Threaded Exclusion Plug With Breakaway Tab for Coupler Thread Protection
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Solution Overview
Problem
Temporary plastic caps in embedded threaded couplers are easily damaged and displaced, leading to foreign material entry and damage to internal threading, requiring costly repairs.
Innovation Solution
A foreign material exclusion plug with a breakaway tab and slot for tool-less installation, which threads into the coupler and breaks off after installation, leaving a flush surface to prevent debris and dust entry, and can be easily removed using a tool or the broken tab.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temporary plastic caps are used to protect embedded threaded couplers, then the internal threading is protected from foreign material, but the caps are easily damaged and displaced by traffic during facility operations
Solution Approach 1:
The protective plug is segmented into a main cylindrical body and a separate breakaway tab. The tab can be manually broken off after installation, separating the installation aid from the final protective component. This segmentation allows the main body to remain securely in place while providing a removable installation feature.
Solution Approach 2:
The breakaway tab is pre-formed as an integral part of the protective plug, ready to be broken off during installation. This preliminary preparation allows for tool-less installation by enabling manual threading through the tab, eliminating the need for complex installation tools while ensuring the tab is positioned correctly for breaking off after the plug is threaded into the coupler.
2Reliability
If temporary plastic caps are used, then internal threading is protected, but continuous repairs and mitigation efforts are required due to damage and displacement
Solution Approach 1:
The protective plug features a substantially cylindrical body with a rounded top surface, providing a smooth, continuous shape that resists catching on debris or objects in high-traffic areas. This curved geometry reduces the likelihood of displacement compared to flat or angular cap designs, thereby reducing maintenance frequency.
Solution Approach 2:
The protective plug is designed with specific dimensional parameters including a cylindrical body shape and a breakaway tab configuration that optimizes both installation ease and long-term stability. The tab breaks off at a predetermined point, leaving a clean, low-profile surface that is less susceptible to damage from traffic and debris.
3Reliability
If spot checks of temporary plastic caps are performed, then proper positioning can be ensured, but time and resources are consumed for inspection
Solution Approach 1:
The protective plug incorporates visual features including a colored breakaway tab and a slot that may be visible from above, providing immediate visual confirmation of proper installation. The contrast between the tab color and the cylindrical body, or the visibility of the slot, allows for quick visual inspection without requiring detailed examination, thereby reducing inspection time while maintaining reliability.
4Object-affected harmful factors
If foreign material enters the embedded threaded coupler, then internal threading can be damaged, but prevention requires complex protective measures
Solution Approach 1:
The breakaway tab is extracted as a separate, removable feature from the main protective plug body. After the plug is threaded into the coupler, the tab is manually broken off and removed, leaving only the simple cylindrical body with a slot. This extraction eliminates the need for complex sealing mechanisms or removable covers, providing effective foreign material protection through a simple, clean design.
Data Source
AI summary
A foreign material exclusion plug is disclosed. The foreign material plug includes a cylindrical body, a slot, and a breakaway tab. The cylindrical body includes an externally-threaded cylindrical structure. The slot is formed in the cylindrical body extending into the cylindrical body from a top surface of the cylindrical body. The breakaway tab is connected to the cylindrical body and extends outwards from the top surface.