Note: Descriptions are shown in the official language in which they were submitted.
CA 02628675 2008-04-08
VALVE NUT REMOVAL AND REPLACEMENT SYSTEM
CROSS REFERENCES TO RELATED APPLICATIONS
100011 This application claims benefit from the earlier filed U.S.
Provisional Application No. 60/809,768 entitled "Adjustable Actuating Lock-on
Wrench
with Nut Puller" filed May 31, 2006, and is hereby incorporated into this
application by
reference as if fully set forth herein.
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
[0002] The present invention relates to water distribution systems, and
more particularly, relates to above ground servicing of underground water
distribution
valve nuts which have deteriorated or which have been damaged beyond suitable
use. A
system having multiple and configurable tool devices is used to remove and
replace such
water valve nuts.
DESCRIPTION OF THE PRIOR ART
[0003] Various wrench systems and nut removal tools and nut puller
devices have existed and been used for some time. Wrench systems and nut
removal
tools are shown, for example, in the following United States of America
patents:
[0004] USP 7,118,091. Tool for controlling water supply (Price.
October 10, 2006). A tool for shutting off water supplies; however, this tool
is not
designed for other environments and applications, such as sanitary sewer
valves or
replacing a rounded valve stem nut. Also, a shim may be needed for adjustment.
[0005] USP 7,000,897. Apparatus and method for operating a water valve
(Chick. February 21, 2006). Uses a spring-loaded button to engage and hold an
inner
shaft to an outer shaft, which provides less than optimal size adjustment
capability.
Designed for water valve applications only.
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[0006] USP 6,928,906. Large self-forming socket (Marks. August 16,
2005). Requires a collar with shelf around the center pin to protect the bias
spring from
over-compression.
[0007] USP 6,802,337. Valve can extension (Phipps. October 12, 2004).
This invention relates to an underground access conduit for the adaptation or
extension of
the access conduit to grade level. Also, this invention is designed for use on
a curb stop
accessed through a conduit (known as a valve can, valve box, or curb box),
which makes
this invention less than universal.
100081 USP 6,776,068. Valve operator (Reuschel, et al. August 17, 2004).
This invention requires a motor and a torque converter for power, making it
less cost
efficient and more cumbersome to operate.
[0009] USP 6,349,622. Multipurpose valve opening tool (Lemaire, et al.
February 26, 2002). A compact tool designed to grip a number of different size
valve
stems, but not a rounded valve stem nut.
SUMMARY OF THE INVENTION
[0010] The general purpose of the present invention is to provide a valve
nut removal and replacement system which will repair or maintain a sanitary
sewer valve,
a fire hydrant supply valve, or water main systems from above ground, thereby
eliminating the need to excavate at the site. The invention includes
configurable
components having one or more associated subcomponents located at one or more
ends
of different sufficiently long shafts or tubes. The use of such components
facilitates
delivery of the subcomponents or other features of the invention to the
underground site
of and for interfacing with water control valve nuts and associated
components. The
components of the present invention can be arranged and utilized in different
combinations and sequences as each step involved in use of the invention
dictates. Major
components, structures or assemblies of the present invention include, but are
not limited
to, a valve nut puller tool, an accessory tool shaft for use with a plurality
of accessory tool
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attachments, such as brushes or other attachable devices, a removably
attachable T-handle
which can be secured to and used in conjunction with the valve nut puller tool
and also
with the accessory tool shaft and associated plurality of accessory tool
attachments, a
valve nut replacement tool, a valve nut supply plate which can include
configured
replacement valve nuts or other suitably sized and configured valve nuts, and
a stem
matching plate used for determining the size and/or shape of a valve nut
center cavity.
Various components can be assembled for use as a cleaning device where one of
a
plurality of attachments, such as a rotary brush, can be used with the
accessory tool shaft
and removably attachable T-handle to clean debris, dirt or other foreign
objects to
suitably expose a retainer nut or retainer bolt which secures a damaged water
valve nut to
a valve stem. Another combination of components, such as the accessory tool
shaft and a
nut socket tool, can be arranged to rotatably remove a retainer nut or
retainer bolt from
the valve stem of the underground valve. Other components can be assembled
including
the valve nut puller tool having a configurable fixture at one end and the
removably
attachable T-handle at the other end combined to forcibly extract a damaged
water valve
nut from a valve stem of an underground valve. The valve nut puller tool is
used to
extend along and through a valve box to contact, grasp and extract the damaged
valve nut.
The nut replacement tool is used to position a suitable replacement valve nut
on a bared
underground valve stem.
[0011] According to one embodiment of the present invention, there is
provided a valve nut removal and replacement system for use in the removal of
and
replacement of an underground damaged valve nut without removing the
underground
valve from the earth.
[00121 One significant aspect and feature of the present invention is a
valve nut removal and replacement system which is operated remotely from above
ground.
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[0013] Another significant aspect and feature of the present invention is
the use thereof as a cleaning device which has removably attached cleaning
brushes,
thread cleaners as well as other attachments which may be utilized for other
than
cleaning, including a tap and a die, each of which may be operated remotely
above
ground to the underground site of a valve.
[0014] Still another significant aspect and feature of the present invention
is the use of a nut socket tool in conjunction with an accessory tool shaft
for remote
removal of a retainer nut on an underground valve stem.
[0015] Yet another significant aspect and feature of the present invention
is the use of a valve nut puller tool, the components of which can be
configured and
utilized for multiple uses.
[0016] A further significant aspect and feature of the present invention is
the use of a fixture at the end of the valve nut puller tool which can be
configured and
used as a guide for the cleaning tool and associated components thereof.
[0017] A further significant aspect and feature of the present invention is
the use of a fixture at the end of the valve nut puller tool which can be
configured and
used as a guide for the accessory shaft when in use with accessory tool
attachments and
associated components thereof.
[0018] A further significant aspect and feature of the present invention is
the use of a fixture at the end of the valve nut puller tool which can be
configured and
used remotely and forcibly to remove a damaged valve nut in various stages of
disrepair
from the valve stem of an underground valve.
[0019] A still further significant aspect and feature of the present
invention is the use of a threaded actuator shaft interacting with a cam to
pivotally
position opposed levered arms for entry into a valve box for facilitating the
entry of a
valve nut into a receptor cavity.
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[0020] A still further significant aspect and feature of the present
invention is the use of a threaded actuator shaft interacting with a cam to
position
opposed levered arms for grasping and forcibly removing a remotely located
valve nut
from a remotely located valve stem.
[0021] A still further significant aspect and feature of the present
invention is the use of a valve nut replacement tool to deliver and install a
replacement
valve nut upon a remotely located valve stem on a remotely located valve.
[0022] A still further significant aspect and feature of the present
invention is the use of a valve nut supply plate and a stem matching plate to
readily and
easily determine and supply a suitably sized replacement valve nut.
[0023] A still further significant aspect and feature of the present
invention is the use of interface devices which protect threaded surfaces of
threaded
components of the invention.
[00241 Having thus briefly described embodiments of the present
invention and having mentioned some significant aspects and features of the
present
invention, it is the principal object of the present invention to provide a
valve nut removal
and replacement system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Other objects of the present invention and many of the attendant
advantages of the present invention will be readily appreciated as the same
becomes
better understood by reference to the following detailed description when
considered in
connection with the accompanying drawings, in which like reference numerals
designate
like parts throughout the figures thereof and wherein:
[0026] FIG. 1 is an isometric view of a valve nut removal and
replacement system of the present invention;
[0027] FIG. 2 is an exploded view of a valve nut puller tool of the system
shown in FIG. 1;
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100281 FIG. 3 is a view of the assembled end structure of the valve nut
puller tool aligned with a damaged valve nut;
[0029] FIG. 4 is a cross section view along line 4-4 of FIG. 3 showing the
relationship of the end structure to a connecting tube and threaded actuator
shaft;
[0030] FIG. 5 is an isometric view of one of the replacement valve nuts in
spaced alignment with a nut receptacle socket at one end of the valve nut
replacement
tool;
[0031] FIG. 6 is a cross section view of the replacement valve nut along
line 6-6 of FIG. 5;
[0032] FIG. 7 is a bottom view of the replacement valve nut;
[0033] FIG. 8 shows the cleaning process incorporating components of
the invention to clean the area around and about a retainer nut prior to using
a socket tool
and nut socket;
[0034] FIG. 9 illustrates the use of a socket tool to remove a retainer nut
from a valve stem in order to allow subsequent removal of a damaged valve nut;
[0035] FIG. 10 illustrates the insertion of a fully assembled valve nut
puller tool into a valve box for the purpose of the subsequent engagement with
and
removal of a damaged valve nut;
[0036] FIG. 11 illustrates the capture of a damaged valve nut within a nut
receptor cavity;
[0037] FIG. 12 illustrates the unitary removal of the valve nut puller tool,
the damaged valve nut and other closely associated components from a valve box
where
the damaged valve nut has been disengaged from the valve stem of a valve;
[0038] FIG. 13 illustrates the use of the extended interface/thread
protector and valve nut puller tool to remove a damaged valve nut from a valve
stem
having an internally threaded hole where the fully assembled valve nut puller
tool is
inserted into the valve box;
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[0039) FIG. 14 illustrates the capture of the damaged valve nut within the
valve nut receptor cavity;
[0040] FIG. 15 illustrates the unitary removal of the valve nut puller tool,
the damaged valve nut and other closely associated components from the valve
box where
the damaged valve nut has been disengaged from the valve stem;
[0041] FIG. 16 illustrates the replacement of a valve nut on a valve stem
utilizing the valve nut replacement tool;
[0042] FIG. 17 shows a replacement valve nut installed on and secured
upon a valve stem by a new retainer nut in engagement with the threads of the
valve stem;
and,
[0043] FIG. 18 shows a shortened valve nut puller tool, an alterna.tive
embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0044] FIG. 1 is an isometric view of a valve nut removal and
replacement system 10 of the present invention including, but not limited to,
a valve nut
puller tool 12, an accessory tool shaft 14, a removably attachable T-handle
16, a valve nut
replacement tool 18, a valve nut supply plate 19 having posts upon which
various size
and style replacement valve nuts 20a-20n, which preferably are stainless
steel, can be
stored, and a stem matching plate 22 having various size numbered stems 23a-
23n
extending vertically therefrom. Components of the valve nut puller tool 12
include an
elongated tube 24, an end structure 26 having variable geometry aligned and
secured to
one end of the tube 24, a hex head 28 at one end of a threaded actuator shaft
30, whereby
the threaded actuator shaft 30 extends along the interior of the tube 24 to
threadingly
engage and operate a cam 32 in the end structure 26, a top shouldered bushing
34 (best
seen in FIGS. 2 and 8) including a bevel 33 (FIG. 8) located at the lower
portion of the
bushing passage aligned and secured within the upper end of the elongated tube
24 for
guidance of the upper region of the threaded actuator shaft 30 or for guidance
of other
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components, a washer 36 and nut 37 (FIGS. 1 and 2), the latter of which
threadingly
engages the upper region of the threaded actuator shaft 30, and opposed
levered arms 38
and 40 pivotally mounted in the end structure 26 interacting with a cam 32 for
angular
positioning of opposed levered arms 38 and 40. For the purpose of
illustration, brevity
and clarity, a one-piece housing 42, which is a component of the end structure
26, is
shown divided in section form as housing halves 42a and 42b where the housing
half 42a
is shown distanced from the opposite housing half 42b where the latter is
shown in fixed
engagement with one end of the elongated tube 24. An interface/thread
protector 39 and
an extended interface/thread protector 41 are included for attachment at the
lower end of
the threaded actuator shaft 30 for use thereupon depending on the style of the
damaged
valve nut which is to be removed and are used as an interface and to prevent
damage to
the end of the threaded actuator shaft 30 and to the external or internal
threads of a valve
stem associated with a particular style of valve nut. Additional components of
the end
structure 26 in association with other components and features of the
invention are shown
in detail in FIGS. 2 and 3, as well as in other figures.
[0045] The accessory tool shaft 14 also shown in FIGS. 1, 8 and 9 is
preferably and generally round having one end configured as a hex head 46 or
other
suitable configuration for connection and communication with the removably
attachable
T-handle 16 or with an electric drill or other rotational device in order to
rotate the
accessory tool shaft 14 and appropriate attachment tool later described in
detail. The
opposite end of the accessory tool shaft 14 includes a square drive connector
47 having a
body hole 49 extending therethrough. The square drive connector 47 can
accommodate a
tool receptor 48 having a bore 50, whereby the tool receptor 48 can be secured
to the
square drive connector 47, such as by the use of a pin 51 extending through
opposed
holes 53 (one shown) of the tool receptor 48 and through the body hole 49 in
the square
drive connector 47. A plurality of opposed threaded mounting holes 52 (one
shown) near
the lower end of the tool receptor 48 are used for fixing a variety of
accessory tool
attachment devices within the bore 50 of the tool receptor 48. Set screws 54
extend
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through the threaded mounting holes 52 to secure the selected accessory tool
attachment
to the tool receptor 48. The variety of useful accessory tool attachments can
include, but
are not limited to, a thread cleaner die 56, a rotary brush 58 having internal
inwardly
extending bristles, a rotary brush 60 having outwardly and downwardly
extending
bristles, a tap drill 62 and a tap 64 each of which includes shafts 56a, 58a,
60a, 62a
and 64a, respectively. The square drive connector 47 can also accommodate a
nut socket
too165 of appropriate features and desired size by the use of a pin 66
extending through
opposed holes 67 (one shown) in the nut socket tool 65 and through the body
hole 49 of
the square drive connector 47.
100461 The removably attachable handle 16 shown in FIG. 1 can be
brought into rotary action use by connecting it to the hex head 28 of the
valve nut puller
tool 12 or to the hex head 46 of the accessory tool shaft 14. The removably
attachable
handle 16 includes a body 68, a triangular shaped mating hole 69 in the body
68 which
hole can suitably accommodate the hex heads 28 and 46 of the valve nut puller
tool 12
and accessory tool shaft 14, respectively, where each hex head 28 or 46 can be
secured
therein by using a threaded locking shaft 70 which threadingly engages the
body 68 and
which is operated by a three bar handle 71. Actuating bars 72a and 72b are
secured to
and extend from the body 68 for applying rotary motion to the valve nut puller
tool 12 or
accessory tool shaft 14.
[0047] The valve nut replacement tool 18 shown in FIG. 1 includes a
robust tube 74 with a striking surface 76 at one end which is suitable for
repeated forceful
blows thereupon by a mallet or hammer. A nut receptacle socket 78, being
substantially a
square and open structure having an open end, is located at the opposite end
of the
tube 74 for loading one of the valve replacement nuts 20a-20n.
[00481 FIG. 2 is an exploded view of the end structure 26 of the valve nut
puller tool 12, as well as other previously described components of the valve
nut puller
tool 12. FIG. 3 is a view of the assembled end structure 26 aligned with a
representative
damaged valve nut 80. With reference to FIG. 2 and FIG. 3, the present
invention is
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further described. As previously described, the housing 42 is shown as a
housing half 42a
and as a housing half 42b for purposes of illustration and clarity, although
the housing 42
is a unitary structure. The housing 42 is described referring to the housing
half 42a with
the understanding that various features or structures are common to both
housing
halves 42a and 42b, except as noted. Continuously connected and adjacent round
cavities, passageways, collars or partial arcuate cavities included at the
upper portion of
the housing 42 are utilized to accommodate tubular or round components of the
valve nut
puller 12 which connect thereto or which are located therein, including a
bottom
shouldered bushing 86, the lower end of the tube 24 and the lower end of the
threaded
actuator shaft 30. A collar 88 of tubular shape at the upper portion of the
housing 42
accommodates the interior bottom end of the tube 24 which is suitably secured
thereto.
The interior of the collar 88 defines a passageway 90, preferably being round,
for the
accommodation of a bottom portion of the threaded actuator shaf130. A beve191
at the
top end of the collar 88 assists in the alignment and entry of the lower end
of the threaded
actuator shaft 30 with the collar 88 and other components. A bushing cavity 92
conforming to the general shape of the bottom shouldered bushing 86 is
continuous with
and extends downwardly from the passageway 90 for accommodation of the bottom
shouldered bushing 86 which is frictionally engaged therein. The bottom
shouldered
bushing 86 guidingly accommodates the lower portion of the threaded actuator
shaft 30 or
of other devices, such as the accessory tool shaft 14. A tool acconunodation
cavity 94,
preferable being round, is continuous with and extends downwardly from the
lower
region of the bushing cavity 92 for accommodation of tools such as, but not
limited to,
the nut socket tool 65 or the tool receptor 48 which can be used with the
accessory tool
shaft 14 and associated for cleaning or other associated functions. The tool
accommodation cavity 94 also accommodates the upper portion of the cam 32, as
later
shown in FIG. 4. In different modes of operation, the threaded actuator shaft
30 or the
accessory tool shaft 14 can pass directly or indirectly or align within one or
more of the
following components including the tube 24, the collar 88, the passageway 90,
the bottom
CA 02628675 2008-04-08
shouldered bushing 86, the bushing cavity 92, the tool accommodation cavity 94
and the
lower region of the housing 42. An arcuate tool accommodation space 96 shown
at the
mid-portion of the housing half 42b and an opposing mirror image like arcuate
tool
accommodation space 97 similar to the arcuate tool accommodation space 96
extend
downwardly from the tool accommodation cavity 94 at the mid-portion of the
housing 42.
[0049] The lower portions of the housing 42 form a valve nut receptor
cavity 98 having a square profile for alignment with and accommodation of a
damaged
valve nut 80, as seen in FIG. 3, or in rare occurrences, one of the
replacement valve
nuts 20a-20n. The valve nut receptor cavity 98 is formed of opposed front and
back
planar walls 100 and 102 and opposed interrupted left and right planar walls
104 and 106
extending downwardly to form the lower portion of the housing 42 (i.e.,
housing
halves 42a and 42b) where opposed vertically oriented slots 108 and 110 (FIG.
3) are
included in the interrupted left and right planar walls 104 and 106,
respectively, to
accommodate movement of the levered arm 38 and the levered arm 40. The slot
110 is
delineated by a vertically aligned planar surface 109a, a horizontally aligned
surface 109b, and a vertically aligned surface 109c. The slot 108 is
delineated by a
vertically aligned planar surface llla, a horizontally aligned surface 11lb,
and a
vertically aligned surface l l lc. The levered arm 38 and the levered arm 40
are similar
wherein each arm includes a follower cam 112, a pivot hole 114 extending
through the
follower cam 112, and an inwardly extending jaw 116 whereby the jaws 116 are
utilized
to intimately engage a damaged valve nut 80, such as described later in
detail.
Horizontally aligned body holes 118 and 120 extend through the mid-body region
of the
housing 42 (housing half 42a) in alignment with oppositely aligned threaded
holes 122
and 124 of the mid-body region of the housing 42 (housing half 42b). Pivot
bolts 126
and 128 preferably having Allen heads extend through the body holes 118 and
120,
through the pivot holes 114 of the levered arms 38 and 40, respectively, and
are secured
in the threaded holes 122 and 124 to thereby pivotally and removably attach
the levered
arms 38 and 40 to the housing 42. The levered arms 38 and 40 can be pivotally
actuated
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by the cam 32 to operate about the pivot bolts 126 and 128, whereby the
levered arms 38
and 40 align within and are accommodatingly positioned in and along the slots
108
and 110. The cam 32, which includes an interior threaded hole 130 and a bevel
131 at the
top of the threaded hole 130, aligns between the arcuate accommodation spaces
96 and 97
of the housing 42 and also aligns within the tool accommodation cavity 94 to
be vertically
positioned therealong by engagement with and by rotary action of the threaded
actuator
shaft 30 which is turned by the removably attachable T-handle 16. The bevel
131 assists
in alignment and entry of the lower end of the threaded actuator shaft 30 with
the
threaded hole 130. The cam 32 includes opposing top lobes 132a and 132b,
opposing
bottom lobes 134a and 134b, a non-lobe flat surface 136 between the top lobe
132a and
the bottom lobe 134a and are opposite non-lobe flat surface 138 between the
top
lobe 132b and the bottom lobe 134b where appropriate features thereof interact
with the
follower cam 112 of the levered arm 38 and the levered arrn 40, respectively,
to angularly
position the levered arm 38 and the levered a.rm 40 about the pivot bolts 126
and 128,
respectively. The cam 32 also includes vertically oriented opposed flat
surfaces 113
and 115 extending substantially between the edges of the top lobes 132a and
132b, the
edges of the bottom lobes 134a and 134b and between the edges of the non-lobe
flat
surfaces 136 and 138. Also shown in FIG. 2 are the interface/thread protector
39 and the
extended interface/thread protector 41 which are threadingly engaged and
affixed to the
bottom of the threaded actuator shaft 30 and which interface with various
styles of valve
stems. The interface/thread protector 39 has internal threads and includes a
contact
plate 39a at the lower region for contacting the top of a valve stem and the
extended
interface/thread protector 41 has internal threads and includes a contact
shaft 41 a for
contacting a valve stem having an internally threaded hole, as shown later in
detail.
[0050] FIG. 4 is a cross section view along line 4-4 of FIG. 3 showing the
relationship of the end structure 26 to the elongated tube 24 and the threaded
actuator
shaft 30. Shown in particular is the relationship of the cam 32 with the
levered arms 38
and 40. The follower cams 112 of the opposed levered arms 38 and 40 are shown
in
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alignment to the non-lobe flat surfaces 136 and 138, respectively, of the cam
32 without
contact with but in near proximity to the top lobes 132a and 132b and the
bottom
lobes 134a and 134b of the cam 32. The threaded actuator shaft 30 is shown
extending
directly through the elongated tube 24, the passageway 90 of the collar 88,
the center of
the bottom shouldered bushing 86, the tool accommodation cavity 94, and in
threaded
engagement with and extending slightly beyond the threaded hole 130 of the cam
32. The
threaded actuator shaft 30 also extends indirectly through the bushing cavity
92.
Attachment of and rotation of the removably attachable T-handle 16 (FIG. 1) to
the hex
head 28 at one end of the threaded actuator shaft 30 provides for the rotation
of the
threaded actuator shaft 30 to position the centrally located cam 32 upwardly
or
downwardly along the vertical axis of the end structure 26. The cam 32 is
precluded from
rotation about the vertical axis of the fixture 26 by the close relationship
of a portion of
the flat surface 115 (FIG. 2) of the cam 32 against the upper region of the
planar
surfaces 109a and 111 a and a portion of the flat surface 113 of the cam 32
against the
upper region defined by the planar surfaces 109c and 111 c of the housing 42.
The cam 32
interacts with the follower cams 112 of the levered arms 38 and 40 to
pivotally position
the levered arms 38 and 40 inwardly or outwardly about the pivot bolts 126 and
128,
respectively, whereby the levered arms 38 and 40 are utilized in various modes
of
operation.
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100511 FIG. 5 is an isometric view of one of the replacement valve
nuts 20a in spaced alignment with the nut receptacle socket 78 at one end of
the valve nut
replacement tool 18, FIG. 6 is a cross section view of the replacement valve
nut 20a
along line 6-6 of FIG. 5, and FIG. 7 is a bottom view of the replacement valve
nut 20a.
The nut receptacle socket 78 (FIG. 5) is used to grasp and to place the
universal
replacement nut 20a or other nuts, such as, but not limited to, the valve nuts
20a-20n on
the stem of various valves, such as later described in detail. Each of the
replacement
valve nuts 20a-20n has externally located opposed grooves 140a and 140b in
close
proximity to its bottom and a centrally located valve stem receptacle 142 in
the general
shape of a truncated pyramid including a plurality of successively smaller
angled gripping
surfaces 144a-144n on the walls of the valve stem receptacle 142 which leads
to a circular
opening 145 and a top recess 146. The replacement valve nut 20a also has a
bottom
recess 147 in axial alignment with the valve stem receptacle 142. The top
recess 146
accommodates the head of a retainer bolt or a retainer nut used to fasten a
replacement
valve nut 20a-20n to a valve stem and the circular opening 145 accommodates
either a
valve stem or the threaded portion of a retainer bolt. The nut receptacle
socket 78
includes a robust end plate 148, opposed side plates 150 and 152 connected to
and
extending from the end plate 148, and opposed flexible side plates 154 and
156, whereby
each side plate 150, 152, 154 and 156 is common to and extends perpendicularly
from the
end plate 148. A passage hole 157 is included in the end plate 148 which
aligns with and
communicates with the interior of the tube 74. The passage hole 157 can
accommodate
the upper portion of a valve stem, if required. The end plate 148 is suitably
attached,
such as by a weldment, to the tube 74 of the valve nut replacement tool 18.
The flexible
side plates 154 and 156 include inwardly extending angled tabs 154a and 156a,
respectively, which forcibly engage grooves 140a and 140b of the replacement
valve
nut 20a in order to facilitate capture of any such nut within the interior of
the nut
receptacle socket 78. Accordingly, the replacement valve nut 20a includes
beveled
edges 158 and 160 which facilitate the flexing of the angled tabs 154a and
156a
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CA 02628675 2008-04-08
outwardly when the replacement valve nut 20a is forcibly loaded into the nut
receptacle
socket 78. The replacement valve nut 20a is seated fully into the nut
receptacle socket 78
when the angled tabs 154a and 156a are forcibly and intimately engaged in the
grooves 140a and 140b in order to retain the replacement valve nut 20a within
the nut
receptacle socket 78 for placement on a valve stem, as later described in
detail.
Preferably, the top of the replacement valve nut 20a or other such nut
intimately contacts
the end plate 148 of the nut receptacle socket 78. A mallet, a hammer, or
other suitable
and substantial striking device is used to strike the striking surface 76 of
the valve nut
replacement tool 18 containing the replacement valve nut 20a to forcibly
engage the
replacement valve nut 20a with a valve stem. Subsequent to placement on a
valve stem,
the angled tabs 154a and 156a can be forcibly disengaged from intimate contact
with the
grooves 140a and 140b, whereby the nut receptacle socket 78 is then freed from
engagement with the replacement valve nut 20a which frictionally engages the
valve
stem.
MODE OF OPERATION
100521 FIGS. 8-17 illustrate the various modes of operation of the present
invention.
100531 FIGS. 8-17 are cross section views illustrating various situations
involving the relationship of various components of the invention to a valve
162 having a
valve stem 164 and including the damaged valve nut 80 of questionable
integrity which
could be wom, deformed, corroded or otherwise unsuitable for general use,
including nut
flats which have been rounded or deformed to the point of unuseability. The
nut in
question can be removed and replaced with another nut which could be an
identical nut or
which could be one of the replacement valve nuts, such as 20a, for example and
illustration. A retainer nut 168 engages threads 170 at the top of the valve
stem 164 in
order to maintain suitable intimate engagement of the interior flatted and
tapered surfaces
(a truncated pyramid shape) of the damaged valve nut 80 with the corresponding
and
CA 02628675 2008-04-08
similar complementary shape of the valve stem 164. The valve 162 is shown at
the
bottom of a valve box 172 extending downwardly to a location in the earth 174
distant
from the surface of the earth.
[0054] FIG. 8 illustrates the cleaning process incorporating components
of the invention to clean the area around and about the retainer nut 168 using
the
accessory tool shaft 14, the tool receptor 48, and the rotary brush 60. To
accomplish the
cleaning process, the pivot bolts 126 and 128 are removed to allow removal of
the levered
arms 38 and 40 from the end structure 26. The threaded actuator shaft 30 is
rotated to
disengage from the cam 32, thereby allowing removal of both from the end
structure 26,
thus creating room in the end structure 26 for accommodating the accessory
tool shaft 14
and rotary brush 60, the latter of which is attached to the lower end of the
accessory tool
shaft 14 through use of the tool receptor 48. Preferably, the hex head 46 of
the accessory
tool shaft 14 is bottom loaded through the lower and open end of the housing
42, along
and through the arcuate accommodation space 96, the tool accommodation cavity
94, the
bottom shouldered bushing 86, the collar 88, the interior of the elongated
tube 24, and the
top shouldered bushing 34. In the alternative, the accessory tool shaft 14
only can be top
loaded in the reverse order of that just described and the tool receptor 48
and rotary
brush 60 can be attached to the square drive connector 47 by use of the pin 51
and the set
screws 54, respectively. Thus, the accessory tool shaft 14 is aligned within
and guided by
the top shouldered bushing 34 and the bottom shouldered bushing 86, whereby
the
remaining associated components of the end structure 26, the tube 24, and the
accessory
tool shaft 14, and closely associated components are lowered down through the
valve
box 172 to engage the damaged valve nut 80. The valve nut receptor cavity 98
at the
bottom of the end structure 26 assists in the alignment over and about a
portion of the
damaged valve nut 80, thereby centering and aligning the rotary brush 60 over
and about
the retainer nut 168. A powered device, such as an electric drill, or the
removably
attachable tool handle 16 or other hand operated device, can then be attached
to the hex
head 46 of the accessory tool shaft 14 to rotate the accessory tool shaft 14
and attached
16
CA 02628675 2008-04-08
rotary brush 60 to clean the threads 170 of the valve stem 164 and the
retainer nut 168
and the area around and about the retainer nut 168 in order to facilitate the
use of the
accessory tool shaft 14 and nut socket tool 65. Manual rotation of the
accessory tool
shaft 14 and attached rotary brush 60 without any mechanical advantage device
can also
be used if desired. The same insertion methods can be used to load and to use
other
components associated with the accessory tool shaft 14, such as, but not
limited to, use of
the thread cleaner die 56, the rotary brush 58, the tap drill 62, or the tap
64.
[0055] FIG. 9 illustrates the use of the accessory tool shaft 14 and the nut
socket tool 65 to remove the retainer nut 168 from the valve stem 164 in order
to allow
subsequent removal of a damaged valve nut 80. If the cleaning procedure has
been
accomplished, and the rotary brush 60 or other attachment is then removed from
the end
structure 26. If the retainer nut 168 does not require cleaning, as in the
procedure
described in FIG. 8, use of the rotary brush 60 is not required, whereby the
end
structure 26 can be configured for affixing the nut socket tool 65 to the
accessory tool
shaft 14. Such configuration requires removal of the pivot bolts 126 and 128
in order to
remove the levered arms 38 and 40 from the end structure 26 subsequent to
which the
threaded actuator shaft 30 is rotated to disengage from the cam 32, thus
allowing removal
of the threaded actuator shaft 30 and the cam 32 from the end structure 26 in
order to
create room in the end structure 26 for accommodating the accessory tool shaft
14 and the
nut socket tool 65. Top loading of the accessory tool shaft 14 can be
initiated by inserting
the end of the accessory tool shaft 14 with its square drive connector 47
through the top
shouldered bushing 34, the interior of the tube 24, the collar 88, the bottom
shouldered
bushing 86, the tool accommodation cavity 94, along and through the arcuate
accommodation space 96, and thence through the lower and open end of the
housing 42
where the square drive connector 47 can suitably engage and be secured to the
nut socket
tool 65 by use of the pin 66. In the alternative, the accessory tool shaft 14
can be bottom
loaded in reverse order through the components previously described, whereby
the hex
head 46 of the accessory tool shaft 14 is inserted first through the lower
region of the
17
CA 02628675 2008-04-08
remaining components of the end structure 26. With this method, the nut socket
too165
can be secured to the square drive connector 47 before or after bottom
loading. In either
loading method, the accessory tool shaft 14 is aligned within and guided by
the top
shouldered bushing 34 and the bottom shouldered bushing 86, whereby the
remaining
components of the end structure 26, the tube 24, the accessory tool shaft 14,
and nut
socket tool 65, and closely associated components, are lowered unitarily
through the
valve box 172 to engage the retainer nut 168. The valve nut receptor cavity 98
at the
bottom of the fixture 26 assistingly aligns over and about a portion of the
damaged valve
nut 80, thereby centering and aligning the nut socket tool 65 over and about
the retainer
nut 168 for mutual engagement. The accessory tool shaft 14 can then be
rotated, such as
by the use of an electric drill, or the removably attachable T-handle 16 in
engagement
with the hex head 46 of the accessory tool shaft 14 to cause disengagement of
the retainer
nut 168 from the threads 170 of the valve stem 164, whereby the retainer nut
168 is
removed therefrom. After removal of the retainer nut 168 from the valve stem
164, the
end structure 26, the accessory tool shaft 14, and nut socket tool 65, the
tube 24 and
closely associated components are unitarily removed from the valve box 172
pending
removal of the damaged valve nut 80 or other nut. The retainer nut 168 is then
removed
from the valve box 172.
[0056] FIG. 10 illustrates the insertion of the fully assembled valve nut
puller tool 12 into the valve box 172 for the purpose of subsequent engagement
with and
removal of a nut, such as, but not limited to, the damaged valve nut 80. Prior
to such
insertion, the valve nut puller tool 12 is preconfigured to pivotally position
the jaws 116
of the levered arms 38 and 40. For purposes of example and illustration, if
the tube 24 of
the valve nut puller tool 12 were to be held constant in space without any
other support,
the weight of the threaded actuator shaft 30 would cause downward
gravitational
positioning of the threaded actuator shaft 30 and the cam 32, whereby the
opposed top
lobes 132a and 132b would come into intimate contact with the follower cams
112 of the
levered arms 38 and 40, thereby causing the outward positioning of the levered
arms 38
18
CA 02628675 2008-04-08
and 40 about the pivot bolts 126 and 128, respectively, whereby the levered
arms 38
and 40 are extended in an outward direction, such as represented by the
position of the
levered arms 38 and 40 shown in dashed lines. Such extension may be
incompatible with
the size of the valve box 172 and, as such, the degree of extension may be
controlled by
adjustably rotating the nut 37 downwardly along the threaded actuator shaft 30
and
against the washer 36 and the top of the tube 24, thereby raising the threaded
actuator
shaft 30 and the cam 32, whereby the opposed top lobes 132a and 132b of the
cam 32
with the aid of gravity are repositioned during intimate contact with the
follower
cams 112 to adjust the levered arms 38 and 40 inwardly, with gravitational
assistance, to
a lesser extended mid-position at a desired angle, as shown in FIG. 10,
suitable for
descent into the valve box 172. Such an adjustable configuration provides for
angular
control of the levered arms 38 and 40 and jaws 116. The valve nut puller tool
12 in this
configuration is preferably grasped by the tube 24 and lowered unitarily into
the valve
box 172 to insert the damaged valve nut 80 into the valve nut receptor cavity
98 until the
interface/thread protector 39, which is firmly engaged and threadingly engaged
over and
about the lower end of the threaded actuator shaft 30, intimately contacts the
top of the
valve stem 164. The threads 170 of the valve stem 164 and the threads of the
threaded
actuator shaft 30 are protected by using the interface/thread protector 39, as
well as
providing an interface between such threaded components.
[0057] FIG. 11 illustrates the capture of the damaged valve nut 80 within
the valve nut receptor cavity 98. Capture of the damaged valve nut 80 is
accomplished by
rotation of the threaded actuator shaft 30 within the tube 24 by turning the
removably
attached T-handle 16. The threaded actuator shaft 30 is actuated moving the
cam 32
upwardly along the threaded actuator shaft 30, whereby the follower cams 112
on the
levered arms 38 and 40 are disengaged from the top lobes 132a and 132b to
transit the
non-lobe flat surfaces 136 and 138 without engagement therewith until the
bottom
lobes 134a and 134b are forcibly engaged by the follower cams 112 of the
levered
arms 38 and 40, thereby pivoting the levered arms 38 and 40 about the pivot
bolts 126
19
CA 02628675 2008-04-08
and 128 to cause levered arms 38 and 40 and their jaws 116 to move inwardly.
Such
action forcibly positions the lower portion of the levered arms 38 and 40
against the
damaged valve nut 80 and forces the opposing jaws 116 of the levered arms 38
and 40 to
a fixed and locked position beneath the opposed lower edges of the damaged
valve
nut 80, thus fixing and locking the position and relationship of the levered
arms 38 and 40
with respect to the bottom lobes 134a and 134b of the cam 32 and to the cam 32
into a
unitary structure the geometry of which is virtually unalterable. Further
rotation of the
threaded actuator shaft 30 is continued, whereby the threaded actuator shaft
30 and
interface/thread protector 39 increasingly bear against the top of the valve
stem 164 to
cause the positionally fixed opposed levered arms 38 and 40, in fixed
combination with
the cam 32, to move unitarily and transfer an upwardly directed force between
the
jaws 116 of the opposed levered arms 38 and 40 and the top of the valve stem
164 to
forcibly remove the damaged valve nut 80 from the valve stem 164. Once the
damaged
valve nut has been separated, the nut 37 can be adjusted downwardly to bear
against the
washer 36 and the top shouldered bushing 34, thereby fixing the position of
the threaded
actuator shaft 30 in relationship to the unitarily fixed and combined cam 32,
levered
arms 38 and 40, and damaged valve nut 80. Then, the valve nut puller tool 12
is removed
from the valve box 172 by grasping the tube 24 or the removably attached
handle 16.
Upward movement of the cam 32 in the housing 42 is accommodated by the tool
accommodation cavity 94. During any positioning of the cam 32, the opposed
levered
arms 38 and 40 and the jaws 116 are accommodated by the opposed slots 108 and
110,
respectively.
[0058] FIG. 12 illustrates the unitary removal of the valve nut puller
tool 12, the damaged valve nut 80 and other closely associated components from
the
valve box 172 where the damaged valve nut 80 has been disengaged from the
valve
stem 164 of the valve 162 and where the damaged valve nut 80 is now firmly
affixed
within the end structure 26. Replacement of the damaged valve nut 80 by a
suitable
replacement valve nut, such as one of the replacement valve nuts 20a-20n, is
typified by
CA 02628675 2008-04-08
the replacement valve nut 20a from the valve nut supply plate 19 (FIG. 1) and
which can
now be accomplished by use of the valve nut replacement tool 18, as
illustrated in
FIG. 16. The numbered stems 23a-23n of the stem matching plate 22 can be used
to
determine and select a nut 20a-20n of an appropriate internal size and/or
shape as
correspondingly provided on the valve nut supply plate 19.
100591 FIG. 13 illustrates the use of the extended interface/thread
protector 41 during the removal of a damaged valve nut 80 from a different
valve
stem 178 having an internally threaded hole 180 where the fully assembled
valve nut
puller tool 12 is inserted into the valve box 172 for the purpose of the
subsequent
engagement with and removal of a nut, such as, but not limited to, a damaged
valve
nut 80. In FIG. 13, the mode of operation is similar to that described with
respect to
FIG. 10. In this illustration, the extended interface/thread protector 41 has
replaced the
interface/thread protector 39 of FIG. 10. A retainer bolt 176 is shown (for
the purpose of
illustration), which bolt has previously been removed from the valve stem 178
where
such valve stem 178 has an internally threaded hole 180, by the same method
described
with respect to FIG. 9 for removal of the retainer nut 168. The internally
located threads
of the extended interface/thread protector 41 threadably engage the threads at
the bottom
end of the threaded actuator shaft 30. Protection is thus afforded to the
internally
threaded hole 180 of the valve stem 178 and to the threads of the threaded
actuator
shaft 30 by the use of the extended interface/thread protector 41, as well as
providing an
interface between such threaded components.
[0060] FIG. 14 illustrates the capture of the damaged valve nut 80 within
the valve nut receptor cavity 98. In FIG. 14, the mode of operation is
substantially the
same as that described with respect to FIG. 11. The extended interface/thread
protector 41 is shown extending into the internally threaded hole 180 of the
valve
stem 178 for the purpose of providing a forcible contact with the valve stem
178 at the
bottom of the internally threaded hole 180. The same forcible relationship
exists between
the cam 32, the extended interface/thread protector 41, the levered arms 38
and 40,
21
CA 02628675 2008-04-08
jaws 116, the valve stem 178, and the damaged valve nut 80, as previously
described with
respect to FIG. 11.
[0061] FIG. 15 illustrates the unitary removal of the valve nut puller
tool 12, the damaged valve nut 80, and other closely associated components
from the
valve box 172 where the damaged valve nut 80 has been disengaged from the
valve
stem 178 of the valve 162. In FIG. 15, the mode of operation is substantially
the same as
that described with respect to FIG. 12, illustrating the unitary removal of
the valve nut
puller tool 12, the damaged valve nut 80, and other closely associated
components from
the valve box 172 where the damaged valve nut 80 has been disengaged from the
valve
stem 178 of the valve 162.
[0062] FIG. 16 illustrates the replacement of a nut, such as the
replacement valve nut 20a or other suitable nut, such as may be required on
the valve
stem 164 of the valve 162 shown herein. The same method is used to install a
replacement valve nut 20a on the alternative valve stem 178 of the valve 162
(shown in
FIG. 14). With reference to FIG. 5 and FIG. 16, the process for replacement is
now
described. The replacement valve nut 20a is loaded into the nut receptacle
socket 78,
whereby the flexible side plates 154 and 156 and the angled tabs 154a and 156a
are
flexibly urged outwardly by forcible contact with the beveled edges 158 and
160 of the
replacement valve nut 20a, whereupon the replacement valve nut 20a is
subsequently and
forcibly maneuvered into the confines of the nut receptacle socket 78 until
the angled
tabs 154a and 156a springingly engage the grooves 140a and 140b, respectively,
on the
exterior surfaces of the replacement valve nut 20a. The valve nut replacement
tool 18,
including the replacement valve nut 20a, is lowered into the valve box 172 to
align the
valve stem receptacle 142 of the replacement valve nut 20a over and about the
valve
stem 164 and to place the replacement valve nut 20a on the valve stem 164.
Upon such
suitable alignment and placement, the remotely located striking surface 76 of
the tube 74
can be suitably struck by a mallet or hammer to impart a downwardly directed
force on
the tube 74 to the nut receptacle socket 78, whereby such force is further
transmitted to
22
CA 02628675 2008-04-08
the replacement valve nut 20a, thereby causing suitable frictional engagement
of the inner
gripping surfaces 144a-144n of the replacement valve nut 20a with the angled
planar
sides of the valve stem 164. Upon such suitable frictional engagement, as just
described,
the valve nut replacement tool 18 is pulled upwardly to cause flexible
disengagement of
the angled tabs 152a and 154a from the grooves 140a and 140b, and thus from
the
replacement valve nut 20a which is now frictionally engaged upon the valve
stem 164.
The valve nut replacement tool 18 is withdrawn from the valve box 172 and a
new
retainer nut 168 (FIG. 17) is made to engage the threads 170 of the valve stem
164 and to
engage the top of the replacement valve nut 20a by the combined use of the
accessory
tool shaft 14 and nut socket tool 65 with the appropriately configured end
structure 26
and associated components in use with the tube 24 which provides for suitable
alignment
in a manner mostly similar to that as previously described for removal of a
retainer
nut 168 such as shown in FIG. 9.
100631 FIG. 17 shows a replacement valve nut 20a installed on and
secured upon the valve stem 164 by a new retainer nut 168 in engagement with
the
threads 170 of the valve stem 164. The retainer nut 168 is located in and
maintains a low
profile within the top recess 146 of the replacement valve nut 20a. A new
retainer
bolt 176 can also be installed (in a manner similar to that described for
installation of the
new retainer nut 168) to engage and maintain a low bolt head profile within
the top
recess 146, whilst engaging the internally threaded hole 180 of the
alternative valve
stem 178 shown in FIG. 13.
[00641 FIG. 18 shows an alternative embodiment of a valve nut puller
tool 12a of the present invention. It can be appreciated that the valve nut
removal and
replacement system 10 may be used to remove a damaged valve nut 80 at a
location lying
well beneath the surface of the earth or at street level. However, other
conditions may
exist where an excavation is made where a valve having a damaged valve nut is
totally
unearthed, whereby personnel have close and direct access at the same level as
the
damaged valve nut. In such a scenario, use of the valve nut removal and
replacement
23
CA 02628675 2008-04-08
system 10, such as shown in FIG. 1, is possible, but difficult, due to the
complexity of
support of personnel in accessing the upwardly located top regions of the
invention.
Conceivably, personnel could stand on a ladder to use the invention, but a
more practical
approach is to provide a valve nut puller tool 12a, which is a shortened and
slightly
modified version of the valve nut puller tool 12 and which can be used at the
same level
as the damaged valve nut. The main differences are the exclusion of the tube
24 and the
removably attached T-handle 16 and the permanent addition of a T-handle 182 to
a
shortened threaded actuator shaft 30a. However, for compactness and other
considerations, such as bulkiness, ease of packaging, shipping and the like,
the valve nut
puller 12a could be furnished for use with the removably attachable T-handle
16, whereby
a hex head, such as hex head 28, would be located at the top of the threaded
actuator
shaft 30a in lieu of the T-handle 182. The teachings of and the operation of
the valve nut
puller tool 12a are similar to that described for the operation of the valve
nut puller
tool 12. The accessory tool shaft 14 and the valve nut replacement tool 18
could also be
shortened for use as previously described.
[0065) Various modifications can be made to the present invention
without departing from the apparent scope thereof.
24
CA 02628675 2008-04-08
VALVE NUT REMOVAL AND REPLACEMENT SYSTEM
PARTS LIST
10 valve nut removal and replacement system
12 valve nut puller tool
12a valve nut puller tool
14 accessory tool shaft
16 removably attachable T-handle
18 valve nut replacement tool
19 valve nut supply plate
20a-n replacement valve nuts
22 stem matching plate
23a-n numbered stems
24 tube
26 end structure
28 hex head
30 threaded actuator shaft
30a threaded actuator shaft
32 cam
33 bevel
34 top shouldered bushing
36 washer
37 nut
38 levered arm
39 interface/thread protector
39a contact plate
40 levered arm
41 extended interface/thread protector
41a contact shaft
42 housing
42a housing half
42b housing half
46 hex head
47 square drive connector
48 tool receptor
49 body hole
50 bore
51 pin
52 mounting hole
53 opposed holes
54 set screws
56 thread cleaner die
29
CA 02628675 2008-04-08
56a shaft
58 rotary brush
58a shaft
60 rotary brush
60a shaft
62 tap drill
62a shaft
64 tap
64a shaft
65 nut socket tool
66 pin
67 opposed holes
68 body
69 mating hole
70 threaded locking shaft
71 handle
72a-b actuating bars
74 tube
76 striking surface
78 nut receptacle socket
80 damaged valve nut
86 bottom shouldered bushing
88 collar
90 passageway
91 bevel
92 bushing cavity
94 tool accommodation cavity
96 arcuate accommodation space
97 arcuate accommodation space
98 valve nut receptor cavity
100 front planar wall
102 back planar wall
104 left planar wall
106 right planar wall
108 slot
109a-c planar surfaces
110 slot
11 l a-c planar surfaces
112 follower cam
113 flat surface
114 pivot hole
115 flat surface
116 jaw
CA 02628675 2008-04-08
118 body hole
120 body hole
122 threaded hole
124 threaded hole
126 pivot bolts
128 pivot bolts
130 threaded hole
131 bevel
132a-b top lobes
134a-b bottom lobes
136 non-lobe flat surface
138 non-lobe flat surface
140a-b grooves
142 valve stem receptacle
144a-n gripping surfaces
145 circular opening
146 top recess
147 bottom recess
148 end plate
150 side plate
152 side plate
154 side plate
154a angled tab
156 side plate
156a angled tab
157 passage hole
158 beveled edge
160 beveled edge
162 valve
164 valve stem
168 retainer nut
170 threads
172 valve box
174 earth
176 retainer bolt
178 valve stem
180 inteinally threaded hole
182 T-handle
31
