U.S. patent application number 09/854350 was filed with the patent office on 2002-11-14 for debris cap and method therefor.
Invention is credited to Calder, Rodger, Campbell, Lucky.
Application Number | 20020166291 09/854350 |
Document ID | / |
Family ID | 25318445 |
Filed Date | 2002-11-14 |
United States Patent
Application |
20020166291 |
Kind Code |
A1 |
Campbell, Lucky ; et
al. |
November 14, 2002 |
Debris cap and method therefor
Abstract
A debris cap apparatus and method, which provides a secure and
debris resistant seating of a debris cap within a valve box. The
debris cap has two outwardly projecting annuli--a debris seal
located near the top of the cap and a retention gasket located
distal from the top of the cap. The debris seal blocks debris from
entering the valve box when the debris cap is in position. The
retention gasket is designed to be pushed down past an inwardly
projecting flange within the valve box, to deform as it passes the
flange, and then to resume its original shape when past the flange
so as to preclude accidental dislodging of the debris cap from the
valve box. Where the debris cap is to be used within a pre-existing
valve box, an adapter may be provided. It is further preferred to
provide a removal tool so as to permit ready removal of the debris
cap from the valve box or valve box adapter.
Inventors: |
Campbell, Lucky; (Phoenix,
AZ) ; Calder, Rodger; (Bountiful, UT) |
Correspondence
Address: |
WEISS & MOY PC
4204 NORTH BROWN AVENUE
SCOTTSDALE
AZ
85251
US
|
Family ID: |
25318445 |
Appl. No.: |
09/854350 |
Filed: |
May 14, 2001 |
Current U.S.
Class: |
52/20 ; 52/19;
52/21 |
Current CPC
Class: |
E02D 29/1445 20130101;
E02D 29/14 20130101; E02D 29/149 20130101 |
Class at
Publication: |
52/20 ; 52/21;
52/19 |
International
Class: |
E02D 029/14 |
Claims
I claim:
1. A debris cap apparatus comprising, in combination: a debris cap;
an annular debris seal positioned about an exterior portion of said
debris cap proximate an upper portion of said debris cap and
projecting upwardly and outwardly from said debris cap; an annular
gasket seal positioned about an exterior portion of said debris cap
distal from an upper portion of said debris cap; a valve box; and
an inwardly projecting annular flange positioned about an interior
portion of said valve box; wherein said inwardly projecting annular
flange is positioned within said valve box so that when said debris
cap is inserted into said valve box, said annular gasket seal will
contact said inwardly projecting annular flange, deform in shape so
as to be able to pass by said inwardly projecting annular flange,
and return to its original shape below said inwardly projecting
annular flange so as to secure said debris cap in position in said
valve box.
2. The debris cap apparatus of claim 1 wherein said annular gasket
seal is formed from a deformable and energy absorbent material.
3. The debris cap apparatus of claim 2 wherein said deformable and
energy absorbent material is Kraton.RTM..
4. The debris cap apparatus of claim 1 further comprising means for
removing said debris cap from said valve box.
5. The debris cap apparatus of claim 4 wherein said debris cap
removal means comprises: at least one slot located about an edge
portion of said debris cap; and a removal tool dimensioned to be
inserted into said at least one slot and then to be agitated so as
to impart a substantially upward force so as to cause said annular
gasket seal to move in an upward direction past said inwardly
projecting annular flange and thereby to permit removal of said
debris cap.
6. The debris cap apparatus of claim 5 wherein said removal tool
comprises: a handle portion; two spaced apart flat legs projecting
downward at right angles from said handle portion; wherein each
said flat leg has on an end portion thereof distal from said handle
portion an angled edge dimensioned to be inserted into said slot;
wherein each said flat leg further has thereon proximate said
angled edge an inwardly recessed area dimensioned to mate with an
edge portion of said debris cap when said angled edge is inserted
into said slot; wherein each said flat leg further has thereon an
outwardly projecting post positioned slightly above said inwardly
recessed area; and a lock bar slidably positioned on said flat legs
between said outwardly projecting posts and said handle
portion.
7. A debris cap apparatus comprising, in combination: a debris cap;
an annular debris seal positioned about an exterior portion of said
debris cap proximate an upper portion of said debris cap and
projecting upwardly and outwardly from said debris cap; an annular
gasket seal positioned about an exterior portion of said debris cap
distal from an upper portion of said debris cap; a valve box
adapter having an external configuration dimensioned to conform to
an internal configuration of a valve box; and an inwardly
projecting annular flange positioned about an interior portion of
said valve box adapter; wherein said inwardly projecting annular
flange is positioned within said valve box adapter so that when
said debris cap is inserted into said valve box adapter, said
annular gasket seal will contact said inwardly projecting annular
flange, deform in shape so as to be able to pass by said inwardly
projecting annular flange, and return to its original shape below
said inwardly projecting annular flange so as to secure said debris
cap in position in said valve box adapter.
8. The debris cap apparatus of claim 7 wherein said valve box
adapter is round.
9. The debris cap apparatus of claim 8 wherein said valve box
adapter is four-sided.
10. The debris cap apparatus of claim 7 wherein said annular gasket
seal is formed from a deformable and energy absorbent material.
11. The debris cap apparatus of claim 10 wherein said deformable
and energy absorbent material is Kraton.RTM..
12. A method for positioning a debris cap within a valve box in a
secure and debris resistant manner comprising the steps of:
providing a debris cap; providing an annular debris seal positioned
about an exterior portion of said debris cap proximate an upper
portion of said debris cap and projecting upwardly and outwardly
from said debris cap; providing an annular gasket seal positioned
about an exterior portion of said debris cap distal from an upper
portion of said debris cap; providing one of a valve box and a
valve box adapter; providing an inwardly projecting annular flange
positioned about an interior portion of said one of said valve box
and said valve box adapter; wherein said inwardly projecting
annular flange is positioned within said one of said valve box and
said valve box adapter so that when said debris cap is inserted
into said one of said valve box and said valve box adapter, said
annular gasket seal will contact said inwardly projecting annular
flange, deform in shape so as to be able to pass by said inwardly
projecting annular flange, and return to its original shape below
said inwardly projecting annular flange so as to secure said debris
cap in position in said one of said valve box and said valve box
adapter; and inserting said debris cap into said one of said valve
box and said valve box adapter until said annular gasket seal
passes by said inwardly projecting annular flange and returns to
its original shape below said inwardly projecting annular
flange.
13. The method of claim 12 wherein said annular gasket seal is
formed from a deformable and energy absorbent material.
14. The method of claim 13 wherein said deformable and energy
absorbent material is Kraton.RTM..
15. The method of claim 12 further comprising the step of providing
means for removing said debris cap from said valve box.
16. The method of claim 15 wherein said step of providing debris
cap removal means comprises the steps of: providing at least one
slot located about an edge portion of said debris cap; and
providing a removal tool dimensioned to be inserted into said at
least one slot and then to be agitated so as to impart a
substantially upward force so as to cause said annular gasket seal
to move in an upward direction past said inwardly projecting
annular flange and thereby to permit removal of said debris
cap.
17. The method of claim 16 wherein said removal tool comprises: a
handle portion; two spaced apart flat legs projecting downward at
right angles from said handle portion; wherein each said flat leg
has on an end portion thereof distal from said handle portion an
angled edge dimensioned to be inserted into said slot; wherein each
said flat leg further has thereon proximate said angled edge an
inwardly recessed area dimensioned to mate with an edge portion of
said debris cap when said angled edge is inserted into said slot;
wherein each said flat leg further has thereon an outwardly
projecting post positioned slightly above said inwardly recessed
area; and a lock bar slidably positioned on said flat legs between
said outwardly projecting posts and said handle portion.
18. The method of claim 15 further comprising the step of removing
said debris cap from said one of said valve box and said valve box
adapter with said debris cap removal means.
19. The method of claim 16 further comprising the step of removing
said debris cap from said one of said valve box and said valve box
adapter with said debris cap removal means.
20. The method of claim 17 further comprising the step of removing
said debris cap from said one of said valve box and said valve box
adapter with said debris cap removal means.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] This invention relates generally to debris and access caps
for access pipes originating at a below-ground shut-off valve and
opening at street level, and more specifically, to a debris cap
providing both a secure fit and improved debris protection.
[0003] 2. Background of the Invention
[0004] Municipal utilities typically bury their mains under public
rights of way, such as streets, at spaced intervals throughout the
system. Normally, open shut-off valves are incorporated for the
purpose of isolating main breaks so they can be repaired, or so new
connections can be established.
[0005] The shut-off valves are frequently buried several feet
beneath the street, and access pipes are provided which extend
upwardly from the valve to near street level, ending in a valve
box. The access pipe provides a passage for a tool which can be
manipulated from street level to actuate the valve.
[0006] A cover assembly with a removable lid is usually
incorporated in the pavement to cover the opening to the valve box,
and possibly also to prevent debris from entering the access pipe.
It has been customary to fabricate the cover assembly from cast
iron. Cast iron has the advantages of being inexpensive and
durable. Iron castings, however, are notorious for dimensional
variations from one casting to the next. Consequently, it
frequently is the case that there is a poor fit between the cover
assembly and valve box--with the result that cover assemblies can
become dislodged, creating a potential hazard.
[0007] Nevertheless, cast iron has remained the material of choice
because it is strong and capable of withstanding the rigors to
which a pavement-mounted assembly is subjected. It has more
recently been recognized that quality cover assembly components can
be modeled from light-weight synthetic polymeric material. U.S.
Pat. No. 4,048,766, granted Sep. 20, 1977, to P. H. Dantzer et al.
for "Closure Lid Assembly for Protective Housings" suggests the
components be formed by a structural foam molding process. The
light weight of the lid in the Dantzer et al. assembly requires
that special retaining means and a locking system be provided in
the design to prevent the lid from being accidentally
dislodged.
[0008] There continues to be a need for an access cover assembly
which can be easily molded from polymeric material and which will
perform reliably in service--providing both a secure fit (i.e.,
resisting dislodging), able to be removed in a convenient manner,
and also preventing debris from entering the access pipe. There is
further a need for a cover assembly having these qualities and
which can be retrofitted to existing valve boxes of different
sizes. The present invention satisfies these needs and provides
other, related, advantages.
SUMMARY OF THE INVENTION
[0009] It is an object of the present invention to provide a
light-weight debris cap for an access pipe that provides a secure
fit that will resist accidental dislodging.
[0010] It is a further object of the present invention to provide a
light-weight debris cap for an access pipe that provides a secure
fit that will resist accidental dislodging and that further
provides improved debris prevention.
[0011] It is yet a further object of the present invention to
provide a light-weight debris cap for an access pipe that may be
removed in a convenient manner.
[0012] It is still a further object of the present invention to
provide a light-weight debris cap for an access pipe that provides
a secure fit that will resist accidental dislodging and that
further provides improved debris prevention, and that still further
may be retrofitted to different-sized valve boxes.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] In accordance with one embodiment of the present invention,
a debris cap apparatus is disclosed. The apparatus comprises, in
combination: a debris cap; an annular debris seal positioned about
an exterior portion of the debris cap proximate an upper portion of
the debris cap and projecting upwardly and outwardly from the
debris cap; an annular gasket seal positioned about an exterior
portion of the debris cap distal from an upper portion of the
debris cap; a valve box; and an inwardly projecting annular flange
positioned about an interior portion of the valve box; wherein the
inwardly projecting annular flange is positioned within the valve
box so that when the debris cap is inserted into the valve box, the
annular gasket seal will contact the inwardly projecting annular
flange, deform in shape so as to be able to pass by the inwardly
projecting annular flange, and return to its original shape below
the inwardly projecting annular flange so as to secure the debris
cap in position in the valve box.
[0014] In accordance with another embodiment of the present
invention, a debris cap apparatus is disclosed. The apparatus
comprises, in combination: a debris cap; an annular debris seal
positioned about an exterior portion of the debris cap proximate an
upper portion of the debris cap and projecting upwardly and
outwardly from the debris cap; an annular gasket seal positioned
about an exterior portion of the debris cap distal from an upper
portion of the debris cap; a valve box adapter having an external
configuration dimensioned to conform to an internal configuration
of a valve box; and an inwardly projecting annular flange
positioned about an interior portion of the valve box adapter;
wherein the inwardly projecting annular flange is positioned within
the valve box adapter so that when the debris cap is inserted into
the valve box adapter, the annular gasket seal will contact the
inwardly projecting annular flange, deform in shape so as to be
able to pass by the inwardly projecting annular flange, and return
to its original shape below the inwardly projecting annular flange
so as to secure the debris cap in position in the valve box
adapter.
[0015] In accordance with still another embodiment of the present
invention, a method for positioning a debris cap within a valve box
in a secure and debris resistant manner is disclosed. The method
comprises the steps of: providing a debris cap; providing an
annular debris seal positioned about an exterior portion of the
debris cap proximate an upper portion of the debris cap and
projecting upwardly and outwardly from the debris cap; providing an
annular gasket seal positioned about an exterior portion of the
debris cap distal from an upper portion of the debris cap;
providing one of a valve box and a valve box adapter; providing an
inwardly projecting annular flange positioned about an interior
portion of the one of the valve box and the valve box adapter;
wherein the inwardly projecting annular flange is positioned within
the one of the valve box and the valve box adapter so that when the
debris cap is inserted into the one of the valve box and the valve
box adapter, the annular gasket seal will contact the inwardly
projecting annular flange, deform in shape so as to be able to pass
by the inwardly projecting annular flange, and return to its
original shape below the inwardly projecting annular flange so as
to secure the debris cap in position in the one of the valve box
and the valve box adapter; and inserting the debris cap into the
one of the valve box and the valve box adapter until the annular
gasket seal passes by the inwardly projecting annular flange and
returns to its original shape below the inwardly projecting annular
flange.
[0016] The foregoing and other objects, features, and advantages of
the invention will be apparent from the following, more particular,
description of the preferred embodiments of the invention, as
illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a perspective, partially cut-away, view of an
embodiment of the debris cap of the present invention in position
in a valve box located at street level, and also illustrating the
insertion of the removal tool for the debris cap.
[0018] FIG. 2 is a side, cross-sectional view of the debris cap of
FIG. 1, and the valve box into which the debris cap is to be
inserted.
[0019] FIG. 3 is a side, cross-sectional view of the debris cap of
FIG. 1, in position in a valve box.
[0020] FIG. 4 is a side, cross-sectional view of the debris cap of
FIG. 1, shown being removed from a valve box using the removal tool
shown in FIG. 1.
[0021] FIG. 5 is a top view of the base portion of the debris cap
of FIG. 1, showing the compartment into which a wireless
transmitter may be placed.
[0022] FIG. 6 is a perspective, exploded view of another embodiment
of the debris cap of the present invention, showing a debris cap,
adapter, and cylindrical valve box into which the adapter is to be
fitted so that the debris cap may be used with an otherwise
non-conforming valve box.
[0023] FIG. 7 is a perspective, exploded view of another embodiment
of the debris cap of the present invention, showing a debris cap,
adapter, and four-sided valve box into which the adapter is to be
fitted so that the debris cap may be used with an otherwise
non-conforming valve box.
[0024] FIG. 8 is a side of the embodiment of the debris cap of FIG.
7, showing the positioning of the adapter within the valve box and
the positioning of the debris cap within the adapter.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Referring first to FIGS. 1-5, a debris cap 10 of the present
invention is shown. The debris cap 10, as indicated in FIGS. 1-4,
is designed to be fitted within a valve box 12, which valve box 12
is generally positioned in a street 14 or other surface.
[0026] Referring specifically to FIG. 2, the debris cap 10
comprises a lid 14, an annular debris seal 16 positioned about the
lid 14 and angled in an upward and outward direction as shown in
FIGS. 2-4, a base 18, and an annular retention gasket 20 positioned
about the base 18 and angled in an upward and outward direction as
shown in FIGS. 2-3.
[0027] The debris cap 10 is preferably made from a thermoplastic
material. The debris seal 16 is preferably made from a rubber type
of material. The retention gasket 20 is preferably made from a
deformable, energy absorbent material, such as Kraton.RTM., so as
to prevent rebound and absorb energy. If the retention gasket 20
was made from a non-energy absorbent material, the application of
downward force on the debris cap 10--such as by the passage
thereover of a vehicle--could cause the retention gasket 20 to
"bounce" and spring upward, with the result that the debris cap 10
could be accidentally dislodged from the valve box 12.
[0028] Preferably, as shown in FIGS. 2-4, the debris cap 10 is a
multi-piece assembly, with the lid 14 being detachable from the
base 18. In this regard, bolts 22 are positioned within posts 24
projecting from the bottom of the lid 14. The bolts 22 enter posts
26 projecting from the top of the base 18, exit recessed openings
28 in the base 18, and are secured with nuts 30. One of the
advantages to having the base 18 separable from the lid 14 is to
provide a compartment 32 within the base 18, which may be accessed
from an upper portion thereof (see FIG. 5) by removing a
compartment lid 34 which is retained in position with a screw 36
secured within a post 38, and which may be used to house a wireless
transmitter (not shown). Of course, it would be possible to
construct a debris cap 10 in which the lid 14 and base 18 comprised
a single piece assembly, with the compartment 32 either eliminated
or made accessible from the bottom of the base 18.
[0029] Still referring to FIGS. 2-4, the valve box 12 has an
inwardly projecting annular flange 40. When the debris cap 10 is
inserted into the valve box 12, the retention gasket 20 will
compress inwardly so as to pass by the flange 40. When the
retention gasket 20 has cleared the flange 40, it will return to
its original outwardly projecting shape as shown in FIG. 3. In this
position, the retention gasket 20 will strongly retain the debris
cap 10 in position in the valve box 12 by resisting efforts to pull
it past the flange 40. When the retention gasket 20 is in position
below and against the flange 40 as shown in FIG. 3, the debris seal
16 will occupy the opening between the lid 14 and the valve box 12,
so as to prevent (or at least minimize) the passage of debris into
the valve box 12.
[0030] When the debris cap 10 is in position, it will strongly
resist efforts to remove it from the valve box 12. To do so most
efficiently and safely, a removal tool 42 is provided, as shown in
FIG. 1. The removal tool 42 comprises a handle portion 44 with two
hand grips 46 thereon. Projecting downward at right angles from the
handle portion 44 are two flat legs 48, each having an angled edge
50, an inwardly recessed area 52 above the angled edge 50, and an
outwardly projecting post 54 positioned slightly above the inwardly
recessed area 52. A lock bar 56 is slidably positioned on the flat
legs 48, with the posts 54 preventing the lock bar 56 from sliding
off of the flat legs 48. The purpose of the lock bar 56 is to
maintain the proper positioning of the flat legs 48 for removal of
the debris cap 10.
[0031] To remove the debris cap 10, the lock bar 56 is slid in an
upward direction toward the handle portion 44. The angled edges 50
are then inserted into slots 58 in the lid 14, until the lid 14 is
secured within the inwardly recessed areas 52. The lock bar 56 is
then slid in a downward direction toward the lid 14. At this point,
the debris cap 10 may be removed by the user grasping the hand
grips 46 and pulling up, first on one side and then on the
other.
[0032] The debris cap 10 as described herein and the valve box 12
are preferably part of a single system, with the valve box 12
having the appropriate internal diameter and flange 40 to mate with
the debris cap 10 in a manner that will result in the proper
positioning of the debris seal 16 and the retention gasket 20.
However, it may be desired to fit a debris cap 10 to an existing
valve box, which valve box may already be secured in a street or
other location from which it is not readily removable, and which
valve box may not be appropriately dimensioned to accept the debris
cap 10. Referring now to FIGS. 6-8, a debris cap 10 which may be
retrofitted to an existing, non-confirming valve box, is shown.
[0033] Referring first to FIG. 6, the main components of a retrofit
system are the debris cap 10, as described above, an existing valve
box 120, and an adapter 130. The adapter 130 will have an external
diameter conforming to the internal diameter of the particular
valve box 120 with which it is to be used. Preferably, adapters 130
will come in different sizes, so as to conform to different valve
boxes 120.
[0034] The adapter 130, like the debris cap 10, is preferably made
from a thermoplastic material. It has an inwardly projecting
annular flange 140, which has the same dimension and performs the
same function as the flange 40. To permit fixation of the adapter
130 to the inside of a valve box 120, a plurality of openings 142
are provided in the adapter 130, through which set screws 144 may
be inserted and secured to the valve box 120. This will permit a
debris cap 10 to be fitted to an existing valve box 120, after
fixation of an adapter 130, with the same quality of fit as where a
debris cap 10 is fitted to a valve box 12 having a flange 40. This
also permits the creation of adapters 130 having different external
configurations and sizes to conform to different valve boxes 120,
and one or a relatively small number of internal configurations so
that a single debris cap 10 could be fitted to multiple different
valve boxes 120.
[0035] Referring now to FIGS. 7 and 8, a retrofit system like that
shown in FIG. 6 is disclosed, with the difference being that the
system of FIGS. 7 and 8 is intended for use with four-sided valve
boxes 120'. Thus, the debris cap 10' is four sided, with a debris
seal 16' and a retention gasket 20' positioned thereon in the
manner and for the purposes described above with respect to the
debris cap 10. The adapter 130', like the adapter 130, will be
dimensioned externally to conform to the internal dimensions of the
particular valve box 120' with which it is to be used--with there
preferably being adapters 130' in different sizes, so as to conform
to different four-sided valve boxes 120'. The adapter 130', like
the adapter 130, is preferably made from a thermoplastic material.
The adapter 130', like the adapter 130, has an inwardly projecting
annular flange 140', which has the same dimension and performs the
same function as the flange 40. To permit fixation of the adapter
130' to the inside of a valve box 120', a plurality of openings
142' are provided in the adapter 130, through which set screws 144'
may be inserted and secured to the valve box 120.
[0036] It should be recognized that it would be possible to have an
adapter with a four-sided external configuration like that of
adapter 130' so as to mate with a four-sided valve box like that of
valve box 120', yet with a circular internal configuration like
that of adapter 130 so as to accept a circular debris cap like
debris cap 10--and vice versa.
[0037] While the invention has been particularly shown and
described with reference to preferred embodiments thereof, it will
be understood by those skilled in the art that the foregoing and
other changes in form and details may be made therein without
departing from the spirit and scope of the invention.
* * * * *