Threaded Exclusion Plug With Breakaway Tab for Coupler Protection
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Solution Overview
Problem
Temporary plastic caps used to exclude foreign materials from embedded threaded couplers in facilities are easily damaged and displaced, leading to continuous repairs and potential damage to the internal threading of the couplers.
Innovation Solution
A foreign material exclusion plug with a breakaway tab and a slot, allowing for tool-less installation and easy removal, which protects the embedded threaded couplers from debris and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temporary plastic caps are used to exclude foreign materials from embedded threaded couplers, then foreign material exclusion is improved, but the caps are easily damaged and displaced requiring continuous repairs
Solution Approach 1:
The plug is segmented into a main body and a separate breakaway tab. The breakaway tab is designed to fracture at a predetermined location after installation, separating the installation tooling function from the permanent plug structure. This segmentation allows for tool-less installation while maintaining reliability.
Solution Approach 2:
The breakaway tab is designed as a disposable component that is intentionally broken off after serving its installation purpose. This allows the main plug body to remain as a permanent, reliable foreign material exclusion device without requiring removal of installation aids.
2Reliability
If temporary plastic caps are used to protect threaded couplers, then foreign material exclusion is improved, but the caps are easily displaced by traffic requiring mitigation efforts
Solution Approach 1:
The breakaway tab is designed with an asymmetric geometry that provides directional stability during installation. The tab extends perpendicular to the plug body and is oriented to engage with the coupler threads in a specific orientation, preventing displacement by lateral forces such as traffic.
Solution Approach 2:
The breakaway tab is pre-configured to provide installation leverage and directional guidance before being broken off. This preliminary structural feature ensures proper positioning and stability during the installation process, preventing displacement before the tab is intentionally fractured.
3Manufacturing precision
If spot checks of temporary plastic caps are performed to ensure proper positioning, then position accuracy is improved, but time consumption increases
Solution Approach 1:
The breakaway tab design provides self-verifying installation features. The tab's geometry and fracture pattern inherently indicate whether the plug has been properly installed and positioned, eliminating the need for separate spot checks while maintaining position accuracy.
4Reliability
If damage to embedded threaded couplers occurs due to foreign material entry, then repair costs increase, but the damage can be prevented with proper protection
Solution Approach 1:
The plug is installed beforehand to prevent foreign material from entering the threaded coupler. The breakaway tab design ensures the plug remains securely in place during facility operations, providing prior protection that prevents damage before it occurs, thereby avoiding costly repairs.
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.