Abstract:
An electrical conduit fitting installation system and method of use for replacement of conduit fittings in existing installations and for new building construction is disclosed. The present system includes a plurality of electrical conduit fittings and couplings which are manufactured in mating half-sections that can be assembled by use of fasteners, gaskets and associated hardware. The use of such replacement conduit bodies of the present system allows replacement of a damaged conduit body of conventional unitary construction using standard tools without the need for disconnection and withdrawal of wiring from the conduit required to replace a conventional conduit body. The present system includes conduit bodies, couplings and accessory conduit components which are available in various configurations and standard sizes used in the industry. The replacement conduit bodies of the present system are fabricated of materials such as engineered plastics, metals and explosion proof materials to provide an industry approved installation.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Patent Application No. 61/964,356 filed Jan. 2, 2014, entitled Electrical Conduit Fitting Installation System and Method of Use. 
     BACKGROUND OF INVENTION 
     1. Field of Invention 
     The present invention relates to electrical conduit and fittings and, more particularly, to a method and apparatus for the repair and replacement of damaged conduit fittings and also relates to installation of electrical conduit in new construction. 
     Conduit is generally installed by electricians at the site of electrical equipment installation. Its use, form and installation details are often specified by wiring regulations such as the U.S. National Electrical Code (NEC) or other local codes. The term conduit is commonly used by electricians to describe any system that contains electrical wiring or conductors. 
     Electrical conduit provides necessary protection to enclosed wiring from impact, moisture and chemical vapors. When installed with proper sealing fittings, a conduit will not permit the flow of flammable gases and vapors, which provides protection from fire and explosion hazard in areas handling volatile substances. 
     It is not uncommon for conduit and fittings installed on electrical equipment to be damaged during building construction or during remodeling by movement of building materials on the worksite, vehicular impacts or other accidental contact requiring repair and/or replacement of the conduit and fittings. Further, the exposure of conduit and fittings to inclement weather causes corrosion and degradation necessitating replacement of such fittings to avoid an unsafe condition. 
     In the conventional practice to repair or replace damaged conduit fittings, the electrical power must be turned off and existing wiring disconnected and pulled from the conduit to remove the damaged fitting. Thereafter, the conduit fitting is replaced and the wiring must be routed though the new conduit and/or fitting and reconnected often causing extensive disruption of electrical service until the repair is complete. This results in substantial down time of the affected residential and/or commercial equipment and expensive labor costs to complete the repairs. 
     Thus, there is a need for a method and apparatus for repair and replacement of damaged conduit fittings, which will reduce the time and expense involved in completing such repairs and restoring service. 
     2. Description of Related Prior Art 
     Prior art patents are available, which include information that may be helpful in understanding the advantages of the present invention, and should be considered by the Patent Office with respect to this application. 
     U.S. Pat. No. 3,406,987 to Hunder et al. discloses a split-sleeve sheet metal pipe coupling useful in joining or repairing pipes comprising two stamped sheet metal casings which together form a cylinder and which have inclined flanges and pipe receiving guides for clamping the casings around a pipe. The casings include inwardly directed indentations for spacing the casings away from the pipe thereby forming a circumferential mold cavity adapted to receive a sealant between the pipe and the casing necessary to complete the repair. 
     U.S. Pat. No. 5,007,666 to Kyfes discloses a pipe fitting for encompassing a conduit comprising a pair of interlocking segments wherein each segment comprises an arcuate configuration having at least two longitudinal edges with one edge of each segment comprising a tongue split longitudinally in a direction substantially perpendicular to its length. The other of the edges comprising a groove conforming to and receiving the tongue formed on the juxtaposed edge of the other of the segments causing the tongue to engage with the groove thereby interlocking the segments of the pipe fitting together. 
     U.S. Pat. No. 5,443,096 to King discloses a pipe repair coupling comprising a pair of semi-circular separate and independent coupling segments. Each segment is identical in cross section, length and width. When coupled together along one elongated edge in a snap fit relationship, the interconnected segments may be placed about a cylindrical pipe to repair a hole therein and then squeezed together to lock along the other free elongated edges thereof. 
     U.S. Pat. No. 6,305,719 B1 to Smith et. al. discloses a pipe repair clamp for repairing a damaged pipe member wherein shell members are matingly engaged around the damaged pipe. Segmented inserts are received in a complementary annular channel formed in an inside face of the shell members to form a ring assembly supporting annular seals between the ring assembly and the damaged pipe member. A shell-sealing annular channel is formed between the ring assembly and the shell member to receive a liquid sealant necessary to complete the repair to form an annular seal between the ring assembly and the shell members. 
     While these devices fulfill their respective, particular objectives and requirements, the aforementioned patents do not disclose the present Electrical Conduit Installation System and Method of Use, which allows the relatively simple replacement of damaged conduit bodies of various configurations within a preexisting residential or commercial equipment installation. In the present invention the replacement process is accomplished using standard tools without the need for disconnection and withdrawal of wiring from such damaged conduit body that is typically required to remove a conventional conduit fitting. 
     SUMMARY OF THE INVENTION 
     Accordingly, the present invention is an Electrical Conduit Fitting Installation System and Method of Use for the installation/repair of electrical conduit in commercial/residential settings, which can be utilized for the replacement of preinstalled conduit fittings, which have been damaged. The present system and method of use comprises a plurality of electrical conduit fittings or so-called conduit bodies of various configurations, which are manufactured in generally symmetrical, half-sections and include complimentary hardware, gaskets and covers for a complete installation. The conduit bodies of the present system can be conveniently assembled and/or disassembled by use of fasteners such as machine screws and by the use of optional seals and adhesives, which interconnect the mating half-sections of each conduit fitting. 
     The method of use of such conduit bodies of the present system allows relatively simple replacement of a damaged conduit body of unitary construction using standard tools without the need for disconnection and withdrawal of wiring from the conduit required to remove a conventional conduit body. 
     The present system includes conduit body assemblies, conduit coupling assemblies and accessory conduit fittings, which are available in various configurations and trade sizes (i.e. ½ inch to 4 inch diameters) commonly used in the industry and are fabricated of materials such as engineered plastics, metals and explosion proof materials to achieve an industry approved installation. 
     There has thus been outlined, rather broadly, the important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. 
     Those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other components, methods, and systems for carrying out the purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. 
     Other features and technical advantages of the present invention will become apparent from a study of the following description and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The novel features of the present invention are set forth in the appended claims. The invention itself, however, as well as other features and advantages thereof will be best understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures, wherein: 
         FIG. 1  is a perspective view of a prior art conduit body and is labeled Prior Art; 
         FIG. 2  is a composite perspective view of a plurality prior art conduit bodies for which the conduit bodies of the present system are utilized as replacements and is labeled Prior Art; 
         FIG. 3  is an elevation view of an embodiment of a replacement conduit body assembly (LB-R) of the present invention showing details thereof; 
         FIG. 3A  is an elevation view of an alternative embodiment of a replacement conduit body assembly (LB-R) of the present invention showing details thereof; 
         FIG. 4  is an elevation view of a prior art LL conduit body in an installed condition (shown with access plate removed) and is labeled Prior Art; 
         FIG. 5  is an expanded perspective view of a coupling component of the present invention; 
         FIG. 6  is an expanded perspective view of an alternative embodiment of a coupling component of the present invention; and 
         FIG. 7  is an elevation view of an alternative embodiment of a replacement conduit body assembly (LB-R) of the present invention including additional conduit accessory components. 
         FIG. 8  is a plan view of an embodiment of a gasket for insertion between mating half-sections of a conduit coupling assembly. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following description is presented to enable any person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiment and applications without departing from the spirit and scope of the present invention. 
     Prior to describing the novel features of the present invention in detail, it may be beneficial to briefly review the structure and installation of an electrical conduit fitting of the prior art in order that the description of the present invention that follows may be better understood and that the present contribution to the art may be better appreciated. 
       FIG. 1  illustrates a generally L-shaped conduit body assembly or so-called LB fitting of the prior art, indicated generally at  100 . The prior art LB fitting  100  includes a body member  115  with an access plate  122  and further includes a wiring inlet  112  and a wiring outlet  114  formed therein, which are adapted to receive a length of electrical conduit  120  fabricated of approved materials such as engineered plastics and metals to achieve an industry approved installation for a given application. Conduit bodies are attached to conduit  120  when a change of direction is required and save installation costs by eliminating the bending of large conduits in order to change the direction of conduit runs. 
     Referring to  FIG. 2  industry nomenclature has been developed to describe various conduit bodies such as L-shaped bodies (so-called “Ells”) including the LB, LL and LR, where the inlet  112  is in line with the access plate  122  and the outlet  114  is on the back, left or right respectively); T-shaped bodies (so-called “Tees”) which feature an inlet in line with the access plate  122  and outlets  114  to both the access plate&#39;s left and right; C-shaped bodies (so-called “Cees”) have identical openings above and below the access plate  122  and are used to pull conductors in straight runs as they make no turn between inlet and outlet; and “Service Ell” bodies (SLBs), shorter ells used where a circuit passes through an exterior wall from outside to inside of a structure. 
     Referring again to  FIG. 1  body member  115  includes an access plate  122  attached by fasteners such as machine screws  116 , which allow an installer to remove the plate and to grasp/pull wiring through the body member during an initial installation procedure or to perform repair operations. An access plate gasket (not shown) of suitable material is typically installed between body member  115  and plate  122  to prevent infiltration of moisture and/or chemical vapors. 
     It is not uncommon for electrical conduit  120  and/or such LB fittings  100  and other similar fittings ( FIG. 2 ) installed on commercial/residential buildings to be damaged during building construction by vehicular impacts or other accidental contact requiring their replacement. Further, the exposure of such conduit  120  and fittings  100  to inclement weather causes corrosion and degradation necessitating periodic replacement to avoid an unsafe condition. 
     In the current industry practice of replacing such damaged prior art fittings  100 , the electrical power must be turned off, the access plate  122  removed as shown in  FIG. 4  and existing wiring  117  disconnected and withdrawn from the conduit  120  back to the location of the damaged fitting. Thereafter, the wiring  117  must be routed though another prior art conduit fitting  100  and reconnected often causing extensive disruption of service until the repair is complete. This results in substantial down time of the affected residential/commercial equipment and expensive labor costs to complete the repairs. 
     The present invention has been developed to resolve this problem and will now be described. The following description of the present system is provided to enable any person skilled in the art to make and use the invention, and is presented in the context of a particular replacement scenario and its requirements. It will be appreciated that various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined hereinbelow may be applied to replace any of the prior art conduit bodies shown in  FIG. 2  and numerous other embodiments (not shown) without departing from the spirit and scope of the present invention. 
     With further reference to the drawings,  FIGS. 3 and 3A  illustrate embodiments of conduit body assemblies of the present system, indicated generally at  10 ,  10 ′ respectively for the replacement of damaged conduit fittings  100  of the types shown in  FIGS. 1 and 2 . The present conduit body assemblies  10 ,  10 ′ or LB-Replacement (hereinafter “LB-R”  10  or “LB-R”  10 ′) are defined by a tubular body member comprising generally L-shaped half-sections  10 A,  10 B ( FIG. 3 ) and  10 A″,  10 B″( FIG. 3A ) mechanically attached along a transverse center plane thereof. As shown each half-section  10 A,  10 B ( FIG. 3 ) and  10 A″,  10 B″ ( FIG. 3A ) includes an integrally formed flange member  10 A′,  10 B′ ( FIG. 3 ) and  10 A′″,  10 B′″ ( FIG. 3A ) respectively formed in generally perpendicular relation to each half-section, which is detachably secured by fasteners such as machine screws  15 ,  15 ″. LB-Rs  10 ,  10 ′ may also include additional hardware i.e. threaded inserts, washers and gaskets (not shown) advantageous for a given installation. 
     In accordance with the present system, it will be understood that LB-Rs  10 ,  10 ′ are configured for common repair scenarios, that is, LB-R  10  LB-R  10 ′ as illustrated in  FIG. 3  and  FIG. 3A  respectively include a female end as at  10 C,  10 C′ dimensioned to receive conduit  120 ,  120 ″ of different sizes, for example, projecting from a building structure  150  ( FIG. 4 ). As shown in  FIGS. 3, 3A  the opposite ends of LB-R  10 , LB-R  10 ′ include a male end as at  10 D ( FIG. 3 ),  10 D′ ( FIG. 3A ) dimensioned to be inserted into a mating female coupling, indicated generally at  20  ( FIG. 3 ),  20 ′ ( FIG. 3A ) respectively. In turn, couplings  20 ,  20 ′ would each receive a section of conduit  120  of a different size emerging from the ground or concrete slab  160  ( FIG. 4 ). 
     However, it will be understood by those skilled in the art that alternative embodiments of the LB-R  10  and LB-R  10 ′ are included within the present system. For example, alternative versions of LB-R  10 , LB-R  10 ′ having two female ends  10 C,  10 C′ (not shown) to receive conduit  120 ,  120 ″ and/or LB-R  10 , LB-R  10 ′ having two male ends  10 D,  10 D′ (not shown) are contemplated in the present system. Thus, the embodiments disclosed in  FIG. 3  and  FIG. 3A  are intended to be illustrative and not restrictive in any sense. 
     Coupling assemblies  20  ( FIGS. 3 ) and  20 ′ ( FIG. 3A ) respectively each define a tubular body member comprising mating half-sections  20 A,  20 B ( FIGS. 3 ) and  20 A″,  20 B″ ( FIG. 3A ) mechanically attached along a center plane thereof. As more clearly shown in  FIG. 5 , each half-section  20 A,  20 B of coupling assembly  20  includes a pair of integrally formed flange members  20 A′,  20 B′ respectively formed along a center plane of the coupling and projecting from each tubular half-section in generally perpendicular relation thereto. Half-sections  20 A,  20 B are detachably secured by fasteners such as machine screws  15  ( FIG. 3 ) that engage mating threads formed in screw holes  25  ( FIG. 5 ). Coupling assemblies  20 ,  20 ′ may also include additional hardware i.e. threaded inserts, washers and a gasket, indicated generally at  30 , as shown in  FIG. 8  as necessary for a given installation. 
     It will be appreciated that coupling  20  as shown in  FIG. 3  is configured for a specific repair scenario. Coupling  20  includes a first female end as at  20 E dimensioned to receive conduit  120  having a predetermined outside diameter as more clearly shown in  FIG. 5 . An opposite end of coupling  20  includes a second female end as at  20 F dimensioned to receive the male end  10 D of LB-R  10  of the same diameter in mating engagement ( FIG. 3 ). Coupling  20  may be provided with an integrally formed stop ring  24  as shown in  FIG. 5  that limits the depth to which a male end  10 D ( FIG. 3 ) extends into the coupling  20 . 
     Mating half-sections  20 A,  20 B of coupling  20  may also include a sealing means including, but not limited to the following structural elements. In the embodiment shown in FIG.  5 , it can be seen each flange member  20 A′ of half-section  20 A includes an elongated rectangular boss  26  which is adapted for mating engagement with a slot or groove  27  formed along the entire length of flanges  20 B′ of half-sections  20 B as shown. The sealing means may include an optional gasket (not shown), which may be disposed within slot  27  and compressed by bosses  26  during assembly of the coupling  20  to ensure a proper seal. 
     Other configurations of the aforementioned bosses  26  and grooves  27  (not shown) are contemplated within the scope of the present invention. For example, bosses  26  and mating grooves  27  may be semicircular in cross-section and similarly function to join the mating half-sections  10 A,  10 B of conduit body  10  ( FIG. 3 ) and coupling body  20  ( FIG. 5 ) in mating engagement. Thus, the embodiments disclosed in  FIG. 3, 5  are intended to be illustrative and not restrictive in any sense. 
     Accessory conduit fittings in accordance with the present system are provided as described below in various axial lengths and configurations to accommodate different repair scenarios and/or atypical installations. For example, a coupling  20 C having a stepped diameter shown in  FIG. 6  is provided to reconnect to conduit  120  broken off flush concrete slab  160  or with a solid wall of a building structure  150  wherein such coupling  20 G must be fitted to the inside diameter of the damaged conduit. It will be appreciated that such coupling  20 C is also configured for this specific repair scenario, that is, coupling  20 C as shown in  FIG. 6  includes a first female end as at  20 F dimensioned to receive conduit  120  having a predetermined outside diameter. An opposite end of coupling  20  includes a male end having a stepped down outside diameter as at  20 G dimensioned to be inserted within the preinstalled conduit  120  broken off flush with concrete slab  160 . In all other respects coupling  20 C functions in the manner described in relation to coupling  20  above. 
     In accordance with the present system, a pair of couplings  20  can be utilized in combination with a length of split conduit  120 ′ ( FIG. 7 ) that is divided into semi-cylindrical half-sections  120 A′,  120 B′. Such split conduit  120 ′ is inserted between the pair of couplings  20  to add vertical/horizontal length in a replacement installation wherein a conduit body  100  and a section of its attached conduit  120  have been damaged. 
     It will be appreciated by those skilled in the art that the present system includes a plurality of LB-Rs  10 ,  10 ′ or other suitable LB-Rs and mating couplings such as couplings  20  ( FIG. 3 ),  20 ′ ( FIG. 3A ),  20 C ( FIG. 6 ) for replacement of the entire range of trade sizes (i.e. ½ inch to 4 inch diameters) commonly used in the industry including other L-shaped conduit bodies “Ells” (not shown); T-shaped conduit bodies “Tees” (not shown); C-shaped conduit bodies “Cees”; and Service Ells (SLBs) adapting the concepts of the present invention to alternative installations. 
     In a method of use of the present system, the conduit body  100  to be replaced is initially removed by cutting conduit  120  with a tubing cutter (not shown), a Dremel® tool (not shown) or other tool suitable for this purpose. Such cuts are made through conduit  120  at locations adjacent to wiring inlet  112  and wiring outlet  114  exercising caution not to damage the electrical wires  117  contained within conduit  120  ( FIG. 4 ). Thereafter, access plate  122  is removed and body member  115  including wiring inlet  112  and a wiring outlet  114  are cut through using a rotary cutting tool such as a Dremel® tool along the length thereof such that the body member can be removed and only the intact wires  117  extending between sections of existing conduit  120  remain. 
     Next, an LB-R  10 , LB-R  10 ′ or other suitable LB-R and a coupling assembly  20 ,  20 ′ or another suitable coupling assembly of the appropriate size, material and configuration are selected from the inventory of LB-Rs and couplings of the present system. It is reiterated that the present system includes a full range of such LB-Rs  10 , LB-Rs  10 ′ or other LB-Rs and coupling assemblies  20 ,  20 ′ which correspond to various industry sizes (i.e. ½ inch to 4 inch diameters) and configurations commonly used in the trade. 
     Next, the selected LB-R  10 , LB-R  10 ′ and a matching coupling assembly  20 ,  20 ′ are disassembled into mating half-sections by removal of machine screws  15 ,  15 ′. Thereafter, the half-sections  10 A,  10 B of the LB-R  10  ( FIG. 3 ) or  10 A″,  10 B″ of LB-R  10 ′ ( FIG. 3A ) and matching half-sections  20 A,  20 B of coupling assembly  20 , ( FIG. 3 ) or matching half-sections  20 A″,  20 B″ ( FIG. 3A ) of coupling assembly  20 ′ are arranged such that the existing wiring  117  and both sections of conduit  120  or conduit  120 ″ are disposed within the respective LB-R and coupling assembly to be utilized in the repair. 
     Next, screws  15 ,  15 ′ are advanced into threaded holes  25  and tightened to secure the LB-R  10  or LB-R  10 ′ and a mating coupling assembly  20 ,  20 ′ and/or any needed accessory components such as split conduit  120 ′ in position to complete the repair. 
     Although not specifically illustrated in the drawings, it should be understood that additional equipment and structural components will be provided as necessary and that all of the components described above are arranged and supported in an appropriate fashion to form a complete and operative Electrical Conduit Fitting Installation System and Method of Use incorporating features of the present invention. 
     Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of invention.