Abstract:
Embodiments of an integrated piping conduit in accordance with aspects of the present invention include a push-to-connect fitting integrated with an adaptor device and associated methods that facilitate the re-use of push fittings without damage to the fitting elements or the pipe, while also facilitating connection to boxes such as electrical boxes in a manner that meets requirements and saves time for professionals dealing with the otherwise challenging management of multiple wires, cables and/or connections. Embodiments can incorporate an integrated release pusher and locking mechanism that allows for quick locking and unlocking of piping elements within a fitting. Embodiments can also include an adaptor having integrated head and body portions, and an ear member extending at least partially radially outwardly and at least partially axially outwardly from the outer surface of the body portion.

Description:
FIELD OF THE INVENTION 
     The present invention relates to piping conduits, and more particularly to a push-to-connect fitting adaptor device, conduit and method that facilitates protection of contents. 
     BACKGROUND OF THE PRESENT INVENTION 
     Piping systems exist to facilitate the flow of fluids (e.g., liquid, gas (such as air) or plasma), contain contents internally and provide other functions. For example, piping systems can include conduits that maintain electrical wiring, effectively bundling and containing wiring within a confined and protected area, so that the inserted wires can be collectively transported, shielded and joined from one point to another. In many instances, one of the end points for the conduit is an electrical box. For purposes of the present disclosure, the term “tube”, “pipe”, “piping”, “conduit”, “conduit element” or “piping element” will be understood to encompass one or more pipes, tubes, conduits, piping elements and/or tubing elements, and may be used interchangeably. 
     Electrical boxes, which can be referred to as utility boxes, can come in a variety of shapes and sizes, and generally operate to enclose wire connections for indoor electrical applications such as light switches, electrical outlets, fan switches and similar applications. Electrical boxes can be designed for use indoors, outdoors, in an exposed fashion outside of a wall, and in a hidden fashion within a wall, for example. Invariably, electrical boxes include openings to facilitate wiring connections and mounting in desired locations. Various conduits can be employed for collecting and facilitating connection wires through interfacing with one of the electrical box openings, thereby making it safer and easier to connect wires entering from the outside of the box to power sources and ground lines inside of the box, for example. As a specific example, an indoor electrical box for a light switch may have wiring entering the box from a central home power source, and may separately have wiring entering the box from the lighting fixture to be controlled by the light switch. The home power source wiring is connected to the light switch, and the lighting fixture wiring is also connected to the light switch, after which the lighting fixture can be controlled from the electrical box housing the described connections. If the wiring is not securely maintained, or the box improperly positioned or secured, problems can result. 
     The conduits or piping connections for managing loose wires are generally tube-shaped elements with a hollow interior for permitting wiring to pass through. Such conduits are useful in properly protecting the wires and cables contained therein. If unprotected, the loose wires and/or cables can be damaged, cut (such as against a metal edge of the electrical box opening) and can potentially cause a short circuit, shock, or fire. While code regulations exist to help prevent these problems, various installations may not meet code requirements. When traditional conduits are positioned within an electrical box opening, they may be unsecured, or possibly secured through a basic form of attachment such as a threaded engagement. 
     In recent years, push-fit technology has been employed with piping systems, and particularly with plumbing systems, to reduce the dangers and time involved in soldering joints and other connection methods. Push-fit methods require minimal knowledge of pipe fittings and involve far fewer materials than soldering. For example, one may only need the pipes, quick-connect fittings, a chamfer/de-burring tool and tubing cutter in order to connect pipes using push-fit technology. The steps involved in connecting piping systems using push-fit technology can be outlined as follows. First, the pipe is cut to the appropriate length and the end of the pipe is cleaned with the de-burring tool. Then the pipe and fitting are pushed together for connection. The fitting is provided with a fastening ring (also called a collet, grip ring or grab ring) having teeth that grip the pipe as it is inserted. The fastening ring device is employed to provide opposing energy, preventing the device from disconnection while creating a positive seal. Accordingly, no wrenches, clamping, gluing or soldering is involved. Push-fit and/or quick-connect technology for piping systems can be obtained, for example, through Quick Fitting, Inc. of Warwick, R.I., USA, suppliers of the CoPro® line of push fittings and related products. Also, such technology is described, for example, in U.S. Pat. Nos. 7,862,089, 8,205,915, 8,210,576, 8,398,122, and 8,480,134, the disclosures of which are incorporated herein by reference in their entireties. 
     SUMMARY 
     The present invention provides, in part, a push-to-connect fitting integrated conduit with adaptor device and method that facilitates the re-use of push fittings without damage to the fitting elements or the pipe, while also facilitating connection to boxes such as electrical boxes in a manner that meets requirements and saves time for professionals dealing with the otherwise challenging management of multiple wires, cables and/or connections. The present invention connects piping and utility boxes using no tools, clamps, solder or glues, while creating a highly effective seal at the connected joining area. Further, the present invention can incorporate an integrated release pusher and locking mechanism that allows for quick locking and unlocking of piping elements within a fitting. In embodiments of the present invention, the packing arrangement is also tamper-resistant, and can be provided in accordance with the devices, systems and methods described, for example, in co-owned and pending U.S. Pat. No. 9,068,680 issued Jun. 30, 2015 and U.S. application Ser. No. 14/291,740, both filed on Jun. 2, 2014, the disclosures of which are hereby incorporated by reference in their entireties. 
     In various embodiments, the quick connection pipe joint assembly package provided as part of the present invention employs a lockable release pusher that, when in the unlocked position, permits the pusher to move axially inwardly of the fitting, lifting teeth of a fastening ring and thereby facilitating the insertion and release of a cylindrical object such as a piping element held within the fitting. When a piping element is desired to be removed, axially applied pressure can be provided again to the release pusher, lifting the fastening ring teeth off of the inserted pipe to allow it to be removed. In one embodiment of the present invention, the release pusher is permanently secured to the fitting and is part of the packing arrangement. 
     For purposes of the present disclosure, a fitting can encompass a valve member and other piping elements including, but not limited to: a coupling joint, an elbow joint, a tee joint, a stop end, a ball valve member, tubing and other objects having substantially cylindrical openings. In one embodiment of the present invention, one or more sealing member gasket inserts (e.g., O-ring members) fit within a sealing compartment defined in the interior of the fitting. A sealing ring stabilizer element can also be provided to provide support for the one or more sealing rings. In addition, at each pipe receiving end of the fitting, a locking compartment is machined into the interior wall of the fitting to receive other members, such as, for example, a snap ring member and a locking pusher member and to assist in retaining the edges of the fastening ring. The interior compartments and housing elements provide integrated support for the sealing members and fastening ring when opposing force is applied to piping elements that have been inserted into the fitting. 
     Aspects of the present invention further provide a connector or adaptor device that can be positioned in or through an opening in a utility or electrical box and secured thereto, while being positioned and secured at the other end to a conduit fitting device, which can house various embodiments of fitting insertion components to permit a piping or conduit element to be removably secured therein. Such aspects can further include a releasable locking component as described above and in the references incorporated by reference noted above, for example. The fitting can be considered a conduit, and the combined fitting and adaptor device can be considered a conduit, in accordance with various embodiments of the present invention. 
     Other methods, devices and arrangements as described herein are provided by the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an exploded front perspective view of a conduit arrangement with adaptor in accordance with embodiments of the present invention. 
         FIG. 2  is a perspective view showing the elements of the arrangement of  FIG. 1  in cross-section. 
         FIG. 3  is a front elevational view of one embodiment of the arrangement of the present invention positioned in front of a utility box. 
         FIG. 4  is an exploded cross-sectional view of the arrangement as taken along line  4 - 4  of  FIG. 3 . 
         FIG. 5  is a front perspective view of a conduit arrangement with adaptor as installed in a utility box in accordance with embodiments of the present invention. 
         FIGS. 6 and 7  are rear perspective views of a conduit arrangement with adaptor as installed in a utility box in accordance with embodiments of the present invention. 
         FIG. 8  is a front elevational view of an adaptor in accordance with embodiments of the present invention. 
         FIG. 9  is a right side view of the adaptor of  FIG. 8 . 
         FIG. 10  is a rear elevational view of the adaptor of  FIG. 8 . 
         FIG. 11  is a left side cross-sectional view of the adaptor of  FIG. 8  as taken along line  11 - 11  of  FIG. 10 . 
         FIG. 12  is a front elevational view of a fastening ring in accordance with embodiments of the present invention. 
         FIG. 13  is an enlarged view of the portion of the fastening ring taken from encircled portion  13 - 13  of  FIG. 11 . 
         FIG. 14  is a left side view of the fastening ring of  FIG. 12 . 
         FIG. 15  is a front elevational view of a piping element or fitting in accordance with embodiments of the present invention. 
         FIG. 16  is a right side cross-sectional view of the piping element of  FIG. 15 , taken along the line  16 - 16  of  FIG. 15 . 
         FIG. 17  is an enlarged view of the portion of the piping element taken from encircled portion  17 - 17  of  FIG. 16 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In the conduit assembly  10  of embodiments of the present invention as shown in  FIGS. 1 through 17 , elements of the joint assembly as shown include: a fitting (i.e., fitting body member)  12  having an interior wall  21 , an exterior wall  27 , end walls  23 ,  25 , one or more sealing members  14  (which can be optionally lubricated), a fastening ring  19 , a pusher locking member  18  and a release pusher  20 . The fastening ring  19 , sealing member(s)  14 , pusher locking member  18 , release pusher  20  and various other internal components, together, and in subset combinations, provide embodiments of a packing arrangement employable in accordance with embodiments of the present invention, and each has a substantially ring-shaped body forming an opening extending through the body along axis A. The interior wall  21  forms an axial opening or cavity  29 , which allows for smooth and snug engagement of an external conduit, piping or tubing element external surface (not shown). As noted above, push-to-connect technology for piping and conduit systems that can be employed in accordance with embodiments of the present invention is shown and described in the above-referenced patent documents. In various embodiments of the present invention, as shown in  FIGS. 12 through 14 , for example, the fastening ring  19  can be provided with a base  160 , and a plurality of individual teeth  162  extending therefrom, wherein the teeth are provided with side edges  163  and a radially internal edge  164 . In various embodiments of the present invention, the fastening ring  19  has a bifurcated design, and edges  164  are formed in a curved fashion so as to facilitate gripping action against an inserted piping element, which may be a galvanized steel pipe, for example. 
     As further shown in  FIG. 2 , the release pusher  20  can be positioned at a first end  22  of the fitting  12 , and an adaptor mounting end  25  can be positioned adjacent an adaptor  30 . Further, as shown in  FIGS. 2 and 4 , the exterior surface of the fitting  12  at the adaptor mounting end  24  can be provided with an external thread  26  and a wedge portion  28 , for engaging the adaptor  30  as described further herein. 
     As shown in  FIGS. 16 through 18 , the fitting  12  further includes a collar portion  60  extending radially outwardly of the fitting exterior wall  27  and further extending radially inwardly of the fitting interior wall  21 . The collar portion  60  includes an axially inner surface  62  and an axially outer surface  64 , wherein the axially outer surface  64  has a pipe engaging portion  65  within the fitting cavity  29 , and wherein the collar portion axially inner surface  62  has an adaptor engaging surface  66  external of the cavity  29 . The external surface  67  of the collar portion  60  can be considered part of the exterior wall  27  of the fitting  12 . As shown in  FIGS. 16 through 18 , the collar portion  60  extends radially outwardly of the wall  27  between the approximate mid-section  31  of the fitting  12  and the wedge portion  28  of the fitting  12 . By so doing, the collar portion  60  provides a surface  66  against which the adaptor  30  can engage, as described elsewhere herein.  FIG. 5  illustrates the connection of the fitting  12  with the adaptor  30 , and with the joined conduit  10  inserted and secured in box  50 . 
     In various embodiments of the present invention, as shown in  FIG. 17 , for example, the radial distance C from the fitting axis A to the approximate mid-point  69  of the thread  26  can range from approximately 0.26 inches to approximately 2.78 inches, inclusive, and the radial distance D from the axis A to the tip  71  of the thread  26  can range from approximately 0.51 inches to approximately 3.03 inches, inclusive. Further, in various embodiments, the height E of the thread  26  can range from approximately 0.125 inches to approximately 0.75 inches, inclusive, and the axial distance F between radially extending walls  72  and/or thread heights of the thread  26  can range from approximately 0.005 inches to approximately 0.250 inches, inclusive. 
     In various embodiments, the interior surface  21  of the fitting  12  can extend in a stair step fashion to accommodate the connections and purposes of the fitting described herein. For example, the interior surface  75  of the wedge portion  28  extends a radial distance from axis A that is less than the radial distance from axis A to the interior surface  76  of the intermediate portion  31  of the fitting, and the radial distance from axis A to the interior surface  76  is less than the radial distance from axis A to the interior surface  77  of a sealing ring compartment  97 . Further, the radial distance from axis A to the interior surface  77  is less than the radial distance from axis A to the interior surface  78  of a fastening ring compartment  98 , and the radial distance from axis A to the interior surface  78  is less than the radial distance from axis A to the interior surface  79  of a pusher locking member compartment  99 . Also, the radial distance from axis A to the interior surface  78  is greater than the radial distance from axis A to the interior surface  96  of the end wall  25 . In this way, interior surface  96  is part of a pocket or compartment  99  for retaining a pusher locking member  18  shown in  FIGS. 2 and 4 , when a suitable packing arrangement is employed in the fitting. In operation, a packing arrangement such as that described above in connection with  FIGS. 2 and 4  is positioned within compartments  97 ,  98  and  99 , and a piping element is inserted into the cavity  29 . The release pusher  20  lifts the fastening ring teeth  162  so that the piping element can be inserted, and the piping element will stop at the wall  65  of the collar portion  60  of the fitting  12 . Once in place, the piping element can be retained within the cavity  29  and restricted from axial movement back out of the cavity by the fastening ring teeth  162 , which make contact with the piping element outer wall once the release pusher  20  is released. In addition, wiring can be inserted through the opening  29 , any inserted piping element, and thus into the utility box  50  for the purposes described herein. 
     As shown in  FIGS. 2, 4 and 8 through 11 , the adaptor  30  has a head portion  35  at a first end  32 , and a body portion  40  integrally formed with and extending from the head portion  35  to a second end  34 . The adaptor  30  can be substantially ring-shaped in the sense that the adaptor  30  has an interior surface  73  forming an opening  74  extending axially through the head portion  35  and the body portion  40  along axis B. The head portion  35  can extend radially outwardly of the body portion  40 , as shown in  FIGS. 9 and 11 , for example. The body portion includes an interior wall  38  and an exterior wall  41 . In various embodiments, the body portion  40  comprises a neck portion  80 , a shoulder portion  82  and a ledge portion  84 , wherein the neck portion  80  has an external surface  81  that extends axially from the head portion  35  in substantially parallel relation to axis B. The shoulder portion  82  further has an outer surface  83  and the ledge portion  84  also has an outer surface  85 . Outer surfaces  81 ,  83  and  85  form the exterior wall  41  of the adaptor  30 . In various embodiments, the radial distance from axis B to the outer surface  81  of neck portion  80  is less than the radial distance from axis B to the outer surface  83  of shoulder portion  82 . In various embodiments, the outer surface  83  of shoulder portion  82  extends from a longer radial distance from axis B at edge  88  adjacent neck portion  80  to a shorter radial distance from axis B at edge  89  adjacent ledge portion  84 . Such a relative dimensioning can assist, for example, with inserting the adaptor  30  into a box  50  during installation, for example. In specific embodiments, the outer surface  83  of shoulder portion  82  extends substantially linearly from edge  88  to edge  89 . The relative dimensions of the neck  80 , shoulder  82  and ledge  84  portions help provide a strong base for supporting the ear member  55 . Further, the radial distance from axis B to the outer surface  81  of neck portion  80  matches the radius R of the opening  52  in the box  50  to ensure snug engagement of the adaptor  30  within the box  50 . 
     In various embodiments of the present invention, the outer surface  85  of ledge portion  84  of adaptor  30  extends radially inwardly from edge  89  adjacent shoulder portion  82  to edge  90  forming the axially inner end  92  of the adaptor  30 . In this way, a portion of the outer surface  85  has a radial distance from axis B that exceeds the radial distance from axis B to the outer surface  81  of the neck portion  80 , while outer surface  85  also has a portion with a radial distance from axis B that is less than the radial distance from axis B to the outer surface  81  of the neck portion. In specific embodiments, the outer surface  85  of ledge portion  84  extends substantially linearly from edge  89  to edge  90  in chamfered form. In other embodiments, the outer surface  85  can be rounded. With the arrangement as shown in  FIGS. 9 and 11  and described above, the adaptor  30  maintains core strength at neck portion  80  while providing stability for ear member  55  as described hereinafter. 
     As further shown in  FIG. 2 , the first end  32  of the adaptor  30  is adapted to engage the adaptor mounting end  24  of the fitting  12 . In embodiments of the present invention, the thread  26  on the adaptor mounting end  24  of the fitting  12  can threadingly engage an interior thread-receiving cavity  36  of the adaptor  30 . Further, the wedge portion  28  of the fitting  12  can engage interior wall(s)  38  of the adaptor  30  such that, as the fitting threadingly engages the adaptor, the wedge portion  28  pushes the interior wall  38  of the adaptor outwardly, assisting in secure connection between the adaptor  30  and a utility box  50  as described elsewhere herein. In various embodiments of the present invention, the thread arrangement can include a buttress thread, a standard thread, a rectangular thread, a square thread and/or a double buttress thread design. The thread design can include, for example, a ½ inch thread or a ¾ inch thread. As shown in  FIGS. 15 through 17 , for example, the fitting  12  can be provided such that the thread  26  on the adaptor mounting end  24  has an outer diameter D, a pitch diameter and a thread pitch consistent with the discussion elsewhere herein. The dimensions of these measurements can vary depending upon the implementation, but can generally result in a very tight fitting that helps to keep the fitting securely connected with the box. 
     As shown in  FIGS. 4 and 11 , as the interior wall  38  moves away from the head portion  35  and axially outwardly thereof, the interior wall  38  also extends radially inwardly. In various embodiments, this radially inward movement begins from a first radial inner wall point  39 , where the inner wall is of substantially the same radius as the thread-receiving cavity  36  of the adaptor  30 . As the wall  38  moves axially outwardly to the second end  34 , the wall radius becomes smaller. In embodiments of the present invention as shown in  FIGS. 2 and 6 through 11 , the adaptor  30  further includes ear member  55  extending outwardly from the outer surface of the adaptor  30  at or near the second end  34 . In various embodiments, the ear member  55  is secured to the outer surface  83  of shoulder portion  82 , and in additional embodiments, the ear member  55  is secured to the outer surface  83  of shoulder portion  82  and the outer surface  85  of ledge portion  84 . In various embodiments, the ear outer edge  155  is provided with a top squared off edge  157 , and chamfered side edges  159  such that the full side edges  159  can mate with the floor  51  of the box  50  as it is rotated during operation, as shown in  FIG. 7 . In this way, the ear member  55  provides greater and more stable resistance to turning, which facilitates secure connection of the adaptor to the fitting during operation. 
     The ear member  55  can be of varying shapes, thicknesses and sizes, and can extend both radially and axially outwardly from the body portion  40  so as to be capable of suitably engaging an inner wall  51  of a utility box  50  when installed. It will be appreciated that the ear member  55  can thus extend at least partially radially outwardly from the body portion  40  as well as at least partially axially outwardly of the body portion  40 , and that the radial outward extension of the ear member  55  does not necessitate an extension that is perpendicular to the adaptor axis. In various embodiments, the ear member  55  extends primarily radially outwardly from the body portion  40 . It will be appreciated that by extending outwardly from the outer surface  83  (and also optionally outer surface  85 ), the ear member  55  has a substantially flat surface that is angled radially outwardly and axially outwardly from the body portion  40  in order to operate smoothly when engaging and disengaging from the inner wall  51  of utility box  50 . 
     In addition to the above, the body portion  40  of the adaptor  30  can be formed with one or more axially extending grooves  42 . The grooves  42  permit the body member  40  to flex during operation, such that the body member  40  can extend through an opening  52  in a utility box  50  during installation or de-construction. In embodiments of the present invention, the grooves  42  extend in a direction that is coaxially aligned with the axis of the opening through the adaptor  30 . In other embodiments, the grooves  42  can extend at non-coaxial angles. In various embodiments, the grooves  42  extend from the head portion xx to the second end xx of the adaptor. 
     The electrical and/or utility box  50  shown in the drawings is representative of various utility boxes where manual wiring connections can take place. As shown in  FIGS. 1 through 7 , the box  50  includes a floor  51  and one or more openings  52 . Typically, the openings  52  are formed in the box and may have rough edges, but can generally be formed with a substantially rounded or circular shape. 
     For installation, the second end  34  of the adaptor  30  can be inserted through an opening  52  in the box  50 , whereby the ear member  55  is most likely inserted through the opening first, followed by the body portion  40 . Once the adaptor is through the opening  52 , it can be pushed with manual pressure at the head portion  35  until a base surface  39  of the head portion  35  abuts the outside surface  59  of the box  50 . At such time, the ear member  55  resides completely within the box  50 , as shown in  FIGS. 5 through 7 . It will also be appreciated that the outer surface  81  of the neck portion  82  of the body portion  40  mates with the edges  53  of the opening  52  when installed. The fitting can then be inserted into the first end  32  of the adaptor  30 , whereupon the wedge portion  28  of the fitting engages or nearly engages the inner wall  38  of the adaptor, and the external thread  26  of the fitting engages the thread-receiving cavity  36  of the adaptor  30 . As the fitting is rotated (e.g., clockwise), the threaded engagement of the fitting  12  with the adaptor  30  moves the wedge portion  28  further within the adaptor, and begins to put pressure on the internal wall  38  to expand outwardly. The expansion of the internal wall  38  outwardly is facilitated by the gaps  42 , and thus the body portion  40  can more snugly engage the edges  53  of the opening  52  of the box  50 . Further, the rotation of the fitting  12  and engaged adaptor  30  causes the ear member  55  to rotate such that outer edge  159  will contact the floor  51  of the box, as shown in  FIG. 7 . In this way, the adaptor and fitting are snugly engaged with the box, and a pipe or conduit element can then be inserted into the first end  22  of the fitting as described elsewhere herein. Any wiring or cabling within the conduit element can then be drawn through the fitting and adaptor for ready manipulation within the box  50 . 
     In embodiments, the fitting  12  and can be forged CW617N brass, with full porting and full flow fitting, for example. In other embodiments, the fitting  12  can be a plastic material. Similarly, the adaptor  30  can be plastic, to provide slight malleability for insertion through an opening  52  in the utility box  50  or other compartment where employed. 
     It will be appreciated that the present invention provides various methods for assembling and operating piping joint assemblies, including, for example, providing a fitting as described elsewhere herein, wherein the fitting has an outer wall, and an inner wall, wherein the inner wall defines a locking compartment and a pipe receiving cavity extending along a longitudinal axis of the fitting; inserting a pusher locking member into the fitting so as to be maintained within the locking compartment; and securing a release pusher to the pusher locking member, the release pusher having a substantially cylindrical outer wall having an axially outer end, a substantially cylindrical inner wall having an axially outer end, and an axially outer wall connecting the axially outer end of the outer wall and the axially outer end of the inner wall, wherein the release pusher is secured to the locking member such that the inner wall is axially movable into the cavity, and rotatable about the fitting longitudinal axis. The present invention can further include tamper-resistant features to dissuade any unscrupulous individual from attempting to tamper with the device and/or internal components. 
     It will be appreciated that any and all dimensions described herein are exemplary and provided as embodiments associated with proper working operation of the present invention. Further, it will be appreciated that, in one embodiment of the present invention, the members of the push connect joint assembly can be formed through hydroforming processes. 
     The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the claims of the application rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.