Patent ID: 12234854

DESCRIPTION OF EMBODIMENTS

In various embodiments, the present disclosure relates to systems and methods for a foreign material exclusion plug that is a compact, robust plug for structural threaded couplers. Structural threaded couplers are typically embedded in the floor of a facility, such as a warehouse. The foreign materials exclusion plug of the present disclosure includes an externally-threaded cylindrical structure, a breakaway tab, and a slot.

The breakaway tab facilitates tool-less mating between the foreign material exclusion plug and the structural threaded coupler as the breakaway tab is adapted to receive a torsional force for threading the externally-threaded cylindrical structure of the foreign materials exclusion plug into the structural threaded coupler. Further, the breakaway tab is adapted to break off from a top surface of the foreign material exclusion plug leaving a flat surface that is flush (save for the slot) with the floor of the facility. The slot remains and facilitates removal of the foreign material exclusion plug.

While installed, the foreign material exclusion plug prevents debris, dust, and small objects from entering into the structural threaded coupler, which protects the internal threads of the structural threaded coupler from being damaged.

FIG.1is a perspective view of an illustrative embodiment of a foreign material exclusion plug100. Referring toFIG.1, the foreign material exclusion plug100includes a cylindrical body110, a slot114, and a breakaway tab120. In the embodiment illustrated, the cylindrical body110includes an externally-threaded portion116and a flange112.

The externally-threaded portion116includes an externally-threaded cylindrical structure with external threads117. In some embodiments, the external threads117are structural threads and are adapted to thread to the structural threads of a structural threaded coupler. In one embodiment, the external threads117are ¼ inch of male thread. However, other types of threading and thread spacing are contemplated, such as those for standard structural bolt sizes and thread pitches, tapered threads, and the like.

The flange112extends radially from the cylindrical body110at a top surface111of the cylindrical body110. In some embodiments, the flange112includes one of a cylindrical structure and a frusto-conical structure. In some embodiments, the flange112includes a thread boss118. In embodiments, the thread boss118faces at least partially in the cylindrical direction relative to an axis of the cylindrical body110. Further, in embodiments, an external thread117extends to the thread boss118. Thus, in embodiments, the external thread117extends into the flange112and to the top surface111.

The slot114is formed in the cylindrical body110and extends into the cylindrical body110from the top surface111of the cylindrical body110. The slot114is adapted to receive at least one of an end of a tool, a coin, and a portion of the breakaway tab120broken off from the cylindrical body110. In embodiments, the tool is a tool capable of applying a torsional force, such as a screwdriver and the like. The coin is a standard coin, such as a quarter, nickel, and the like.

As such, in embodiments, a length and a width of the slot are sized to be larger than the end of the tool. The width of the slot is sized to be wider than the thickness of a standard coin. And the length and the width of the slot are sized to be larger than a length and a thickness of the breakaway tab120, and in particular, a distal end124(FIG.3) of the breakaway tab120.

The breakaway tab120is connected to the cylindrical body110and extends out from the top surface111in a direction perpendicular to the top surface111. In some embodiments, the breakaway tab is integrally formed with the cylindrical body as a unitary structure. For example, in embodiments, the foreign material exclusion plug and all of the components thereof are manufactured using an additive manufacturing process such that the breakaway tab is unitarily formed with the cylindrical body110.

In some embodiments, the breakaway tab120is oriented such that the breakaway tab120crosses over the slot114and is integrally connected to the cylindrical body110on one of opposing sides and opposing ends of the slot114. In the embodiment illustrated, the breakaway tab120is oriented perpendicular to the slot114and is connected to the cylindrical body110on each of opposing sides of the slot114. However, in other embodiments, the breakaway tab120is parallel to the slot114, extends substantially the length of the slot, and is connected to the cylindrical body on each of opposing ends of the slot114. Orientations where the breakaway tab120and the slot114are oriented at other angles are also contemplated.

In the embodiment illustrated, each of the slot114and the breakaway tab120are perpendicular to and align with the axis of the cylindrical body110. However, in some embodiments, at least one of the slot114and the breakaway tab120are offset from the axis.

The breakaway tab120is adapted to break off from the cylindrical body110at a base122of the breakaway tab120. The base122adjoins the top surface111of the cylindrical body110. In embodiments, the breakaway tab120is adapted to break off from the cylindrical body110upon application of a predetermined force. In embodiments, the predetermined force is greater than a force required to thread the foreign material exclusion plug100into a threaded coupler. In embodiments, the predetermined force for breaking off the breakaway tab120is established by an amount of material at the base122of the breakaway tab120. For example, a thickness of the base122and a length of the base122are selected based on the structural strength provided thereby, such that the predetermined force will overcome the structural strength by one of the application of a torsional force and the application of a lateral force. Further, in embodiments, the base122includes one or more holes, perforations, slots, and the like, to reduce the amount of material connecting the base122to the top surface111of the cylindrical body110.

In embodiments, the base122includes less material than other portions of the breakaway tab120to ensure that the breakaway tab120breaks off at the base122. For example, in some embodiments, the base120has a narrower thickness than other parts of the breakaway tab120. In any event, the user twists the breakaway tab120to thread the cylindrical body110into the structural threaded coupler via the applied torque, which the breakaway tab120can withstand by design. To remove the breakaway tab120, a greater torque is applied after cylindrical body seating, or the breakaway tab120is subjected to a lateral force in a direction in which the breakaway tab120is intentionally made relatively weaker, thereby breaking the breakaway tab120off. When made by an additive manufacturing technique, the breakaway tab-to-cylindrical body interface plane is a layer-to-layer fusion plane, which provides a clean separation plane.

In some embodiments, the distal end124has a length and a thickness that is less than a length and a width of the slot114. As such, in these embodiments, the distal end124of the breakaway tab120is receivable in the slot114and is usable for applying the requisite force for removing the foreign material exclusion plug from the structural threaded coupler.

In some embodiments, the foreign material exclusion plug100includes an annular slot for receiving a gasket, such as an O-ring and the like. In embodiments, the annular slot is positioned in the flange112or in the cylindrical body, such as at a base of the flange112.

FIG.2is a perspective view of the foreign material exclusion plug100ofFIG.1threaded into an embedded threaded coupler200.FIG.3is a cross-sectional view of the foreign material exclusion plug100threaded into the embedded threaded coupler200ofFIG.2. Referring toFIGS.2and3, the embedded threaded coupler200includes an internally-threaded portion220with an internally-threaded cylindrical structure. In embodiments, the embedded threaded coupler200is a structural threaded coupler.

As can be seen inFIG.3, the externally-threaded cylindrical structure of the cylindrical body110is adapted to thread into the internally-threaded cylindrical structure of the internally-threaded portion220.

In embodiments, the embedded threaded coupler200includes a flush mount portion210adjoining the internally-threaded portion220. The flush mount portion210is adapted to receive the flange112such that the top surface111is flush with the floor10of a facility, such as a factory. In some of these embodiments, the flush mount portion210includes one of a counterbore with a flat bottomed enlargement of the internally threaded portion220and a countersink with a conical enlargement of the internally threaded portion220. The structure of the flange112is based on the structure of the flush mount portion210.

Referring toFIG.3, in embodiments where the flange112includes the threaded boss118, the thread boss118is adapted to engage an internal thread222of the internally threaded portion220and lock the foreign material exclusion plug100in place relative to the embedded threaded coupler200. As the external thread117extends into the flange112and to the thread boss118in these embodiments, the internal thread222similarly extends into the flush mount portion210.

In some embodiments, the breakaway tab120is adapted to break off from the cylindrical body110upon application of a force while the thread boss118is engaged with the internal thread222. In embodiments, this force is the predetermined force discussed above.

FIG.4is a perspective view of the foreign material exclusion plug100threaded into the embedded threaded coupler200ofFIGS.2and3with the breakaway tab120broken off. As can be seen inFIG.4, upon removal of the breakaway tab120, the foreign material exclusion plug100is received into the embedded threaded coupler200and is flush with the floor10of the facility.

FIG.5is a flowchart of a method500for coupling a foreign material exclusion plug100to a structural threaded coupler200. The method500includes providing the structural threaded coupler200including an internally threaded portion220with an internally-threaded cylindrical structure at step502. The method500also includes providing the foreign material exclusion plug100including a cylindrical body110with an externally-threaded cylindrical structure, a slot114formed in the cylindrical body110extending into the cylindrical body110from a top surface111of the cylindrical body110, and a breakaway tab120connected to the cylindrical body110and extending perpendicularly outwards from the top surface111at step504. The breakaway tab120is integrally formed with the cylindrical body110as a unitary structure. The method500further includes threading the cylindrical body110into the internally threaded portion220by applying a force to the breakaway tab120such that the foreign material exclusion plug100turns relative to the structural threaded coupler200.

In some embodiments, the method500yet further includes breaking the breakaway tab120off from the cylindrical body110at a base122of the breakaway tab120after the cylindrical body110is threaded into the internally threaded structure. In some of these embodiments, the foreign material exclusion plug100further includes a flange112radially extending from the cylindrical body110at the top surface. The flange112includes a thread boss118facing at least partially in the cylindrical direction, an external thread117of the externally-threaded cylindrical structure extends to the thread boss118, and the structural threaded coupler200further includes a flush mount portion210adapted to receive the flange112. In these embodiments, threading the cylindrical body110into the internally threaded portion220includes applying the force until the thread boss118engages an internal thread222of the internally threaded portion220and locks the foreign material exclusion plug100in place relative to the structural threaded coupler200, and breaking the breakaway tab120off from the cylindrical body110includes applying the force to the breakaway tab120after the thread boss118engages and is seated with the internal thread222and the cylindrical body110is threaded to the desired depth.

In some embodiments, the method500still further includes uncoupling the foreign material exclusion plug100from the structural threaded coupler200by inserting one of an end of a tool, a coin, and the breakaway tab120broken off from the cylindrical body110into the slot114and applying a force to thereto such that the foreign material exclusion plug100turns relative to the structural threaded coupler200.

Although the present disclosure has been illustrated and described herein with reference to preferred embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples may perform similar functions and/or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the present disclosure, are contemplated thereby, and are intended to be covered by the following claims.