Abstract:
A stopper device for blocking an aperture in a pipe member wall, a sheetrock wall and so forth, the stopper device comprising a substantially planar cap member with top and bottom sides, the top side further including a plurality of strengthening ribs with even-tapered ends extending along the surface thereof, a stem projecting from the bottom side of the cap member, the stem further including at least a pair of radially-spaced vanes extending along and projecting from its longitudinal axis, and a plurality of spaced apart axially-spaced circumferential webs each projecting radially from the longitudinal axis of the stem, and each being parallel to one another.

Description:
RELATED APPLICATION 
     This Application is related to, and has a common Assignee with, co-pending Design application Ser. No. 29/140,013 filed on Apr. 11, 2001 herein for “PLUG FOR APERTURES.” 
     FIELD OF THE INVENTION 
     The present invention relates generally to stopper devices for blocking apertures, more particularly to stopper or plug devices for blocking lift holes which are typically provided in sidewall portions of tubular conduits, such as utility pipes, and for blocking holes in walls of sheetrock, for example. 
     BACKGROUND OF THE INVENTION 
     Pipes and tubular conduits are commonly used to provide enclosed facilitated passageways for fluids, wires, cables, utility equipment, and other objects which are dispatched therethrough between opposing ends. Such pipes may be composed of metal, concrete, plastic polymer, poured cement, and the like, and are typically assembled in sections. During installation, an opening is typically provided in the side portion of a pipe section usually extending laterally and substantially aligned with the center of gravity of the corresponding section. This opening is usually referred to as a lift aperture or hole, and greatly facilitates the lifting and moving of the pipe section from one place to another. The lift aperture is configured to be operated in association with a lift apparatus. A lift member attached to the end of a cable, sling or arm, for example, of the lift apparatus, is configured to couple with the lift aperture for secure connection therebetween. In this manner, the pipe section can conveniently be lifted and loaded onto suitable transportation vehicles, unloaded at the installation site, and adeptly positioned in a trench along with a series of other pipe sections which are placed end to end to form a continuous conduit. Afterward, the newly formed conduit is ready for conveying drain water, and the like, or dispatching utility and telephone cables and equipment therethrough. 
     Before interring the assembled pipe beneath the ground, the lift apertures or holes must be blocked or plugged to prevent any external moisture, dust, dirt, debris and the like, from entering the pipe&#39;s interior. Such lift aperture, if left unblocked, or partially or ineffectively blocked, can ultimately allow dirt to enter the pipe and contaminate the contents, or can trigger sinkholes and/or initiate other complications which would require costly re-excavation and repair. To prevent such problems, local ordinances and laws typically require workers on site to search in the immediate work area for suitable rocks or other debris of appropriate size and shape, to insert the rock into the lift aperture while ensuring secure fit and retainment. The rock and blocked aperture are covered with an amount of mortar or poured concrete necessary to seal and secure the rock in place. Once the mortar is set, the pipe positioned in the trench, is buried with soil or suitable fill. 
     Such ad hoc techniques of using rocks and debris to block lift apertures, are cumbersome, time-consuming, and very inefficient. Oftentimes, it is particularly difficult to find rocks or other debris of sufficient size and/or girth for insertion into the apertures with a snug fit, and searching for such rocks is often frustrating and time-consuming. Searching in this trial and error manner, takes away significant time and labor from the actual installation work. In addition, the rock plugs can be easily dislodged by construction equipment (i.e., backhoe), rain and moisture, fill soil, and other environmental forces. If insufficient mortar is used, the rock plug can become dislodged, resulting in the problems discussed above. One attempt at minimizing the inefficiency, includes using disposable paper cups filled with poured concrete as aperture stoppers. Although the time spent for searching is reduced, the inefficiencies associated with rock plugs including limited size variability, poor fit and retention, ease of dislodgement, and the need to apply an amount of mortar, remain. 
     For the foregoing reasons, there is a need for an aperture stopper that overcomes the problems encountered in the prior art. It would therefore be a significant advance in the art to develop an aperture stopper for pipe and conduits which provides excellent retention for a range of aperture sizes, is easy and inexpensive to fabricate, foregoes the need for applying poured concrete or mortar over the aperture, is durable and strong over a range of temperatures and environmental conditions, and, above all, is simple to use. 
     SUMMARY OF THE INVENTION 
     The present invention is generally directed to a stopper device for blocking an aperture in a wall of sheetrock, a pipe member wall, and the like, comprised of a cap member with a stem projecting from the cap member. The stem further includes radially directed web means for anchoring the cap member to the pipe aperture in a manner which provides the benefits of efficient and effective blocking of the pipe aperture for maintaining a firm barrier between the exterior and interior portions of the pipe. 
     In particular, one aspect of the present invention is directed to a stopper device for blocking an aperture in a pipe member, a sheetrock wall, and so forth in which the stopper device comprises: 
     a substantially planar cap member with a top side and a bottom side; 
     a stem projecting from the bottom side of the cap member; and 
     a plurality of axially-spaced circumferential webs each radially projecting from the longitudinal axis of the stem. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Various embodiments of the invention are described in detail below with reference to the drawings, in which like items are identified by the same reference designation, wherein: 
     FIG. 1 is a perspective view of one embodiment of a stopper device according to the present invention; 
     FIG. 2 is a top plan view of the stopper device of FIG. 1; 
     FIG. 3 is a bottom plan view of the stopper device of FIG. 1; 
     FIG. 4A is a front elevational view of the stopper device of FIG. 1, the back elevational view being identical thereto; 
     FIG. 4B is a right side elevational view of the stopper device of FIG. 1, the left side elevational view being identical thereto; 
     FIG. 5 is a cross sectional view of the stopper device taken along  5 — 5  in FIG. 4A; 
     FIGS. 6A and 6B are each side cross sectional views of the stopper device inserted into a pipe apertures of differing diameters, respectively; 
     FIG. 7 is perspective view of a second embodiment of a stopper device of the present invention; and 
     FIG. 8 is a cross sectional view of the stopper device of FIG. 7 inserted into a sheetrock wall aperture with a coating of plaster applied thereon. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention is generally directed to a stopper device constructed in a manner that provides a secure closure for an aperture of a pipe, to prevent dirt, moisture, and the like, from entering the interior of the pipe through the aperture. The stopper device can be also used to block holes in level wall surfaces including those consisting of sheetrock, for example. The stopper device is constructed with the advantage of anchoring means to prevent accidental pullout or displacement over a period of time from the blocked aperture, while maintaining the simplicity in design and fabrication, as well as cost effectiveness required for use in construction projects and the like. In addition, the stopper device is constructed in a manner which provides ease of use, long term durability, and effective blocking capability. The cost effective and efficient manner by which these stopper devices are constructed, and their simplicity of use, as opposed to inefficiently searching the grounds for suitable rocks and debris in a trial and error manner, makes the stopper devices of the present invention especially suitable for construction and building use. 
     Conventional pipes made of poured cement, concrete, plastic, metal and the like are typically comprised of pipe sections of a particular length for permitting ease of transport and construction. Such pipes are typically provided at one end with a stepped reduced outer diameter portion for fitting within the enlarged inner diameter portion disposed at the other end, thus providing a mutual interlocking of a series of pipe sections. The pipe may be circularly or elliptically cylindrical, but can be made with other cross sectional shapes and sizes as desired. 
     Each pipe section is provided with one or more lift apertures which are appropriately set laterally in the walls of the pipe section for permitting a lifting mechanism such as a crane, for example, to effectively lift the pipe section along its center of gravity. The lift aperture allows a lift member connected to a lift apparatus for coupling with the lift aperture. In this manner, the lifting apparatus can maneuver the corresponding pipe section for safe lifting and transporting. When the pipe section is placed at a final installation site, and the lifting member is disengaged from the lift aperture, the pipe section is left oriented with the lift aperture opened upwardly. Unfortunately, this leaves the aperture open to dirt, liquid, and the like, permitting undesirable entry thereof into the pipe section, which over time can result in major cost and repair, due to necessary excavation of the burred pipe section. 
     Before describing the details of the present invention, the stopper device of the present invention, in addition to effectively and securely blocking the lift aperture in the wall of the pipe section, eliminates the need to use conventional means including searching for a rock, brick, a piece of concrete, debris and the like which can often be time-consuming and inefficient. Also, such searching can effectively hold up the completion of the construction project and generate cost overruns and the like. 
     Referring to FIG. 1, a stopper device  10  of the present invention includes a substantially planar cap member  12 , and a stem  14  extending from a bottom side  15  of the cap member  12 . The stem  14  further comprises a plurality of vanes  16  radially-spaced apart and extending outwardly and along its longitudinal axis. The stopper device  10  further includes a plurality of circumferential webs  18  radially projecting from the stem  14 , and a plurality of strengthening ribs  20  disposed on a top side  22  of the cap member  12 . The stopper device  10  can be of a unitary construction or a composition of individual parts fastened together with suitable means. 
     The stopper device  10  can be composed of any durable and rigid to semi-rigid material preferably including plastic materials such as polyamide, polyethylene, low density polychloropene, polyvinyl chloride, polyester, polypropylene, polystyrene, polytetrafluoroethene, and polyurethane, and the like, but more preferably polypropylene. The materials may also include elastomeric materials including silicone rubber, ethylene propylene diene monomer (E.P.D.M.), neoprene, santroprene rubber, polychloroprene, nitrile butadiene rubber, polyurethane, polybutadiene rubber, natural rubber, and the like. It is understood that the stopper device  10  of the present invention can be composed of any material which can effectively block the lift aperture of a pipe, and be securely retained therein over a range of environment forces and conditions Such a material must also be able to withstand the shear and compressive forces subjected to the aperture, and the surrounding areas during and after construction of the pipe. 
     With reference to FIG. 2, the cap member  12  and the plurality of the circumferential webs  18  of the stopper device  10  are circular in shape to conform with a cylindrically-shaped aperture. The cap member  12  is preferably larger in diameter than the other portions of the stopper device  10 , mainly to prevent the stopper device  10  from completely passing through the aperture of the pipe. It is noted that the stopper device  10  can be sized for blocking or plugging a plurality of different size holes. The plurality of the strengthening ribs  20  further comprises a central rib  24  and a plurality of transverse ribs  26  extending orthogonally from the central rib  24 . The strengthening ribs  20  provide the cap member  12  significant structural integrity required to withstand the significant weight load of the soil covering the associated pipe, as well as the associated shear and compressive forces, while also providing the flexibility needed to conform to the wall of the pipe for good sealing engagement therebetween. The strengthening ribs  20  are also configured to taper from the middle of the central rib  24  to their respective ends. The central rib  24  tapers from its center to its opposing ends. This configuration along with the low profile of the cap member  12 , minimizes or significantly reduces the frictional conditions on the top side  22  of the cap member  12 . In this manner any object such as the backhoe of an earth-moving equipment or moving debris, would conveniently slide over the cap member  12 , thus reducing the likelihood of accidental dislodgement and displacement of the stopper device  10  from the aperture and ensuring excellent retainment in the associated aperture. 
     Referring now to FIG. 3, the bottom end of the stopper device includes one of the circumferential webs  18  to provide a smooth surface for minimizing any obstruction that may be generated if the end of the stopper device  10  protrudes slightly into the interior or cavity of the pipe. The length of the stopper device  10  is preferably limited to the span of the aperture or thickness of the wall portion to prevent protrusion into the associated pipe interior, thus avoiding any obstruction or interference with any fluid flow or the like in the pipe. Accordingly, the bottom end of the stopper device  10  is preferably made flush with the inside surface of the pipe wall. The vanes  16  provide good structural integrity with minimal material for minimizing lateral bending of the stem  14  and ensuring that the circumferential webs  18  remain substantially orthogonal to the axis of the aperture. 
     Referring to FIGS. 4A and 4B, the bottom portion  15  of the cap member  12  is substantially flat as shown, and is flexible enough to bend into and conform to the curved surface of the associated pipe upon insertion of the stopper device  10  into the lift aperture. The bottom side  15  of the cap member  12  can also be configured to conform and closely follow the curved peripheral contour of the pipe, thereby reducing or minimizing the presence of a space therebetween. The low profile of the cap member  12  and the strengthening ribs  20  are also best shown in FIGS. 4A and 4B for providing a reduced surface area, for minimizing engagement thereof with a moving object passing over the cap member  12 . 
     As shown in FIGS. 4A and 4B, three circumferential webs  18  are provided in a spaced-apart parallel manner. The circumferential webs  18  are varied in diametric size to conform to varying diameters of the aperture, and to better conform to the irregular interior wall surfaces of the associated aperture. The use of multiple webs  18  also improves the sealing engagement and anchoring engagement of the stopper device  10  to the inside surface of the pipe aperture. It is understood that the number of webs  18  is not limited to three, and may include any number as required for secure retainment and blockage. 
     Referring to FIG. 5, the stem  14  is positioned substantially at the center of the bottom side  15  of the cap member  12 , with the stem  14  comprised of the plurality of the vanes  16 . The vanes  16  provides exceptional structural rigidity with minimal material usage and weight. In addition, the vanes  16  provide significant structural support for the circumferential webs  18 , thus improving the anchoring capability of the stopper device  10 . The axis of the stem  14  extends substantially orthogonal to the bottom side  15  of the cap member  12 , and ends with one of the circumferential webs  18  fixed thereon (as shown in FIG.  1 ). The example of the structure is shown in FIG. 5, wherein the vanes  18  are radially-spaced and substantially parallel to each other. 
     Referring to FIGS. 6A and 6B, the stopper device  10  is shown inserted into two apertures  28  of differing diameters, respectively, in a wall portion  30  of a pipe  32 . The stopper device  10  is inserted with the stem  14  end first until the bottom  15  of the cap member  12  contacts the wall portion  30  of the pipe  32 . When inserted into the aperture  28 , it is preferable that the longitudinal length of the stopper device  10  is limited to the depth of the aperture  28  and not extend beyond a bottom opening  34  to prevent or minimize any interference or obstruction with the interior cavity of the pipe. The cap member  12  is preferably sized to extend over and beyond the aperture  28  and to create an overlap of the cap bottom  15  with the wall portion  30 . Any amount of overlap of the cap member  12  is suitable for sufficient blocking or plugging of the aperture  28 . 
     With the stopper device  10  inserted into the aperture  28 , the circumferential webs  18  are configured to strongly bias against an inside wall surface portion  36  of the aperture  28  where it is frictionally and resiliently held to prevent fallout or displacement. Once the stopper device  10  is pushed into the aperture  28 , the circumferential webs  18  are oriented in a manner to prevent pullout. The circumferential webs  18  also permit the stopper device  10  to be used for a range of aperture sizes and irregularities in the surface portion  36 . In addition, the circumferential webs  18  are effective for use in apertures where the diameter varies along its span. Accordingly, an exact fit is not necessary provided one of the circumferential webs  18  possesses a sufficient reach to contact the inside wall surface portion  36  of the aperture  28 . The stopper device  10  is configured to withstand any changes in the environment, and any changes in pressure between the interior exterior areas to the pipe  32 . The design configuration eliminates or reduces the need to apply mortar for secure retainment. 
     The shape of the cap member  12  may also be any convenient shape, such as square, oval, rectangular and the like. The stopper device  10  may be modified to fit differently sized apertures or apertures of varying diameter. The size of the stopper device  10  can likewise vary to match the varying diametric sizes and lengths of a particular aperture. Note that the stopper device  10  of the present invention can easily be configured to plug any type of holes or apertures including such openings in pipe sections, wall sections and the like, where it is desired to seal the interior off from the environment during shipping, transportation and use, for example, or to seal the wall in a home, office or building. 
     Some examples of the standard pipe sizes and lift aperture diameters are provided as follows for reinforced concrete pipes with inside diameters of 12″, 15″18″ and 21″, the lift holes are typically 2¾″±⅛″. For reinforced concrete pipes with inside diameters of 24″, 27″30″ and 36″, the lift holes are typically from about 2⅞″±⅛″ to 3″±⅛″. For reinforced concrete pipes with inside diameters of 42″ and 48″, the lift holes are typically from about 2⅞″±⅛″ to 3″±⅛″. 
     Referring to FIG. 7, an alternative embodiment of a stopper device  50  is shown. The stopper device  50  includes the same features of the stopper device  10  of the first embodiment. The cap member  12  of the stopper  50  includes a flat, thin profile for providing a flush fit with the surface of a level wall. The stopper device  50  can be used to block holes in the level walls during construction and/or repair. The walls can consist of sheetrock, plasterboard, concrete and the like. The flat profile of the cap member  12  allows the stopper device  50  to reside flush with the surface of the wall to provide an even surface over the area of the blocked hole whereby several coatings of plaster or mortar and paint can then be applied for providing a smooth even surface. 
     With reference to FIG. 8, the stopper device  50  is inserted a hole  40  located in a sheetrock wall  38 . The webs  18  provide snug retainment in the hole  40  with the bottom  15  of the cap member  12  contacting the outer surface of the wall  38 . The low profile cap member  12  lies substantially flush with the surface of the wall  38  for permitting smooth surfacing under a layer of plaster  42 . Alternatively, the stopper device  50  may be inserted in the hole  40  of the wall  38  without the layer of plaster  42  on top. 
     Although various embodiments of the invention have been shown and described, they are not meant to be limiting. Those of skill in the art may recognize various modifications to these embodiments, which modifications are meant to be covered by the spirit and scope of the appended claims.