HK1251641B - Sprinkler adapter and pipe plug - Google Patents

Description

Sprinkler adapters and pipe plugs

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based upon and claims the benefit of priority from U.S. Provisional Patent Application No. 62/260,922, filed on November 30, 2015, and U.S. Provisional Patent Application No. 62/359,395, filed on July 7, 2016, both of which are incorporated herein by reference.

Technical Field

The present invention relates to an adapter for mounting a fluid control device to a pipe element and a plug for sealing the end of a pipe.

Background Art

Traditional installation of fire-extinguishing system pipe networks uses steel pipe elements with male cut threads connected by female threaded fittings (tees, elbows, pressure reducers) to position sprinklers in specific locations throughout the structure under construction. The preparation and installation of cut-thread pipe is time-consuming and labor-intensive. Many pipe elements must be prepared on site, where they are individually measured and cut into sections; their ends are threaded using specialized thread-cutting machines and connected to female threaded fittings using pipe dope and/or tape. Thread cutting is particularly labor-intensive because it involves cutting oil, which contaminates and stains the surfaces it contacts, and oily scrap metal shavings must be collected and disposed of.

Given the drawbacks associated with cutting threaded pipe, grooved pipe elements and mechanical pipe couplings and fittings that engage the grooves have become the preferred hardware for constructing pipe networks. The use of grooved pipe elements and mechanical couplings and fittings that engage the grooves essentially eliminates the need to cut threads in the pipe elements, as the mechanical couplings and fittings engage circumferential grooves positioned near the ends of the pipe elements. The grooves are typically cold-formed in the pipe elements on-site using a roller grooving machine that does not use cutting oil or generate scrap metal shavings. Such mechanical pipe couplings also allow fittings that terminate pipe extensions to be attached without cutting threads.

However, to complete the installation, the sprinkler must be connected to its pipe element. The sprinkler has a male threaded end, and the male threaded end is primarily smaller (1/2-3/4 inch pipe sizes), such as the 1-inch Schedule 40 pipe size used in the so-called "arm-over" configuration described below. In the elbow-over configuration, commercially available female-female reducing fittings are used to connect the smaller (male) sprinkler end to the larger (male) pipe element. Therefore, even when using mechanical fittings and couplings that engage grooves, this final pipe element connected to the sprinkler must have male threads cut in the end that connect to the female-female reducing fitting. It would be advantageous to eliminate all thread cutting steps from the process of constructing a pipe network for a fire suppression system. It would be further advantageous if the need for mechanical couplings for sealing the pipe runs could be eliminated.

Summary of the Invention

The present invention relates to an adapter for attaching a sprinkler to a pipe element. In one exemplary embodiment, the adapter includes a body having an inner surface defining a hole therethrough and an outer surface surrounding the inner surface. A plurality of flat surfaces are positioned on the outer surface. At least a first groove is positioned in the outer surface and extends circumferentially about the hole. At least a first seal is positioned within the first groove. At least a first portion of the body is sized to fit within the pipe element so that the first seal can be positioned within the pipe element.

Example embodiments may further include a second seal positioned within the first groove. Another example may further include a second groove positioned in the outer surface and extending circumferentially about the bore. The second seal is positioned within the second groove.

In another exemplary embodiment, a gasket surrounds the outer surface. The gasket is positioned adjacent to a first portion of the body, the first portion of the body being sized to fit within the tubular element. In this exemplary embodiment, an outer groove is positioned in the outer surface and extends circumferentially about the bore. The outer groove is positioned in a spaced relationship away from the first groove. The gasket is positioned within the outer groove.

By way of specific example, the second portion of the body is larger than the first portion of the body so as not to fit within the pipe element. In another example embodiment, the first portion of the outer surface further comprises a plurality of curved surfaces extending around the body. Each of the flat surfaces abuts two of the curved surfaces, and the second portion of the body comprises the plurality of flat surfaces positioned on the outer surface. By way of example, the curved surfaces are convexly curved. In another example embodiment, the pipe threads are positioned on the inner surface.

By way of further example, the second seal surrounds the first seal. The first seal comprises an elastomeric material, and the second seal comprises a flexible material. In a specific example, the second seal has a rectangular cross-section. By way of further example, the second seal can be selected from the group consisting of polyester, silicone adhesive, acrylic adhesive, or an expanding gel seal.

The present invention also includes an adapter for attaching a sprinkler to a pipe element. In an exemplary embodiment, the adapter includes a body having an inner surface defining a hole therethrough. An outer surface surrounds the inner surface. A first portion of the outer surface has a plurality of flat surfaces and a plurality of curved surfaces extending around the body. Each of the flat surfaces abuts two of the curved surfaces. A second portion of the outer surface has a plurality of flat surfaces extending around the body. At least a first groove is positioned in the first portion of the outer surface and extends circumferentially about the hole. At least a first seal is positioned within the first groove.

Another example embodiment further includes a second groove positioned in the first portion of the outer surface. The second groove extends circumferentially about the aperture. The second seal is positioned within the second groove. Another example includes a gasket surrounding the outer surface. The gasket is positioned between the first and second portions of the outer surface. An outer groove may be positioned in the outer surface. In this example, the outer groove extends circumferentially about the aperture. The outer groove is positioned between the first and second portions of the outer surface, and the gasket is positioned within the outer groove.

In an exemplary embodiment, the pipe threads are located on the inner surface.By way of example, the curved surface is convexly curved.

Another exemplary embodiment includes a second seal surrounding a first seal. In this example, the first seal comprises an elastomeric material, and the second seal comprises a flexible material. In a particular exemplary embodiment, the second seal has a rectangular cross-section. The second seal can be selected from the group consisting of polyester, silicone adhesive, acrylic adhesive, and expanding gel seal.

The present invention also includes combinations of a pipe element and an adapter. In an exemplary embodiment, the adapter includes a body having an inner surface defining a bore therethrough. An outer surface surrounds the inner surface. A first portion of the outer surface has a plurality of flat surfaces and a plurality of curved surfaces extending around the body. At least a first groove is positioned in the first portion of the outer surface and extends circumferentially about the bore. At least a first seal is positioned within the first groove. Further by way of example, the pipe element includes a sidewall defining the bore. A first portion of the body is received within the bore. A deformation is positioned in the sidewall and extends circumferentially therearound. The deformation is aligned with the first groove and engages at least partially with the outer surface of the body, thereby retaining the body within the bore.

Another example embodiment further comprises a second portion of the outer surface having a plurality of flat surfaces extending around the body. By way of example, the deformed portion comprises a circumferential groove stamped into the sidewall. In another example, the second seal is positioned within the first groove.

By way of another example, a second groove is positioned in the first portion of the outer surface and extends circumferentially about the aperture. The second seal is positioned within the second groove. In this example, the second groove is adjacent to the first groove, such that the deformation engages both the first and second grooves. Example embodiments further include a gasket surrounding the outer surface. The gasket is positioned between the first and second portions of the outer surface. An outer groove may be positioned in the outer surface to extend circumferentially about the aperture. The outer groove is positioned between the first and second portions of the outer surface. In this example, the gasket is positioned within the outer groove.

In one exemplary embodiment, the pipe threads are located on the inner surface. By way of further example, at a first position on the outer surface, each of the flat surfaces abuts two of the curved surfaces. In another example, the second portion of the body is larger than the diameter of the pipe bore such that the two portions do not fit together within the pipe bore. In one exemplary embodiment, the curved surfaces are convexly curved.

Another example also includes a second seal surrounding the first seal. The first seal comprises an elastomeric material, and the second seal comprises a flexible material. The second seal engages and conforms to the sidewall within the bore. In certain example embodiments, the second seal has a rectangular cross-section. By way of example, the second seal can be selected from the group consisting of polyester, silicone adhesive, acrylic adhesive, and expandable gel seal.

The present invention also includes a plug for closing a pipe element. In one exemplary embodiment, the plug includes a body having a cylindrical outer surface. A circumferential groove extends around the outer surface. A shoulder extends outward from the outer surface. The shoulder is positioned in a spaced relationship away from the groove. At least a first seal is positioned within the groove. At least a second seal surrounds the first seal. In this exemplary embodiment, the first seal comprises an elastomeric material and the second seal comprises a flexible material. By way of example, the second seal can be selected from the group consisting of polyester, silicone adhesive, acrylic adhesive, and expansion gel seal. In another example, a cavity is positioned within the body. Further by way of example, the shoulder is positioned at an end of the body. The cavity extends from the end into the body.

The present invention also includes a combination of a pipe element and a plug. By way of example, the plug includes a body having a cylindrical outer surface. A circumferential groove extends around the outer surface. A shoulder extends outward from the outer surface. The shoulder is positioned in a spaced relationship away from the groove. At least a first seal is positioned within the groove. At least a second seal surrounds the first seal. In this example, the first seal comprises an elastomeric material and the second seal comprises a flexible material. Further by way of example, the pipe element includes a sidewall defining a tube bore. A portion of the body includes a groove received within the tube bore. A deformation portion is positioned in the sidewall and extends circumferentially therearound. The deformation portion is aligned with the groove and engages both the first and second seals and at least a portion of the outer surface of the body, thereby sealingly retaining the body within the tube bore.

By way of example, the second sealant can be selected from the group consisting of polyester, silicone adhesive, acrylic adhesive, and expanding gel sealant. In an exemplary embodiment, the cavity is positioned within the body. Further by way of example, the shoulder is positioned at an end of the body, and the cavity extends from the end into the body.

The present invention also includes a method of achieving a seal between a body and a pipe element. In one example, the method includes:

positioning a seal about the body;

positioning the body and the seal within the pipe element;

A circumferential deformation is formed in the side wall of the pipe element at a location overlying the seal so as to sealingly engage the deformation with the seal.

By way of example, the method may further include positioning a seal within a circumferential groove in the body. Another example includes compressing the seal between the deformed portion and the body. The seal comprises a flexible material and thereby conforms to an inner surface of the pipe element and an outer surface of the body when compressed. Another example includes positioning the body within the pipe element, wherein the body includes a threaded bore.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG1 is an exploded partial cross-sectional view of an elbow joint assembly of a pipe element of a sprinkler system;

FIG2 is a partial cross-sectional view of an exemplary embodiment of an adapter according to the present invention;

FIG3 is an isometric view of the adapter shown in FIG2 ;

FIG4 is a longitudinal cross-sectional view of an exemplary embodiment of a combined pipe element and adapter according to the present invention;

FIG5 is a partial cross-sectional view of an example adapter having a flexible seal;

6 is an isometric view of a flexible seal used in an exemplary embodiment of the present invention.

7 is a partial cross-sectional view of an exemplary embodiment of an adapter having a flexible gel seal according to the present invention;

FIG8 is a longitudinal cross-sectional view of an example combination of a pipe element and an adapter;

9 is a cross-sectional view of an exemplary embodiment of a combination of a pipe element and an adapter taken along line 9-9 of FIG. 8;

FIG10 is an isometric view of an example plug according to the present invention;

FIG11 is a partial cross-sectional side view of the plug shown in FIG10; and

12 is a cross-sectional view of an exemplary combination of a pipe element and a plug according to the present invention.

DETAILED DESCRIPTION

FIG1 illustrates what is commonly referred to as an "elbow-jointed" configuration 10 for positioning sprinklers 12 at desired locations within an area to be protected by a fire suppression system. The elbow-jointed configuration 10 includes a header pipe 14, such as a 2.5-inch pipe, that feeds a plurality of branch lines 16. Multiple sprinklers 12 can be in fluid communication with each branch line 16. In the example shown in FIG1 , the sprinklers 12 are shown connected to the branch lines via a 1-inch, plan 40 size pipe element 18. The pipe element 18 has a bore 20.

According to the present invention, the connection between the sprinkler 12 and the pipe element 18 is achieved via an adapter 22. Adapter 22 is shown in detail in Figures 2 and 3 and includes a body 24. Body 24 can be formed from carbon steel, stainless steel, brass, or other materials and has an inner surface 26 that defines a bore 28 extending through the body. The outer surface of body 24 surrounds inner surface 26. At least portion 30a of body 24 is sized to fit within bore 20 of pipe element 18 (see Figure 1). In the example shown in Figures 2 and 3, portion 30a of outer surface 30 has a plurality of flat surfaces 32 thereon. Curved surfaces 33 are positioned between flat surfaces 32 on portion 30a, such that each flat surface is adjacent to two curved surfaces. In the example, the curved surfaces are convex, but other embodiments may have concave surfaces, for example.

The second portion 30b of the outer surface 30 also has a plurality of flat surfaces 34 thereon. On the second portion 30b, there are no intervening curved surfaces between the flat surfaces 34. The flat surfaces 34 abut one another at protruding corners 35 on portion 30b. The presence of convexly curved surfaces 33 between the flat surfaces 32 on portion 30a of the outer surface 30 reduces the size of the portion of the body 24 and allows it to be accommodated within the bore 20 of the pipe element 18. The outer surface portion 30b without the convexly curved surfaces is larger in size, and the corners 35 where the surfaces 34 intersect engage the pipe element and act as stops, limiting the depth to which the body 24 can be inserted into the pipe bore 20.

The outer surface 30 of the body 24 has additional features, including a groove extending circumferentially around the bore 28. As shown in FIG. 2 , a groove 36 is positioned in a portion 30 a of the outer surface 30 and houses one or more seals 38 that, as described below, seal the space between the body 24 and the pipe element 18 when the adapter is received within the pipe bore 20. In this example, the seal 38 comprises an O-ring made of an elastomer such as EPDM. Other types of seals and other materials are also possible. As shown in FIG. 4 , a second seal accommodating a groove 42 may also be positioned in the portion 30 a of the outer surface 30. In the example embodiment shown, the grooves are adjacent to each other.

In another example adapter embodiment 22a shown in FIG5 , a first seal 38a is positioned within a groove 36 in the outer surface 30 of the body 24. A second seal 37 surrounds the first seal 38a. In this example embodiment, the first seal 38a has a rectangular cross-section when unstretched. As shown in FIG6 , the second seal 37 may also have a rectangular cross-section when undeformed and may comprise a closed ring or strip of material. It is advantageous to form the first seal 38a from an elastic material, such as an elastomer such as EPDM or other rubber compounds. It is further advantageous to form the second seal 37 from a flexible material, such as a polyester, a silicone-based adhesive, or an expansion-locking gel such as ES0105 Expand-A-Seal provided by ND Industries of Clawson, MI. The gel contains microencapsulated beads of a separate epoxy resin and a curing agent that are activated when the gel is compressed. As shown in FIG7 , the gel seal 37 is applied to the first seal 38a within the groove 36. The gel cures and adheres to the first seal 38a. As described below, upon compression of seal 37, the beads are crushed, releasing the resin and curing agent which combine to expand and cure into an effective seal conforming to the space into which they were expanded.

Referring again to FIG. 2 , another groove 44 can be positioned in outer surface 30. Groove 44 defines a boundary between portions 30a and 30b of outer surface 30. Groove 44 accommodates a gasket 46 that projects radially from body 24 and covers the gap between tube bore 20 and body 24 when the body is received therein. The gap is caused by the circular bore 20 receiving the non-circular adapter body 24. Gasket 46 can be made of a plastic, such as polyethylene.

2 and 3, the inner surface 26 of the body 24, in this example, has tapered internal pipe threads 48. The tapered pipe threads allow the adapter 22 to receive the matching tapered threaded end of the sprinkler 12 and form a fluid-tight seal using conventional pipe dope and/or Teflon tape.

In the actual design of the adapter 22, the hexagonal bar stock is opened on a screw cutting lathe to form the hole 28 and cut the pipe threads 48. The lathe is also used to remove corners from portions of the hexagonal bar stock to form the convex curved surface 33 between the flat surfaces 32 on the portion 30a of the outer surface 30. Grooves 36 (42, when present) and 44 are then cut in the outer surface 30, and the washer 46 and seal 38 are positioned in their respective grooves.

Removing the corners of the hexagonal bar stock to form portion 30a of outer surface 30 reduces the size of body 24 so that it fits within pipe bore 20. However, corners 35 remain on portion 30b of outer surface 30 and, because they extend outward from body 24 and are larger than the diameter of pipe bore 20, they will engage the end of pipe element 18 and limit the depth of engagement between the body and the pipe. Limiting this engagement also serves to position grooves 36 and 42 and their seals 38 in precisely known locations to allow body 24 to be installed within the pipe bore, as shown in FIG4 . The effect is similar for adapter embodiment 22a with respect to grooves 36 and seals 37 and 38a (see FIG5 ).

FIG4 shows an exemplary embodiment of a combination of a pipe element 18 and an adapter 22 according to the present invention. Adapter 22 is received within bore 20 of pipe element 18. In one exemplary embodiment, this means that portion 30a of outer surface 30 is within bore 20, while portion 30b remains outside the bore. Grooves 36 and 42 and their seal 38 are thus positioned at a known distance from the end of pipe element 18. Bore 20 of pipe element 18 is defined by sidewall 50. Deformation 52 is positioned in sidewall 50 and extends circumferentially therearound. Deformation 52 is formed in a position that aligns it with grooves 36 and 42 and seal 38. Deformation 52 mechanically engages grooves 36 and 42, seal 38, and flat surface 32 (see FIG2 ). The mechanical engagement between deformation 52 and seal 38 creates a fluid-tight connection between adapter 22 and pipe element 18. The mechanical engagement between deformation 52 and grooves 36 and 42 secures adapter 22 against axial pressure within pipe element 18. The holding force achieved significantly exceeds the forces caused by the maximum expected pressure in the fire suppression system. Furthermore, the mechanical engagement between the deformation 52 and the flat surface 32 prevents relative rotation between the adapter 22 and the pipe element 18 about the pipe element longitudinal axis 54 and allows more than three times the torque to be applied to the adapter 22 compared to if friction were the only force preventing relative rotation.

The example combination shown in FIG4 is expected to be effective for seamless tubular element 18. For tube 18a having a welded longitudinal seam 19 as shown in FIG8 and FIG9 , it is expected that the adapter 22a with first and second seals 37 and 38a shown in FIG5 and FIG7 will be effective. As shown in the cross-section in FIG9 , welded seam 19 forms an irregular protrusion 21 on sidewall 50 within tube bore 20. As shown in FIG8 , to ensure a fluid-tight seal in the area of seam 19, it is advantageous to use first resilient seal 38a as a biasing element and bias second flexible seal 37 against deformation 52. When deformation 52 forms, flexible seal 37 is compressed between the deformation and resilient seal 38a. Due to its flexible nature, flexible seal 37 conforms to the shape of the space between resilient seal 38a and deformation 52 of sidewall 50 to form a fluid-tight seal, adapting to any irregularities in the sidewall surface, such as protrusion 21 of welded seam 19. Additional advantages are realized when using an expanding gel seal 37 as described above.

In addition to attaching the sprinkler to the pipe element, it is also desirable to be able to conveniently seal the pipe element, for example, at the end of a pipe extension. This is easily accomplished using the example plug 54 shown in Figure 10. The example plug 54 includes a body 56 sized to fit within the pipe element. The body 56 has a cylindrical outer surface 58 and can be formed from a round blank opened on a lathe, such as steel, stainless steel, or other metallic material. A circumferential groove 60 is positioned in the outer surface 58 of the body 56, near one end. A shoulder 62 is positioned spaced apart from the groove 60, in this example, near the opposite end of the body 56. The shoulder 62 has a larger diameter than the body 56 and is sized to engage with the end of the pipe element, into which the plug 54 is inserted and to limit the degree of engagement between the plug and the pipe element (see Figure 12). As shown in Figure 11, the groove 60 accommodates one or more seals for achieving a liquid-tight seal between the plug 54 and the pipe element 18. In the example shown, a first seal 64 is positioned within the groove 60 and is formed of a flexible, resilient material, such as an elastomer such as EPDM or other rubber compound. Such a single seal (e.g., an O-ring) may be sufficient to seal against a smooth inner surface of a pipe element; however, for pipe elements having rough or irregular inner surfaces (e.g., welded seam pipe), it may be advantageous to position a second seal 66 around the first seal 64. As described above, the second seal is formed of a flexible material, such as polyester, a silicone-based adhesive, an acrylic adhesive, or an expanding gel sealant, which conforms to the irregular surface within the pipe element to achieve a seal.

10 and 11 also show a cavity 68 formed within the body 56. Cavity 68 can accommodate tools for handling and positioning the plug 54 within the pipe element when a deformation is formed in the pipe element, the deformation cooperating with the seals 64 and 66 to achieve a fluid-tight seal between the plug and the pipe element. An example combination of a pipe element 18 and a plug 54 is shown in FIG12 , the pipe element having a deformation 52 engaged with the seals 64 and 66. The deformation 52 also mechanically engages the body 56 of the plug 54 within the groove 60 to retain the plug within the pipe element against internal pressure.

By way of example, for both the adapter 22 (and 22a) and the plug 54, the deformation 52 of the tubular element 18 is formed by a circumferential groove 70 stamped into the sidewall 50. Once the adapter or plug is in position within the tubular element, the formation of the circumferential groove 70 is conveniently achieved by cold working the tubular element 18. The groove 70 is formed at such a location that the deformation 52 engages the groove 36 in the adapter or the groove 60 in the plug, along with their associated seals. Cold working of the tubular element can be accomplished via roller grooving methods and apparatus, as well as apparatus employing a rotating cam.

The use of the adapter according to the present invention completely eliminates thread cutting during the installation of the pipe network. Thus, thread cutters, with their attendant oil and scrap metal, are no longer necessary. The same means for forming the grooves (roller grooves, cam grooves) that deform the pipe element to secure and seal the adapter according to the present invention within it are also used to cold-form circumferential grooves in the pipe element so that they can be coupled via a mechanical coupling of the engaging grooves, significantly improving the efficiency and convenience of the process.

Claims (16)

1. A combination of a tubular element and an adapter, the adapter comprising: A body having an inner surface that defines a hole through the body; The outer surface surrounding the inner surface; The first portion of the outer surface has a plurality of flat surfaces and a plurality of curved surfaces extending around the body; At least a first groove, the first groove being positioned in a first portion of the outer surface and extending circumferentially about the hole; At least a first seal, which is positioned within the first groove; The tubular component includes: The sidewalls defining the orifice, the first portion of the body being received within the orifice; A deformable portion positioned in the sidewall and extending circumferentially around the sidewall, the deformable portion being aligned with the first groove and engaging at least a portion of the outer surface of the body, thereby retaining the body within the orifice. 2. The combination according to claim 1, further comprising a second portion of the outer surface having a plurality of flat surfaces extending around the body. 3. The combination according to claim 1, wherein the deformable portion includes a circumferential groove embossed into the sidewall. 4. The combination according to claim 1, further comprising a second seal positioned within the first groove. 5. The combination of claim 1, further comprising a second groove positioned in the first portion of the outer surface and extending circumferentially about the hole, the second seal being positioned within the second groove. 6. The combination according to claim 5, wherein the second groove is adjacent to the first groove, such that the deformed portion engages both the first groove and the second groove. 7. The combination of claim 2, further comprising a washer surrounding the outer surface, the washer being positioned between the first portion and the second portion of the outer surface. 8. The combination of claim 7, further comprising an outer groove positioned in the outer surface and extending circumferentially about the hole, the outer groove being positioned between the first portion and the second portion of the outer surface, the washer being positioned within the outer groove. 9. The combination according to claim 1, wherein the pipe thread is positioned on the inner surface. 10. The combination of claim 1, wherein, on the first portion of the outer surface, each of the flat surfaces is adjacent to two of the curved surfaces. 11. The combination according to claim 2, wherein the second portion of the body is larger than the diameter of the orifice so as to be misfitting within the orifice. 12. The combination according to claim 1, wherein the curved surface is convexly curved. 13. The combination of claim 1, further comprising a second seal surrounding the first seal, wherein the first seal comprises an elastic material and the second seal comprises a flexible material, the second seal engaging the sidewall within the bore and conforming to its shape. 14. The combination according to claim 13, wherein the second seal has a rectangular cross-section. 15. The combination of claim 13, wherein the second seal is selected from polyester, silicone adhesive, acrylic adhesive or expandable gel seal. 16. A method for installing a seal between a body and a tubular element in a combination according to any one of claims 1-15, the method comprising: Positioning seal around the main body; Position the body and the seal within the tubular element; A circumferentially deformable portion is formed in the sidewall of the tube element at the location covering the seal, so that the deformable portion is sealingly engaged with the seal.