Abstract:
Aspects of the present invention are directed to a tapered plug. The plug has a bottom base having a geometrical shape. In some embodiments the base has a well-defined geometrical shape, such as a circle, an ellipse, a triangle, a square, a rectangle, a rhombus, and the like. In other embodiments, the shape of the base is not a regular, well-defined shape. In some embodiments, the plug comes to a point at the top, with a shape analogous to a cone, while in other embodiments, the top of the plug is flat. In some embodiments, the plug has a smooth or nearly smooth surface, made of an easily compressible or semi-compressible material. It is for use in stopping or slowing the flow of a fluid or gas or other flowable material through an opening that the plug is inserted into.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Application No. 61/672,694 filed Jul. 17, 2012, the contents all of which are hereby incorporated by reference in their entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention is in the field of plugs, and in particular, in the field of configurable plugs to stop or slow the flow of a fluid or gas or flowable material either inward or outward through an opening. 
       BRIEF SUMMARY OF THE INVENTION 
       [0003]    Aspects of the present invention are directed to a tapered (and additional shapes as later described) plug. The plug has a bottom base having a geometrical shape. In some embodiments the base has a well-defined geometrical shape, such as a circle, an ellipse, a triangle, a square, a rectangle, a rhombus, and the like. In other embodiments, the shape of the base is not a regular, well-defined shape. In some embodiments, the plug comes to a point at the top, with a shape analogous to a cone or an Egyptian pyramid, while in other embodiments, the top of the plug is flat, with a shape analogous to a Mayan pyramid. In some embodiments, the plug has a smooth or nearly smooth surface, made of an easily compressible or semi-compressible material. It is for use in stopping or slowing the flow of a fluid or gas or other flowable material (such as but not limited to a powder) through an opening (either coming in or going out, for example, with reference to an interior of a vessel, through an opening as the case may be) that the plug is inserted into. 
         [0004]    In some embodiments the plug is made of a compressible material such as foam (either open or closed cell) of a certain density and compressibility and slow to fast rebound rate, or a pliable material such as a plastic (or multi-layered plastic filled with a softer material or fluid) or a semi-compressible material such as rubber. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0005]      FIG. 1 : Shows the 3-segmented plug, side and top view. The cone defining the plug&#39;s outer shape in some embodiments has an apex angle of 90 degrees, in other embodiments as little as 1 degree, and between these two extremes (as shown in this  FIG. 1 ) in still other embodiments. The plug in some embodiments is pointed and in other embodiments is truncated and in still other embodiments is blunt-tipped despite how it is depicted in this and other figures. Note that in some embodiments the apex of the cone is narrow and the base angle (angle of the side compared to the plane of the base) approaches 90 degrees and the degree of truncation such that the truncated top of the plug is very close to the same diameter as the base of the plug. Though this and other figures show an embodiment of a right circular cone (where right means that the axis passes through the centre of the base suitably defined at right angles to its plane, and circular means that the base is a circle) with a circular cross-section, other embodiments utilize an ellipse, a triangle, a square, a rectangle, a rhombus, and the like as their cross-sections, and still other embodiments use an oblique cone (in which the axis does not pass perpendicularly through the centre of the base) and other embodiments have sides that are not straight but are curved outward when viewed in cross-section and curved inward in still other embodiments. Other embodiments of the plug are wedge-shaped with an edge rather than a point at the top similar to an axe head. The top edge is sharp in some embodiments and flat or rounded in other embodiments. 
           [0006]      FIG. 2 : Shows the plug comprising multiple ridges most of them being somewhat concentric. 
           [0007]      FIGS. 3   a  and  3   b:  Cross-sectional views of the stepped rings or ridges of the plug. The rings or ridges have angular well-defined edges (such as a single edge, and also a flat edge presented by square, rectangular, and polygonal cross-section ridges) in some embodiments as shown in these figures and in other embodiments have rounded edges (such as circular, elliptical, and parabolic ridges, and the like.) Similarly the intervening valleys/channels have angular bottoms (such as a v-shaped bottom, and also a flat bottom presented by a square, rectangular, and polygonal in cross-section valley/channel) in some embodiments as shown in this figure and have rounded bottoms (such as circular, elliptical, parabolic, and the like) in other embodiments. 
           [0008]      FIG. 4 : Cross-sectional view, magnified of the plug. Plug in some embodiments is pointed and in other embodiments is truncated and in still other embodiments is blunt-tipped despite how it is drawn here. 
           [0009]      FIG. 5 : Side view of broken and/or alternated ridges of the plug. 
           [0010]      FIG. 6 : Side and top view of the surface of the plug with a spiked or bumped design. 
           [0011]      FIG. 7 : Cross-sectional view of the plug indicating a punt or depression added to the bottom. 
           [0012]      FIG. 8 : Cross-sectional view of the plug with the addition of an optional base flange. 
           [0013]      FIG. 9 : View of the plug with a lanyard in the center of the base. The addition of a base flange is optional. 
           [0014]      FIG. 10 : Side view of the plug the an elliptical cylinder where the sides are parallel and the top and bottom edge diameters are square and in another embodiment are rounded. A cylinder is simply a cone whose apex is at infinity. Intuitively, if one keeps the base fixed and takes the limit as the apex goes to infinity, one obtains a cylinder, the angle of the side increasing, in the limit forming a right angle. In some embodiments the base has a well-defined geometrical shape, such as a circle, an ellipse, a triangle, a square, a rectangle, a rhombus, and the like despite how it is depicted in this and other figures. In other embodiments, the shape of the base is not a regular, well-defined shape. 
           [0015]      FIG. 11 : Side and top view of the plug with a widened and flattened head that is compressed or folded, either by hand or with the aid of a tool and inserted into or through an opening. Figure is not necessarily proportional and head portion in some embodiments is limited to a narrow height and in other embodiments is expanded to encompass a majority of the height of the entire plug. 
           [0016]      FIG. 12 : Side and top view of the plug with a conical hollow head that is compressed or folded when needed and inserted into or through an opening. Figure is not necessarily proportional and head portion in some embodiments is limited to a narrow height and in other embodiments is expanded to encompass a majority of the height of the entire plug. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0017]    The basic material and manufacturing method of some embodiments of the plug disclosed herein are very similar to those described in the U.S. patent application entitled “Emergency Repair Plug To Slow Down Water Inflow Through An Opening” (US Patent Application No: 2010/0132,605, the relevant sections of which, directed to the manufacture and materials, are incorporated by reference herein. However there are substantial differences disclosed below including sectioning elements, configurability, surface geometry, surface coating, different geometries for the base, different geometries for the tip or head of the plug, different sizes, and different materials. 
         [0018]    The plug is segmented longitudinally (parallel to the central axis) into two to eight sections or more (in some ways similar to an orange or a banana.) See  FIG. 1 . Although the figure shows a 3-segmented plug, the skilled artisan will know that the plug can have many different segments and that the disclosure is not limited to the single embodiment shown in the figure. The skilled artisan will also know that the plug can be of considerably different sizes ranging from under six inches (6″) in height and under one inch (1″) in base diameter to over three feet (3′) in height and over two feet (2′) in base diameter and that the disclosure is not limited to a specific size. 
         [0019]    The segmentation is achieved by sectioning elements including grooves or channels (molded into the plug as it is created), slices (either continuous or in a broken series, cut in after molding), or a series of perforations (molded in or cut in). In some embodiments the grooves or channels are produced by raised elements such as fins or vanes protruding into the interior surface of the plug molds. As the plug material sets within the mold these elements leave behind an impression on the plug surface and deeper into the interior of the molded plug equal to the dimensions of these fins or vanes. In other embodiments slices are cut on the surface and as deep into the plug as desired after the plug is removed from the mold. These slices are in continuous or in broken series, and are cut in after molding by means of a conventional knife under pressure, rotary blades, or stamping blades entering the plug either longitudinally or laterally from the side. In some embodiments the sectioning elements are single or a series of perforations. These are molded in by means of pins or posts protruding into the interior surface of the plug molds. In other embodiments the perforations are punched into the surface and as deep into the plug as desired after the plug is removed from the mold. These perforations are in continuous or broken series, and are punched in after molding by means of needles or teeth under pressure, rotary drills, or multiple small blades entering the plug either longitudinally or laterally from the side. The skilled artisan will know that there are many different methods to producing these sectioning elements and that the disclosure is not limited to the several embodiments explained above. In some embodiments, the plug is first manufactured in the form of the slices, but then the slices are attached together by means of a fastening device, such as glue, pins, etc., to form the plug. 
         [0020]    These sectioning elements create intentional weak points in the plug material that facilitate separation and tearing along selected dimensions. In some embodiments, a tear is started at a single point of a sectioning element and then further separation and tearing is directed by the groove/channel/cut/perforation. In other embodiments, a tear is started at one end of the plug by pulling in opposite directions across the end of the sectioning element. In still other embodiments, a tear is started at the midpoint or at any point along the groove/channel/cut/perforation by forcing a finger or tool into the sectioning element, and even by pulling in opposite directions across the midpoint, and then continuing this tear in the direction facilitated by the groove/channel/cut/perforation. In some embodiments these sectioning elements are grooves or channels, from 1/16″ deep from the outer surface of the plug to the entire depth of the material as measured from the surface to the central axis, and all the way past the central axis in the case of perforations. In addition to directing the tearing and separation at the outer surface of the plug, these grooves/channels also allow this to occur in three dimensions within the outer surface of the plug, conceptually similar to how the structure of an orange allows it to be segmented in half or in thirds or into many sections. This segmentation allows easier, faster, and more precise tearing of the plug(s) without tools into sections and allows the user to fashion the plug(s) into better shapes for stopping the flow through the particular opening they encounter. For example the shape of a single plug is readily altered by removing section(s) and thereby reducing the plug&#39;s girth or diameter and allowing it to fit better into an opening. In some embodiments, a removed section is also used by itself to better fill an opening, such as a longer or narrower opening or crack. In further embodiments, several removed sections are combined to fill a larger opening, such as laying one plug or section against the other for one configuration and reversing one section end-for-end with other sections for another configuration. Multiple plugs are also readily combinable in whole or in part, such as an entire plug plus section(s) of another used together in an even larger opening. 
         [0021]    Due to the sectioning elements (groove, slice, or perforation) a wide variety of shapes are created from single or multiple plugs, by hand without tools. This enables separating or tearing plug(s) more precisely and more easily and faster than products currently on the market such as TruPlug (US Patent Application No: 2010/0132,605) that do not have sectioning, and this in turn enables the user to produce a better fit for a variety of opening shapes and sizes including round or irregular openings and also for fitting the ends of or breaches in pipes and round-to-oval lines. This sectioning ability also allows for better and easier insertion than currently available products into the opening to be blocked, and greater holding power against the liquid or gas or flowable material. 
         [0022]    Independent of the sectioning, in some embodiments the smooth to nearly smooth surface of the plug is modified to be rough or irregular, such as a sharkskin or sandpaper-like surface, achieved by texturizing the interior of the mold or selecting a coating material that crinkles or puckers on its own after the plug is demolded or post molding processing such as sand/bead blasting or applying a reactive component that reacts with the first coating. In other embodiments a post molding coating consisting of a texturizer (such as sand or plastic granules) and a binder (such as polyurethane or vinyl) is applied (by brush or spray or dipping) to provide the desired texture. Also in some embodiments higher-relief shapes are added, such as embedded cubes or gravel-like texture, and such additions are molded-in (created by the design of the mold cavity) and in other embodiments achieved by adding in separate material(s) at the surface while molding or by adding separate materials into the base plug material that migrate to the plug outer surface during the molding process and in other embodiments by adhering or embedding the separate material to the outside of the plug after molding by applying an adhesive coating to the plug and then dusting on or rolling the plug in a bed of the separate material (like sand on sandpaper.) The skilled artisan will also know that there are many different methods for modifying molded surfaces and that the disclosure is not limited to a specific method. 
         [0023]    In some embodiments the plug is made of an impermeable (such as solid rubber and closed cell foam) or permeable (such as open cell foam) material. Permeability is defined with respect to the particular use of the plug. For example, a particular material may be impermeable to liquids but permeable to gases. In general, an “impermeable” material is a material that cuts down the flow of a fluid (whether gas or liquid, depending on the use) by 95% as compared to when the material is not present. Suitable open cell and closed cell foams include Polyurethane (from reaction between a diisocyanate, either aromatic or aliphatic types, and a polyol, typically a polypropylene glycol or polyester polyol, in the presence of catalysts and materials for controlling the cell structure), polyester (by simultaneously cross-linking an unsaturated polyester resin and generating carbon dioxide as a blowing agent), polyether, polyvinyl, polystyrene, Ethafoam, and memory foam (viscoelastic), Suitable solid synthetic rubber and synthetic rubber foams include polyisoprene, polychloroprene/neoprene, polybutadiene/buna, chloro isobutylene isoprene/butyl, chlorosulphonated polyethylene/hypalon, polysiloxane/silicone rubber. Suitable soft plastics include plastisol, alumisol, highly plasticized PVC with phthalates. The foregoing are examples of materials for various embodiments and do not limit the scope of the invention. 
         [0024]    When made of a permeable material the sectioning also allows for better (compared to existing products referenced above), faster, and more reliable infiltration of the fluid or gas into the interior of the plug. This is achieved because the sectioning elements penetrate the outer surface of the plug and increases the speed and extent of absorption and permeation into the interior of the plug. This in turn accelerates the equalization of the internal pressure of the foam to the external pressure of the fluid or gas and thereby allowing greater and/or faster expansion of the plug material itself and producing increased holding power and sealing efficiency of the plug inhibiting flow through the opening. 
         [0025]    Independent of the sectioning or material, in some embodiments the plug described above also has a surface with a ringed or ridged design. See  FIG. 2 . This comprises multiple ridges most of them being somewhat concentric. The spacing of these ridges is variable and generally close together from approximately 1/16″ to over ¾″ ridge-to-ridge for a plug of approximately 9″ height. For larger plugs the lower spacing limit stays the same and the upper limit scales proportionally to the plug height. 
         [0026]    Independent of size and location of the ridges, in some embodiments the ridges are stepped or toothed or barbed depending on the degree of undercut (below each ridge as the plug stands on its base) or rounded, square, rectangular or polygonal. See  FIGS. 3   a  and  3   b.  The stepped surface is where the ridge has a vertical to slanted-inward orientation (12:00 to 1:00 in a clock dial or more) or where the angle “B” is equal to or less than the slope of the taper angle “A” and there is no undercut. See  FIG. 4 . The toothed surface is where the ridge has a vertical to slanted-outward orientation (12:00 to 9:00) or where the angle “B” is greater than the angle “A” but less than or equal to Angle “A” plus 90 degrees and there still is no undercut. A barbed surface is where the ridge has horizontal orientation or undercut at the bottom edge (9:00 to 7:00) or where angle “B” is greater than angle “A” plus 90 degrees. 
         [0027]    In some embodiments the ridges are broken or alternated or random around the plug circumference. See  FIG. 5 . The ridges in some embodiments are placed in a more random pattern and in other embodiments are narrowed laterally to become more like individual teeth than ridges. 
         [0028]    Independent of the sectioning or material of the plug described above, some embodiments have a surface with a spiked or bumped design. See  FIG. 6 . This comprises a design of many such bumps or spikes in a pattern on the plug surface to allow each to contact the edge or interior of an opening, depending on the opening&#39;s shape and size. The height of the spikes/bumps varies from less than 0.020 (or shark skin like) to over 0.375 and diameter of less than 0.010″ to over 0.375″ for a plug of approximately 9″ height. For larger plugs the lower measurement limit stays the same and the upper limit scales proportionally to the plug height. The ends of the spikes or bumps in various embodiments are rounded or pointed or flat. 
         [0029]    Independent of shape or surface design, the surface of the above plugs certain embodiments are coated with sticky/high coefficient of friction material such as soft vinyl. Such material tends to adhere to the edges or interior surface of the opening to be plugged and thereby provides increased holding power in the opening, and particularly in an opening with smooth sides where the sticky plug surface coating adheres such as a pipe. Other embodiments are uncoated meaning that the core of the plug is directly exposed to the fluid/gas/flowable material. This direct exposure increases the speed and extent of absorption and permeation into the interior of the plug. This in turn accelerates equalizing the internal pressure of the foam to the external pressure of the fluid or gas and thereby allowing greater and/or faster expansion of the plug material itself and producing increased holding power and sealing efficiency of the plug inhibiting flow through the opening. 
         [0030]    Independent of plug design and surface and material, in some embodiments a punt or depression is added to the bottom. See  FIG. 7 . In various embodiments this depression is of any shape such as conical, rounded, and a more geometric shape. See  FIG. 8 . This punt has multiple purposes and provides multiple benefits such as facilitating tearing, making it easier to handle and insert, and enabling maximum base sizes to plug effectively. The punt facilitates tearing the plug by hand without tools by enabling the user to grasp the edges at the base from both sides (i.e. outside surface and inside surface) more firmly and to focus their effort on a specific groove/channel/cut/perforation in that area and then continue that tearing along segment lines or otherwise. The inclusion of a punt also allows the user to firmly grasp the base edge by allowing simultaneous gripping/pinching of the outside surface and inside surface with one hand (as compared to having to span the entire width of the base when there is no punt) which in turn makes it easier to manipulate and control the plug while inserting it or removing it from an opening. The punt also allows the base of the plug to be more easily compressed or collapsed or folded because compressible material is absent and the base is somewhat hollow. This in turn facilitates inserting a larger base of maximum diameter than would otherwise be possible into an opening or pipe. 
         [0031]    Because the material absent from a punt allows the user to make the base smaller than would otherwise be possible, this type of collapsible or easily compressible base also facilitates inserting the plug base-first into or through a given size opening and thereafter allowing the base to expand and flare out either within or on the opposite side of an opening from where it is inserted. For example this is useful in stopping or slowing the flow coming from the opposite side of an opening, such as a hole in a tank when applied from outside the tank. In some embodiments the depth of the punt or depression is shallow, while in other embodiments the punt or depression is deep. In some embodiments, the punt or depression comprises a hollow center that extends almost up to the top or tip of the plug. The punt or depression in these embodiments is independent of, or is combined with, a flange at the base. See  FIG. 8 . 
         [0032]    Independent of plug design, material, and surface, in some embodiments the plug comprises a lanyard. See  FIG. 9 . Though the figure shows the lanyard in the center of the base, in various embodiments it is usefully installed at the edge of the base, on the side, or at the tip of the plug. The purpose of the lanyard is to facilitate storage of the plug at a chosen location and to also ensure that a lanyard is available to tie the plug in place if necessary when inserted into an opening. The lanyard is made of any material. In some embodiments, the lanyard is molded into the plug, while in other embodiments it is inserted with a means to keep it in place, such as an anchoring barb. The strength of the installation in various embodiments is adjusted to facilitate storage and allow pull-out when the plug is taken for emergency use, or more securely ensure the lanyard is still attached for securing it in the opening when used. 
         [0033]    Another embodiment of the plug is a round and another embodiment is an elliptical cylinder where the sides are parallel and the top and bottom edge diameters are square and in another embodiment are rounded. See  FIG. 10 . The surface treatment of the plug and the material it is made of and the segmentation are as described above. 
         [0034]    Another embodiment of the plug is with a widened and flattened head that is compressed or folded, either by hand or with the aid of a tool and inserted into or through an opening. See  FIG. 11 . The flattened head is rounded with a flat underside (as in sample drawing) in one embodiment, or with a faceted top or an oblate conical top and a flat underside, or with a flat top and a rounded or faceted or oblate conical underside. The head is compressed or folded when needed and, when inserted into the opening, deploys/expands on the other side of the opening where the flow is coming from or within a lengthier opening such as inside a pipe of any shape. This gives the head of the plug increased holding power through increased friction in the opening and through an overlap or lock with the inside edge of the opening, thereby resisting the flowing material and pressure attempting to bypass or expel the plug. In some embodiments the head portion is limited to a narrow height and in other embodiments is expanded to encompass a majority of the height of the entire plug. The plug is inserted into the opening either base first or head first. In some embodiments the plug design uses a base identical or similar to the head described in this paragraph above. Although the figure shows a flattened head of a given proportion, the skilled artisan will know that the plug head can have different dimensions and that the disclosure is not limited to the single embodiment shown in the figure. 
         [0035]    Another embodiment of the plug is with a conical hollow head that is compressed or folded when needed and inserted into or through an opening. See  FIG. 12 . This functions similarly to the flattened head embodiment above. In some embodiments the conical head uses a punt/depression in the head, and in other embodiments a hollow center making the head conceptually similar to a coffee cup-type or flower pot-type shape. In some embodiments the head portion is limited to a narrow height and in other embodiments is expanded to encompass a majority if the height of the entire plug. The plug is inserted into the opening either base first or head first. In some embodiments the plug uses a base identical or similar to the head described in this paragraph above. Although the figure shows a conical hollow head of a given proportion, the skilled artisan will know that the plug head can have different dimensions and that the disclosure is not limited to the single embodiment shown in the figure. 
         [0036]    Independent of sectioning elements, configurability, surface geometry, surface coating, different geometries for the base, different geometries for the tip or head of the plug, and different sizes, in some embodiments the plug utilizes different materials. Those described in the U.S. patent application entitled “Emergency Repair Plug To Slow Down Water Inflow Through An Opening” (US Patent Application No: 2010/0132,605) are limited to polyether and methylene diphenyl diisocyanate or MDI. Some embodiments of the plug disclosed herein use aromatic isocyanates such as but not limited to toluene diisocyanate (TDI) and other embodiments use aliphatic isocyanates such as hexamethylene diisocyanate (HDI) or isophorone diisocyanate (IPDI). Separate from the different isocyanates, various embodiments of the plug disclosed herein use a class of polyethers, such as but not limited to phenyl ether polymers, that contain aromatic cycles in their main chain, one such embodiment using polyphenyl ether (PPE) and another embodiment using poly(p-phenylene oxide) (PPO). To create a foam, blowing agents such as but not limited to water is used in one embodiment and certain halocarbons such as HFC-245fa (1,1,1,3,3-pentafluoropropane) in other embodiments, and hydrocarbons such as n-pentane is incorporated into still other embodiments. In some embodiments the foam cell structure is controlled by addition of surfactants to modify the characteristics of the polymer during the foaming process. In other embodiments temperature of the mold is used to control the foam cell structure. The skilled artisan will also know that the plug can be of considerably different formulations and that the disclosure is not limited to a specific formulation. 
         [0037]    In the embodiments where the plug is made of a compressible material such as foam the density of this foam is controlled to produce the desired characteristics. Light density is defined to fall in the range of 1 to 4 pounds per cubic foot (Lb/CuFt) range, medium density in the greater than 4 to 12 Lb/CuFt range, and high density in the greater than 12 Lb/CuFt range. Compressible material, (such as but not limited to foams) is defined as that which can be compressed by 10% up to 90% of its initial volume by hand without tools and semi-compressible material, (such as but not limited to solid or near-solid rubber, is defined as that which can be compressed by less than 10% of its initial volume by hand without tools. The skilled artisan will also know that the plug can be of considerably different densities and compressibilities and that the disclosure is not limited to a specific density or compressibility.