Self-sealing, self-cutting saddle tap assembly with coupon extraction

Abstract

A saddle tap assembly, including: a saddle mountable onto a polymeric pipe, the saddle comprising a cylindrical boss defining an internal through-passageway; a cap comprising a tubular body configured to be received over the boss, having a central element which defines an internal through-bore with a bottom end which extends below a bottom periphery of the cap and comprises a circular cutting head; and a coupon extractor comprising a shaft, wherein the shaft terminates at a bottom end thereof in a piercing extension, and wherein the shaft is configured to be received within the through- bore of the central annular element, wherein the coupon extractor is configured to engage the cap such that the coupon extractor and the cap can be rotatably advanced in lockstep toward the sidewall, wherein the cutting head cuts a circular coupon from the sidewall and the piecing extension penetrates through and attaches to the coupon.

Description

SELF-SEALING, SELF-CUTTING SADDLE TAP ASSEMBLY WITH COUPON EXTRACTIONCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Application Ser. No. 63 / 652,280, filed May 28, 2024, entitled “Self-Sealing, Self-Cutting Saddle Tap Assembly with Coupon Extraction,” the contents of which are hereby incorporated herein by reference in their entirety.BACKGROUND

[0002] The invention relates to the field of tapping conduits, pipes, or tube-like elements for connection with another conduit.

[0003] Many common fluid delivery systems, such as irrigation or gas main systems, use polyethylene or similar polymeric pipes. These pipes can be readily tapped at any desired location along the length of the pipe, to establish fluid communication from the main line to a branch or service line.

[0004] Tapping a main line may be achieved using self-tapping saddles. The saddle is mounted to the pipe at any desired location along the pipe. Then, a drill-like cutting head is threadedly advanced through a sidewall of the main pipe and cuts a coupon from the pipe. The cut coupon defines an opening through the sidewall of the pipe, which provides for a fluid passage between the main pipe and the saddle assembly. A branch line or another attachment can then be connected to the tap, to establish fluid communication from the main line to the branch line.

[0005] The foregoing examples of the related art and limitations related therewith are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the figures.SUMMARY

[0006] The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, not limiting in scope.

[0007] There is provided, in an embodiment, a saddle tap assembly comprising: a saddle configured to be mounted along a polymeric pipe at a desired location, wherein the saddle comprises a cylindrical boss which extends perpendicularly relative to a sidewall of the polymeric pipe, and wherein the boss defines an internal throughpassageway; a tapping cap comprising a tubular body having an open top, an inner peripheral wall configured to be received over the boss, and a central annular element which defines an internal through-bore extending downwardly from the open top along a centerline of the tapping cap and configured to be received within the internal throughpassageway of the boss, the central annular element having a bottom end which extends below a bottom periphery of the tapping cap and comprises a circular cutting head; and a coupon extractor comprising a shaft which terminates at a bottom end thereof in a piercing extension, wherein the shaft is configured to be received within the through- bore of the central annular element, such that a tip of the piercing extension extends below the cutting head, wherein the coupon extractor is configured to engage the tapping cap such that the coupon extractor and the tapping cap can be rotatably advanced in lockstep relative to the boss toward the sidewall, such that the cutting head cuts a circular opening in the sidewall which creates a circular coupon, and the piercing extension penetrates through the sidewall at a point within the area of the coupon and attaches to the coupon before or during said cutting of said coupon.

[0008] In some embodiments, the saddle comprises a spilt band configured to be moved between (i) an open position which defines a first diameter configured to receive the pipe therein and to allow the split band to move freely along the pipe, and (ii) a closed position which defines a second diameter configured to achieve contact of the split band with at least a portion of a circumference of the sidewall.

[0009] In some embodiments, the split band comprises at respective ends thereof a mating pair of semi-cylindrical halves of the boss, wherein, when the split band is in the closed position, the mating pair of semi-cylindrical halves are in contact engagement with each other at opposed edges thereof, so as to form the boss.

[0010] In some embodiments, the mating pair of semi-cylindrical halves comprise cooperating releasable retention means configured to retain the split band in the closed position.

[0011] In some embodiments, the circular cutting head comprises one of: a peripheral blade; an annular plurality of saw teeth, blades, or serrations; or a heat -based cutting element.

[0012] In some embodiments, the central annular element has a tapered shape which gradually widens in circumference from bottom to top along at least a section of the central annular element, wherein, when the cutting head rotatably advances through the sidewall of the polymeric pipe, the central annular element self-seals against the periphery of the circular opening.

[0013] In some embodiments, the coupon extractor comprises a tool interface at a top end thereof configured to interface with a tool suitable to apply rotational movement to the coupon extractor.

[0014] In some embodiments, the tip of the piercing extension is located relative to the cutting head such that the tip makes contact with the sidewall before the circular cutting head makes contact with the sidewall.

[0015] In some embodiments, upon the cutting of the circular opening, the coupon extractor is configured to be extricated from within the through-bore, wherein the coupon attached to the piercing extension is extricated therewith.

[0016] In some embodiments, the boss is externally threaded, wherein the tapping cap comprises cooperating internal threading.

[0017] In some embodiments, the cutting head is configured as an insert to be inserted at a bottom end of the central annular element.

[0018] In some embodiments, the saddle tap assembly further comprises an annular sealing element disposed between a bottom end of the saddle tap assembly and the pipe.

[0019] In some embodiments, an upper-end portion of the through-bore, located toward the open-top, includes a coupling mechanism configured to couple one or more attachments or devices, to establish a fluid communication between the saddle tap assembly and the one or more other attachments or devices.

[0020] There is also provided, in an embodiment, a method for tapping into a polymeric pipe, the method comprising: providing a saddle tap assembly, comprising a saddle configured to be mounted along a polymeric pipe at a desired location, wherein the saddle comprises a cylindrical boss which extends perpendicularly relative to a sidewall of the polymeric pipe, and wherein the boss defines an internal through-passageway, a tapping cap comprising a tubular body having an open top, an inner peripheral wall configured to be received over the boss, and a central annular element which defines an internal through-bore extending downwardly from the open top along a centerline of the tapping cap and configured to be received within the internal through-passageway of the boss, the central annular element having a bottom end which extends below a bottom periphery of the tapping cap and comprises a circular cutting head, and a coupon extractor comprising a shaft which terminates at a bottom end thereof in a piercing extension, wherein the shaft is configured to be received within the through-bore of the central annular element, such that a tip of the piercing extension extends below the cutting head, wherein the coupon extractor is configured to engage the tapping cap such that the coupon extractor and the tapping cap can be rotatably advanced in lockstep relative to the boss toward the sidewall, such that the cutting head cuts a circular opening in the sidewall which creates a circular coupon, and the piercing extension penetrates through the sidewall at a point within the area of the coupon and attaches to the coupon before or during said cutting of said coupon; mounting the saddle at a desired location along the polymeric pipe; positioning the tapping cap over the boss; positioning the coupon extractor within the through-bore of the central annular element of the tapping cap, so as to engage the tapping cap; rotatably advancing the tapping cap and the coupon extractor in lockstep over the boss, to cause the cutting head to cut the circular opening in the sidewall so as to create the circular coupon, and to cause the piercing extension to penetrate through the sidewall at a point within the area of the coupon and to attach to the coupon before or during said cutting of said coupon; and upon tightening of said tapping cap over said boss, extricating said coupon extractor from within said through- bore, wherein said coupon attached to said piercing extension is extricated therewith.

[0021] In some embodiments, the saddle comprises a spilt band configured to be moved between (i) an open position which defines a first diameter configured to receive the pipe therein and to allow the split band to move freely along the pipe, and (ii) a closed position which defines a second diameter configured to achieve contact of the split bandwith at least a portion of a circumference of the sidewall, wherein the mounting of the saddle at a desired location along the polymeric pipe further comprises locating the saddle in the open position at the desired location, and moving the saddle into the close position.

[0022] In some embodiments, the split band comprises at respective ends thereof a mating pair of semi-cylindrical halves of the boss, and wherein, when the split band is in the closed position, the mating pair of semi-cylindrical halves are in contact engagement with each other at opposed edges thereof, so as to form the boss.

[0023] In some embodiments, the mating pair of semi-cylindrical halves comprise cooperating releasable retention means configured to retain the split band in the closed position.

[0024] In some embodiments, the circular cutting head comprises one of: a peripheral blade; an annular plurality of saw teeth, blades, or serrations; or a heat -based cutting element.

[0025] In some embodiments, the central annular element has a tapered shape which gradually widens in circumference from bottom to top along at least a section of the central annular element, and wherein, when the cutting head rotatably advances through the sidewall of the polymeric pipe, the central annular element self-seals against the periphery of the circular opening.

[0026] In some embodiments, the coupon extractor comprises a tool interface at a top end thereof configured to interface with a tool suitable to apply rotational movement to the coupon extractor, wherein the rotatably advancing of the tapping cap and the coupon extractor in lockstep over the boss further comprises using the tool to apply the rotational movement to the coupon extractor via the tool interface.

[0027] In some embodiments, the tip of the piercing extension is located relative to the cutting head such that the tip makes contact with the sidewall before the circular cutting head makes contact with the sidewall.

[0028] In some embodiments, the boss is externally threaded, wherein the tapping cap comprises cooperating internal threading, and wherein the positioning of the tapping cap over the boss further comprises threading the cooperating internal threading of the tapping cap over the boss.

[0029] In some embodiments, the cutting head is configured as an insert to be inserted at a bottom end of the central annular element.

[0030] In some embodiments, the saddle tap assembly further comprises an annular sealing element disposed between a bottom end of the saddle tap assembly and the pipe.

[0031] In some embodiments, an upper-end portion of the through-bore, located toward the open-top, includes a coupling mechanism configured to couple one or more attachments or devices, to establish a fluid communication between the saddle tap assembly and the one or more other attachments or devices, wherein the method further comprises coupling an attachment to the saddle tap assembly via the coupling mechanism to establish the fluid communication between the saddle tap assembly and the attachment.

[0032] In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the figures and by study of the following detailed description.BRIEF DESCRIPTION OF THE FIGURES

[0033] Exemplary embodiments are illustrated in referenced figures. Dimensions of components and features shown in the figures are generally chosen for convenience and clarity of presentation and are not necessarily shown to scale. The figures are listed below.

[0034] FIGS. 1A-1D show a saddle tap assembly of the present disclosure, in a perspective view, a part-exploded view, an exploded view, and a perspective view with a coupon extractor engaged therewith, respectively.

[0035] FIGS. 2A-2C show an exemplary saddle of the present disclosure in perspective, front, and side views, respectively.

[0036] FIGS. 2D-2F show an exemplary saddle of the present disclosure in open and closed positions, respectively, in relation to a pipe.

[0037] FIG. 2G shows a variation of an exemplary saddle of the present disclosure in perspective and top views.

[0038] FIGS. 3A-3C show an exemplary tapping cap of the present disclosure in perspective, side, and cross-sectional views, respectively.

[0039] FIGS. 3D-3H show an exemplary tapping cap of the present disclosure without a cutting head, in perspective top, perspective bottom, side, top, and cross-sectional views, respectively.

[0040] FIGS. 4A-4C show an exemplary cutting head of the present disclosure, in perspective, side, and top views, respectively.

[0041] FIGS. 5A-5B shows cross-sectional and cross-sectional exploded views of a variation of the exemplary tapping cap in which the cutting head is formed as a separate insert.

[0042] FIGS. 5C-5D show in perspective exploded and transverse cross-sectional views, the variation of tapping cap shown in FIGS. 5A-5B, as part of an installed tap assembly of the present disclosure.

[0043] FIGS. 5E-5H show a sealing element in perspective, side, and cross-sectional views.

[0044] FIGS. 6A-6D show an exemplary coupon extractor of the present disclosure, in a perspective view, a side view, as mounted to a tapping cap, and a top view, respectively.

[0045] FIGS. 6E-6F show an exemplary piercing extension of the present disclosure, in perspective and side views, respectively.

[0046] FIG. 7 is a flowchart which illustrates the functional steps in a method for using a saddle tap assembly of the present disclosure.

[0047] FIGS. 8A-8F illustrate four functional steps, respectively, in a method for using a saddle tap assembly of the present disclosure.DETAILED DESCRIPTION

[0048] A saddle tap assembly which provides for self-sealing, self-cutting, and coupon extraction, is disclosed herein.

[0049] In some embodiments, the saddle tap assembly of the present disclosure is configured to enable tapping into a main pipe at any desired location along the length of the main pipe, to establish fluid communication from the main line to a branch or service line, or any suitable or desired attachment.

[0050] In some embodiments, the present saddle tap assembly in its various aspects is intended for use with polymeric pipes, such as high-density polyethylene (HDPE). Polymeric pipes exhibit a high level of impermeability and strong molecular bond, which makes them suitable for high pressure pipelines utilized in various residential, municipal, agricultural, and industrial piping systems. Polymeric pipe are used for applications such as water mains, gas mains, sewer mains, irrigation, fire system supply lines, and stormwater and drainage pipes.

[0051] In some embodiments, the present saddle tap assembly may be mounted to a main pipe at any desired location along the pipe. In some embodiments, the present saddle tap assembly may be mounted at the desired location along the main pipe using a saddle suitable for mechanically seating, mounting, coupling, or otherwise securing the present saddle tap assembly to a main pipe. In some embodiments, the present saddle comprises a split band which defines an internal cylindrically- shaped bore therethrough. However, any other type of branching saddle known in the industry may be used, including a flexible collar or band-type saddle, an open-ended press-fit saddle, a rigid two-part clamp, or any other clamp-type saddle.

[0052] In some embodiments, the present saddle is comprises a split band which may be resiliently moved between an open position, which defines an opening for receiving a main pipe therein, and a closed position, in which the band is closed around the main pipe to achieve circumferential mating with at least apportion of an outside surface of the main pipe.

[0053] In some embodiments, the split band comprises at respective ends thereof a mating pair of semi-cylindrical halves of a cylindrical boss, wherein, when the band is in the closed position over a main pipe, the mating pair of semi-cylindrical halves are in contact engagement with each other at opposed edges thereof, so as to form the cylindrical boss. The mating pair of semi-cylindrical halves are located in facing relation, and are configured to be brought into contact engagement with each other at opposed edges thereof, to form the cylindrical boss, when the band is in the closed position over the main pipe. Then, the saddle may be closed and secured over the main pipe at the desired location, by means of a tapping cap which is received over the cylindrical boss formed by the mating pair of semi-cylindrical halves, e.g., by way of threading the tapping cap over external threads of the cylindrical boss.

[0054] Thus, the present saddle allows for a quick and efficient initial mounting of the saddle tap assembly to a main pipe by a single person, by simply mounting the split band over a pipe at a desired location, bringing the mating pair of semi-cylindrical halves into contact engagement with each other to close the band around the main pipe, and then threading or otherwise rotatably-advancing a tapping cap over the boss (formed by the mating pair of semi-cylindrical halves), to secure the saddle at the desired location without the need to use bolts or similar fasteners. In some embodiments, the band may comprise releasable retention means configured to retain the band in the closed position, such as one or more resilient detent latches positioned on a first one of the semi- cylindrical boss halves and configured to releasably engage cooperating notches on the opposing one of the semi-cylindrical boss halves.

[0055] In some embodiments, the present tapping cap comprises internal threading configured to cooperate with the external threading of the cylindrical boss formed by the closed band. In some embodiments, the tapping cap comprises an annular male-type element extending internally centrally and downwardly from the top portion of the tapping cap, along the center axis of the tapping cap, to terminate at a point below a bottom end of the outer circumferential wall of the tapping cap. In some embodiments, the central annular element has a bottom edge which defines a circular hole-saw like cutting head. When the tapping cap is rotatably-advanced over the cylindrical boss of the band (e.g., by rotatably-threading the tapping cap over the cylindrical boss) in the direction of a sidewall the pipe, the circular cutting edge is simultaneously rotatably- driven through the sidewall of the pipe, to cut a circular coupon therefrom. In some embodiments, the central annular element has a tapered shape which gradually widens in circumference from bottom to top. Thus, upon completing the cutting of the circular coupon from the sidewall of the main pipe, as the central annular element continues to advance through the opening established through the sidewall of the main pipe, the widening circumference of the concentric male element peripherally self-seals against the periphery of the opening in the sidewall of the main pipe. Thus, the fluid communication established from the main line to a branch or service line is fluid-tight to prevent fluid from passing therethrough when pressure is applied in the main pipe. In some embodiments, the present tap assembly further comprises a separate sealing configured to the tap assembly against the outside surface of the main pipe.

[0056] In some embodiments, the present saddle tap assembly further comprises a coupon extractor which comprises a top winged or another similar handle portion and a shaft extending downwardly therefrom, wherein the shaft terminates at a bottom end thereof in a piercing extension. The coupon extractor is configured to be received within a center through-bore of the central annular element of the tapping cap. The winged or handle portion is configured to engage one or more exterior surface features disposed over an external peripheral surface of the tapping cap, wherein the shaft of the coupon extractor extends downwardly therefrom, and wherein the piercing extension extends downwardly from the internal through-passage of the circular cutting head. In some embodiments, the piercing extension extends downwardly generally centrally through the internal through-passage of the circular cutting head, wherein a tip of the piercing extension extends at least slightly past a bottom edge of the cutting head.

[0057] In some embodiments, the coupon extractor comprises a tool interface at a top end thereof, configured to interface with any suitable tool to apply rotational movement to the coupon extractor. In some embodiments, rotating the coupon extractor causes the tapping cap (with which the coupon extractor is axially and / or rotatably engaged) to also rotate and advance relative to the boss, axially toward a sidewall the pipe, as described above.

[0058] As the tapping cap is rotatably-advanced (which may be by way of threading the tapping cap over the boss) relative to the boss toward the sidewall of the main pipe, both of the piercing extension and the circular cutting head are rotatably -driven in lockstep toward the sidewall of the pipe. The tip of the piercing extension generally makes first contact with the sidewall, to pierce and penetrate at least partially through the thickness of the sidewall, at a point which may be approximately at the center, or otherwise within the area, of a circular coupon to be cut therefrom by the circular cutting head, in a way which ensures that the cut coupon will be securely attached to the piercing extension.

[0059] As the piercing extension and the circular cutting head continue to be rotatably - driven in lockstep toward the sidewall of the pipe, the circular cutting edge then makes contact with the sidewall to begin cutting the circular coupon therefrom, while the piercing extension continues to penetrate the full thickness of the sidewall, to ensure that the cut coupon is securely attached to the piercing extension.

[0060] Finally, once the coupon is fully cut, the coupon extractor can be disengaged from the tapping cap and removed from within the center through-bore of the central annular element, wherein the cut coupon that is attached to the piercing extension is removed therewith and can be discarded. The tapping cap remains secured in place over the boss, wherein the central annular element extends into, and self-seals against, the opening in the sidewall of the main pipe.

[0061] By extending into the opening in the sidewall of the main pipe, the central annular element establishes a permanent peripheral self-seal relative to the periphery of the circular opening in the sidewall of the main pipe, and at the same time acts as an anchor which prevents any axial and / or lateral movement of the saddle tap assembly relative to the main pipe. In addition, by removing the cut coupon, it is ensured that the coupon does not fall into the main pipe or otherwise clogs or obstructs the flow of fluids in the main pipe or the newly-established fluid connection in any way.

[0062] An upper end portion of the through-bore of the central annular element, located toward the open top end of the tapping cap, may include internal threading, a snap connection, or any other suitable coupling mechanism as is conventional, to couple one or more other attachments or devices to the saddle tap assembly, for example, via flexible branch tubing, to establish a fluid communication between the saddle tap assembly and the one or more other attachments or devices.

[0063] Thus there is established a sealed fluid-communication connection between the saddle tap assembly and the main line, which ensures that the saddle tap assembly is secured to the main pipe so as to prevent axial, lateral, and / or rotational movement of the saddle tap assembly relative to the main pipe, while providing for maximal fluid flow rate to the newly-established fluid connection.

[0064] Reference is now made to FIGS. 1A-1D, which show a saddle tap assembly 100 of the present disclosure, in perspective view, part-exploded view, exploded view, and perspective view with a coupon extractor engaged therewith, respectively.

[0065] In some embodiments, saddle tap assembly 100 comprises the following components:A saddle 104; a tapping cap 110 comprising a cutting head 120; anda coupon extractor 140 comprising a piercing extension 150.

[0066] As used throughout this description, the terms ‘top’ and ‘bottom’ are used to denote directions relative to axis X-X (shown in FIG. 1A) extending along a centerline of saddle tap assembly 100, wherein ‘bottom,’ ‘downward,’ ‘downwardly,’ or ‘below’ generally denote a direction towards pipe 102, while ‘top’ and synonymous terms denote the opposite direction.

[0067] Reference is also made to FIGS. 2A-2C, which show an exemplary saddle 104 in perspective, front, and side views.

[0068] Reference is further made to FIGS. 2D-2E, which show exemplary saddle 104 in open and closed positions in relation to a pipe 102.

[0069] In some embodiments, exemplary saddle 104 is configured to be positioned at a desired location along the length of a pipe 102, and to be secured to the outside surface of pipe 102 at the desired location.

[0070] In some embodiments, saddle 104 comprises a split band 106 which defines a cylindrically-shaped bore therethrough. Split band 106 may be moved between (i) an open position (shown in FIGS. 1C, 2A-2B, and 2D), in which respective ends of split band 106 define an opening for receiving pipe 102 therein, and / or split band 106 defines a first, open- position diameter configured to allow split band 106 to move freely along a length of a pipe 102; and (ii) a closed position (shown in FIGS. IB and 2E), in which split band 106 defines a second, closed-position diameter configured to achieve circumferential mating with at least a portion of an outside surface of pipe 102.

[0071] As shown in FIGS. 2A-2E, split band 106 may a unitary band made in one piece. The unitary band may be at least partially flexible or bendable, to allow split band 106 to move between the first and second diameters defining the open and closed positions of split band 106, around the outer circumference of pipe 102. For example, as shown in FIG. 2D, when in its open position, the arms of split band 106 may be spread apart, by urging the respective ends of split band 106 further apart, to widen the opening between the respective ends of split band 106, to achieve the first, open-position diameter which facilitates positioning of saddle 104 over pipe 102, e.g., by allowing saddle 104 to move freely along a length of a pipe 102 and / or by allowing pipe 102 to be received through the opening defined by the respective ends of split band 106 whenin the open position. Split band 106 may then to the closed position (shown in FIGS. IB and 2E), by bringing the ends of split band 106 together over pipe 102.

[0072] In some variations, however, split band 106 may not be a unitary band, but rather may comprise two or more parts. For example, split band 106 may comprise two arcuate segments pivoted about a hinge at respective ends thereof. The arcuate segments may be adapted to mover between the open and closed positioned described above in the same manner as a unitary split band 106.

[0073] In all of these embodiments, saddle 104 may be sized and configured to achieve, in the closed position, circumferential mating with at least a portion of an outside surface of pipe 102, so as to resist movement of saddle 104 relative to pipe 102, e.g., axial movement along the length of pipe 102 and / or rotational movement about the circumference of pipe 102. In some embodiments, saddle 104 may be made in various sizes, configured to fit pipes of different standard diameters.

[0074] In all of these embodiments, each respective end of split band 106 comprises one of a mating pair of semi-cylindrical halves 108a, 108b of a cylindrical boss 108. The complementary pair of mating halves 108a, 108b are in facing relation and are configured to form boss 108 when saddle 104 is in the closed position. Each complementary half 108a, 108b of boss 108 has a semi-cylindrical shape. In the closed position of saddle 104, the mating pair of boss halves 108a, 108b are brought into contact engagement with each other at opposed edges thereof, thereby forming cylindrical boss 108 which extends perpendicularly relative to an outside surface of pipe 102, and defines an internal through-bore.

[0075] In the exemplary embodiment of FIGS. 2A-2E, boss 108 has external threading 109. In some embodiments, each complementary half 108a, 108b of boss 108 comprises external threading 109, such that in the closed position of saddle 104, the mating pair of boss halves 108a, 108b form a cylindrical boss 108 with external threading 109. The closed position of saddle 104 can then be maintained by threading a tapping cap 110 over externally-threaded boss 108, as shown in FIG. 2E and as shall be further detailed hereinbelow.

[0076] However, in other embodiments, boss 108 does not feature external threading, and may comprise any other suitable mechanism, such as a snap mechanism, for receiving and securing a tapping cap thereon.

[0077] FIG. 2F show releasable retention means of saddle 104. The releasable retention means are configured to retain the mating pair of boss halves 108a, 108b in the closed position. In one example, such retention means may comprise resilient detent latches Illa positioned on a first one of the semi-cylindrical boss halves 108a, 108b, and configured to releasably engage cooperating notches 111b on the opposing one of the semi-cylindrical boss halves 108a, 108b. Thus, when semi-cylindrical boss halves 108a, 108b are brought together to close saddle 104 around pipe 102, detent latches Illa engage notches 111b to retain saddle 104 in the closed position.

[0078] FIG. 2G shows a variation of saddle 104 further comprising opposing internal notches 107 formed in the semi-cylindrical boss halves 108a, 108b. Notches 107 extend along a height of each semi-cylindrical boss halves 108a, 108b, and are configured to receive corresponding projections of a sealing element, to prevent rotational movement of the sealing element upon rotating of tapping cap 110, as shall be further detailed hereinbelow.

[0079] Saddle 104 may be fashioned as a unitary, integrally -formed component made of a single material, or otherwise comprise multiple segments or layers of one or more different materials. The various parts comprising saddle 104 may be made using any suitable manufacturing process, such as injection molding, over-molding, additive printing, etc. In some embodiments, saddle 104 may be integrally formed as a single component. In other embodiments, saddle 104 may be formed of two or more separate components, (e.g., split band 106 and boss halves mating pair 108a, 108b) then subsequently coupled together as desired (e.g., welded together, mechanically coupled together, etc.) to form saddle 104. In some embodiments, the various parts comprising saddle 104 may be made in whole or part of any suitable one or more polymeric materials, such as polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), polyethylene (PE), high density polyethylene (HDPE), medium density polyethylene (MDPE), polypropylene (PP), etc., and or polyetheretherketone (PEEK), polyoxymethylene (POM), polyphenylsulfone (PPSU), poiyetherimide (PEI), poly etherketoneketone (PEKK), poly aryletherketone (PAEK), and / or other polymers. In some embodiments, one or more of the parts comprising saddle 104 may comprise at least a portion fashioned of a non-polymeric material, such as a metal (e.g., brass, steel, iron, stainless steel), for example, where specific mechanical properties, such as increased hardness, tensile or compressive strength, are required.

[0080] Reference is now made to FIGS. 3A-3C, which show an exemplary tapping cap 110 in perspective, side, and cross-sectional views. FIGS. 3D-3H show exemplary tapping cap 100 without an exemplary cutting head 120, in perspective top, perspective bottom, side, top, and cross-sectional views. FIGS. 4A-4C show exemplary cutting head 120 alone, in perspective, side, and top views.

[0081] In some embodiments, tapping cap 110 comprises a generally cylindrical body having an open top comprising:An outer circumferential cap surface 112.An inner peripheral wall comprising internal threading 114 configured to engaged the external threading 109 of boss 108.A central annular male-type element 116 extending along a centerline of tapping cap 110 and defining a trough-bore 117. Bore 117 extends between the open top end of tapping cap 110 and a bottom end of central annular element 116. As can be seen in the cross-sectional view of FIG. 3H, central annular element 116 further defines an annular gap between an external wall of central annular element 116 and the internally-threaded inner peripheral wall 114. This annular gap is configured to receive the cylindrical wall of boss 108 therein, such that central annular element 116 extends downwardly through the throughpassageway of boss 108.

[0082] In some embodiments, through-bore 117 is configured to provide fluid communication from pipe 102 through saddle tap assembly 100 when installed at a desire location along pipe 102. In some embodiments, an upper end portion of through- bore 117, located toward the open top end of tapping cap 110, includes internal threading 119 or another coupling mechanism configured to couple one or more other attachments or devices to saddle tap assembly 100 as is conventional, for example, via flexible branch tubing, to establish the fluid communication between saddle tap assembly 100 and the one or more other attachments or devices.

[0083] In some embodiments, tapping cap 110 comprises one or more exterior surface features 113 disposed over outer circumferential cap surface 112. In some embodiments, the exterior surface features 113 are configured to engage a winged or handle portion of a coupon extractor 140 of the present disclosure, to cause tapping cap to rotate in lockstep with coupon extractor 140. In some embodiments, the rotational movement oftapping cap 110 causes tapping cap 110 to engage the threading 109 of boss 108, such that tapping cap 110 rotatably-advances relative to boss 108, toward a sidewall of pipe 102, wherein cutting head 120 rotatably cuts a circular opening in the side wall of pipe 102.

[0084] In some embodiments, the engaging by coupon extractor 140 of the surface features 113 of tapping cap 110 causes coupon extractor 140 to similarly advance in lockstep with tapping cap 110 toward the sidewall of pipe 102. In some embodiments, the engaging by coupon extractor 140 of the surface features 113 of tapping cap 110 causes coupon extractor 140 and tapping cap 110 to move axially and / or rotationally in lockstep.

[0085] In some embodiments, central annular element 116 is an annular wall located generally centrally within the interior of tapping cap 110, and defining through -bore 117. In some embodiments, central annular element 116 extends generally from an open top portion of tapping cap 110, centrally and downwardly along a centerline of tapping cap 110, and terminates at a point extending bellow a bottom end of tapping cap 110. In some embodiments, central annular element 116 has a circular hole saw-like cutting head 120 at a bottom end thereof. In some embodiments, cutting head 120 defines a hole-saw like element having, at a bottom edge thereof a cutting edge 122 comprising a peripheral blade; an annular plurality of saw teeth, blades, or any similar suitable serrations; or any other suitable circular cutting element, such as a heat-based cutting device. In some embodiments, cutting edge 122 is configured to create a circular opening 103 in a sidewall of pipe 102 (opening 103 is shown, e.g., in FIG. 2D).

[0086] When saddle 104 is in its closed position over pipe 102, and tapping cap 110 is rotatably-advanced over externally-threaded boss 108 axially toward a sidewall of pipe 102, peripheral cutting edge 122 of cutting head 120 is rotatably driven in lockstep through the side wall of pipe 102, to cut a circular coupon therefrom. In some embodiments, central annular element 116 has a tapered section along at least a portion of its length, wherein the tapered section gradually widens in circumference from bottom to top. Thus, upon completing the cutting of the circular coupon from the sidewall of pipe 102, as tapping cap 110 continues to be rotated to rotatably-advance relative to boss 108 axially toward a side wall of pipe 102, such that central annular element 116 continues to advance through the opening 103 established through the sidewall of pipe 102, the widening circumference of central annular element 116 peripherally self- sealsagainst the slightly-resilient periphery of freshly-cut opening 103 in the sidewall of pipe 102. Thus, the fluid communication established from the pipe 103 to saddle tap assembly 100 is rendered fluid-tight.

[0087] By achieving a peripheral self-seal relative to the periphery of a circular opening103 in the sidewall of pipe 102, seal saddle tap assembly 104 achieves a good seal for the fluid connection between saddle tap 104 and pipe 102.

[0088] However, in some embodiments, saddle tap 104 further comprises a separate sealing element configured to provide additional sealing between elements of saddle tap104 and the outside surface of pipe 102.

[0089] Tapping cap 110 may be fashioned as a unitary, integrally-formed component made of a single material, or otherwise comprise multiple segments or layers of one or more different materials. The various parts comprising tapping cap 110 (such as tapping cap 110 itself, central annular element 116, and / or cutting head 120) may be made using any suitable manufacturing process, such as injection molding, over-molding, additive printing, etc. In some embodiments, tapping cap 110 may be integrally formed as a single component. In other embodiments, tapping cap 110 may be formed of two or more separate components, (e.g., tapping cap 110 itself, central annular element 116, and / or cutting head 120) then subsequently coupled together as desired (e.g., welded together, mechanically coupled together, bonded together, etc.) to form tapping cap 110. In some embodiments, the various parts comprising tapping cap 110 may be made in whole or part of any suitable one or more polymeric materials, such as polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), polyethylene (PE), high density polyethylene (HDPE), medium density polyethylene (MDPE), polypropylene (PP), etc., and or polyetheretherketone (PEEK), polyoxymethylene (POM), polyphenylsulfone (PPSU), poiyetherimide (PEI), polyetherketoneketone (PEKK), polyaryletherketone (PAEK), and / or other polymers.

[0090] In some embodiments, one or more of the parts comprising tapping cap 110 (e.g., annular cutting edge 122) may comprise at least a portion fashioned of a non- polymeric material, such as a metal (e.g., brass, steel, iron, stainless steel), for example, where specific mechanical properties, such as increased hardness, tensile or compressive strength, are required.

[0091] As noted above, in some embodiments, tapping cap 110 may be formed of two or more separate components. For example, in a variation, cutting head 120 may be formed as a separate component which functions as an insert, e.g., to be received at the bottom of central annular element 116. In this variation, saddle tap 104 may further comprise a sealing element 118 disposed between elements of saddle tap 104 and pipe 102.

[0092] Reference is now made to FIGS. 5A-5B, which show in cross-sectional and cross-sectional exploded views, a variation of tapping cap 110 in which cutting head 120 is formed as a separate insert to be inserted at the bottom of central annular element 116. A sealing element 118 is shown in its installed position within tapping cap 110.

[0093] Reference is further made to FIGS. 5C-5D, which show in perspective exploded and transverse cross-sectional views, the variation of tapping cap 110 shown in FIGS. 5A-5B as part of an installed tap assembly of the present disclosure.

[0094] Reference is further made to FIGS. 5E-5H, which show sealing element 118 in perspective, side, and cross-sectional views.

[0095] In this variation, sealing element 118 defines an annular ring seal made of any suitable material, such as silicone rubber or similar elastic material. Sealing 118 defines a stepped profile (seen in cross-section in FIG. 5F) comprising an annular lip 118c extending inwardly from a top periphery of sealing element 118. Sealing element 118 further comprises two protrusions 118b extending outwardly from the periphery of sealing element 118 on opposing sides thereof. A bottom end of sealing element 118 may define a curvature configured to correspond to the radius of pipe 102, such that the bottom end of sealing element 118 makes contact engagement with the outer wall of pipe 102 along its entire periphery.

[0096] As can be seen in FIGS. 5A-5B, sealing element 118 is configured to be received within a stepped annular cavity 117a of trough -bore 117 at the bottom of central annular element 116 (FIG. 5B). Cutting head 120 is then configured to be inserted into the annular cavity 117a, wherein annular lip 118c of sealing element 118 is pressed between a top end of stepped annular cavity 117a and an annular rim 121 of cutting head 120.

[0097] Thus, when saddle 104 is in its closed position over pipe 102, tapping cap 110 (into which sealing element 118 and cutting head 120 are inserted) may be rotatably-advanced over externally-threaded boss 108 axially toward a sidewall of pipe 102. At the same time, central annular element 116 (with sealing element 118 and cutting head 120 inserted at the bottom thereof) is received within the internal through-bore of boss 108. With reference to FIG. 5H, protrusions 118b of sealing element 118 are received within corresponding vertical notches 107 of boss 108.

[0098] As tapping cap 110 is rotatably-advanced over boss 108, cutting head 120 (comprising cutting edge 122) and sealing element 118 are rotatably driven in lockstep therewith in the direction of pipe 102. During this stage, vertical notches 107 are configured to prevent sealing element 118 from rotating relative to boss 108, so as to maintain a desired orientation of the bottom curvature of sealing 118 relative to pipe 102. As cutting head 120 is advanced through the side wall of pipe 102 to complete the cutting of the circular coupon from the sidewall of pipe 102, central annular element 116 self- seals against the periphery of the opening in the side wall, while sealing element makes annular contact with the exterior surface of pipe 102, wherein the curvature at the bottom end of sealing element 118 ensures that sealing element 118 makes contact engagement with the outer wall of pipe 102 along its entire periphery. At the end of this process, when the fluid communication is established between saddle tap 104 and pipe 102, sealing element 118 provides further sealing between pipe 102 and the various components of saddle tap 104.

[0099] Reference is now made to FIGS. 6A-6D, which show exemplary coupon extractor 140 of the present disclosure, in perspective, side, mounted to tapping cap 110, and top views.

[0100] FIGS. 6E-6F show an exemplary piercing extension 150 of the present disclosure alone, in perspective and side views.

[0101] In some embodiments, coupon extractor 140 comprises a top handle portion 142 and a shaft 144 extending downwardly therefrom, wherein the shaft terminates at a bottom end thereof in the piercing extension 150. Shaft 144 of coupon extractor 140 is configured to be received within through-bore 117 of central annular element 116 of tapping cap 110. In some embodiments, when shaft 144 is received within through-bore 117, at least a tip 154 of piercing extension 150 extends downwardly past a bottom edge of cutting head 120.

[0102] In some embodiments, handle portion 142 comprises wings 142a, 142b configured to engage one or more exterior surface features 113 disposed over outer circumferential cap surface 112 of tapping cap 110, as can be seen in FIG. 6C. However, any type of a suitable handle portion 142 may be used, as long as it is configured for engaging one or more matching surface features on tapping cap 110.

[0103] When the handle portion 142 engages the one or more exterior surface features 113, any rotational movement applied to coupon extractor 140 is transmitted to tapping cap 110 (and vice versa). As noted above, the rotational movement of tapping cap 110 causes tapping cap 110 to engage the external threading of boss 108 so as to rotatably- advance relative to boss 108 toward a sidewall of pipe 102. At the same time, the engaging by coupon extractor 140 of the surface features 113 of tapping cap 110 causes coupon extractor 140 to similarly advance in lockstep with tapping cap 110 toward the sidewall of pipe 102. In some embodiments, the engaging by coupon extractor 140 of the surface features 113 of tapping cap 110 causes coupon extractor 140 and tapping cap 110 to move axially (along axis X-X) and / or rotationally in lockstep.

[0104] In some embodiments, coupon extractor 140 further comprises a tool interface 146 at a top end thereof, configured to interface with any tool suitable to apply rotational movement to coupon extractor 140 (and thereby to tapping cap 110). Tool interface 146 can be seen in FIG. 6D as a shaped throat, however, tool interface may also define any shaped throat or protrusion configured to interface with different types of tools, such as a square throat, a hex shaped throat, a Torx shaped throat, a flathead, slotted, Phillips, hexagonal, octagonal, or any proprietary type tool. However, in some embodiments, handle portion 142 may be configured for manual turning without the use of a tool.

[0105] In some embodiments, piercing extension 150 comprises a threaded portion 152, which may be slightly tapered and includes threads similar to those found on a wood screw or any other suitable threading configured to pierce, penetrate, and securely- attach to the cut coupon. In some embodiments, piercing extension 150 terminates at a bottom edge thereof in a tip 154 configured to pierce through the sidewall of pipe 102.

[0106] In some embodiments, piercing extension 150 comprises a self-tapping or selfdrilling screw, configured to tap and / or drill its own hole as it is rotatably -driven into the sidewall of pipe 102. In some embodiments, at least threaded section 152 comprises threads configured to cut and form a corresponding thread in the polymeric material ofpipe 102 as it penetrates and drill through its sidewall. The cut thread then helps piercing extension 150 to securely attach to and retain the coupon to be cut from pipe 102, as further described herein. In some embodiments, tip 154 tapers to a sharp or gimlet point configured to form at least an initial hole in the polymeric material of pipe 102.

[0107] In some embodiments, one or more of tapping cap 110, coupon extractor 140, and / or piercing extension 150 are sized and shaped to ensure that piercing extension 150 penetrates through the full thickness of the sidewall of pipe 102 at a location defining approximately the center, or otherwise within the area, of a coupon to be cut from the sidewall, before cutting head 120 begins cutting the coupon, or at least before the coupon is fully cut by cutting head 120. In other embodiments, one or more of tapping cap 110, coupon extractor 140, and / or piercing extension 150 are sized and shaped to ensure that piercing extension 150 penetrates at least partially through the sidewall of pipe 102 (e.g., by piercing the sidewall with at least tip 154, or by penetrating with at least a first portion of the threaded section of piercing extension 150) at a location defining approximately the center, or otherwise within the area, of a coupon to be cut from the sidewall, before cutting head 120 begins cutting the coupon or at least before the coupon is fully cut by cutting head 120. In some embodiments, one or more of tapping cap 110, coupon extractor 140, and / or piercing extension 150 are sized and shaped to ensure that piercing extension 150 begins to penetrate through the sidewall of pipe 102 at or about the same time that cutting head 120 begins cutting a coupon therefrom. In each case, by penetrating through the sidewall of pipe 102, piercing extension 140 ensures that the cut coupon will be securely attached to the piercing extension.

[0108] Coupon extractor 140 may be fashioned as a unitary, integrally-formed component made of a single material, or otherwise comprise multiple segments or layers of one or more different materials. The various parts comprising coupon extractor 140 may be made using any suitable manufacturing process, such as injection molding, overmolding, additive printing, etc. In some embodiments, coupon extractor 140 may be integrally formed as a single component. In other embodiments, coupon extractor 140 may be formed of two or more separate components, (e.g., coupon extractor 140 itself and piercing extension 150) then subsequently coupled together as desired (e.g., welded together, mechanically coupled together, bonded together, etc.) to form coupon extractor 140. In some embodiments, the various parts comprising coupon extractor 140 may be made in whole or part of any suitable one or more polymeric materials, such as polyvinylchloride (PVC), chlorinated polyvinyl chloride (CPVC), polyethylene (PE), high density polyethylene (HDPE), medium density polyethylene (MDPE), polypropylene (PP), etc., and or polyetheretherketone (PEEK), polyoxymethylene (POM), polyphenylsulfone (PPSU), poiyetherimide (PEI), polyetherketoneketone (PEKK), polyaryletherketone (PAEK), and / or other polymers. In some embodiments, one or more of the parts comprising coupon extractor 140, such as piercing extension 150, may comprise at least a portion fashioned of a non-polymeric material, such as a metal (e.g., brass, steel, iron, stainless steel), for example, where specific mechanical properties, such as increased hardness, tensile or compressive strength, are required.

[0109] Reference is now made to the flowchart of FIG. 7, which illustrates the functional steps in a method 700 for using a saddle tap of the present disclosure, such as exemplary saddle tap assembly 100, for tapping into a polymeric main pipe at any desired location along the length of the main pipe, to establish fluid communication from the main pipe to a branch or service line, or any suitable or desired attachment. The various steps of method 700 will be described with continued reference to FIGS. 8A-8F.

[0110] Method 700 begins in step 702, as can be seen in FIG. 8 A, wherein a saddle 104 of the present disclosure is in an open position in which split band 106 defines a first, open- position diameter configured to allow split band 106 to move freely along a length of a pipe 102. In some embodiments, when in its open position, the arms of split band 106 may be further spread apart, by urging the respective ends of split band 106 further apart, to widen the opening between the respective ends of split band 106, so as to facilitate positioning saddle 104 along pipe 102 at a desired location.

[0111] In step 704, as can be seen in FIG. 8B, saddle 106 is brought into its closed position around pipe 102, in which saddle 104 is closed around pipe 102 to achieve circumferential mating with at least a portion of an outside surface of pipe 102. In the closed position shown in FIG. 8B, the mating pair of boss halves 108a, 108b are brought into contact engagement with each other at opposed edges thereof, thereby forming cylindrical boss 108 having external threading 109. Optionally, resilient detent latches Illa positioned on a first one of the semi-cylindrical boss halves 108a, 108b, engage cooperating notches 111b on the opposing one of the semi-cylindrical boss halves 108a, 108b, to retain saddle 104 in the closed position.

[0112] In step 706, with reference to the cross-sectional view in FIG. 8C, tapping cap 110 may be placed over boss 108.

[0113] Optionally, tapping cap 110 is formed in two or more parts, such that cutting head 120 is formed as a separate insert to be inserted at the bottom of central annular element 116.

[0114] Optionally, sealing element 118 may be received within a stepped annular cavity 117a of trough-bore 117 at the bottom of central annular element 116, wherein cutting head 120 is then configured to be inserted into the annular cavity 117a, wherein annular lip 118c of sealing element 118 is pressed between a top end of stepped annular cavity 117a and an annular rim 121 of cutting head 120. When tapping cap 110 may be threaded over boss 108, protrusions 118b of sealing element 118 are received in cooperating vertical notches 107.

[0115] In step 708, with continued reference to the cross-sectional view in FIG. 8C, coupon extractor 140 may be inserted into through-bore 117 of central annular element 116 of tapping cap 110, as indicated by the arrow. Coupon extractor 140 may be inserted all the way through into through-bore 117, such that handle portion 142 engages the one or more exterior surface features 113 disposed over outer circumferential cap surface 112 of tapping cap 110, shaft 144 extends down a centerline of through -bore 117, and at least tip 154 of piercing extension 150 extends downwardly past a bottom edge of cutting head 120.

[0116] In step 710, with reference to the cross-sectional view in FIG. 8D, coupon extractor 140 beings to be rotated, to cause tapping cap 108 to be tightened over boss 108, cutting head 120 to be simultaneously rotatably-driven into and through the side wall of pipe 102, and at least simultaneously or potentially slightly preceding it, piercing extension 150 to be driven generally toward a center point, or otherwise within the area circumscribed by cutting head 120.

[0117] In some embodiments, any suitable tool may be used to engage with tool interface 146 at a top end of coupon extractor 140, to apply rotational movement to coupon extractor 140. However, in some embodiments, coupon extractor 140 and / or tapping cap 110 may be manually rotated.

[0118] As noted above, when rotated by a tool engaged with tool interface 146, or otherwise rotated manually, any rotational movement applied to coupon extractor 140causes tapping cap 110 (with which coupon extractor 140 is engaged by virtue of handle portion 142 and exterior surface features 113 disposed over outer circumferential cap surface 112 of tapping cap 110) to likewise rotate in lockstep and thus to rotatably- advance relative to boss 108 toward a sidewall of pipe 102. At the same time, the engaging by coupon extractor 140 of the surface features 113 of tapping cap 110 causes coupon extractor 140 to similarly advance in lockstep with tapping cap 110 toward the sidewall of pipe 102.

[0119] In step 712, as shown in the cross-sectional view of FIG. 8E, tapping cap 110 continues to be rotatably-advanced over boss 108 (and with it coupon extractor 104), wherein annular cutting edge 122 of cutting head 120 is likewise simultaneously rotatably-driven into and through the side wall of pipe 102, to cut a circular coupon therefrom, thereby creating a circular opening 103. Slightly before or at the same time that coupon 160 is being cut, piercing extension 150 is likewise driven generally toward a center point, or otherwise within the area, of the coupon before or during the cutting process by cutting head 120. As coupon extractor 140 and tapping cap 110 continue to be rotated, tip 154 of piercing extension 150 pierces the sidewall of pipe 102, and then threaded portion 152 burrows and penetrates through the thickness of the coupon being created by cutting head 120 to securely attach thereto.

[0120] At the conclusion of step 712, tapping cap 110 is completely tightened and selfsealed over boss 108, cutting head 120 has cut circular opening 103 through the side wall of pipe 102 to create cut coupon 160, wherein cut coupon 160 is attached to piercing extension 150.

[0121] In step 714, as shown in the cross-sectional view of FIG. 8F, once tapping cap 10 is tightened over coupon 160 is cut, coupon extractor 140 can be disengaged from the surface features 113 of tapping cap 110 and extricated from within through-bore 117, wherein cut coupon 160 that is attached to threaded portion 152 of piercing extension 150 is removed therewith.

[0122] Tapping cap 110 remains screwed in place over externally -threaded boss 108, such that a bottom portion of central annular element 116 extends downwardly into opening 103 cut in the sidewall of pipe 102. By extending into opening 103 cut in the sidewall of pipe 102, central annular element 116 establishes a permanent peripheral self-seal relative to the periphery of circular opening 103, and at the same time acts asan anchor to prevent or at least resist any lateral movement of saddle tap assembly 100 relative to the pipe 102.

[0123] Optional sealing element 118 makes annular contact with the exterior surface of pipe 102, wherein the curvature at the bottom end of sealing element 118 ensures that sealing element 118 makes contact engagement with the outer wall of pipe 102 along its entire periphery. Thus, sealing element 118 provides further sealing between pipe 102 and the various components of saddle tap 104.

[0124] In step 716, one or more other attachments or devices may be coupled to saddle tap assembly 100 via internal threading 119 at the open top end of tapping cap 110, e.g., via flexible branch tubing, to establish the fluid communication between saddle tap assembly 100 and the one or more other attachments or devices.

[0125] In the description and claims, each of the terms “substantially,” “essentially,” and forms thereof, when describing a numerical value, means up to a 20% deviation (namely, ±20%) from that value; similarly, when such a term describes a numerical range, it means an up to 20% broader range (10% on each side of the range). Additionally, when each of the terms “substantially,” “essentially,” and forms thereof is used to describe a geometrical term defining an angle (such as “perpendicular,” “orthogonal,” “parallel,” “planar,” “co-planar,” “co-axial,” “horizontal,” “vertical,” etc.), it means up to a 25 degrees deviation (namely, ±25°) from that angle, or more specifically up to ±10°, ±15°, or ±20°. This applies, inter alia, to the aforementioned end posts, pickets, barrier, module, and any other element mentioned in association with such geometrical term.

[0126] The description of a numerical range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range, such that each such subrange and individual numerical value constitutes an embodiment of the invention. This applies regardless of the breadth of the range. For example, description of a range of integers from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. Similarly, description of a range of fractions from 0.6 to 1.1 should be considered to have specifically disclosed subranges such as from 0.6 to0.9, from 0.7 to 1.1, from 0.9 to 1, from 0.8 to 0.9, from 0.6 to 1.1, from 1 to 1.1 etc., as well as individual numbers within that range, for example, 0.6, 0.7, 0.8, 0.9, 1, and 1.1.

[0127] The descriptions of the various embodiments of the present invention have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.

[0128] In the description and claims of the application, each of the words “comprise,” “include,” and “have,” as well as forms thereof, are not necessarily limited to members in a list with which the words may be associated.

[0129] Where there are inconsistencies between the description and any document incorporated by reference, it is hereby intended that the present description controls.

Claims

CLAIMSWhat is claimed is:

1. A saddle tap assembly, comprising: a saddle configured to be mounted along a polymeric pipe at a desired location, wherein said saddle comprises a cylindrical boss which extends perpendicularly relative to a sidewall of said polymeric pipe, and wherein said boss defines an internal through-passageway; a tapping cap comprising a tubular body having an open top, an inner peripheral wall configured to be received over said boss, and a central annular element which defines an internal through-bore extending downwardly from said open top along a centerline of said tapping cap and configured to be received within said internal through-passageway of said boss, said central annular element having a bottom end which extends below a bottom periphery of said tapping cap and comprises a circular cutting head; and a coupon extractor comprising a shaft which terminates at a bottom end thereof in a piercing extension, wherein said shaft is configured to be received within said through-bore of said central annular element, such that a tip of said piercing extension extends below said cutting head, wherein said coupon extractor is configured to engage said tapping cap such that said coupon extractor and said tapping cap can be rotatably advanced in lockstep relative to said boss toward said sidewall, such that said cutting head cuts a circular opening in said sidewall which creates a circular coupon, and said piercing extension penetrates through said sidewall at a point within the area of said coupon and attaches to said coupon before or during said cutting of said coupon.

2. The saddle tap assembly of claim 1, wherein said saddle comprises a spilt band configured to be moved between (i) an open position which defines a first diameter configured to receive said pipe therein and to allow said split band to move freely along said pipe, and (ii) a closed position which defines a second diameter configured to achieve contact of said split band with at least a portion of a circumference of said sidewall.

3. The saddle tap assembly of claim 2, wherein said split band comprises at respective ends thereof a mating pair of semi-cylindrical halves of said boss, and wherein, when said split band is in said closed position, said mating pair of semi- cylindrical halves are in contact engagement with each other at opposed edges thereof, so as to form said boss.

4. The saddle tap assembly of claim 3, wherein said mating pair of semi -cylindrical halves comprise cooperating releasable retention means configured to retain said split band in said closed position.

5. The saddle tap assembly of any one of claims 1-4, wherein said circular cutting head comprises one of: a peripheral blade; an annular plurality of saw teeth, blades, or serrations; or a heat-based cutting element.

6. The saddle tap assembly of any one of claims 1-5, wherein said central annular element has a tapered shape which gradually widens in circumference from bottom to top along at least a section of said central annular element, and wherein, when said cutting head rotatably advances through said sidewall of said polymeric pipe, said central annular element self-seals against the periphery of said circular opening.

7. The saddle tap assembly of any one of claims 1 -6, wherein said coupon extractor comprises a tool interface at a top end thereof configured to interface with a tool suitable to apply rotational movement to said coupon extractor.

8. The saddle tap assembly of any one of claims 1-7, wherein said tip of said piercing extension is located relative to said cutting head such that said tip makes contact with said sidewall before said circular cutting head makes contact with said sidewall.

9. The saddle tap assembly of any one of claims 1-8, wherein, upon said cutting of said circular opening, said coupon extractor is configured to be extricated from within said through-bore, wherein said coupon attached to said piercing extension is extricated therewith.

10. The saddle tap assembly of any one of claims 1-9 wherein said boss is externally threaded, and wherein said tapping cap comprises cooperating internal threading.

11. The saddle tap assembly of any one of claims 1-10, wherein said cutting head is configured as an insert to be inserted at a bottom end of said central annular element.

12. The saddle tap assembly of any one of claims 1-11, further comprising an annular sealing element disposed between a bottom end of said saddle tap assembly and said pipe.

13. The saddle tap assembly of any one of claims 1-12, wherein an upper-end portion of said through-bore, located toward said open-top, includes a coupling mechanism configured to couple one or more attachments or devices, to establish a fluid communication between said saddle tap assembly and said one or more other attachments or devices.

14. A method for tapping into a polymeric pipe, the method comprising: providing a saddle tap assembly, comprising: a saddle configured to be mounted along a polymeric pipe at a desired location, wherein said saddle comprises a cylindrical boss which extends perpendicularly relative to a sidewall of said polymeric pipe, and wherein said boss defines an internal through-passageway, a tapping cap comprising a tubular body having an open top, an inner peripheral wall configured to be received over said boss, and a central annular element which defines an internal through-bore extending downwardly from said open top along a centerline of said tapping cap and configured to be received within said internal through-passageway of said boss, said central annular element having a bottom end which extends below a bottom periphery of said tapping cap and comprises a circular cutting head, and a coupon extractor comprising a shaft which terminates at a bottom end thereof in a piercing extension, wherein said shaft is configured to be received within said through-bore of said central annular element, such that a tip of said piercing extension extends below said cutting head, wherein said coupon extractor is configured to engage said tapping cap such that said coupon extractor and said tapping cap can be rotatably advanced in lockstep relative to said boss toward said sidewall, such that said cutting head cuts a circular opening in said sidewall which creates a circular coupon, and said piercing extension penetrates through said sidewall at a point within the area ofsaid coupon and attaches to said coupon before or during said cutting of said coupon; mounting said saddle at a desired location along said polymeric pipe; positioning said tapping cap over said boss; positioning said coupon extractor within said through-bore of said central annular element of said tapping cap, so as to engage said tapping cap; rotatably advancing said tapping cap and said coupon extractor in lockstep over said boss, to cause said cutting head to cut said circular opening in said sidewall so as to create said circular coupon, and to cause said piercing extension to penetrate through said sidewall at a point within the area of said coupon and to attach to said coupon before or during said cutting of said coupon; and upon tightening of said tapping cap over said boss, extricating said coupon extractor from within said through-bore, wherein said coupon attached to said piercing extension is extricated therewith.

15. The method of claim 14, wherein said saddle comprises a spilt band configured to be moved between (i) an open position which defines a first diameter configured to receive said pipe therein and to allow said split band to move freely along said pipe, and (ii) a closed position which defines a second diameter configured to achieve contact of said split band with at least a portion of a circumference of said side wall, and wherein said mounting of said saddle at a desired location along said polymeric pipe further comprises locating said saddle in said open position at said desired location, and moving said saddle into said close position.

16. The method of claim 15, wherein said split band comprises at respective ends thereof a mating pair of semi-cylindrical halves of said boss, and wherein, when said split band is in said closed position, said mating pair of semi-cylindrical halves are in contact engagement with each other at opposed edges thereof, so as to form said boss.

17. The method of claim 16, wherein said mating pair of semi -cylindrical halves comprise cooperating releasable retention means configured to retain said split band in said closed position.

18. The method of any one of claims 14-17, wherein said circular cutting head comprises one of: a peripheral blade; an annular plurality of saw teeth, blades, or serrations; or a heat-based cutting element.

19. The method of any one of claims 14-18, wherein said central annular element has a tapered shape which gradually widens in circumference from bottom to top along at least a section of said central annular element, and wherein, when said cutting head rotatably advances through said sidewall of said polymeric pipe, said central annular element self-seals against the periphery of said circular opening.

20. The method of any one of claims 14-19, wherein said coupon extractor comprises a tool interface at a top end thereof configured to interface with a tool suitable to apply rotational movement to said coupon extractor, and wherein said rotatably advancing of said tapping cap and said coupon extractor in lockstep over said boss further comprises using said tool to apply said rotational movement to said coupon extractor via said tool interface.

21. The method of any one of claims 14-20, wherein said tip of said piercing extension is located relative to said cutting head such that said tip makes contact with said sidewall before said circular cutting head makes contact with said sidewall.

22. The method of any one of claims 14-21 wherein said boss is externally threaded, and wherein said tapping cap comprises cooperating internal threading, and wherein said positioning of said tapping cap over said boss further comprises threading said cooperating internal threading of said tapping cap over said boss.

23. The method of any one of claims 14-22, wherein said cutting head is configured as an insert to be inserted at a bottom end of said central annular element.

24. The method of any one of claims 14-23, wherein said saddle tap assembly further comprises an annular sealing element disposed between a bottom end of said saddle tap assembly and said pipe.

25. The method of any one of claims 14-24, wherein an upper-end portion of said through-bore, located toward said open-top, includes a coupling mechanism configured to couple one or more attachments or devices, to establish a fluid communication between said saddle tap assembly and said one or more other attachments or devices,and wherein the method further comprises coupling an attachment to said saddle tap assembly via said coupling mechanism to establish said fluid communication between said saddle tap assembly and said attachment.

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