and another embodiment using poly(p-phenylene oxide) (PPO). To create a foam, blowing agents such as but not limited to water is used in one embodiment and certain halocarbons such as HFC-245fa (1,1,1,3,3-pentafluoropropane) in other embodiments, and hydrocarbons such as n-pentane is incorporated into still other embodiments. In some embodiments the foam cell structure is controlled by addition of surfactants to modify the characteristics of the polymer during the foaming process. In other embodiments temperature of the mold is used to control the foam cell structure. The skilled artisan will also know that the plug can be of considerably different formulations and that the disclosure is not limited to a specific formulation.
In the embodiments where the plug is made of a compressible material such as foam the density of this foam is controlled to produce the desired characteristics. Light density is defined to fall in the range of 1 to 4 pounds per cubic foot (Lb/CuFt) range, medium density in the greater than 4 to 12 Lb/CuFt range, and high density in the greater than 12 Lb/CuFt range. Compressible material, (such as but not limited to foams) is defined as that which can be compressed by 10% up to 90% of its initial volume by hand without tools and semi-compressible material, (such as but not limited to solid or near-solid rubber, is defined as that which can be compressed by less than 10% of its initial volume by hand without tools. The skilled artisan will also know that the plug can be of considerably different densities and compressibilities and that the disclosure is not limited to a specific density or compressibility.
Claims
1. A compressible plug to stop or slow the flow of a fluid or gas or flowable material either inward or outward through an opening comprising:
- a) a body made from a made of an easily compressible or semi-compressible material capable of being reduced in cross-sectional size by squeezing or twisting by hand and that tends to return toward its original size;
- b) said body having a flat planar base of a well-defined geometrical shape, such as a circle, an ellipse, a triangle, a square, a rectangle, a rhombus, and the like;
- c) said body having sides extending upwardly from said base forming a tapered body with an outer surface;
- d) said surface of the plug being rough or irregular geometry, such as a pebbled, sharkskin or sandpaper-like surface.
2. A compressible plug as in claim 1, wherein said body is segmented longitudinally (parallel to the central axis) into two to eight sections or more (in some ways similar to an orange or a banana.)
- a) said segmentation is achieved by sectioning elements including grooves or channels (molded into the plug as it is created), slices (either continuous or in a broken series, cut in after molding), or a series of perforations (molded in or cut in)
- b) said sectioning elements create intentional weak points in the plug material that facilitate separation and tearing by hand along selected dimensions
3. A compressible plug as in claim 1, wherein said surface geometry is comprised of multiple concentric ridges that are barbed due to the degree of undercut.
4. A compressible plug as in claim 1, wherein said surface geometry is broken, alternated ridges that are narrowed laterally to become more like individual teeth.
5. A compressible plug as in claim 1, wherein said surface geometry comprises a design of many bumps or spikes in a pattern on the plug surface to allow each to contact the edge or interior of an opening.
6. A compressible plug as in claim 1, wherein said body is made of a permeable material that allows for better, faster, and more reliable infiltration of the fluid or gas into the interior of the plug.
Type: Application
Filed: Jul 17, 2013
Publication Date: Jun 26, 2014
Inventors: R. Scott Foresman (San Juan Capistrano, CA), William N. Hanna (Olympia, WA)
Application Number: 13/944,092
International Classification: B65D 39/00 (20060101);