Corrosion protection apparatus

Abstract

 An apparatus for protecting a substrate includes a collapsible reservoir filled with a three-dimensional elastic gel which is relatively soft and has an ulti­mate elongation of at elast 200%. The apparatus is disposed in contact with a substrate having a recess therein to be environmentally protected, and a force is applied to the reservoir to at least partially collapse the reservoir forcing the gel from an open surface of the reservior into the recess so as to substantially fill and encapsulate the recess.

Description

[0001] The present invention relates to apparatuses for protecting substrates against corrosion, electrical currents, and other adverse environmental effects.

[0002] Various methods have been proposed in the prior art for protecting a substrate from adverse environmental effects. A typical method used in the prior art is to dispose a viscous grease around the substrate in an attempt to keep adverse environmental contaminants, such as water, from corroding the substrate being pro­tected or providing an electrical path thereto. Another common method used in the prior art has been to apply paint to the substrate. Both of these methods are disadvantageous in that insufficient corrosion pro­tection is afforded, re-entry is difficult, the protec­tion lasts for a relatively short period of time, they are labor intensive, and relatively expensive.

[0003] Debbaut, U.S. Serial Nos. 434,0ll, 504,000, and 507,433, all assigned to the assignee of the present invention and incorporated herein by reference, disclose various containers which are substantially filled with gel material, the container subsequently being disposed in contact with a substrate subsequent to curing the gel. Though these containers are quite effective in protecting substrates, a problem still exists in the art in providing adequate environmental protection to a substrate having a recess therein since condensation oftentimes can still occur within a void surrounded by the recess. Furthermore, some substrates are disposed in installations wherein very little room is available for disposing a relatively large gel filled container thereat so as to completely enclose the substrate to be protected with gel.

[0004] Accordingly, it is an object of the invention to eliminate the above-noted drawbacks and to provide an article for protecting a substrate which is relatively inexpensive to produce, is easy to install over the substrate, lasts a relatively long period of time, and can be made easily re-enterable, if desired.

[0005] These and other objects are achieved by an appara­tus which includes a reservoir filled with a gel, the gel comprising a three dimensional open cell network, the gel being elastic, and having finite elongation characteristics, preferably in excess of 200%, and having a cone penetration between l00 and 350 (l0^-l mm), more preferably between 200 and 300 (l0^-l mm), and most preferably between 250 and 280 (l0^-l mm). The reservoir is collapsible and has an open face through which gel can be disposed outward therefrom when a portion of the reservoir is collapsed such that upon collapsing the reservoir, the gel is dispensed through the open side of the reservoir and into a recess of a substrate to be protected such that the gel can completely fill the recess.

[0006] According to an alternative embodiment of the invention, a plurality of reservoirs, either collap­sible or non-collapsible, are interconnected by flexible bridging members which allows the use of rela­tively small reservoirs to be incorporated in an apparatus for protecting a plurality of contact areas on a substrate such that a major portion of the appara­tus does not contain gel so as to allow the apparatus to be disposed in installations where very little room is available for protecting the substrate.

Figures l-4 illustrate various alternative embodi­ments of collapsible reservoir constructions;

Figure 5 is a plan view, and Figure 6 is a side view, of a plurality of collapsible reservoirs disposed on an apparatus for protecting a plurality of contact areas of a substrate;

Figure 7 is a plan view, and Figure 8 is an end view of one preferred embodiment of the invention, this embodiment being particulary useful for protecting con­tact areas on a modular telephone jack;

Figures 9 and l0 illustrate an alternative embodi­ment for protecting contact areas on a modular phone jack;

Figure ll illustrates yet a further embodiment for protecting contact areas on a modular phone jack, with Figures l2-l5 illustrating various installation steps of the embodiment of Figure ll.

[0007] Figures l-4 illustrate various embodiments of a collapsible reservoir 2 constructed in accordance with the teachings of the present invention.

[0008] Each of the reservoirs 2 includes a gel 3 therein. The gel is preferably one of the types described in Debbaut, U.S. Serial Nos. 434,0ll, filed November l2, l982; 504,000, filed June l3, l983; 507,433, filed June 23, l983; and Chang, U.S. Serial No. 646,555, filed October 3l, l984; all assigned to the assignee of the present invention. In particular, the gel can comprise a urethane, a silicone, or a non-silicone liquid rubber with low or no unsaturation which has been cross-­linked, with urethanes and silicones being preferred embodiments. The gel is a material having an open loop three-dimensional network such that it is elastic and has a finite amount of elongation, and is relatively soft. A preferred embodiment is to use a gel having a cone penetration between l00 and 350 (l0^-l mm), and an ultimate elongation of at least l00%, as measured in accordance with American National Standard Designation ASTM-D2l7 and ASTM-D638, respectively. Preferably, the cone penetration is between 200 and 300 (l0^-l mm), and more preferably between 250 and 280 (l0^-l mm). In addition, the ultimate elongation is also more pre­ferably in excess of 200%, and more preferably in excess of 500%. In addition, the gel is also pre­ferably elastic such that it tends to resist defor­mation and generates a restoration force upon being deformed.

[0009] The reservoir 2 is collapsible such that when sub­jected to a force indicated by arrow l0, the gel 3 within the reservoir 2 is displaced out of the reser­voir through an open side 4 thereof as illustrated in Figures l-4. In Figure 2, an open side 7 having a tun­nel cross-sectional configuration is formed on a side of the collapsible reservoir 2, this embodiment allowing a substrate to be protected to be inserted and/or removed from the reservoir from its side. In addition, it is preferable that the gel have an ulti­mate elongation sufficiently large such that the gel does not tear when the reservoir collapses.

[0010] Preferably, the collapsible container 2 is made of a material, or has an internal construction such that, the gel 3 has an adhesion strength thereto greater than the gels cohesive strength, with the adhesive strength of the gel to the substrate contact area it is intended to protect being preferably less than its cohesive strength and its adhesive strength to the substrate member, to facilitate re-entry.

[0011] In the embodiment of Figure l, the open side 4 is substantially circular in configuration, though ellip­tical, rectangular, or other shapes can be used where the substrate contact area to be protected is similarly shaped. In the embodiment of Figure 3, the open side 4 has a tapered skirt construction which has the advan­tage of enlarging a substrate contact area which can be surrounded and protected while minimizing a volume of the gel 3 required to fill the collapsible reservoir 2.

[0012] Each of the embodiments of Figures l-4 utilizes a collapsible reservoir 2 which collapses downward, with the embodiment of Figure l having a telescopic profile having a largest cross-sectional area thereof forming the open side through which the gel is dispensed, with a next smaller cross-sectional area 7 being adjacent thereto, with the smallest cross-sectional area l5 being on an opposite end of the reservoir than is the open side 4, as illustrated. Accordingly, if subjected to a force l0, the reservoir collapses such that the section l5 can be received within the section 7 which can be received within the section l7, if total collap­sibility is a design criterion. Alternatively, the reservoir can be constructed such that only the section 5 collapses within the section 7. Upon collapsing, this section l5 acts substantially like a piston, this being the mode of collapsing in the embodiments of Figures 2 and 3 wherein piston section 8 collapses within larger section l7 formed so as to define the open side 4, 7. In the embodiment of Figure 4, the collapsible reservoir 2 has a corrugated outer surface 24 which allows an accordian-type compression to occur when subjected to a force l0 so as to dispense gel out of the open side 4. Each of the embodiments of Figures l-4 functionally allows a gel to be dispensed from the reservoir 2 upon being subjected to a force l0 such that the gel is available for filling a recess on a substrate having a contact area incorporating a recess to be protected.

[0013] The remaining figures illustrate practical embodi­ments of the invention, with Figure 5 illustrating a plurality of collapsible reservoirs 2 disposed in line on a strip ll, with the strip ll having a pressure sen­sitive adhesive l2 on a surface thereof. In use, the strip ll is disposed in contact with a substrate having a plurality of contact areas thereon to be protected such that the collapsible reservoirs 2 respectively line up with respective contact areas to be protected, and then the collapsible reservoir is subjected to a force causing the reservoirs to at least partially collapse so as to partially dispense gel therefrom so as to totally incapsulate the contact areas to be protected.

[0014] A practical embodiment of the invention will next be described with reference to a substrate corresponding to a telephone modular jack 5, illustrated in Figures ll-l6. Referring to Figure ll, the apparatus l includes first and second collapsible reservoirs 2 and third and fourth reservoirs l4, the reservoirs l4 being either collapsible or non-­collapsible, though in the embodiment shown the reser­voirs l4 do not need to be collapsible. The reservoirs 2 each have a substantially rectangular cross-sectional profile l3, since a recess 40 on a back side 26 of the jack 5 also has a rectangular cross-sectional profile. The recess on the back side 26 of the jack 5 corresponds to a cavity through which contact screws or bolts 28 extend, the screws 28 being held in place by a metallic mounting bracket 43, shown in Figure l6. To environmentally protect the contents of the jack 5, the screws 28 and brackets 43 must all be protected.

[0015] The apparatus l further includes flexible briding members l9 interconnecting each of the reservoirs 2, l4. To install the apparatus l on the phone jack 5 so as to protect contact bolts 28 and brackets 43 and areas therearound from corrosion and various environ­mental contaminants, the jack is first loosened from its mounting surface, such as a wall, as illustrated in Figure ll. Subsequently, the collapsible reservoirs 2 are slid behind the jack 5 as illustrated in Figure l2 such that the rectangular cross-sectional profiles l3 of the collapsible reservoirs 2 are disposed over recess contact areas 40 on the back side 26 of the jack 5, as illustrated in Figures l2 and l6, and sub­sequently the phone jack is re-secured to its mounting surface. Thereafter, the additional reservoirs l4 are wrapped around the jack 5 as illustrated by arrow 30 in Figure l4 and disposed over ends of the contact screws or bolts 28. In this embodiment, it is not necessary to completely remove the jack 5 from its mounting surface to install the collapsible reservoirs around the recesses, though the jack can be so removed if desired. Rather, all that is required is that the jack be loosened enough so that the reservoirs 2 can be slid behind the jack. Re-securing the jack 5 tightly to its mounting surface by tightening screws 44 as illustrated in Figure l3 provides the force means l0 for collapsing the reservoirs 2.

[0016] Since the screws or bolts 28 protrude from a front surface of the jack 5, the gel 3 is readily elastically displaced around ends of the screws or bolts 28 and maintained in close and conforming contact therewith so long as held under some force by some additional force means l0', this force means being provided by jack cover 22 which is screwed over the phone jack 5, as illustrated in Figure l5. Preferably, the gel has a tacky surface so as to facilitate adhesion of the gel to the contact area of the substrate to be protected while being held under compression.

[0017] The embodiment of Figures ll-l6 is further advan­tageous in that a plurality of the reservoirs 2, l4 are interconnected by flexible bridging members l9 which allows a plurality of substrate contact areas to be protected utilizing a minimum amount of gel with the apparatus l occupying a minimum amount of room, as com­pared to other prior art constructions wherein relati­vely large reservoirs 2 are provided for enclosing entire substrates so as to protect various contact areas thereon.

[0018] Figures 7-l0 illustrate further alternative embodi­ments of the invention. In the embodiment of Figures 7 and 8, the apparatus 3l includes flexible bridging mem­bers l9 arranged such that eight reservoirs in total are included with the apparatus. In use, the jack 5 is removed from its mounting surface rather than simply loosened as in the embodiment of Figures ll-l6, and the apparatus 3l is disposed on the mounting surface such that the reservoirs 2 are disposed at a location such that they will come in contact with substrate recess contact areas 40 to be protected when the jack 5 is replaced on the mounting surface, with holes l6 being provided on the flexible bridging member for providing a means of properly orienting the apparatus 3l, and in particular the rectangular shaped open sides l3 of the collapsible reservoirs 2. The holes l6 will line up with attachment holes 2l (Figure ll) through which screws extend for attaching the phone jack 5 to its mounting surface and providing a force means l0. The force means l0 causes the reservoirs to collapse, as previously explained. Subsequent to re-attaching the phone jack to its mounting surface, reservoirs l4 are pivoted about a l80° semicircle in a manner similar to that illustrated by arrow 30 in Figure l4 so as to cover all the exposed and protruding contact screws or bolts 28. The embodiment of Figure 3l is particularly advantageous in that it comprises only a single article, is easily installable, and provides an indica­tion means l6 confirming proper orientation of the apparatus. In the apparatus of Figures ll-l4, orien­tation indication means is provided by the shape of the rectangular shaped open sides l3 of the reservoirs 2 which corresponds to the rectangular shape of the con­tact areas 40.

[0019] The embodiment of Figures 9 and l0 comprises first and second pieces 32, 33, with the first piece 32 con­taining a plurality of collapsible reservoirs 2 having the gel 3 disposed therein, the piece 32 being adapted for being located on the back side 26 of the phone jack 5 after its removal such that upon re-attachment of the phone jack 5 each of the reservoirs 2 is collapsed so as to exert gel therefrom into contact area recesses 40 on the back side of the phone jack 5. Subsequently, the piece 33 is disposed over the front side of the phone jack so as to encapsulate each of the bolts or screws 28, with the force means to the piece 33 being preferably provided by pressure sensitive adhesive 45 located on a side of the piece 33 in contact with the jack 5. Additional force means can also be provided by re-attaching the cover 22, as illustrated in Figure l5.

[0020] The embodiment of Figures 9 and l0 is advantageous in that relatively few pieces are required to ade­ quately protect a phone jack, indication means is pro­vided to facilitate proper installation thereof, and a plurality of reservoirs are interconnected with flexible bridging members thus reducing the component parts required to adequately protect the phone jack 5.

[0021] It is to be understood that the inventions of pro­viding collapsible reservoirs are useful in a wide variety of applications, and not specifically limited to the particular application of protecting a phone jack, as described herein, and that the invention of providing a plurality of small reservoirs intercon­nected by flexible bridging members so as to allow encapsulation of opposite surfaces of a substrate 5 in a fast and efficient manner is also not limited only to the embodiment of the protection of phone jack 5. The invention is particularly applicable to any appli­cation where a substrate has a contact area which has a recess which requires protection, or in any application where it is desired that gel be pumped into a location relatively remote from a surface of the substrate to which the reservoir is attached, the invention also being useful in any application where opposite sides of a substrate need to be protected in a fast and effi­cient manner. Accordingly, the invention is to be limited only by the appended claims.

Claims

1. An apparatus for protecting a substrate, compri­sing:
a collapsible first reservoir; and
an elastic gel having a cone penetration value bet­ween l00 and 350 (l0^-l mm) and an ultimate elonga­tion of at least 200%, the gel being contained within the reservoir.

2. The apparatus of claim l, the reservoir having an open surface through which the gel is dispensed outward therefrom when a portion of the reservoir is collapsed, the gel preferably being elastically dispensed.

3. The apparatus of claim l or 2, further comprising means for collapsing the reservoir.

4. The apparatus of claim l or 2, the reservoir having a tapered telescopic profile extending from the open sur­face thereof such that a cross-sectional area of the reservoir in a vicinity of the open surface is larger than a cross-sectional area of the reservoir in a vici­nity remote from the open surface thereof, the tapered telescopic profile preferably including at least two discrete reservoir sections having different cross-­sectional areas thereacross, a largest of the sections preferably forming the open surface, a smaller one of the sections preferably being on an opposite side of the reservoir than is the open surface.

5. The apparatus of claim 2, 3 or 4, the reservoir having a structural strength such that when subject to an axial force the reservoir first collapses in a region remote from the open surface, the reservoir collapsing in a piston-like manner.

6. The apparatus of claim 5, the open surface being substantially smaller than a cross-sectional area of the reservoir so as to focus dispensing of the gel.

7. The apparatus of claim 5, the open surface of the reservoir having a cross-sectional area substantially the same as a largest cross-sectional area of the reservoir.

8. The apparatus of claim 2, 3, 4, 5, 6, or 7, further comprising a substrate having a recess therein, the reservoir having the gel therein being disposed on the substrate such that the open surface of the reservoir faces the recess, and further comprising force means for at least partially collapsing the reservoir so as to dispense gel through the open surface and into the substrate recess, the substrate preferably comprising a modular telephone jack, the reservoir being disposed on a back side of the jack confronting an end of a contact screw and mounting means therefor.

9. The apparatus of claim 2, further comprising second, third and fourth reservoirs filled with the gel, the reservoirs being interconnected by flexible bridging members, and each having an open surface, the second, third and fourth reservoirs preferably each being collapsible such that the gel therein is displaced outward through a respective open surface when the respective reservoir is collapsed, the bridging members preferably being flexible enough to allow the third and fourth reservoirs to be moved from a first position whereat their respective open surfaces lie in a substantially common plane with the open sur­faces of the first and second reservoirs to a second position whereat the open sides of the third and fourth reservoirs confront the open sides of the first and second reservoirs, the substrate preferably comprising a modular telephone jack, the first and second reser­voirs preferably being disposed on a back side of the jack such that the open surfaces of the reservoirs confront recesses on the back side of the jack, and further comprising force means for at least partially collapsing the first and second reservoirs so as to dispense gel through the open surfaces thereof and into the recesses, the third and fourth reservoirs being disposed opposite the first and second reservoirs on a front side of the jack, and further preferably comprising fifth, sixth, seventh and eighth reservoirs and means for interconnecting the fifth, sixth, seventh and eighth reservoirs to the first, second, third and fourth reservoirs, at least four of the reservoirs being collapsible, the interconnecting means preferably including means for aligning the reservoirs with the recesses.

l0. An apparatus for protecting a substrate, compri­sing:
first, second, third and fourth reservoirs;
an elastic gel having a cone penetration between l00 and 350 (l0^-l mm) and an ultimate elongation of at least 200%, the gel being contained within the reservoirs;
means for flexibly interconnecting the reservoirs such that the third and fourth reservoirs can be moved from a first position whereat an open surface of each of the reservoirs lies in substantially a common plane to a second position whereat the open surfaces of the third and fourth reservoirs confront the open surfaces of the first and second reservoirs.

11. The apparatus of claim l0, further comprising fifth, sixth, seventh and eighth reservoirs filled with gel, means for interconnecting the fifth, sixth, seventh and eighth reservoirs to the first, second, third and fourth reservoirs such that the seventh and eighth reservoirs can be moved from a third position whereat their respective open surfaces lie in substan­tially a common plane with open surfaces of the fifth and sixth reservoirs to a fourth position wherein the open surfaces of the seventh and eighth reservoirs confront the open surfaces of the fifth and sixth reservoirs, and preferably further comprising means for aligning the reservoirs with contact areas on the substrate to be protected, the substrate preferably comprising a modular telephone jack having four recesses on a back side thereof into which contact screws extend from the front side of the phone jack.

12. An apparatus for protecting a modular telephone jack, comprising:
a first member having first, second, third and fourth reservoirs therein;
an elastic gel having a cone penetration between l00 and 350 (l0^-lmm) and an ultimate elongation of at least 200%, the gel being contained within the reservoirs; and
a pressure sensitive adhesive located on a face of the first member which bonds the first member to a modular telephone jack such that the gel is deformed and held in close and conforming contact with contact surfaces on the jack.

Drawing