Patent Description:
Water systems often allow for testing at certain areas of the system. To that end, water systems can include test cock connection ports which allow test cocks to connect to the system. Test cocks can include gauges or sensors to measure characteristics at a given port connection. In particular, test cocks are often used around valves, such as backflow prevention valves, to ensure that the valves are operating properly.

Often, test cocks connect to a port via a small threaded stem. When it is time to remove the test cock, these stems sometimes break, leaving the end of the stem lodged in the port with no easy way to unscrew the stem. This can result in a long and tedious manual extraction process. Therefore, there is a need for a test cock designed such that the stem can be easily extracted from a test cock port should it break off while lodged therein.

<CIT> discloses a series of tools for repairing and replacing diverter valves.

<CIT> discloses a faucet-seat tool with a substantially straight elongated shaft having multiple hex-shaped or square-shaped steps on one end of the shaft and having a head on the other end of the shaft which is adapted to receive an external wrench or ratchet socket wrench into a hole having a biased detent inside the head.

<CIT> discloses a ball valve removal tool providing a handle sliding along the length of a shaft. One end of the shaft is secured within an interior cavity of a ball valve while the opposite end of the shaft defines a stop member. By providing a manual sliding force to the handle, the handle impacts the stop member and transmits the force to the ball valve. The direction of the force is along the shaft of the removal tool and disengages the ball valve from the ball valve housing.

The present invention provides a test cock configured to connect to a test cock port. The test cock includes a body portion defining a flowpath between a distal end and a proximal end. The test cock also includes an intake stem at the proximal end having external threads configured to connect the test cock to the test cock port. The intake stem defines an intake opening connected to the flowpath. The intake opening has a non-circular shape. The test cock also includes an extraction tool. The extraction tool has an end forming the non-circular shape of the intake opening, the end being sized to fit within and engage the intake opening. The body portion of the test cock includes a sidewall and the extraction tool is integrally formed as part of the sidewall such that the end of the extraction tool protrudes from the sidewall.

In some embodiments, the end of the extraction tool protrudes from the sidewall orthogonal to the flowpath.

In some embodiments, the non-circular shape of the intake opening and the end of the extraction tool are both a hexagonal shape. In some cases, the non-circular shape of the intake opening and the end of the extraction tool are both a double-hex socket shape. In some cases, the non-circular shape of the intake opening and the end of the extraction tool are both a polydrive socket shape. In some embodiments, the non-circular shape of the intake opening and the end of the extraction tool are a pentalobular shape. In some cases, the non-circular shape of the intake opening and the end of the extraction tool are a spline socket shape. In some embodiments the non-circular shape of the intake opening and the end of the extraction tool are a torx socket shape.

In some embodiments the flowpath is also the non-circular shape. In some cases, the test cock includes a ball valve arranged such that actuation of the ball valve towards a closed position restricts flow along the flowpath.

So that those having ordinary skill in the art to which the disclosed system pertains will more readily understand how to make and use the same, reference may be had to the following drawings.

The subject technology overcomes many of the prior art problems associated with extraction of broken test cocks from water systems. In brief summary, the subject technology provides a test cock with a stem which can be easily extracted using an integrated extraction tool should it break off within a test cock port. The advantages, and other features of the systems and methods disclosed herein, will become more readily apparent to those having ordinary skill in the art from the following detailed description of certain preferred embodiments taken in conjunction with the drawings which set forth representative embodiments of the present invention. Like reference numerals are used herein to denote like parts. Further, words denoting orientation such as "upper", "lower", "distal", and "proximate" are merely used to help describe the location of components with respect to one another. For example, an "upper" surface of a part is merely meant to describe a surface that is separate from the "lower" surface of that same part. No words denoting orientation are used to describe an absolute orientation (i.e. where an "upper" part must always at a higher elevation).

Referring now to <FIG>, a typical backflow preventer (BFP) <NUM> includes an inlet shutoff valve <NUM> and an outlet shutoff valve <NUM> with a backflow prevention valve <NUM> positioned between the inlet and outlet shutoff valves where the forward flow direction F is shown. It is noted that many different configurations of backflow prevention assemblies are commercially available, each being different in configuration, and the BFP <NUM> presented here is merely an example. To facilitate testing, the BFP <NUM> includes a number of test cocks (TCs) 102a-102d (generally <NUM>), each of which is threadably connected to couple with a fluid path within the BFP <NUM> via a corresponding TC port 125a-125d (generally <NUM>) on the BFP <NUM>. There are, in the most common implementation, four TCs <NUM> located on the BFP <NUM> in order to allow for temporarily attaching measuring equipment to measure the flow to ensure that the BFP <NUM> is functioning correctly.

Referring now to <FIG>, a TC <NUM> in accordance with the subject technology is shown. <FIG> show the TC <NUM> secured within a TC port <NUM> similar to the TC ports <NUM>, while <FIG> show the TC <NUM> isolated. It should be understood that while a TC port <NUM> on the BFP <NUM> is used by way of example, the TC <NUM> can be used within most known TC ports which allow for a connection via a threaded port. Use of the TC <NUM> is therefore not limited to use within a TC port for a BFP. The TC <NUM> can be used in connection with other types of valves, or other areas of a water transmission system where a connection is required for testing.

The TC <NUM> includes an elongated body <NUM> between a proximal end <NUM> and a distal end <NUM>. The body <NUM> has a stepped, generally cylindrical exterior <NUM>, while the interior <NUM> defines a flowpath <NUM> (see <FIG>) along a vertical axis <NUM> between the proximal and distal ends <NUM>, <NUM>. The proximal end <NUM> forms an intake stem <NUM> which is designed to connect the TC <NUM> to the TC port <NUM> and accept water into the TC <NUM>. As such, the stem <NUM> has a threaded exterior <NUM> which is designed to engage the threaded interior <NUM> of the TC port <NUM>. The stem <NUM> defines an opening <NUM> which leads to the flowpath <NUM>, the flowpath <NUM> directing water flow to an outlet <NUM> through the distal end <NUM>. When not in use, the distal end <NUM> is sealed by a cap <NUM>. The TC <NUM> also has a ball valve <NUM> which can be actuated to allow or restrict flow along the flowpath <NUM>. In particular, actuation of the ball valve <NUM> towards a closed position will restrict flow along the flowpath <NUM>.

The stem <NUM> of the TC <NUM> is often thin as compared to the body <NUM> of the TC <NUM> to allow the proximal end <NUM> to fit within a TC port <NUM> without unduly restricting flow. Thus, it is common for the stem <NUM> to break off during removal of the TC <NUM>, leaving much of the stem <NUM> lodged within the TC port <NUM>. In particular, <FIG> shows an exemplary break line <NUM> across the stem <NUM> of the TC <NUM> while <FIG> shows the TC <NUM> after a break during removal. The break in <FIG> causes the stem <NUM> to be left within the TC port <NUM> after the body <NUM> has been moved away. Ordinarily, the broken stem <NUM> would be extremely difficult to extract, and could require significant time and effort on the part of a technician.

In the present example, the TC <NUM> includes a modified opening <NUM> and integrated extraction tool <NUM> which allow for the easy extraction of broken stems <NUM>. As best seen in <FIG>, the stem opening <NUM> is hexagonal in shape, which can be engaged by a similarly shaped tool. The hexagonal shape continues throughout the length of the stem <NUM>, and in some cases, throughout the flowpath <NUM> of the body <NUM>. Therefore, if the stem <NUM> breaks off within the TC port <NUM>, a similarly shaped hexagonal tool can be inserted into the hexagonal opening <NUM> within the stem <NUM> and rotated to unscrew the broken stem <NUM> from the TC port <NUM>. The TC <NUM> therefore includes an extraction tool <NUM> with a hexagonally shaped end <NUM> which compliments the hexagonal opening <NUM>. In particular, the end <NUM> of the extraction tool is has the same hexagonal shape as the opening <NUM>, and it is sized to be small enough to fit within the opening <NUM> while still being large enough that the exterior of the end <NUM> couples with the interior of the opening <NUM>. In some cases, the entire extraction tool <NUM> can be the hexagonal shape.

The extraction tool <NUM> is integrally formed with the sidewall of the body <NUM> of the TC <NUM> on an opposite side of the ball valve <NUM>. The extraction tool <NUM> is designed to protrude from the body <NUM> horizontally, at a <NUM> degree angle (i.e. orthogonal to the vertical axis <NUM>). When the stem <NUM> breaks, the stem <NUM> and the body <NUM> are separated and the extraction tool <NUM> can be moved separately from the stem <NUM>. Therefore, the extraction tool <NUM> can be turned sideways, as shown in <FIG>, and the end <NUM> can then be inserted into the opening <NUM> of the broken stem <NUM>. Once inserted, the edges of the hexagonal end <NUM> engage the interior edges of the opening <NUM> within the stem <NUM>. The body <NUM> can then be rotated around the vertical axis <NUM>, the hexagonal end <NUM> turning the stem <NUM> as the body <NUM> turns. Since the stem <NUM> is connected to the TC port <NUM> via threads <NUM>, <NUM>, rotation of the stem <NUM> in the correct direction (e.g. counter-clockwise) will cause the stem <NUM> to disengage from the TC port <NUM>. In this way, turning the body <NUM> can force the broken stem <NUM> to disengage from the TC port <NUM>, allowing the broken stem <NUM> to be easily extracted from the TC port <NUM> via a simple turning motion.

The end <NUM> of the extraction tool <NUM> will usually be shaped and sized to fit within at least the opening of the stem <NUM>. In some cases, the flowpath <NUM> through the entire body <NUM> can be of a similar shape and size. While a hexagonal shaped opening <NUM>, flowpath <NUM>, and extraction tool end <NUM> are shown in <FIG> by way of example, it should be understood that other non-circular shapes can also be used, so long as the extraction tool <NUM> can engage the interior of the opening <NUM> and turn the broken stem <NUM>. In particular, other non-circular shapes may be used, which allow for the edges of the extraction tool <NUM> to engage the interior edges of the stem <NUM> to allow for the necessary rotation.

To that end, referring now to <FIG>, exemplary stems 800a-<NUM> (generally <NUM>) with openings 802a-<NUM> (generally <NUM>) of different shapes are shown. It should be understood that while only a bottom view of each stem <NUM> is shown in <FIG>, the stems <NUM> can be configured similarly to the stem <NUM>, except as otherwise described herein. Further, the stems <NUM> can be incorporated as part of the TC <NUM>, except as otherwise described herein.

The shape of the end <NUM> of the extraction tool <NUM> for a given TC <NUM> will be dependent on the shape of the opening <NUM> within the stem <NUM>. The end <NUM> of the extraction tool <NUM> will always be shaped and sized to fit within, and engage, the opening <NUM> of the stem <NUM> on a given TC <NUM>. Therefore, for TCs <NUM> having a stem <NUM> with an opening <NUM> of one of the shapes shown in <FIG>, it should be understood that the extraction tool <NUM> would likewise include an end <NUM> of the same shape. Similarly the opening <NUM> shapes shown in <FIG> are advantageous in that they correspond to the shapes of common non-round drivers. Thus, even if no extraction tool is integrated within the TC <NUM>, the stems <NUM> it may still be possible to extract the stems <NUM> with readily available tools carried by a technician.

Referring to <FIG>, the stem 802a includes a hexagonal shaped opening 802a, similar to the opening <NUM> of the stem <NUM>. The hexagonal shaped opening 802a is suitable to be engaged with a standard hex driver, in the event the corresponding TC does not include an integrated extraction tool. The other openings 802b-<NUM> likewise include shapes that correspond to standard driver shapes. In particular, the opening 802b has a double-hex shape while the opening 802c has a polydrive shape, suitable for corresponding drivers. The double hex opening, 802b, has the benefit of an improved flow-path size, while retaining operability with the common hex drive. The opening 802d has a square shape, suitable for a square, or Robertson driver. The opening 802e is a torx shape, or <NUM>-pointed star, suitable for a corresponding torx driver. The opening 802f is a penta-lobular shape, and the opening <NUM> is a spline shape- both suitable for corresponding drivers of the same shape, as are known. However, to eliminate the need for a separate driver altogether, it should be understood that the stems <NUM> can be included as part of a TC with an integrated extraction tool corresponding to the shape of the opening 802a. In this way, the stem <NUM> can always be easily extracted should the TC <NUM> break, without the need for additional tools or significant labor.

All orientations and arrangements of the components shown herein are used by way of example only. Further, it will be appreciated by those of ordinary skill in the pertinent art that the functions of several elements may, in alternative embodiments, be carried out by fewer elements or a single element. Similarly, in some embodiments, any functional element may perform fewer, or different, operations than those described with respect to the illustrated embodiment. Also, functional elements shown as distinct for purposes of illustration may be incorporated within other functional elements in a particular implementation.

Claim 1:
A test cock (<NUM>) configured to connect to a test cock port, comprising:
a body portion (<NUM>) defining a flowpath (<NUM>) between a distal end (<NUM>) and a proximal end (<NUM>), the body portion (<NUM>) including a sidewall;
an intake stem (<NUM>, <NUM>) at the proximal end (<NUM>) having external threads (<NUM>) configured to connect the test cock (<NUM>) to the test cock port, the intake stem (<NUM>, <NUM>) defining an intake opening (<NUM>, <NUM>) connected to the flowpath (<NUM>);
and an extraction tool (<NUM>);
characterised in that:
the intake opening (<NUM>, <NUM>) has a non-circular shape,
the extraction tool (<NUM>) has an end (<NUM>) forming the non-circular shape of the intake opening (<NUM>, <NUM>), the end being sized to fit within and engage the intake opening (<NUM>), and
the extraction tool (<NUM>) is integrally formed as part of the sidewall, the end (<NUM>) of the extraction tool (<NUM>) protruding from the sidewall.