1. Field of the Invention
The present invention relates to gaskets for use in pipe joint applications in which a gasket seals a connection between an opening in a structure and a pipe extending through the opening.
2. Description of the Related Art
Pipe joint gaskets are well known in the art for sealing a pipe joint connection between a pipe and a structure to which the pipe is connected. In one particular application, a pipe joint is formed between a sewer pipe and a concrete manhole riser, for example, in which a sewer pipe is inserted through a gasket embedded within the concrete wall of the manhole riser. In other applications, pipe joints may be provided to connect pipes to septic tanks, for example, or may be provided in any other structure to which pipes are connected.
Pipe joint gaskets are typically made from relatively rigid materials, such as plastics, or alternatively, from relatively resilient materials, such as rubber or other elastomers. Gaskets made of plastics are usually injection or compression molded, while gaskets made of elastomers are typically compression molded or alternatively, are formed by cutting a length of extruded elastomeric material and securing the ends thereof to one another by vulcanization, adhesion, or another suitable manner to form an annular shaped gasket. Subsequently, the plastic or elastomeric gasket is mounted within an opening in a structure, typically by embedding a portion of the gasket in the structure when the structure is cast. Alternatively, an expansion band may be used to radially compress an elastomeric gasket into engagement with the interior wall of an opening in a cast structure.
When a pipe is inserted through the opening of a plastic gasket, the outer surface of the pipe engages an inwardly-extending sealing portion of the gasket to create a fluid tight seal between the pipe and the gasket. Specifically, in gaskets made of relatively rigid materials, such as plastics, an inwardly-extending sealing portion, or sealing blade, of the gasket engages the outer surface of the pipe in a deflecting or wiping manner to form a fluid tight seal.
Elastomeric gaskets may be sealed to pipes using separate clamping bands which externally clamp a sealing portion of the gasket to the outer surface of the pipe to effect a fluid tight seal between the gasket and the pipe. Alternatively, the gasket may include a inwardly-depending sealing lobe which is compressed between the pipe and the gasket body upon insertion of the pipe through the gasket, forming what is known as a “stab joint”.
Although elastomeric gaskets form robust, effective seals with pipes, a disadvantage of same is that elastomeric materials are typically expensive and therefore increase the cost of gaskets which are made of these materials. On the other hand, although plastic materials are less expensive, plastics are typically less flexible and/or compressible than elastomeric or rubber materials and may be less suitable for sealing pipes in certain applications.
What is needed is a gasket for providing a fluid tight connection between a pipe and a structure, which is an improvement over the foregoing.
The present concept relates to a gasket which may be cast in place within a concrete structure, such as a manhole riser or septic tank, for example, to seal a connection between a pipe and the concrete structure. The gasket includes a main body portion and a sealing portion which are made from different materials. The main body portion may be made of a substantially rigid material, such as a semi-rigid plastic, for example. The sealing portion, which is united with the body portion, may be made of a substantially resilient material, such as flexible plastic or a rubber-type material, for example. In this manner, the substantially rigid portion of the gasket provides for effective anchoring in a cast wall, and the substantially resilient portion is compressible to provide a robust seal with a pipe that is inserted through the gasket.
The gasket may advantageously be manufactured using a two-shot injection co-molding process. In this method, the material for the main body portion is heated and injected into a mold die. Then, before the substantially rigid material fully cures, the cores in the mold die are moved and a second, substantially resilient material is injected into the die and molded to the substantially rigid material, the substantially resilient material forming the sealing portion of the gasket. This two-shot injection molding process allows the second material to form a firm structural bond with the first material before the first material completely cures.
In use, the gasket is placed within forms for casting within a concrete structure, wherein the gasket is held in place either by the concrete forms and a mandrel structure or by a concrete reinforcing structure, such as reinforcement bar structure or by a wire mesh. Prior to casting, the sealing portion of the gasket can be folded inwardly with respect to the main body portion of the gasket to protect it during the casting process. After the concrete has been poured and substantially cured, the forms are stripped away to expose the main body portion of the gasket firmly anchored in an opening cast in the concrete. Alternatively, materials other than concrete, and processes other than casting, may be used to form the structure. Further, the structure may be pre-formed prior to the attachment of the gasket. In such an embodiment, an expansion band may be used to compress the body portion of the gasket into sealing engagement with the interior wall of the opening.
In an exemplary embodiment, the main body portion, which is made of a substantially rigid material, includes an integral annular anchoring flange. The anchoring flange extends radially from the outside surface of the body portion and is enveloped by concrete during the casting process. The anchoring flange has a geometry that allows the gasket to be retained in place after the concrete has cured. Alternatively, in other embodiments, the anchoring flange is not integral with the body portion and can comprise a separate component that is secured to the main body portion through an adhesive or fasteners.
In one embodiment, the sealing portion of the gasket is foldable between a first position in which the sealing portion is folded radially inwardly with respect to the main body portion and a second position in which the sealing portion extends axially outwardly from the main body portion. In one exemplary application, the sealing portion of the gasket may remain in its folded-in condition if a pipe of a relatively smaller diameter is inserted through the gasket. In this configuration, the pipe radially outwardly compresses the sealing portion of the gasket against the main body portion thereby providing a compression seal or “stab joint”. In another exemplary use, the sealing portion of the gasket may be unfolded from its folded-in position to its extended position if a pipe of a relatively larger diameter will be inserted through the gasket. After the pipe has been inserted through the sealing portion of the gasket, an annular external clamping band may be used to clamp the sealing portion of the gasket to the outer surface of the pipe to provide a compressive, fluid tight seal between the gasket and the pipe.
Advantageously, the substantially rigid material of the main body portion stiffens the gasket in the gasket region that interfaces with concrete structure, while the substantially resilient material of the sealing portion provides flexibility in the gasket region that seals to the pipe. This design allows the gasket to rigidly hold its shape during the casting process whereas a gasket entirely made of a resilient material could potentially more easily deform from the weight of the wet concrete. Similarly, a gasket made of an entirely resilient material requires a mandrel to maintain the shape of the gasket during the casting process whereas the body portions of the present embodiments may be constructed of a sufficiently rigid material such that a mandrel may not be needed.
Furthermore, the present gasket, made of both substantially rigid and substantially resilient materials, is less expensive to construct than a gasket entirely made of a substantially resilient material, such as rubber, due to the higher costs of the substantially resilient materials. The anchoring flange of the present embodiments may also be made of the same substantially rigid material as the body portion and thus strengthen the connection between the gasket and the concrete structure to prevent the gasket from becoming dislodged. Further, the relatively resilient portion of the gasket allows the gasket to easily seal to a pipe via a clamped seal or compression seal whereas a gasket entirely made of a rigid material would be less able to conform to the shape and irregularities of a pipe.
In one form thereof, the present invention provides a gasket for providing a seal between a concrete structure and a pipe, the gasket including an annular main body portion having an anchoring flange projecting radially outwardly thereof, the main body portion formed of a first material; and an annular sealing portion unitarily bonded to the main body portion and disposed radially inwardly of the main body portion, the sealing portion formed of a second material which is more flexible than the first material.
In another form thereof, the present invention provides a gasket for providing a seal between a structure and a pipe, the gasket including an embedment portion having an anchoring flange projecting therefrom, the embedment portion formed of a first, relatively rigid material; and a sleeve bonded to the embedment portion, the sleeve formed of a second, relatively resilient material which is more flexible than the first material, the sleeve including a pipe engaging portion.
The above-mentioned and other features and objects of this invention will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent embodiments of the present invention, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the present invention. The exemplifications set out herein illustrate preferred embodiments of the invention and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
Referring first to
Although the pipe joint application shown in
As illustrated in
Sealing portion 38, which is bonded to, or united with, body portion 20 in the manner described below, is made of a substantially resilient material, such as a flexible plastic or a rubber-type material, for example. Suitable materials for sealing portion 38 include thermoplastic rubbers, or thermoplastic vulcanizates (“TPVs”), such as Santoprene™, available from Advanced Elastomer Systems, an affiliate of ExxonMobil Chemical. TPV materials can include cured ethylene propylene dimonomer (“EPDM”) rubber which helps to give the TPV materials rubber-like properties, such as flexibility and compressibility with good material memory, i.e., the ability of the material to return to its original shape after deformation or compressive forces are removed.
As discussed above, main body portion 20 is comprised of a substantially rigid material and sealing portion 38 is comprised of a substantially resilient material. In this embodiment, for example, the modulus of elasticity of the relatively resilient material of sealing portion 38, such as Santoprene™ may be approximately 250-600 psi, 250-450 psi, or 250-350 psi, for example, while the modulus of elasticity of the relatively rigid material of body portion 20, such as polypropylene, is approximately 200,000 psi. In other embodiments, the modulus of elasticity of the main body portion material can be at least one order of magnitude higher than the modulus of elasticity of the sealing portion material.
An advantage of this design is that the substantially rigid material of body portion 20 stiffens the gasket in the region that interfaces with concrete structure 10 while the substantially resilient material of sealing portion 38 provides flexibility in the region that seals to pipe 14. The substantially rigid material of body portion 20 allows gasket 12 to hold its shape during the casting process whereas a gasket entirely made of a resilient material could potentially deform from the weight of wet concrete. Additionally, integral anchoring flange 32 is also comprised of the same substantially rigid material as body portion 20 and thus this material strengthens the connection between gasket 12 and concrete structure 10. As the integral anchoring flange and body portion are comprised of a substantially rigid material, these portions of gasket 12 are less susceptible to deformation as compared to a gasket entirely made of an elastomeric material, while the substantially resilient material of sealing portion 38 also allows gasket 12 to effectively seal to pipe 14.
Gasket 12 is preferably manufactured according to a two-shot injection co-molding process. Such a process can be performed using a Ube two-shot injection molding machine, available from Ube Machinery of Ann Arbor, Mich. This machine includes two hoppers, each one for receiving a different material, and two injection sprues and nozzles which are connected to a mold die mounted in the machine. In this method, the substantially rigid material used to create main body portion 20 is heated and injected into the mold die through a first opening. In one embodiment, LDPE material is heated to approximately 3250 Fahrenheit and injected into the mold die. Then, before the substantially rigid material completely cures, the cores in the mold die are moved and a second, substantially resilient material is injected into the mold through a second opening. In the above-mentioned embodiment, Santoprene™ is heated to approximately 350-425° Fahrenheit when injected into the mold die. The second, relatively resilient material which forms sealing portion 38 of the gasket, upon curing with the first, relatively rigid material which forms body portion 20 of the gasket, becomes permanently bonded, molded, or united with to the body portion 20. Thus, the foregong two-shot injection molding process allows the second material to form a firm bond with the first material before the first material completely cures.
In the above-mentioned embodiment, the surface of the LDPE material is not permitted to cool below 180° Fahrenheit before the Santoprene™ material is injected such that the LDPE material and the Santoprene™ material can bond together, although the the chemistry of the foregoing bonding at the molecular lever is not fully known, it is thought that the LDPE material and Santoprene™ material form a firm physical bond upon curing, and perhaps also chemically bond with one another at the heated interface therebetween upon curing. As illustrated in
Although the above process is the preferred method of manufacture, gasket 12 may also be formed by other suitable methods. For example, body portion 20 and sealing portion 38 may be co-extruded, cut, and subsequently folded into an annular configuration followed by securing the strip ends to one another by an adhesive or by a process in which the strip ends are heated, compressed together, and cooled. Alternatively, body portion 20 may be made by an injection molding process wherein body portion 20 and sealing portion 38 are subsequently united together by an adhesive or by a process similar to the heating process discussed above. On the other hand, body portion 20 and sealing portion 38 do not necessarily have to be united or bonded together. For example, the body and sealing portions may have a mating thread-like interface wherein the portions are screwed together and tightened to create a seal. Other methods by which gasket 12 may be formed will be apparent to those skilled in the art.
Referring to
Forms 44 and 46 isolate exterior surface 22 of body portion 20 and anchoring projection 32 to prevent concrete from contacting the internal surfaces of gasket 12. Form 44 includes wall portion 48 having aperture 50 wherein the interior surface of aperture 50 contacts body portion 20 to create a seal to prevent wet concrete from flowing onto sealing portion 38. Form 46 includes wall portion 54 having aperture 56 wherein the interior surface of aperture 56 contacts body portion 20. Mandrel 47, which comprises annular member 51 and flange 47 attached to one end of annular member 51, extends inwardly into body portion 20. Annular member 51 engages the interior surface 24 of body portion 20 wherein the contour of annular member 51 substantially parallels the contour of interior surface 24. Flange 49 of mandrel 47 abuts form 46 to control the depth in which mandrel 47 is inserted into gasket 12. The void between forms 44 and 46 comprises an area 62 for receiving concrete 66 to form structure 10.
After gasket 12 is assembled with forms 44 and 46 and mandrel 47, concrete 66 or another suitable material is poured into area 62, filling area 62 around the outer surface of gasket 12. Concrete 66 surrounds anchoring projection 32 of gasket 12 to permanently embed anchoring projection 32 within concrete 66 and lock gasket 12 in position within opening 16 formed in concrete structure 10. Specifically, the portion of concrete 66 around the tapered neck portion 34 (
Sealing portion 38 of gasket is movable between a first position shown in
In another embodiment, gasket 112, illustrated in
The diameter of pipe 14 may vary slightly wherein the pipe diameter may not be exactly equal to the inner diameter of the inwardly folded sealing portion of gasket 12, illustrated as opening 13 in
In the second position of sealing portion 38, shown in
As an alternative to the above, gasket 12 may lack anchoring projection 32, wherein such a gasket is installed within a pre-formed opening in a structure using an internal expansion band assembly, for example, to compress the body of the gasket into sealing engagement with the wall of the opening. One such internal expansion band is disclosed in U.S. Published Patent Application No. 2004/0080118, assigned to the assignee of the present invention, the disclosure of which is expressly incorporated herein by reference.
Further, the first and second positions of sealing portion 38 need not necessarily be stable. For example, after sealing portion 38 of gasket 12 is folded inwardly to its second position, sealing portion 38 could be manually or otherwise held in that position until pipe 14 is inserted through gasket 12.
A method of casting gasket 12 in place according to an alternative embodiment is shown in
While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.
This application claims the benefit under Title 35, U.S.C. § 119(e) of U.S. Provisional Patent Application Ser. No. 60/607,615, entitled PIPE JOINT GASKET, filed on Sep. 7, 2004.
Number | Date | Country | |
---|---|---|---|
60607615 | Sep 2004 | US |