Abstract:
The present invention provides a tire repairing plug, a kit comprising a plurality of such plugs with different dimensions and designs to fit different tires and different damages thereon, and a method of using the plug to repair a damaged tire in vehicles such as bicycles, motorcycles, cars, and trucks etc. The plug incudes a cap and an elongated body, and a middle portion of the body is bigger than any other portions of the body. The invention exhibits numerous technical merits such as simpler operation, higher effectiveness and improved reliability in repairing a damaged tire, among others.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This non-provisional application is a Continuation-in-Part of, and expressly claims the benefit of, U.S. Application with Ser. No. 12/287,752 filed Oct. 14, 2008 titled “Barrel formed bolt for repairing flat tire”, which is incorporated by references as if set forth in its entirety. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not applicable. 
       NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT 
       [0003]    Not applicable. 
       REFERENCE TO AN APPENDIX SUBMITTED ON COMPACT DISC 
       [0004]    Not applicable. 
       FIELD OF THE INVENTION 
       [0005]    The present invention generally relates to a tire repairing plug, a kit or a tool box comprising a plurality of such plugs with different dimensions and designs to fit different tires and different damages thereon, and a method of using the plug to repair a damaged tire in vehicles such as bicycles, motorcycles, cars, and trucks etc. 
       BACKGROUND OF THE INVENTION 
       [0006]    During a trip, especially on highway where there is no auto-body shop nearby, it is very troublesome to repair a flat tire, because the flat tire has to be removed from wheel before it can be repaired. Moreover, a flat tire repair kit available on the market contains band rubbers, a tube of super glue and a needle, but it is also difficult to insert the band rubbers into nail hole with needle. 
         [0007]    In the prior art, metal sheathing of aluminum has come into wide usage, and in applying the same, people have attempted to electrically insulate the securing elements or fastening elements employed, such as nails, screws, etc., from the aluminum, to avoid electrolytic action. People have also attempted to design structures providing an efficient and thorough sealing means to prevent entrance of moisture under the heads of the fasteners, since the moisture is likely to penetrate the sheathing about the fastener shanks and through the holes or openings formed in the sheathing as the fasteners are driven. Due to temperature changes, there is an expansion or contraction of the sheathing, people have attempted to make sealing means that is an elastomer or be compressible. This is to allow for such expansion without the loosening of the fastener in the under material into which they have been driven and whereby the seal remains effective by expansion of the sealing means on contraction of the sheathing. For example, U.S. Pat. No 2,724,303 issued to Holcomb provides a fastener such as nails and screws The fastener has on the shank thereof a coating adapted to peel back along the shank of the fastener as the shank is driven into an object. When the fastener is driven, the material comprising the coating is concentrated about that portion of the shank immediately under the fastener head and provides a seal between the fastener head and the object into or through which the fastener shank has been driven and also forms a seal between the shank and the hole formed by the latter as it is driven 
         [0008]    U.S. Pat. No. 2,724,303 discloses some specific design of nails as shown in  FIG. 1 , and methods of using these nails as shown in  FIG. 2 . The nail  20  includes a shank  21  and a head  22 . On an intermediate portion of the shank  21  is a coating  23  in the form of a band of the elastomer. However, coating  23  will peel or roll back along the nail shank as the latter is driven Coating  23  is free of the shank in that it is only supported thereby and is not tightly adhered or bonded thereto. In  FIG. 1 , wood screw  24  includes a head  25 , a shank including a pointed end and a lower threaded portion  26  and an upper unthreaded, smooth portion  27  immediately under the head  25 . On this smooth portion  27  is a coating  28  In use, as the screw  24  is threaded home, the coating  28  is rolled or peeled back and accumulates at the underside of the head  25  and about the extreme upper portion of the shank of the screw. In  FIG. 1 , machine screw  29  includes a head  30 , a lower threaded shank portion  31  and an upper smooth or unthreaded shank portion  32  immediately under the head of the screw. On shank portion  32  is a coating  33 . This machine screw is employed in the usual manner and when threaded home, the coating material peels or rolls back or up along the screw shank and accumulates at the underside of the screw head. 
         [0009]      FIG. 2  illustrates the manner of how to use nail  20  As shown in  FIG. 2 , when such a nail  20  is driven, the coating material  23  will be peeled or rolled back and accumulate under the nail head and about the shank portion immediately under the nail head so as to form a seal as indicated by the accumulation (from A to B) of the coating of the nail  20  In  FIG. 2 , wood  14  is the siding of a building or the like. The same is covered by metal sheathing  15  which may be aluminum, copper, tin, etc. As the shank  21  of the nail is driven through the sheathing  15 , a hole or opening  16  is formed in the latter. As the nail shank is driven inwardly, the elastomer coating  23  is entirely peeled back from the part of the shank penetrating the wood. As the driving of the nail  20  continues, the coating material  23  continues to peel or roll back along the nail shank  21  and in the final home position of the nail. This material is all accumulated under the head of the nail as at B The material is entirely about the nail shank and is shown as partly entered into opening  16  completely filling said opening about the nail shank and completely insulating the nail shank as well as the head of the nail from the sheathing. 
         [0010]    U.S. Pat. No. 5,053,089 issued to Ristich provides a unitary threaded plug made of thermoplastic polymer composition for emergency tire repair As shown in  FIG. 3 , unitary plug  1  is circular in cross-section and tapered over the majority of its length to the finest practical point  2 , forming a body  3 . The untapered portion  4  at the top, or driving end, forms a head that has a shallowly concave contour  5  of its lateral silhouette which gives easy purchase for fingers to screw the plug into the puncture by hand. The larger untapered end portion, or head, has a greater diameter than the maximum diameter of the tapered portion, or body, affords increased mechanical advantage for torque applied with the fingers alone. The flat surface of the head  4  may be provided with a recess shaped for engagement by a tool such as a Philips head screwdriver for screwing the plug in. A coating such as asphalt coating may be pre-applied in manufacture, so that the repair procedure may omit a separate adhesive application step. The pre-applied coating provides means of safe self-rescue to the motorist, with a minimum of equipment and procedural steps. However, repairs made with this system enhanced by application of a moderate amount of rubber cement before insertion may be more leak-tight. Plug  1  is used by screwing it into the puncture opening in the tire T to a satisfactory depth, and thereafter the user removes most of the excess material of the plug left protruding outside the tire carcass, either by nipping it off with side-cutter pliers, by cutting it off with a utility knife, or by heating it with a match or a butane lighter, enough to soften a portion near the tire tread surface, and then twisting off the remainder with finger force, in any case leaving about one-quarter inch of material protruding 
         [0011]    U.S. Pat. No. 594,066 issued to Cluxton teaches some means, devices, and appliances for repairing or closing and sealing punctures on pneumatic tires of cycles  FIG. 4  shows a cross-section of a tire A and a plug partly elongated prior to insertion, the plug is then partly inserted; the plug is inserted and the tool is partly retracted; and the plug is inserted, cemented, and the tool is removed. Referring to  FIG. 4 , puncture  2  is designed to receive the plug  3 , which comprises a tubular shank or stem  4 , a hollow head  5 , usually provided with an apex  6 , and with perforations  7 , opening into the chamber of said head and arranged in any suitable manner adjacent to the base of said stem. The apex  6  is created by adding stock at that point, and this protects the head against perforation by the tool  8  and also permits more ready entrance of the plug into the puncture. This tool may be a rod or the tubular nozzle of any suitable injector  9 . It is inserted into the stem, the head having been lubricated by cement, and the apex applied to the puncture. Then the pressure upon said tool will elongate and stretch said head so that it will substantially lie against the sides of the tool for more ready or easier insertion. When inserted, the partial retraction of the tool will permit said head to resume its normal form transverse to said stem. Then the injection of cement into said head will cause it to flow through said perforations onto the face adjacent to the base of said stem. If the faces are then in contact, said cement will thereby be applied to both of them and the tool can be removed. This permits the tire to resume its normal condition and to expansively close the neck of the plug and the-opening therein, and the pressure of air forced into the tire will close the chamber in the head, force it tightly against the tire, force a modicum of cement into the neck of the stem, and the puncture is closed, cemented, and sealed. After this the projecting end of the stem can be cut off. The cement applied to lubricate the plug will coat the walls of the puncture and cement them to said stem. The cement is thus applied through the stem and head of the plug directly to the faces to be secured together, the neck of the stem closed and cemented, the walls of the chamber in the head are cemented together, and the walls of the puncture are cemented to the stem. Therefore, U.S. Pat. No. 594,066 provides a different means for closing, sealing, and repairing punctures in pneumatic tires. A repair plug is composed of a flexible hollow head mounted upon a tubular shank or stem and provided in its face, adjacent to the base of said stem, with perforations whereby the sealing cement can be applied to the face and to the interior face of the tire through said stem and head and its perforations. This plug is elastic, except as to the stem; but this is also expansible laterally. The head is elastic, so that by longitudinal pressure against its central portion it can be elongated and thereby reduced in size laterally, so as to be substantially of the size of the tool used, with the thickness of the material added, whereby it can be readily inserted through a small opening, and when the head is thus inserted and the tool is retracted slightly said head will re-expand into its normal shape. Then suitable cement is suitably forced through said stem into said head and through its perforations onto its outer face around said stem and onto the inner wall of the tire, and then said plug can be drawn out to bring it into close contact with the tire and the puncture is closed and the projection of the plug is then cut off. 
         [0012]    U.S. Pat. No. 570,942 issued to Merritt discloses a plug or closing device for closing tube punctures. As shown in  FIG. 5 , a plug or closing device is inserted in the puncture in a rubber-tube wheel-tire T The plug may work with the screw for holding a driving plate or tool in position. A punch may be employed to prepare the puncture to receive the plug. Referring to  FIG. 5 , the closing device or plug P has a head or enlargement H at one extremity, and integral with it is a tapering portion having a helical groove g in its surface. The entering end e is of small diameter, and at the junction between the head H and the conical or tapering portion there is a circular groove G. The underside or undersurface of the head H is concave, as at C. The object of the groove G and concavity C is to provide a seat for the edge of the punctured tube-wall. The wall can be crowded into position by the wedge action due to the helical groove g, which, when the closing device is rotated, jams the rubber tube-wall into the groove G and cavity C, and the sharp edge of the concave head H enters or engages the outer surface of the tube T. The head of the closing device is drilled out and screw-threaded at t to receive a screw s. D is a slotted driving plate for attachment to the closing device or plug P, and is employed as a turning or driving tool for rotating the plug into position. The head H is slotted at  19  to receive a screw-driver end. When a rubber plug or tire is punctured, a user can cut a round hole at or near the center of the puncture and insert the plug half way, by screwing the driving tool D thereto. When the rubber tube is a wheel-tire, the user can next force air in to render the tube more rigid, and the user may then continue the rotation of the driving tool D until the edge of the concave head H engages the outer surface of the tube and until the helical groove in the surface has forced the edge of the rubber wall into the groove G and concavity C, which result is attained by making one or two turns after the edge of the head H engages the surface of the tube. The user may then disengage the turning or driving, tool, remove screw s, and complete the inflation of the tube T until it is rigid in the rim R. A punch B can be used for cutting a round hole at or near the center of the puncture. It has a sharp cutting edge  8  and a transverse perforation  9   
         [0013]    Advantageously, the present invention provides a solution which is simpler but more effective than all the known devices and methods in the prior art. 
       SUMMARY OF THE INVENTION 
       [0014]    One aspect of the present invention provides a plug for repairing a flat tire. The plug includes a cap and an elongated body extending from a proximal end that is connected to or integrated with the cap to a distal end. The elongated body is circular in cross section and has a rotational axis along the elongation direction. The elongated body has cross sectional diameter Dx at a position Px along the rotational axis, and distance Lx is defined as a distance from the proximal end to positon Px along the rotational axis. Therefore, the proximal end is at position P 0  with L 0 = 0  and has a cross sectional diameter D 0 ≠ 0 . The distal end is at position Pd with Ld (maximal value of Lx) and has a cross sectional diameter Dd which is near  0 . Mathematically speaking, one feature of the invention is that a cross sectional diameter Dm at position Pm with Lm is greater than cross sectional diameters at any other positions along the rotational axis. Moreover, diameter Dm at position Pm remains unchanged after the flat tire repairing is completed. In other words, the plug is not deformed at all after the flat tire repairing is completed. 
         [0015]    Another aspect of the invention provides a method of repairing a flat tire using the plug as described above. The method includes the following steps: (1) providing a plug as described above, (2) applying a coating onto the elongated body of the plug, and (3) inserting the entire elongated body into a nail hole of said flat tire from external side of the tire. The cap of the plug remains at external side of the tire after a complete insertion of the elongated body. Step (4) is curing or solidifying the coating, and step (5) is inflating the repaired flat tire to normal pressure. 
         [0016]    Still another aspect of the invention provides a flat tire repairing kit comprising a plurality of the plugs as described above. At least two of the plugs in the kit have different Dm values and/or different Lm values, to fit different tires and different damages thereon. 
         [0017]    The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0018]    The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements. All the figures are schematic and generally only show parts which are necessary in order to elucidate the invention. For simplicity and clarity of illustration, elements shown in the figures and discussed below have not necessarily been drawn to scale. Well-known structures and devices are shown in simplified form, omitted, or merely suggested, in order to avoid unnecessarily obscuring the present invention. 
           [0019]      FIG. 1  shows various sealing nails in the prior art. 
           [0020]      FIG. 2  illustrates how to use the sealing nails of  FIG. 1  in the prior art. 
           [0021]      FIG. 3  shows a unitary threaded plug for emergency tire repair in the prior art. 
           [0022]      FIG. 4  shows a cross-section of a tire and another plugging device in the prior art. 
           [0023]      FIG. 5  shows a plug or closing device being inserted in the puncture in a rubber-tube wheel-tire in the prior art. 
           [0024]      FIG. 6  illustrates a flat tire repairing plug in accordance with an exemplary embodiment of the present invention. 
           [0025]      FIG. 7  demonstrates a flat tire repairing plug in accordance with an exemplary embodiment of the present invention. 
           [0026]      FIG. 8  depicts a method of repairing flat tire in accordance with an exemplary embodiment of the present invention. 
           [0027]      FIG. 9  schematically shows a flat tire repairing kit in accordance with an exemplary embodiment of the present invention. 
           [0028]      FIG. 10  illustrates two specific designs of flat tire repairing plug in accordance with an exemplary embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0029]    In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It is apparent, however, to one skilled in the art that the present invention may be practiced without these specific details or with an equivalent arrangement. 
         [0030]    Where a numerical range is disclosed herein, unless otherwise specified, such range is continuous, inclusive of both the minimum and maximum values of the range as well as every value between such minimum and maximum values. Still further, where a range refers to integers, only the integers from the minimum value to and including the maximum value of such range are included. In addition, where multiple ranges are provided to describe a feature or characteristic, such ranges can be combined. 
         [0031]    It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the invention. For example, when an element is referred to as being “on”, “connected to”, or “coupled to” another element, it can be directly on, connected or coupled to the other element or intervening elements may be present. In contrast, when an element is referred to as being “directly on”, “directly connected to”, or “directly coupled to” another element, there are no intervening elements present. 
         [0032]    Referring to  FIG. 6 , plug  100  is designed for repairing punctured tubes or pipes of flexible material, like rubber (e.g. a flat tire) by closing the aperture therein. These tubes are usually expanded by air under pressure, and often become punctured in use at a distance from convenient facilities for repairing. The punctures in tubes usually occur in the form of slits or slots and are produced by winning over a fragment of glass or stone having a ragged cutting edge As will be explained in details, plug  100  enables a quick repair to a tire in side-of-the-road self-rescue, without the need for removing either the tire or the rim from the vehicle. 
         [0033]    Referring to  FIG. 6 , plug  100  includes a cap  61  and an elongated body  60  extending from a proximal end  60 P that is connected to or integrated with the cap  61  to a distal end  60   d  (or entering end into a tire). The elongated body  60  is circular in cross section (irregularity such as grooves, if any, on the body will be ignored or approximated for simplicity of this model and its description) and has a rotational axis RA along the elongation direction. Elongated body  60  has cross sectional diameter Dx at a position Px along the rotational axis RA. Distance Lx is defined as a distance measured from the proximal end  60 P to positon Px along the rotational axis RA. 
         [0034]    In this model, the proximal end  60 P is at position P 0  with L 0 = 0  and has a cross sectional diameter D 0 ≠ 0 , as shown in  FIG. 7 . The distal end  60   d  is at position Pd with Ld and has a cross sectional diameter Dd which is near  0 . At position Pm with Lm (in other words, when Lx=Lm), there exists a corresponding cross sectional diameter Dm, which is greater than cross sectional diameters at any positions other than Pm along the rotational axis RA. In preferred embodiments, diameter Dm at position Pm remains unchanged after the flat tire repairing is completed. For example, the entire body  60  may be a single piece made of iron, steel or any other sufficiently rigid polymeric material, and it maintains its structural integrity after the tire repairing process. Therefore, when the plug  100  is driven inwardly into a tire, the mass in positon  60   m  region will not be peeled or rolled back, which is different from elastomer coating  23  as shown in  FIGS. 1 and 2 . There is no specific requirement for cap  61 . Cap  61  and body  60  may be single integrated piece, or they may be two pieces secured to each other. For example, the cap  61  may be round with a thickness Tcap and a diameter Dcap. Generally, Dcap is greater than both D 0  and the size of the hole on the tire that is to be repaired. 
         [0035]    In various embodiments, diameter Dx monotonously increases from D 0  at the proximal end P 0  to Dm at position Pm, and then monotonously decreases from Dm to Dd at distal end Pd In other words, body  60  is tapering along two directions (up and down along RA) from position Pm In preferred amendments, Lm is greater than 50% of Ld, greater than 60% of Ld, greater than 70% of Ld, greater than 80% of Ld, or greater than 90% of Ld. Dm is greater than D 0 , for example, Dm may be greater than 1.5D 0 , 2.0D 0 , 2.5D 0 , 3.0D 0 , 3.5D 0 , or higher 
         [0036]      FIG. 8  illustrates a method of repairing a flat tire  50  using the plug  100 . The method includes (1) providing a plug  100 , (2) applying a coating  70  such as rubber cement onto the elongated body  60 , and (3) inserting the elongated body  60  into a nail hole  58  of said flat tire  50  from external side of the tire  50 . Cap  61  remains at external side of the tire  50  after the insertion. Step (4) is curing or solidifying the coating  70 , so that coating  70  adheres or bonds body  60  and the tire material together. Step (5) is inflating the repaired flat tire  50  to normal pressure 
         [0037]    A suitable plug  100  may always be selected for a tire of any dimension and thickness. For example, if the tire  50  has a thickness TH, then a plug with Lm greater than 50% TH may be preferably selected to repair the flat tire. Lm may be greater than 50% TH, 60% TH, 70% TH, 80% TH, or 90% TH. As shown in  FIG. 8 , when Lm is greater than 50% TH, position Pm will pass the half thickness line of the tire TH/ 2 . As a result, the “force down” from the elastic tire material imposed on body  60 , which pushes the plug  100  inwardly, will be greater than the “force up” from the elastic tire material imposed on body  60 , which pushes the plug  100  outwardly. Therefore, plug  100  is sturdily stabilized and maintained inside the tire material. 
         [0038]    As shown in  FIG. 9 , the present invention also provides a kit like a tool box  200  comprising a plurality of the plugs  100   a, b, c, d, e, f, g, h, i,  and etc. At least two of the plugs selected from  100   a, b, c, d, e, f, g, h, i  have different Dm values and/or different Lm values. The kit may further includes a container  201  containing a curable coating material  70 , and a tool  202  for driving the plug  100  into the hole  58 . Kit  200  occupies a small space, and can be quickly applied without the use of special tools, in exposed and otherwise inconvenient locations. 
         [0039]      FIG. 10  illustrates two specific embodiments of plug  100  having a cap and a barrel formed body (as screw or pin, as example of body  60 ) wherein diameter of middle of said body (Dm) is wider than diameter of either end of said body. The cap may be a flat top, or it can have a drive design across the middle of the top, such as cross-shaped groove, I-shaped groove (as shown in top view of  FIG. 9 ) across the middle of the cap top.  FIG. 10  shows a barrel-forming screw  10  including cap  11 , cross-shaped groove  12  or I-shaped groove  18  on the top of cap  11 , and barrel forming crew body  13  (example of body  60 ).  FIG. 10  also shows a barrel forming nail  14  including nail cap  15 , cross-shaped groove  16  or I-shaped groove  18  on the top of nail cap  15 , and barrel forming nail body  17  (another example of body  60 ). 
         [0040]    Before the insertion of barrel formed screw  10  or barrel formed nail  14  into the nail hole of a flat tire, a user can apply coating material  70  such as super glue to barrel formed screw  10  or barrel formed nail  14  for lubrication to facilitate the insertion and to create an airtight sealing. Because of the form/shape of barrel of barrel formed screw  10  or barrel formed nail  14 , and the adhesion of super glue it is very hard for barrel formed screw  10  or barrel formed nail  14  to become loose. By driving car forward or backward slowly inch by inch, one can turn nail hole on flat tire to face the back of car. Once turning nail hole on a flat tire to face the back of car, the user lubricates the barrel formed screw  10  or barrel formed nail  14  with super glue and inserts or hammers it into the nail hole of the flat tire while the tire is still on wheel. After the insertion of barrel formed screw  10  or barrel formed nail  14 , the user can wait for a couple of minutes to let super glue set before he/she inflates the repaired flat tire. A flat tire repair kit (as example of kit  200 ) may contain a barrel formed screw, a barrel formed nail, a tube of super glue, and a screw driver. Barrel formed bolt can be of a variety of size, which is not shown in, but can be inferred from  FIG. 9 . The barrel formed screw or barrel formed nail can be used temporarily to repair a flat tire before the nail hole can be repaired by a machinist at auto body shop. The barrel shaped screw or barrel shaped nail can stay permanently on tire if air leakage of tire does not reoccur. 
         [0041]    In the foregoing specification, embodiments of the present invention have been described with reference to numerous specific details that may vary from implementation to implementation. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense The sole and exclusive indicator of the scope of the invention, and what is intended by the applicant to be the scope of the invention, is the literal and equivalent scope of the set of claims that issue from this application, in the specific form in which such claims issue, including any subsequent correction.