Abstract:
A thermoformed PVC, modified PVC, CPVC, metal or coated metal cover, covering system and method is provided for covering assemblies of pipe and pipe insulation, hangers, support rods and mechanical assemblies wherein the assembly is biocide treated, covered by and completely enclosed by the cover, the cover is sealed in order to prevent bacteria growth within the cover while allowing a smooth outside surface for biocide application. The cover can be modified to facilitate the application of biocide after the assembly is covered by providing resealable openings in said cover.

Description:
This application is a continuation of application Ser. No. 09/605,519, filed Jun. 28, 2000, now U.S. Pat. No. 6,283,158. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to the field of pipe insulation. More particularly, the present invention relates to the field of pipe insulation for industrial food processing installations and the prevention and inhibition of biological contamination of foodstuffs during processing. 
     2. Background of the Related Art 
     Food contamination by bacteria such as salmonella, listeria monocytogenes, campylobacter jejuni,  E. coli , yersenia enterocolitica and possibly others have been the cause of the loss of millions of dollars and pounds of food products being recalled from the market place and disposed of, particularly during recent years. The present invention presents a novel solution to this contamination problem thereby addressing a serious public health problem and eliminating large scale waste of food. 
     Currently, treatment of foods by irradiation appears to be the most efficient means for preventing bacterial contamination of foods. However, the irradiation process tends to affect certain foods, such as changing the color of red meat to an unappetizing brown. In addition, many persons and organizations are concerned about the levels of irradiation being used to ensure uncontaminated food. Therefore, processing the foods under very clean conditions and reducing the amount of irradiation to an acceptable level to ameliorate public concern and minimize aesthetic drawbacks such as color change is a better approach. Unfortunately, maintaining a very strict sanitary environment requires changing piping, hangers, pumps, equipment and all parts of the food processing system. Although generally the present existing systems that are in direct contact with food are designed for easy removal and flushing out with scalding water or steam, other mechanical piping in the area of the system, exterior of process water, including electrical conduit piping, etc. needs to be addressed. Therefore a system of covering over all piping and equipment with thermoformed PVC, higher temperature modified PVC/acrylic, chlorinated vinyl resin (CPVC), metal or coated metal in areas of scalding wash downs or steam cleaning to reduce to an absolute minimum any area where bacteria growth is possible is very important. The system of covering surfaces with PVC is fairly common in food plants, both on bare piping and on insulated piping etc. The use of PVC or CPVC with its high chlorine content deters bacteria growth, and is an ideal primary material for this use. Another advantage is that PVC covers these areas with a minimum disturbance of painted and insulated surfaces on existing systems. However, conventional PVC coverings alone can not guarantee a contaminant-free environment because conventional PVC coverings do not completely encase the assemblies. Therefore, a need exists for PVC or modified PVC pipe coverings that completely encase the mechanical assemblies present in food processing plants. Furthermore, a need exists for pipe covering which can accommodate application of biocides. Finally, there exists a need for a system combining thermoformed PVC or modified PVC-type covering in a food processing plant with reduced irradiation of foods. 
     It is therefore an object of the present invention to provide a PVC or modified PVC cover which is sealed for covering assemblies of pipe and pipe insulation, hangers and support rods, wherein said cover completely encloses the entire assembly in order to prevent bacteria growth while allowing a smooth surface for easy biocide cleaning. 
     It is another object of the present invention to form the aforementioned cover of PVC, modified PVC/Acrylic, CPVC, metal or coated metal or any other suitable material that tends to discourage bacteria growth. 
     It is a further object of the present invention to provide a system wherein biocide can be brushed, wiped or sprayed over all the portions of the assembly to kill bacteria before installing the cover. 
     It is still a further object of the present invention to provide a space under the cover for a thin absorptive sponge type material to which a biocide can be applied periodically through one or more small resealable openings that can be formed in the cover, thereby renewing and refreshing the biocidal activity beneath the cover. 
     It is yet another object of the present invention to provide a cover comprising a split PVC tube that is pressed in place over a PVC coated support rod attached to the hanger of an assembly to be covered. 
     It is still yet another object of the present invention to provide shaped PVC, Acrylic modified PVC, CPVC (or other type) formed elbow, tees, valves, specialty fittings, bare conduit, piping, pumps and equipment that lends itself to being enclosed and/or being treated with biocide prior to being sealed in place. 
     It is still a further object of the present invention to provide a system of the aforementioned coverings for assemblies and fittings in a typical food processing facility to prevent biological contamination of foodstuffs. 
     It is still yet a further object of the present invention to provide a method for preventing biological contamination of foodstuffs in a food processing facility comprising the steps of providing the aforementioned system of coverings and irradiating food at the lowest possible level that will destroy bacteria. 
     SUMMARY OF THE INVENTION 
     The present invention provides a novel thermoformed PVC, modified PVC/acrylic, CPVC, metal or coated metal covering for mechanical assemblies in food plants, such as but not limited to piping, hangers and the like whether the assemblies are insulated, uninsulated, painted, bare or otherwise. The present invention provides a continuous barrier over mechanical assemblies in food plants wherein said assemblies are highly susceptible to bacterial contamination. In one embodiment, the invention is a pipe insulation saddle for covering a clevis-type hanger and a portion of pipe supported by the hanger. It can be seen that this type of mechanical assembly is a fertile ground for bacteria growth. In this embodiment the hanger and pipe cover encases the entire hanger and pipe assembly inside a formed PVC or modified PVC shape that is sealed into place with a suitable adhesive such as but not limited to PVC cement or the like. This allows sprayed or brushed-on biocide such as but not limited to Lysol or other FDA approved material, to be applied onto the assembly prior to the installation of the cover. A small sponge material or the like can be inserted under the cover, preferably saturated with biocide prior to sealing the cover in place. A small opening or openings can be provided in the cover above the sponge area and periodic applications of biocide can be directed onto the sponge area. The opening can be sealed with PVC cement, PVC tape, a PVC patch or any reasonably suitable substitute. This and other modifications of this embodiment results in an atmosphere under the cover that deters and minimizes bacteria growth. 
     The smooth, chemical resistant PVC or modified PVC cover lends itself to easy cleaning such as by wipe on method. 
     In another embodiment the invention comprises substantially a humped formed fitting cover that is made with a deliberate hump molded in to cover existing insulated fittings. This embodiment eliminates the need to shave or remove the fitting for reinsulation, preventing possible asbestos cement contamination in the area. This is a considerable improvement over the current available alternative which is to remove the asbestos under strict regulations at very high costs. In this embodiment the PVC or modified PVC cover can accommodate the application of a biocide between the insulated fitting and the PVC cover. The biocide may be applied to the exterior of the insulated fitting or to the interior of the cover. In another embodiment a material such as a sponge for carrying a biocide may be inserted between the fitting and the formed PVC covering. The cover may further include a resealable opening for applying additional biocide after the covering is installed over the fitting. The hump feature may be applied to fitting covers for 45 degree elbows, tees and all other fittings and assemblies. 
     Fitting covers of all shapes may be employed with the present invention. In addition, fitting covers without the hump feature may be employed in new installations over shaped type insulations. 
     The foregoing embodiments provide for a system wherein a thin sponge material such as but not limited to ⅛″ thick soft polyurethane can he saturated with Food and Drug Administration approved biocide, inserted between a cover of the present invention and fitting or assembly to be covered and the cover sealed over, creating a biocide atmosphere to prevent bacteria growth under the cover. Small openings can be provided in the cover to allow a periodic application of biocide material to maintain an antibacterial atmosphere under the sealed PVC cover or jacket. The opening can be resealed with PVC cement or a round dot of PVC tape or a suitable substitute. On CPVC jacketing and covering the opening is preferably sealed with CPVC cement. In the present invention it is critical that all joints between PVC or modified PVC covers and jacketing be sealed tight with a suitable adhesive or the like. 
     In embodiments in which there is insufficient space for a sponge, the biocide material can be painted on or wiped on, before applying and sealing the cover or jacketing. This system may be employed on all unions, valve covers, Victaulic type covers, specialty fittings such as is disclosed in U.S. Pat. No. 5,335,697 to Botsolas, incorporated herein by reference, flanges and the like. The present invention also applies to all bare fittings and pipes. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a front perspective view of an assembly to be covered by the present invention. 
     FIG. 2 is a front perspective view of a modified version of the assembly of FIG.  1 . 
     FIG. 3 is a perspective view of selected elements of the assembly of FIG.  2 . 
     FIG. 4 is a side perspective view of the assembly of FIG.  2 . 
     FIG. 5 is a front view of a preferred embodiment of the covering of the present invention. 
     FIG. 5 a  is a view of the embodiment of FIG. 5 further depicting the dimensions of said embodiment. 
     FIG. 6 is a side view of the covering FIG. 5 taken along the line A-A′. 
     FIG. 6 a  is a view of the embodiment of FIG. 5 further depicting the dimensions of said embodiment. 
     FIG. 7 is a top plan view of the embodiment of FIG.  5 . 
     FIG. 8 is an exploded view of the covering of FIG. 5 disposed on the assembly of FIG.  4 . 
     FIG. 9 is a side view another embodiment of the present invention. 
     FIG. 10 is a side view of another embodiment of the present invention. 
     FIG. 11 is a side view of a preferred embodiment of the system of the present invention including an exploded view of the invention according to FIGS.  9  and  10 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Now referring to FIG. 1, a typical assembly  10  to be covered by a preferred embodiment of the present invention comprises an insulated pipe  2  supported by a clevis type hanger  6 , said hanger  6  connected to rod  20  by connecting means  22 . Pipe  2  is typically contained in insulation jacketing  4 . Now referring to FIGS. 2,  3  and  4 , assembly  10  may further comprise pipe insulation saddle  12  with long ends  14  having approximate ⅛″ radius bend corners  16  to prevent corners  16  of the saddle  12  from tearing the pipe insulation jacketing  4 . 
     Now referring to FIGS. 5 and 6, the preferred embodiment of the invention is a novel thermoformed cover  30  formed of PVC, modified PVC/acrylic, CPVC, metal or coated metal covering for covering assemblies in food plants, such as but not limited to piping, hangers and the like such as clevis-type hanger and pipe assembly  10  shown in FIGS. 1-4. Cover  30  comprises a continuous barrier which encases the entire assembly  10  and is sealed into place with a suitable adhesive such as but not limited to PVC cement or the like. Now referring to FIG. 7, the cover  30  of the preferred embodiment is shown installed onto assembly  10  as shown in FIGS. 1-4. As best seen in FIGS. 5,  6  and  7 , the cover  30  comprises central wedge-shaped section  32 , elongated sections  34  and  36  formed on opposite sides of said wedge-shaped section  32 , lip  38  forming an opening  39  formed in the top  40  of section  32 , openings  42  and  44  formed in ends  46  and  48  of elongated sections  34  and  36  respectively. Now referring to FIG. 7, cut  50  is preferably formed along the length of cover  30  for facilitating the efficient installation of cover  30  over assembly  10 . The contours of cover  30  as best seen in FIGS. 5,  6 ,  7  and  8  are necessary to cover and enclose assembly  10 . Specifically, wedge-shaped section  32  is contoured to enclose the clevis-type hanger  6  and elongated sections  34  and  36  are contoured to enclose pipe  2 , insulation  4  and saddle  12  including corners  16 . Elongated sections  34  and  36  are Preferably substantially cylindrical to conform to the shape of standard pipe and/or pipe insulation and preferably comprise tapered sections  52  and  54  which provide respace between the interior of cover  30  and pipe  2 , insulation  4  and saddle  12 . Now referring to FIG. 8, the dimensions of the cover  30  are such that a material  60 , preferably a sponge-type material or the like, can be inserted under the cover  30 , preferably saturated with biocide prior to sealing the cover  30  in place over assembly  10 . 
     In another embodiment as shown in FIG. 6, an additional shallow cut  52  is formed along the bottom  41  of cover  30  to form a hinge means to facilitate the full opening of cover  30 . Alternatively, the cover  30  may be formed in two halves. 
     Opening  39  formed in the top  40  of wedge-shaped section  32  further comprises lip  38  for accommodating and at least partially covering rod  20 . 
     Pipes are manufactured in many gauges and pipe insulation in many thicknesses, depending on the desired efficiency. Accordingly, the preferred embodiment of the present invention may be sized to accommodate both bare pipe and insulated pipe. Now referring to FIGS. 5 a  and  6   a , the dimensions of the preferred embodiment of the invention are as follows: as shown in FIG. 5 a , dimension A represents the diameter of openings  42  and  44  which measures from about 2″ to about 8.5″; dimension B represents the diameter of elongated sections  34  and  36  which measures from about 2.5″ to about 91″; dimension C represents the length between the tapered sections  52  and  54  which measures from about 13″ to about 17.5″; dimensions D represents the length between opposite ends  46  and  48  which measures from about 15.5″ to about 21.5 inches; and dimension E represents the length of wedge-shaped section  32  which measures from about 2.25″ to about 3″. Now referring to FIG. 6 a , dimension F represents the widest width of wedge-shaped section  32  which measures from about 5.125″ to about 15″; dimension G represents the height of wedge-shaped section  32  which measures from about 5″ to about 15″; and dimension H represents the width of lip  38  which measures from about 0.375″ to about 0.750″. The preferred embodiment of the invention as described hereinabove is best suited to the measurements of the Examples 1-9 set forth in Table 1 below (all measurements are in inches): 
     
       
         
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
             
           
               
                     TABLE 1 
               
               
                   
               
               
                 Ex. 
                 A 
                 B 
                 C 
                 D 
                 E 
                 F 
                 G 
                 H 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 1 
                 2 
                 2.5 
                 13 
                 15.5 
                 2.25 
                 5.125 
                 5 
                 0.375 
               
               
                 2 
                 2.5 
                 3 
                 13 
                 16.5 
                 3 
                 5 
                 5 
                 0.5 
               
               
                 3 
                 3 
                 3.25 
                 13 
                 14.5 
                 3 
                 6 
                 6 
                 0.5 
               
               
                 4 
                 3.5 
                 4 
                 13 
                 16.5 
                 3 
                 7.25 
                 7.25 
                 0.5 
               
               
                 5 
                 4 
                 4.25 
                 13 
                 15.5 
                 3 
                 7.5 
                 7.5 
                 0.5 
               
               
                 6 
                 4.5 
                 5 
                 3.5 
                 17.5 
                 3 
                 8 
                 8 
                 0.675 
               
               
                 7 
                 5.5 
                 6 
                 12.5 
                 16.5 
                 3 
                 9.25 
                 9.25 
                 0.675 
               
               
                 8 
                 6.5 
                 6.875 
                 12 
                 15.25 
                 3 
                 11 
                 11 
                 0.675 
               
               
                 9 
                 8.5 
                 9 
                 17.5 
                 21.5 
                 3 
                 15 
                 15 
                 0.750 
               
               
                   
               
             
          
         
       
     
     Now referring to FIG. 6, cut  50  substantially bisects cover  30  through lip  38 , wedge-shaped section  32  and elongated sections  34  and  36  to facilitate installation of cover  30  over assembly  10 . After installation of cover  30 , cut  50  is sealed with any suitable adhesive such as but not limited to PVC cement. As best seen in FIG. 5, in a most preferred embodiment at least one sealable opening  66  is formed in the cover  30  to facilitate the introduction of biocide under the cover  30  after the cover  30  is installed. Opening  66  can be sealed with PVC cement, PVC tape, a PVC patch or any reasonably suitable substitute. This and other modifications of this embodiment results in an atmosphere under the cover  30  that deters and minimizes bacteria growth. Prior to installation of the cover  30 , a biocide such as but not limited to Lysol or another suitable FDA approved biocide material, is preferably applied onto the assembly  10  by spraying or brushing. 
     Now referring to FIGS. 6-8, the overhead rod  20  of the assembly  10  from which the clevis-type hanger  6  depends in the preferred embodiment is covered with split tube  62 , preferably formed of PVC. 
     Practice has shown that the tube  62  may be sealed in place with any suitable adhesive. A suitable PVC caulk can be used at the junction  64  of the cover  30  and tube  62 . The ends  46  and  48  of the cover  30  are then adhered with a suitable adhesive to an adjacent fitting. It is important that a suitable caulk be applied to seal all seams including cut  50  to fuse the cover  30  into a unitary composite unit. Alternatively 2″ wide or other suitable width PVC tape can be used to seal the ends  46  and  48  to adjacent fittings. 
     The smooth, chemical resistant PVC or modified PVC cover  30  lends itself to easy cleaning such as by wipe on method. The use of a PVC/Acrylic type cover designed for 205 degree deflection temperature such as for example Proto Exotuff® or CPVC material such as for example Proto Exod® with a deflection temperature of 225 degrees can also be used. The PVC/Acrylic material (Exotuff®) can be used for biocide hot water wash downs or the CPVC material can be used for steam wash downs as long as the steam nozzle is maintained one to two feet from the plastic to prevent warping. 
     Now referring to FIG. 9, in another embodiment the invention comprises substantially a humped formed fitting cover  70  that is made with a deliberate hump  72  molded in to cover existing insulated fitting  32 . This embodiment eliminates the need to shave or remove the fitting for reinsulation, preventing possible asbestos cement contamination in the area. This is a considerable improvement over the current available alternative which is to remove the asbestos under strict regulations at very high costs. In this embodiment the cover  70  can accommodate the application of a biocide between the insulated fitting  82  and the cover  70 . Cover  70  further comprises cut  76  to facilitate installation over fitting  82 . The biocide may be applied to the exterior of the insulated fitting  82  or to the interior of the cover  70  prior to installation of the cover  70 . Now referring to FIG. 11, in another embodiment a material such as a sponge  80  for carrying a biocide may be inserted between the fitting  82  and the formed cover  70 . The cover may further include a resealable opening  74  for applying additional biocide after the cover  70  is installed over the fitting  82 . The hump feature  72  as shown in FIGS. 9 and 11 may be applied and adapted to fitting covers for 45 degree elbows, tees, straight and all other fittings and assemblies. 
     Fitting covers of all shapes may be employed with the present invention. Now referring to FIGS. 10 and 11, fitting covers  90  and  110  without the hump feature may be employed in new installations over shaped type insulations such as  92 . Fitting cover  90  further comprises cut  94 . Fitting cover  110  further comprises a cut (not shown). 
     Now referring to FIG. 11, the foregoing embodiments of the present invention provide for a system wherein a thin material such as but not limited to ⅛″ thick soft polyurethane or sponge  80  can be saturated with biocide, inserted between a cover  72  of the present invention and fitting  82  or other assembly to be covered and the cover sealed over, creating a biocide atmosphere to prevent bacteria growth under the cover. Now referring to FIG. 9, at least one opening  74  can be formed in the cover  72  to allow a periodic application of biocide material to maintain an antibacterial atmosphere under the sealed cover  72 . The opening  74  is resealed with PVC cement or a round dot of PVC tape or a suitable substitute. Where the cover is formed of CPVC the opening is preferably sealed with CPVC cement. Now referring to FIG. 11, in the present invention it is critical that all joints  100  between covers  70 ,  90  and  110  be sealed tight with a suitable adhesive or the like. 
     In embodiments in which there is insufficient space for a sponge, the biocide material can be painted on or wiped on, before applying and sealing the cover. This system may be employed on all unions, valve covers, Victaulic type covers, specialty fittings, flanges and the like. The present invention also applies to all bare fittings, pipes, pumps and other coverable mechanical installations and assemblies. 
     While certain preferred and alternative embodiments of the invention have been set forth for purposes of disclosing the invention, modifications to the disclosed embodiments may occur to those who are skilled in the art. Accordingly, the appended claims are intended to cover all embodiments of the invention and modifications thereof which do not depart from the spirit and scope of the invention.