Abstract
A pipe sealing gasket is shown which is designed to be received within a raceway provided within a socket end of a female bell plastic pipe end which is assembled with a mating male pipe end to form a plastic pipe joint. The raceway in the female bell plastic pipe end is preformed during manufacture and the gasket is installed thereafter. The gasket has a rubber body portion which is reinforced by a hard plastic band formed as a series of integral, spaced wedges which are interconnected by a flexible ribbon. The gasket is flexible enough to be flexed and placed in the pipe raceway and yet the hard plastic band acts to prevent extrusion of the gasket during a variety of pressure conditions as well as preventing displacement during field assembly.
Claims
1. A pipe scaling gasket received within a raceway provided within a female bell socket end of a thermoplastic pipe, the raceway being generally arcuate with a forward facing slope region when viewed in cross section, and wherein the raceway has been previously formed during the manufacture of the pipe and the gasket is installed thereafter, the female bell socket end having a given internal diameter which is being designed to receive a mating male thermoplastic pipe end to form a pipe joint, the male thermoplastic pipe end having a given outer diameter, the gasket comprising: a ring shaped elastomeric body having a main body portion formed of rubber which, when viewed in cross section, includes a leading nose region, a lower compression region and a trailing tail region, the leading nose region facing generally towards the female bell socket end of the pipe once the gasket is inserted within the pipe; wherein the leading nose region of the main body portion of the gasket is reinforced by a hard plastic band having a series of spaced wedges integrated with the band at equi-distantly spaced locations about the circumference of the band, the hard plastic band being embedded within the leading nose region of the main body portion of the gasket during gasket manufacture, each of the wedges having a front edge, a rear edge and opposing side edges, as viewed in cross section, the wedges intersecting the hard plastic band at spaced locations, the wedges on the hard plastic band each having a hollow region which communicates the front and rear edges thereof, whereby rubber can flow through and fill the hollow regions during manufacture of the gasket, the front edges of the wedges being covered by a layer of rubber during manufacture so that they are entirely encapsulated in the rubber of the gasket body; wherein the main body portion of the gasket has a given durometer hardness and wherein the hard plastic band is formed of a synthetic plastic material having a durometer hardness which is greater than the durometer hardness of the main body portion of the gasket while being flexible enough to allow the gasket to accept inverse curvature during installation into the groove provided in the female bell socket end of the thermoplastic pipe; and wherein the wedges on the hard plastic band act in concert with the forward facing slope region of the arcuate raceway to wedge between the outer diameter of the male thermoplastic pipe end and the internal diameter of the female bell socket end, the embedded hard plastic band acting to prevent extrusion of the gasket from the groove provided in the female bell socket end of the thermoplastic pipe once the male thermoplastic pipe end is installed to form a pipe joint.
2. The sealing gasket of claim 1, wherein the main body portion of the gasket is formed of a natural or synthetic rubber.
3. The sealing gasket of claim 2, wherein the main body portion of the gasket is formed of a rubber selected from the group consisting of styrene butadiene rubber, ethylene propylene diene monomer rubber and nitrile rubber.
4. The sealing gasket of claim 2, wherein the synthetic plastic material is an engineered plastic.
5. The sealing gasket of claim 4, wherein the synthetic plastic material is a modified polyphenylene ether.
6. The sealing gasket of claim 2, wherein the lower compression region of the gasket includes a series of circumferential engagement grooves for engaging the mating male thermoplastic pipe end.
7. The scaling gasket of claim 6, wherein the main gasket body has an outer bulbous region which is also provided with a series of circumferential engagement grooves for engaging the female bell socket end of the pipe.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) FIG. 1 is an end view of a section of plastic pipe, partly broken away, and showing the bell end and raceway, with an earlier version of the gasket of the invention in place in the raceway, the male pipe section being position for insertion into the bell.
(2) FIG. 2 is a perspective view of the sealing gasket of FIG. 1, showing an early version of the hard plastic band with its wedges and associated flexible ribbon in dotted lines.
(3) FIGS. 3-6 are simplified views of the steps of installing the hard plastic band within an associated mold, the mold thereafter being injected with rubber and heated and cured to make the completed gasket of the invention.
(4) FIG. 7 is a side, partial cross sectional view of one version of the gasket of the invention in place in the internal groove provided in the female bell socket pipe end, the direction of travel of the mating male pipe member being shown in dotted lines.
(5) FIG. 8 is a broken away view of an earlier version of the hard plastic band used in the manufacture of the gasket of FIG. 7, and illustrating the wedges which are interconnected by the flexible ribbon and the position of the ribbon relative to the spaced wedges.
(6) FIG. 9 is a top view of a portion of the gasket of FIG. 8, showing the placement f the hard plastic band, the rubber portion of the gasket body being shown in phantom lines.
(7) FIG. 10 shows the beginning step of the make-up of a pipe joint with the male pipe end just beginning to make contact with the sealing gasket of FIG. 8.
(8) FIG. 11 is a view similar to FIG. 10, showing a completed pipe joint with an external pressure force acting on the sealing gasket.
(9) FIG. 12 is another view of the completed pipe joint, this time with the sealing gasket having an internal pressure force acting on the gasket.
(10) FIG. 13 is another version of the hard plastic ring used as the reinforcing element in the gasket of the invention where the hard plastic ring is located behind the spaced wedges so that a rear edge of each of the spaced wedges is supported on the continuous band.
(11) FIG. 14 is a side, cross sectional view of the improved gasket of the invention using the reinforcing ring of FIG. 13.
(12) FIG. 15 is a perspective view of the version of the gasket of the invention using the reinforcing ring of FIG. 13.
(13) FIG. 16 is a top, plan view of another version of the reinforcing ring used in the gaskets of the invention with the interconnecting band or ribbon being located approximately half way in and approximately half way behind the associated wedges.
(14) FIG. 17 is a side, cross sectional view taken along lines A-A in FIG. 16.
(15) FIG. 18 is a side, cross sectional view taken along lines B-B in FIG. 16.
(16) FIG. 19 is an isolated view of a portion of the reinforcing ring of FIG. 16, shown in somewhat enlarged fashion, for ease of illustration.
(17) FIG. 20 is a perspective view of yet another reinforcing ring used in the improved gaskets of the invention, showing the hollow wedge segments used in the ring.
(18) FIG. 21 is an isolated view of a portion of the reinforcing ring of FIG. 20 showing the hollow segments thereof in greater detail.
(19) FIG. 22 is a side, cross sectional view of the version of the gasket of the invention using the reinforcing ring of FIG. 20.
DETAILED DESCRIPTION OF THE INVENTION
(20) Turning now to the attached illustrations, FIG. 1 shows an earlier version of the gasket of the invention, designated as 11, in place prior to the assembly of a pipe joint. The gasket 11 is installed within a raceway 13 provided within the belled end 15 of a female pipe section of thermoplastic pipe 17. The female pipe section 17 can be formed of any of a variety of commercially available thermoplastic materials, such as the polyolefin family including polyethylene and polypropylene as well as polyvinyl chloride and similar materials. Thermoplastic pipes of this general type are used in a variety of industrial settings including water, sewage and chemical industries. The belled end 15 of the thermoplastic pipe section has a mouth opening 19 which is engageable with a spigot end 23 of a mating male pipe section 25 to form a pipe joint. The gasket receiving raceway 13 has been pre-formed in the pipe month opening 19 at the pipe manufacturing facility, as by using a collapsible mandrel belling tool. The raceway 13 is generally arcuate as viewed in cross section with a forwardly facing slope region (32 in FIG. 7).
(21) The earlier version of the gasket of FIG. 1 is shown in profile in FIG. 2 and in cross-section in FIG. 7. Preferably, the gasket 13 is an annular, ring-shaped member having a main gasket body 28 formed of a flexible elastomeric material, such as a suitable natural or synthetic rubber. The elastomeric material used to form the body 28 of the gasket will vary in composition depending upon the end application but may encompass a number of different natural and synthetic rubbers including, for example, styrene butadiene rubber (SBR), ethylene propylene diene rubber (EPDM), acrylonitrile-butadiene rubber (NBR), nitrile rubber, etc.
(22) Turning now to FIG. 7, the main gasket body 28 includes an outer convex sealing surface 27 which, in this case, is provided with a series of ribs or serrations 29. The main gasket body also includes a lower, primary sealing surface 31. In the preferred embodiment shown, the primary sealing surface 31 is an evenly sloping face of the gasket body which forms a combination lip and compression seal region for the gasket. The lip region is separated from the outer convex sealing surface 27 and trailing tail portion 30 by a V-shaped recess (shown generally as 33 in FIG. 7). The V-shaped recess allows the lip region of the gasket body to bend inwardly as the mating male, spigot end of a mating pipe section encounters the primary sealing surface 31 of the gasket (see FIGS. 10-12).
(23) Returning to FIG. 7, the main gasket body 28 also has a leading nose region, designated generally as 35 in FIG. 7 which is initially contacted by the mating male spigot pipe end during the assembly of the pipe joint. The leading nose region 35 faces generally towards the female socket end of the pipe once the gasket is inserted within the pipe.
(24) With reference now to FIG. 8, it will be appreciated that the leading nose region of the gasket is reinforced by a hard plastic band 37 formed as a series of integral, spaced wedges (such as wedges 39, 41, 43) interconnected by a flexible ribbon 45. As will be apparent from FIGS. 4 and 8, the wedges 39 each have a front edge 53, a rear edge 55 and opposing side edges 57, 59. The opposing aide edges (such as side edge 59 in FIG. 10) slope evenly from the rear edges 55 to the front edges 53 thereof, as viewed in this cross section. FIG. 2 shows the reinforcing hard plastic band with its associated wedges in phantom lines (see, e.g., wedges 39, 41, 43). The gasket body can thus be thought of as having a rubber element and as having a hard plastic element, the hard plastic element serving as the reinforcing element for the gasket body.
(25) During the manufacture of the gasket, the hard plastic band 37 is embedded within the leading nose region of the gasket during the gasket manufacturing operation. As will be explained in greater detail, the wedges 39 on the hard plastic band 37 act to prevent extrusion of the gasket from the raceway (13 in FIG. 1) provided in the female socket end of the thermoplastic pipe once a spigot end of a mating male pipe is installed to form a pipe joint.
(26) The hard plastic band shown in isolated fashion in FIG. 8 of the drawings is an earlier version of the plastic band which posed certain problems during manufacture, primarily with respect to the injection molding operation. The present invention is directed primarily to improvements in the shape and function of the hard plastic band. The improved versions of the band are shown in FIGS. 13-22 of the drawings. The primary areas of improvement concern the placement of the band or ribbon with respect to the individual spaced wedges that are interconnected by the flexible band, and also the use of hollow wedge segments, and these differences will be discussed in detail in the written description which follows.
(27) As was previously mentioned, the main body portion of the gasket is formed of a natural or synthetic rubber, such as a styrene butadiene rubber, ethylene propylene diene monomer rubber or nitrile rubber. The durometer of the rubber used for the main gasket body may vary depending on the end application but will typically be in the range from about 40-70 Shore A hardness, preferably about 40-60 Shore A. The hard plastic band 37, on the other hand, is formed of a synthetic plastic material having a durometer which is greater than the durometer of the main body portion of the gasket. The synthetic plastic material used for the band is preferably a material which shows an appropriate stiffness for the application at hand while allowing flexing (accepts inverse curvature) during installation. The band can have a higher durometer than the remaining main body portion of the gasket since it does not participate in the sealing function of the gasket to the same extent as the primary sealing region of the gasket.
(28) Various hard plastic type materials may be suitable candidates for use as the hard plastic band. These materials include such materials as polypropylene, polyvinylchloride and various engineered plastics. For example, one such material is those hard plastics which fall into the family group of modified polyphenylene ethers (PPE). These commercially available materials have high heat resistance, making them suitable for injection or compression molding and are generally suitable for plastic/rubber composites. One commercially available family is the VESTORAN family of materials. VESTORAN is the registered trademark of Evonik Degussa GmbH for molding compounds containing poly-2,6-dimethyl-1,4-phenylene ether as polymeric constituent (poly-phenylene ether, PPE, also referred to as PPO).
(29) The method of manufacturing the sealing pipe gasket of the invention will now be described. The gasket is designed for receipt within a bell pipe raceway provided within, a socket end of a female bell pipe member, whereby fitting the gasket within the raceway allows a mating male pipe having a spigot pipe end to be inserted therein to form a continuous pipe joint. The manufacturing method will be described primarily with respect to FIGS. 3-6. FIG. 3 shows one half of an injection molding die 47 of the type that will be familiar to those skilled, in the relevant arts. As can be seen in FIG. 3, the first mold half has a first mold face 49 with a circumferential recess 51. As shown in FIG. 4, in the first step of the manufacturing process, the hard plastic band 37 with its series of integral, spaced wedges interconnected by the flexible ribbon 45 is placed within the circumferential recess 51. It will be appreciated that placing the wedges into the mold as discrete and individual elements would be very time consuming. However, because the teeth are interconnected by the flexible ribbon, they can easily be placed in the mold integrally, in a single step. This also assures the proper spacing of the individual teeth about the circumference of the gasket.
(30) Next, there is provided a second mating mold face which is essentially a mirror image of the first mold face. FIG. 5 shows the hard plastic band partially installed in the circumferential groove of the first mold face, while FIG. 6 shows the band fully installed. The first and second mold faces are then united and the moldable rubber compound is injected into the circumferential recess. In the known manner, heat and pressure are then applied to the mold to form a ring shaped elastomeric body. The heat and pressure in the mold cures the main body portion with the hard plastic band embedded therein, whereby the main body portion of the gasket is reinforced by the hard plastic band, whereby hydraulic pressure due to fluid in the pipe acts upon the wedges on the hard plastic band to push the teeth into tighter engagement with the mating male and female pipe members to prevent extrusion of the gasket from the raceway provided in the female bell socket end of the thermoplastic pipe once a spigot end of a mating male pipe is installed to form a pipe joint and the pipe is conveying fluid.
(31) While the gasket body is reinforced to prevent extrusion under various fluid pressure conditions, as well as from being displaced during field assembly, it remains flexible enough to allow the gasket to be bent by hand and installed within a gasket receiving raceway provided within the belled end of a female pipe member. The sealing gasket can be installed within the gasket receiving raceway by bending the gasket to temporarily transform the gasket from a generally cylindrical shape to a generally elliptical shape, followed by placing the gasket within the gasket receiving groove and releasing the gasket, whereby the gasket returns to the generally cylindrical shape. Hydraulic pressure due to fluid in the pipe acts upon the wedges on the hard plastic band to push the wedges into tighter engagement with the mating male and female pipe members to prevent extrusion of the gasket from the raceway provided in the female bell socket end of the thermoplastic pipe once a spigot end of a mating male pipe is installed to form a pipe joint and the pipe is conveying fluid. FIG. 11 shows a cross section of the gasket of FIG. 7 installed in a pipe joint with external pressure acting upon the gasket. FIG. 12 is a view similar to FIG. 11 but shows the cross sectional shape of the gasket where an internal fluid pressure is acting upon the gasket body.
(32) FIGS. 13-22 show three different versions of the hard plastic band which are used to reinforce the sealing gaskets of the invention. With reference back to FIG. 8, the earlier version of the hard plastic band had the interconnecting band or ribbon running along the entire length of the wedges, in other words, along the entire side edges 57, 59 in FIG. 8. However, as best seen in FIG. 10, the front edges 53 of each wedge was exposed after manufacture so that the hard plastic band as a whole was not interlocked within the rubber of the gasket body. As a result, it had a tendency to slip out of the gasket body at the front edge regions (53 in FIG. 8) of the spaced wedges. The region where no rubber was present was that region indicated generally at 53 in FIG. 8 and also at 53 in FIG. 10.
(33) It has been found that the deficiencies of the earlier version of the gasket can overcome by extending the geometry of the rubber at the nose of the gasket and in front of the plastic band insert so that the insert front edge is completely covered by rubber. In other words, enough rubber is put around the plastic insert to ensure that it can't be detached from the rubber of the gasket body. In this sense, it is interlocked within the rubber gasket body. Most preferably, the band or ribbon portion of the insert (that portion shown as 79 in FIG. 13) is completely surrounded by rubber, except where it attaches to the wedge segments 63, 65, on the rear faces of the segments. The improved plastic band inserts of the invention also have improved geometries which achieve a better interlocked condition with respect to the rubber gasket body and which can be more easily injection molded in some cases.
(34) With further reference to FIG. 13 of the drawings, there is shown one version of the improved hard plastic band used in the sealing gaskets of the invention. Once again, the pipe sealing gasket is designed for receipt within a raceway provided within a female bell socket end of a thermoplastic pipe, the raceway being generally arcuate with a forward facing slope region when viewed in cross section, as previously described. The raceway has been previously formed during the manufacture of the pipe and the gasket is installed thereafter.
(35) The leading nose region of the main body portion of the gasket is once again reinforced by a hard plastic band formed as a series of integral, spaced wedges interconnected by a flexible ribbon, the hard plastic band being embedded within the leading nose region of the main body portion of the gasket during gasket manufacture. As shown in FIGS. 13 and 14, each of the spaced wedges 63, 65, has a front edge 67, a rear edge 69, opposing side edges 71, 73, and top and bottom edges 75, 77. It will be appreciated from FIG. 13 that the opposing side edges 71, 73, slope evenly in the direction of the leading nose region of the gasket when the band is embedded in the rubber gasket body. In this case, however, unlike the band of FIG. 8, the front edges (67 in FIG. 14) of the spaced wedges are covered by a layer of rubber during manufacture so that they are entirely encapsulated in the rubber of the gasket body. Note the thickness of the rubber region t in FIG. 14. Thus, while the top and bottom edges 75, 77, or a selected one of the two edges, of the hard band shown in FIG. 14 may be exposed, the front edge 67 of each of the wedges is covered by the thickness of rubber indicated as t in FIG. 14. This extra layer of rubber keeps the wedges firmly embedded in the rubber of the gasket in use.
(36) In the case of the hard plastic band shown in FIG. 13, the band is formed as a continuous ring 79 with an inner sidewall 81 and an outer sidewall 84, and wherein the rear edges 69 of each of the integral, spaced wedges sit flush at one circumferential position on the inner sidewall 81 of the continuous ring. In the version of the band shown in FIG. 13, the wedges are approximately equi-distantly spaced about the band 79. The band or ring 79 in this version of the invention thus extends continuously behind the wedge segments and is completely embedded in the rubber of the gasket body, helping to further interlock the band with respect to the remainder of the gasket body. It also acts like a circumferential runner in the plastic molding operation discussed earlier with respect to FIGS. 3-6. Even if the front edges of the wedge segments were somehow pushed out from the rubber of the gasket body, they will remain interlocked by means of the band 79. However, this should not occur under normal operating conditions.
(37) FIGS. 16-19 show another version of the improved hard plastic band 87 of the invention. In this version of the band, the opposing side edges of each wedge (such as side 85 in FIG. 17) again slope evenly in the direction of the leading nose region of the gasket once the band is installed during manufacture. The band 87 is not continuous, as shown in FIG. 19, but rather interconnects the series of wedge segments. As will be best appreciated from FIG. 18, the plastic and 87 in this case is positioned approximately half in back of each wedge and half in the middle region of each wedge. In other words, one half of the body length of the band 87, as viewed in the section in FIG. 18, is embedded in the body of the wedge. One half of the body length of the band 87 is exposed. This arrangement makes the structural connection between the band and wedge segments stronger and makes it more difficult for the front edges of the wedge segments to be pushed out of the rubber gasket body so that they somehow become exposed.
(38) FIGS. 20-22 show yet another version of the hard plastic band used in the sealing gaskets of the invention. The band 92 again has a series of wedges 89, 90, which are positioned at equi-distantly spaced locations about the circumference of the band 92. As described with respect to the wedge of FIG. 14, the wedges again have front, rear and opposing side edges and top and bottom edges with the side edges sloping evenly in the direction of the leading nose region of the gasket as viewed in section in FIG. 22. As shown in FIG. 21, the opposing side edges of each wedge (89, 90) are intersected by the band 92 at a location slightly behind the middle region of each wedge. Also, in this case, at least selected ones each of the wedges 90 on the hard plastic band 92 has a hollow region 91 formed therein. The hollow recesses pass entirely through each of the wedge segments, communicating the front side and rear sides thereof. Preferably, all of the wedges in this version of the band are hollow.
(39) Once again, as in the version of the band described in FIG. 14, the front edges 94 of the hollow wedge segments 90 are covered by a layer of rubber so that they are encapsulated within the rubber of the gasket body (see FIG. 22). The hollow segment version of the invention offers a better solution for mold flow problems since it offers more of a uniform thickness of rubber through the entire geometry of the wedge, although splitting around the holes making up the hollows of the wedges. This design generally offers the best connection between the rubber and hard plastic inserts with better interlocking with the rubber. Note, for example, the difference in the location of the surrounding rubber in the cross sectional view of FIGS. 22 and 14. There is a wider contact surface between the wedges segments and the pipe that reduces marks from cyclic pressure loads in use. The hollow regions allow more rubber through and around the band for better interlocking. Less material is used on the band, since it is in a sense discontinuous. As will be appreciated from FIG. 21, the hollow band offers a strong closed frame wedge segment structure. The hollow passages through the wedge insert geometry allowing rubber to flow to split, go through and then join at the front edges of the inserts. The parts are interlocked so no bonding or glues are required between rubber and plastic.
(40) An invention has been provided with several advantages. The method for installing a gasket of the invention allows a pipe gasket to be installed within a preexisting and preformed groove in a thermoplastic pipe. Once the gasket has been secured in position in snap-fit fashion, it is securely retained within the pipe raceway and resists axial forces tending to displace the gasket from the raceway. Because a gasket is inserted within a preformed pipe groove or raceway, the manufacturing and installation processes are simplified and made less costly. The design of the gasket also makes it possible to remove one gasket and reinstall another within a preformed raceway in the selected pipe end.
(41) The gasket which is utilized in the process is simple in design and relatively economical to manufacture. There is no need for an external retaining band or an internal metal ring to assist in securing the gasket within the pipe groove. Because the metal retaining band or ring are not necessary, it is also possible to eliminate the pins necessary to hold the band or ring in place inside the mold during manufacture, as in the previous Reiber gasket art. The hard plastic band with its integral, spaced wedges acts to prevent extrusion of the gasket from the female pipe groove under a variety of fluid pressure situations, or from being displaced during field assembly. Providing the wedges as an integral part of a continuous ribbon simplifies the manufacturing process and saves time. The wedge segments provide high radial stiffness for solid support of the gasket which acts to prevent extrusion under pressurized conditions.
(42) While the invention has been shown in several of its forms, it is not thus limited but is susceptible to various changes and modifications without departing from the spirit thereof.
