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`US007341255B2
`
`c12) United States Patent
`Babiarz et al.
`
`(IO) Patent No.:
`(45) Date of Patent:
`
`US 7,341,255 B2
`Mar. 11, 2008
`
`(54) SEALING FITTING WITH EXPANDING
`MATERIAL
`
`(75)
`
`Inventors: Paul S. Babiarz, Liverpool, NY (US);
`William Bradley Delans, Fayetteville,
`NY (US)
`
`(73) Assignee: Cooper Industries, Houston, TX (US)
`Subject to any disclaimer, the term of this
`( *) Notice:
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 718 days.
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`3,758,916 A * 9/1973 Wetmore ................ 174/152 R
`4,086,736 A * 5/1978 Landrigan .................. 52/220.8
`4,454,381 A * 6/1984 Ito et al. ..................... 174/151
`4,607,469 A * 8/1986 Harrison .................... 52/220.8
`5,137,306 A * 8/1992 Flood ...................... 285/123.2
`5,278,357 A *
`1/1994 Yamanashi .................. 174/151
`5,560,618 A * 10/1996 Wambeke et al.
`.......... 277/314
`6,103,341 A * 8/2000 Barz et al. .................. 428/147
`
`(21) Appl. No.: 10/391,250
`
`(22) Filed:
`
`Mar. 18, 2003
`
`* cited by examiner
`
`(65)
`
`(51)
`
`(52)
`
`(58)
`
`Prior Publication Data
`
`US 2004/0183261 Al
`
`Sep. 23, 2004
`
`Primary Examiner-Vishal Patel
`(74) Attorney, Agent, or Firm-Schwegman, Lundberg &
`Woessner, P.A.
`
`Int. Cl.
`F16L 17/00
`(2006.01)
`F16L 41/00
`(2006.01)
`F16J 15/08
`(2006.01)
`HOJB 17/26
`(2006.01)
`U.S. Cl. ...................... 277/314; 277/627; 285/216;
`174/153 R; 174/157
`Field of Classification Search ................ 277/602,
`277/605, 626-627, 645-646; 285/96-97,
`285/196, 216, 100; 174/157, 153 R, 153 G,
`174/65 R, 65 G; 175/76-77
`See application file for complete search history.
`
`(57)
`
`ABSTRACT
`
`An expanding compound is used to seal conduit fittings. The
`compound is injected into the fitting, and expands to sepa(cid:173)
`rate conductors within the fitting. In one embodiment, the
`compound expands to four times its size, and hardens within
`approximately one hour. In a further embodiment, the com(cid:173)
`pound is a two-part product that is mixed in a self contained
`applicator and injected into the fitting.
`
`10 Claims, 3 Drawing Sheets
`
`120
`
`133
`
`123
`
`/
`
`123
`
`/
`
`210
`
`Cooper Ex. 1004
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`

`

`U.S. Patent
`
`Mar. 11, 2008
`
`Sheet 1 of 3
`
`US 7,341,255 B2
`
`123
`
`/
`
`115
`
`123
`
`/
`
`120
`
`133
`
`FIG. 1
`
`210
`
`FIG. 2
`
`Cooper Ex. 1004
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`

`

`U.S. Patent
`
`Mar. 11, 2008
`
`Sheet 2 of 3
`
`US 7,341,255 B2
`
`310
`
`342
`
`.-t-l-l--l-4-1--1-- 3 4 0
`
`328
`
`320
`
`,323
`
`FIG. 3
`
`Cooper Ex. 1004
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`

`

`U.S. Patent
`
`Mar. 11, 2008
`
`Sheet 3 of 3
`
`US 7,341,255 B2
`
`420
`
`FIG. 4
`
`Cooper Ex. 1004
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`

`

`US 7,341,255 B2
`
`1
`SEALING FITTING WITH EXPANDING
`MATERIAL
`
`FIELD OF THE INVENTION
`
`The present invention relates to sealing conduits, and in
`particular to an expanding conduit sealer.
`
`BACKGROUND OF THE INVENTION
`
`10
`
`2
`The following description is, therefore, not to be taken in a
`limited sense, and the scope of the present invention is
`defined by the appended claims.
`FIG. 1 shows a horizontal fitting 110 for joining two
`5 horizontally disposed conduits via mating sets of threads 115
`and 120 at each end of fitting 110. The length of the fitting
`is approximately the distance between the two sets of thread,
`and the width of the fitting is approximately equal to the
`outside diameter of the fitting.
`Multiple conductors 123 are disposed within the fitting.
`Two openings 125 and 130 are provided in the fitting 110.
`Removable plugs are used to plug the openings. Opening
`125 is shown without the plug installed, and a plug 135 is
`shown installed in opening 130. Opening 130 is larger than
`15 opening 125 in one embodiment. An expanding sealing
`compound 133 is provided in a liquid state inside the fitting
`110. One of the plugs may be removed to allow injection of
`the sealing compound. In this example embodiment, the
`sealing compound is injected through opening 125.
`In one embodiment, the sealing compound 133 is a
`two-part mixture that starts to expand once the two parts are
`mixed. When expanded, it fills the fitting 110 as shown at
`210 in FIG. 2. The expanding compound works its way
`between conductors so that as it expands, the conductors are
`25 separated from each other. In one embodiment, the expand(cid:173)
`ing compound expands four times its size immediately after
`being mixed. It is desired that when the compound is
`expanded, none of the conductors are touching either them(cid:173)
`selves, or sides of the fitting 110, and the compound expands
`30 to fill the fitting 110 over at least a portion of the length of
`the fitting 110 referred to as a sealing chamber 137 which
`extends between the two ends of the fitting 110. In one
`embodiment, the sealing chamber 137 extends approxi(cid:173)
`mately about and partly past the hub stops 140 and 145 on
`35 each end of the fitting. In a further embodiment, the sealing
`compound forms an explosion proof seal.
`In one embodiment, the expanding compound is provided
`in a cartridge with the two parts or materials separated by a
`barrier, such as a foil barrier partway between a top and
`40 bottom of the cartridge. The cartridge is squeezed to deform
`the foil barrier, and a mixing rod is coupled to a plunger in
`the cartridge. The plunger is then pushed to the bottom of the
`cartridge by the rod. The rod is then pushed and pulled
`between the top and bottom of the cartridge for approxi-
`45 mately 40 to 50 strokes, where a stroke is one complete in
`and out cycle. The cartridge is rotated while the rod is
`pushed and pulled to ensure that the plunger is swiping all
`material in the cartridge.
`In one embodiment, mixing is done within 30 seconds of
`50 starting the mixing process, as pressure builds up on the
`inside of the cartridge as the material starts to expand. At the
`last stroke, the mixing rod is pushed all the way to the
`bottom of the cartridge. The rod is then pulled out, while the
`cartridge is squeezed to hold the plunger at the bottom. A
`55 nozzle is then attached to the top of the cartridge where the
`rod was removed, and then the rod is used at the bottom of
`the cartridge to push the plunger. This causes mixed liquid
`material, the expanding compound, to be injected through
`the nozzle. In one embodiment, the cartridge is marked with
`60 volumetric increments corresponding to one-ounce seg(cid:173)
`ments for measuring the amount of compound injected. The
`sealing fitting plug is promptly replaced and tightened to
`prevent the sealing compound from expanding outside the
`fitting and/or gelling around the threads in the fitting that
`65 mate with corresponding threads on the plugs.
`The term "compound" in one embodiment comprises the
`use of two or more materials that are mixed and start
`
`Electrical conduit is used to mechanically protect electri-
`cal conductors. The U.S. National Electrical Code and
`Canadian Electrical Code require that explosion-proof
`enclosures housing arcing and sparking devices be sealed off
`to prevent propagation of flames or gases through the
`conduit system, and to minimize the explosion pressures.
`Such seals minimize the effects of pressure piling by acting
`as a barrier to stop burning gases from traveling through the
`conduit to other parts of the system.
`When sealing conduit fittings, past methods utilize a fiber 20
`material that is weaved around each electrical conductor in
`the conduit to separate them. The fiber material is also
`packed in to form a dam at each end of a horizontal fitting,
`and at the bottom of a vertical fitting. A Portland type cement
`is then mixed with water and poured in through a funnel,
`puddled with a stick to remove air bubbles and left to cure
`for at least 24 hours.
`The past methods were fairly labor intensive and error
`prone. Errors resulted when electrical conductors were not
`separated or fittings were not filled completely full with
`sealing compound. Further labor included obtaining clean
`water and mixing containers and the use of a stick to remove
`air bubbles.
`
`SUMMARY OF THE INVENTION
`
`An expanding compound is used to seal conduit fittings.
`The compound is injected into the fitting, and expands to
`separate conductors within the fitting. In one embodiment,
`the compound expands to four times its size, and hardens
`within approximately one hour. In a further embodiment, the
`compound is a two-part product that is mixed in a self
`contained applicator and injected into the fitting.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is a cross section of a horizontal mount sealing
`fitting illustrating use of a sealing compound.
`FIG. 2 is a cross section of the sealing fitting of FIG. 1
`with expanded sealing compound.
`FIG. 3 is a cross section of a vertical mount sealing fitting
`illustrating use of a sealing compound
`FIG. 4 is a cross section of the sealing fitting of FIG. 2
`with expanded sealing compound.
`
`DETAILED DESCRIPTION OF THE
`INVENTION
`
`In the following description, reference is made to the
`accompanying drawings that form a part hereof, and in
`which is shown by way of illustration specific embodiments
`in which the invention may be practiced. These embodi(cid:173)
`ments are described in sufficient detail to enable those
`skilled in the art to practice the invention, and it is to be
`understood that other embodiments may be utilized and that
`structural, logical and electrical changes may be made
`without departing from the scope of the present invention.
`
`Cooper Ex. 1004
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`

`

`US 7,341,255 B2
`
`3
`expanding. In further embodiments, the compound is a
`single material that may start expanding at a controlled time,
`such as by exposure to air or other gases or by electrical
`stimulation, heat, or any other controllable event.
`Typical applications are for sealing fittings in the 1h inch 5
`to 6 inch trade sizes. The temperature of the compound
`should be between 4° C. and 29° C. The compound in one
`embodiment will expand approximately 4 times its size
`following injection. The amount of compound for different
`size fittings may be established empirically, but is approxi(cid:173)
`mately one fourth of the volume of the sealing chamber.
`Some hazardous areas that the seals may be used in include,
`but are not limited to Class I, Division 1 & 2 Groups A, B,
`C, D and Class I, Zones 0, 1 & 2.
`In one embodiment, the compound used is Chem-Cast 15
`637 sealing foam c/o Chem-Cast 637 isocyanate and Chem
`Cast 637 Polyol. Isocyanate is a dark brown liquid, insoluble
`in water with a boiling point of 392 degrees F. (200 degrees
`C.), a vapor density of 0.00016 (mm Hg) and a specific
`gravity of 1.2 g/ml. Polyol is a gray liquid, partially soluble 20
`in water with a specific gravity of 1.05 g/ml. When mixed
`together the resultant material is gray in color. It has a rise
`time of 1.5-2.5 minutes and a gel time of 4-5 minutes. When
`fully cured the foam density is 15-20 lbs./ft3 The compres(cid:173)
`sion strength is >60 psi, porosity is >90% closed cell and has 25
`a water absorption of <1 %. Chem-cast 637 is a fire resistant
`two-part rigid, polyurethane foam. It expands to fill voids
`inside of the sealing fitting and forms a dense, high strength
`foam. It has excellent adhesion to many surfaces without the
`use of primers.
`FIG. 3 shows a vertical fitting 310 for connecting two
`vertically disposed conduits via threads 315 and 320. Mul(cid:173)
`tiple conductors 323 are disposed within the fitting. One or
`more openings 325 and 327 provide access to the inside of
`the fitting. Threaded plugs are used to plug the openings. 35
`One plug 328 is shown installed in opening 327, which is a
`lower opening. In one embodiment, opening 325 is a top
`opening that provides access to the inside of the fitting 315
`to inject the liquid compound. Opening 327 provides access
`to create a fiber dam 330 at a bottom of the fitting, referred 40
`to as a hub. In one embodiment, the fiber is a mineral fiber,
`such as Chico X® sealing compound provided by Crouse(cid:173)
`Hinds and it is packed using a hardwood stick of other tool
`that will not damage the conductors. Hub sizes range from
`1h inch to 6 inches.
`The fiber is first packed while the conductors are forced
`away from the hub opening and forced apart. The fiber is
`then packed between and around conductors in the hub to
`form the dam 330. An area above the dam 330 is referred to
`as a sealing chamber 340. The dam provides a means of 50
`blocking the un-gelled expanding compound 342 from leak(cid:173)
`ing out of the sealing chamber. Care should be taken to
`ensure no shreds of fiber are left clinging to the side wall of
`the sealing chamber or to the conductors. Such shreds when
`imbedded in the sealing compound may form leakage chan-
`
`45
`
`4
`nels. The completed dam should be even with an internal
`bushing 350, also referred to as a conduit stop. For the
`horizontal fitting, no dams are required, but may be used if
`desired.
`FIG. 4 shows vertical fitting 310 with a plug 410 installed
`quickly after the compound is inserted, and it shows the
`compound in a fully expanded state at 420. The compound
`works its way between conductors as it expands to ensure
`that none are touching each other when the compound is
`10 fully expanded. An explosion proof seal is formed. The term
`"explosion proof' refers to normally encountered explosive
`environments. It is not meant to cover environments not
`normally anticipated in environments where such fittings are
`utilized.
`The invention claimed is:
`1. A method of filling a sealing fitting having conductors
`running through it, the method comprising:
`mixing an expanding sealing compound;
`adding the sealing compound to the sealing fitting,
`wherein the compound is added through an opening;
`allowing the sealing compound to expand in the sealing
`fitting such that the conductors are separated; and
`plugging the opening following addition of the com(cid:173)
`pound.
`2. The method of claim 1 wherein the compound expands
`approximately four times in size after mixing.
`3. The method of claim 1 wherein the compound is added
`prior to significant expansion of the compound.
`4. The method of claim 1 wherein the fitting is between
`30 one-half inch and six inches.
`5. The method of claim 1 wherein the sealing compound
`expands to fill a sealing chamber of the fitting.
`6. The method of claim 5 wherein the sealing compound
`provides an explosion proof seal.
`7. The method of claim 1 wherein the sealing compound
`is mixed at a temperature approximately between 4 ° C. and
`29° C.
`8. The method of claim 1 wherein the sealing fitting
`comprises a horizontally oriented sealing fitting.
`9. A method of filling a sealing fining having electrical
`conductors running through it, the method comprising:
`mixing an expanding sealing compound;
`adding the sealing compound to the sealing fitting through
`an opening having a mating removable plug;
`inserting the removable plug in the opening; and
`allowing the sealing compound to expand in the sealing
`fitting and work its way between conductors to cause
`the electrical conductors to be separated.
`10. The method of claim 1 wherein the conductors are
`electrical conductors, and wherein the sealing compound
`directly contacts the conductors and separates them from
`each other as the sealing compound expands.
`
`* * * * *
`
`Cooper Ex. 1004
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`

`

`UNITED STATES PATENT AND TRADEMARK OFFICE
`CERTIFICATE OF CORRECTION
`
`: 7,341,255 B2
`PATENT NO.
`APPLICATION NO. : 10/391250
`DATED
`: March 11, 2008
`INVENTOR(S)
`: Babiarz et al.
`
`Page 1 of 1
`
`It is certified that error appears in the above-identified patent and that said Letters Patent is
`hereby corrected as shown below:
`
`In column 4, line 41, in Claim 9, delete "fining" and insert -- fitting--, therefor.
`
`Signed and Sealed this
`
`First Day of July, 2008
`
`JONW.DUDAS
`Director of the United States Patent and Trademark Office
`
`Cooper Ex. 1004
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